FiberCUT ™ RAc

Operation Manual
 WARNING
WORKING AROUND HIGH-POWERED LASERS
CAN BE DANGEROUS
Laser Mechanisms, Inc.’s cutting heads must be
operated with the cutting head interlock switch
connected. The switch must be CLOSED when the
head is properly attached. In the event of a crash
and the cutting head becoming dislodged from its
normal operating position, the switch must be
OPEN. This interlock switch must be connected
in a circuit in such a way that it will immediately
turn off the laser and stop all machine motion.
Check the wiring diagrams for your system.
Serious personal injury and/or equipment
damage can occur if the head becomes
dislodged and:
 The head interlock is not connected
properly.
 Any interlock in the Laser Mechanisms’
product or laser system is defeated.
Laser Mechanisms, Inc. assumes no responsibility
or liability for interlock switches or circuits and all
interlocks are the sole responsibility of the purchaser
of this head.
It is the responsibility of the integrator or end user to
install, connect and activate all interlocks in
compliance with the applicable ANSI, CEN, DIN, etc.
standard.
All wiring should be done by personnel
knowledgeable in electrical wiring and in accordance
with the national and local electrical codes.
DISCLAIMER
The information in this manual is subject to change
without notice.
Laser Mechanisms, Inc. makes no warranty of any
kind with regard to the material in this manual,
including but not limited to, the warranties or
merchantability and fitness for a particular purpose.
Laser Mechanisms, Inc. shall not be liable for errors
contained herein or for incidental or consequential
damages in connection with furnishing, performance
or use of this product.
Corporate names and trademarks stated herein are
the property of their respective companies.
PLMNL0215 REV. C Effective Date: 01/08/16
COPYRIGHT
©2016 Laser Mechanisms, Inc. All rights reserved.
No part of this publication may be reproduced in any
form, or by any means without the prior written
permission of Laser Mechanisms, Inc.
PRODUCT WARRANTY
Laser Mechanisms, Inc. warrants this product
against defects in material and workmanship for a
period of one year from the date of shipment from
Laser Mechanisms Inc. or an authorized distributor.
During the warranty period, Laser Mechanisms, Inc.
will at its option, repair or replace products that
prove to be defective.
For all products returned to Laser Mechanisms, Inc.
for warranty service the customer must:
 Call Laser Mechanisms, Inc. for a Return
Material Authorization (RMA) number.
 Properly pack the product with the RMA number
on the outside of the package. Include in the
package, all cables, and all accessories shipped
with the product along with a description of the
problem.
 Prepay shipping charges to Laser Mechanisms,
Inc.
 Insure the shipment in case of loss or damage.
Laser Mechanisms, Inc. will not accept any
liability in case of damage or loss.
Laser Mechanisms, Inc. will pay the shipping
charges, duties and taxes for the products returned
to Laser Mechanisms, Inc. from outside the United
States.
The foregoing warranty will not apply if damage is
incurred resulting from improper or inadequate
maintenance by the customer, unauthorized
modifications or misuse, operation of the product
outside its specifications, interlocks not connected
properly, improper site preparation, parts or
assemblies not supplied by Laser Mechanisms, Inc.
or unauthorized repair by non-Laser Mechanisms,
Inc. authorized personnel.
For complete warranty information visit our web site
at www.lasermech.com.
i FiberCUT™ RAc Operation Manual
INITIAL INSPECTION
Inspect all shipping containers for damage as soon
as the device arrives. It is your responsibility, the
recipient, to notify the freight company of any
damage. The freight company will require you to
provide the container that any goods were shipped
in, all shipping documentation and a list of all
damages. Photographs of the damage are helpful in
settling a freight claim.
Do not return damaged goods to the factory
without a Return Material Authorization Number
(RMA number).
Although it is Laser Mechanisms, Inc.’s intent to
insure you are up and running as soon as possible,
damage incurred during shipment must be settled
with the freight company before arranging for repairs
or replacement. No return shipments will be
accepted without an RMA number clearly printed on
the outside of all shipping containers. Failure to
follow this procedure could void any warranty
coverage on your head. Call your sales engineer at
Laser Mechanisms, Inc. for an RMA number.
Carefully remove the device from its shipping
container and all packing material to avoid damage.
Save all packaging material, including the sealed,
padded pelican case, in the event the head requires
shipping or storage.
Check all items received against the packing list
to verify that all the items were received.
Please note the product you receive may differ
slightly from the illustrations in this manual.
While the drawings may differ, the basic
procedures described within remain the same.
PLMNL0215 REV. C Effective Date: 01/08/16
TERMS USED IN THIS MANUAL
WARNING: The user could be injured
if the warning is not followed.
CAUTION: The device or system
could be damaged if the CAUTION is
not followed.
NOTE: Clarification of a step or steps.
SAFETY
 WARNINGS: Follow all warnings in this
manual.
 SAFETY GLASSES: Everyone in the area
where the laser is being used must wear laser
safety glasses designed for the laser being
used.
 SECONDARY REFLECTIONS: Secondary
reflections are dangerous; never expose any
part of your body to a reflected laser beam.
 INTERLOCKS: Interlocks are safety devices
and should never be defeated.
 ADJUSTMENTS: Always turn off or put the
laser in standby before making any
adjustments to beam delivery components.
 BEAM DUCT: Never open any component of
the beam duct while the laser is operating.
Always turn the laser off before servicing any
beam duct components.
 MANUALS: Always read the instruction
manuals before attempting to install or make
adjustments to any beam delivery component.
ii FiberCUT™ RAc Operation Manual
 TABLE OF CONTENTS
1 Introduction ........................................................................................................................................................1

2 Installation – Mechanicals .................................................................................................................................2

2.1 Robotic Mount ..................................................................................................................................... 2
2.2 Mounting the Cutting Head to the Robot Mount Bracket .................................................................... 2
2.3 Plumbing ............................................................................................................................................. 3
2.3.1 Water Cooling / Assist Gas / Purge Gas ..........................................................................3
2.4 Fiber Input ........................................................................................................................................... 4
2.5 Bundling .............................................................................................................................................. 4
2.6 Electrical Wiring .................................................................................................................................. 4
2.7 Electrical Grounding and Noise .......................................................................................................... 5
2.8 Control Box Mounting ......................................................................................................................... 5

3 Installation – Electrical ......................................................................................................................................7

3.1 Power (P1) .......................................................................................................................................... 7
3.2 Customer Interface (P2) ..................................................................................................................... 7
3.3 Digital Inputs ....................................................................................................................................... 8
3.3.1 Height Select Bits (HS1 – HS3) .......................................................................................8
3.3.2 Teach / Center of Travel (COT) .......................................................................................8
3.3.3 Programmable Retract Position .......................................................................................9
3.3.4 Motion Inhibit (HOLD).......................................................................................................9
3.3.5 Tip Select Bit (TSB) ..........................................................................................................9
3.3.6 Analog Input Enable (AIE) ................................................................................................9
3.3.7 Reset/Servo Disable (RST) ..............................................................................................9
3.3.8 Input Common (IN-COM) .................................................................................................9
3.4 Analog Inputs .................................................................................................................................. 10
3.4.1 Analog Input (ANALOG-IN, ANALOG-GND) ................................................................ 10
3.4.2 Analog Output (ANALOG-OUT) .................................................................................... 10
3.5 Digital Outputs ................................................................................................................................ 10
3.5.1 In-Position (IN-POS)...................................................................................................... 10
3.5.2 Retracted Position (RET-POS) ..................................................................................... 10
3.5.3 Tip Touch (TIP-TOUCH) ............................................................................................... 10
3.5.4 Crash/Fault (CRASH) .................................................................................................... 10
3.5.5 Output Common (OUT-COM) ....................................................................................... 10
3.5.6 Fault Code Status Bits................................................................................................... 11

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 3.5.7 Crash Interlock Relay (INT1, INT2) ............................................................................... 11
3.6 Interface Example ............................................................................................................................. 12
3.7 Ethernet Interface (P3) ..................................................................................................................... 13
3.7.1 Simulating Inputs (i1 – i8) .............................................................................................. 13
3.7.2 Simulate Analog Input (anlg) ......................................................................................... 13
3.7.3 Output Status (MG @OUT[n]) ....................................................................................... 14
3.7.4 Temperature Status (MG tmp1, tmp2, tmp3) ................................................................ 14
3.7.5 Inquire Analog Height Sense (MG @AN[1]) ................................................................. 14
3.7.6 Inquire Analog Head Position (MG @AN[2]) ................................................................. 14
3.7.7 Unsolicited Fault Status................................................................................................. 14
3.8 Head-Control Cable (P4) .................................................................................................................. 15
3.9 Remote I/O Options .......................................................................................................................... 15
3.9.1 EtherNet/IP .................................................................................................................... 16
3.9.2 DeviceNet ...................................................................................................................... 17
3.9.3 Profibus ......................................................................................................................... 18
3.9.4 PROFINET .................................................................................................................... 19

4 Operation ......................................................................................................................................................... 20
4.1 Power Up .......................................................................................................................................... 20
4.2 Sequence of Operation ..................................................................................................................... 20
4.3 Special Cases ................................................................................................................................... 22
4.3.1 Starting Off the Part....................................................................................................... 22
4.4 Centering the Laser through the Tip ................................................................................................. 22
4.4.1 Centering the Beam in the Tip Orifice ........................................................................... 22
4.4.2 Centering the Beam Using the Camera System ........................................................... 23
4.5 Setting Focus to Tip Distance ........................................................................................................... 26

5 FiberCUT™ Monitor ........................................................................................................................................ 29

5.1 System Requirements ...................................................................................................................... 29
5.2 Installation ......................................................................................................................................... 29
5.3 Connecting ........................................................................................................................................ 30
5.4 Firmware Update and Configuration ................................................................................................. 30
5.5 Manage Connections ........................................................................................................................ 31
5.5.1 Add an Address ............................................................................................................. 31
5.5.2 Modify an Address......................................................................................................... 32
5.5.3 Reassign an Address .................................................................................................... 32
5.5.4 Rearrange Addresses ................................................................................................... 32

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 5.6 Temperature Displays ....................................................................................................................... 32
5.7 Position Display ................................................................................................................................ 32
5.8 Active Standoff Display ..................................................................................................................... 33
5.9 Inputs ................................................................................................................................................ 33
5.10 Outputs ............................................................................................................................................. 33
5.11 Status Display / Fault Code History .................................................................................................. 33
5.12 Preferences ....................................................................................................................................... 33
5.13 Diagnostic View ................................................................................................................................ 34

6 Service.............................................................................................................................................................. 35
6.1 Replacing Gas Jet Nozzle Tip .......................................................................................................... 35
6.2 Tip Assembly Removal and Reinstallation ....................................................................................... 36
6.3 Cleaning Optics................................................................................................................................. 37
6.4 Changing the Cover Glass ................................................................................................................ 38
6.5 Changing the Focusing Lens Optics ................................................................................................. 39
6.6 Removing the Cutting Head from the End of the Robot ................................................................... 40
6.7 Fiber Collimator Assembly Removal and Reinstallation ................................................................... 41
6.8 Turning Mirror Removal and Reinstallation ...................................................................................... 42
6.9 Changing the Collimating Lens Cartridge or Optics ......................................................................... 43
6.10 Changing the Collimating Lens Optics ............................................................................................. 44
6.11 Motor Removal and Reinstallation .................................................................................................... 46
6.12 Dust Seal Removal and Reinstallation ............................................................................................. 49

7 Specifications .................................................................................................................................................. 51

8 Troubleshooting .............................................................................................................................................. 52

9 Appendix A – Coolant Specifications ........................................................................................................... 54

10 Appendix B – Assist Gas Specifications ...................................................................................................... 54

11 Appendix C – Beam Delivery Purging ........................................................................................................... 54

12 Appendix D – Fiber End Types ...................................................................................................................... 55

13 Appendix E – Recommended User-Serviceable Parts List ......................................................................... 56

14 Glossary ........................................................................................................................................................... 59

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1 Introduction
The FiberCUT™ robotic laser processing head was This manual explains the steps of installing, setup,
developed to work in the most extreme operation and service of a FiberCUT™ RAc robotic
manufacturing environments. Right angle entry of all laser.
connections, including fiber, provides tight access to
parts, easy cable routing and stress reduction on the
input fiber.
The FiberCUT™ is made up of four main
subassemblies. See Figure 1.
 The robotic mount
 The fiber collimator assembly
 The drive mechanism
 The tip retainer assembly
See Figure 2 for the path of the laser beam through
the FiberCUT™. The robotic mount connects the
cutting head to the robot, often through an optional
collision sensing device. The fiber collimator unit
uses a doublet collimating lens to gather the laser
light and collimate it after it leaves the fiber optic
cable.
 A collimator focal length of 100mm is standard Figure 1
(other focal lengths are available if the
application requires).
The laser beam then reflects 90° off a turning mirror
to the final focusing lens which focuses the beam
through the orifice of the tip. The drive assembly
provides the motion system that allows the tip to
track the surface of the part and maintain laser
focus.
 The drive system has 17mm of travel and is
controlled by a patented drive system which
provides smooth, linear motion.
The tip retainer assembly contains the final focusing
lens and a cover glass that protects the lens from
dirt and debris. The lens housing is threaded into the
tip assembly.
 The tip threads into the end of the tip retainer
and controls gas flow to the work piece.
 The tip retainer assembly also provides the
electrical feedback to maintain a constant gap
between the tip and part.
 The tip retainer assembly comes in various focal
Figure 2
lengths and configurations, allowing the end
user to optimize the cutting head configuration.

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2 Installation – Mechanicals
2.1 Robotic Mount
The robotic mount attaches to the robot and can
provide optional collision sensing to protect the
cutting head during a crash. See Figure 3. The
collision sensor mounts to the robot using an
adapter. The appropriate hardware will be
provided with the cutting head determined at the
time of sale.
2.2 Mounting the Cutting Head to the
Robot Mount Bracket
The cutting head is secured to the robotic mount
with four M5 SHCS and is positioned on two
5mm dowel pins. The robot mount bracket has
multiple hole patterns which allow the end user
to rotate the head in 30° increments. See Figure
4. This set-up provides the flexibility to orient the
cables to best suit the application. It is up to the
end user to identify the best location for a
particular application.

Figure 3

The optional collision sensor (sold separately as

part number PLCPD0084) is a pneumatic
device.
 The sensor requires 6mm OD hose.
Figure 4
 The recommended operating pressure for
the collision sensor is 1 BAR, but can vary
depending on application.
 The hoses need to be suitable for robotic
applications.

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 2.3 Plumbing
2.3.1 Water Cooling / Assist Gas / Purge
Gas
All lines must be suitable for robotic applications
and are supplied by the integrator.
See Figure 5 for line locations.
 The water cooling lines require 6mm OD
hoses. Cooling specifications can be found
in Appendix A.
 Assist gas recommendations:
o A proportional gas valve placed within 8
feet (2.5 meters) of the FiberCUT™
head.
o 8mm OD hose between the proportional
valve and the FiberCUT™ head. A short
flexible hose is included with the cutting
head and should not be removed unless
replaced with an equivalent unit.
Figure 5
PLMNL0215 REV. C Effective Date: 01/08/16
o When the gas source is less than 25
feet (7.5 meters) away from the
FiberCUT™ head, route 8 mm OD hose
between the gas source and the
proportional valve.
o When the gas source is over 25 feet
(7.5 meters) away from the FiberCUT™
head, route 3/8 inch OD (minimum)
hose between the gas source and the
proportional valve.
o Specifications for assist gas can be
found in Appendix B.
o The assist gas line must be rated higher
than the maximum expected pressure.
o For systems that use oxygen (O2), verify
that valves, fittings, and hoses are
compatible.
 The purge gas line requires 6mm OD hose.
A particle filter and two short flexible hoses
are included with the cutting head and
should not be removed unless replaced with
equivalent units. Specifications for purge
gas can be found in Appendix C.
3 FiberCUT™ RAc Operation Manual

2.4 Fiber Input
The fiber input is where the fiber optic cable
plugs into the cutting head. See Figure 5. There
are several industrial standard styles of fibers
ends (QBH, QD/LLK-D, LCA, QS/LLK-B, HCL-8
& PIPA). See Appendix D for sample images of
each. Each of these fibers has a unique method
of securing it to the fiber input adapter. Refer to
the fiber manufacturer’s information for specific
instructions.
2.6 Electrical Wiring
There can be two electrical wires connected to
the cutting head. See Figure 6.
 One is the communication cable between
the cutting head and the control box
(PLCAB0489).
 The other is the optional collision sensor
cable that is plugged into the robot system
interlock (PLCAB0488).

2.5 Bundling
As in any robotic application, cables need to be
bundled in a manner which allows complete tool
movement without pinching or pulling of the
cables. The FiberCUT™ head was designed so
that all cables input in the same location –
allowing a sleek, easy-to-manage bundle.

Cabling should not be tethered to the fiber input

connector or the fiber optic cable. See Figure 5.

The manner in which the cables are

bundled is one of the keys to having
a successful robotic cutting cell. The
end user is responsible for
documenting and training personnel
on the best bundling methods for
their application.

Figure 6

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 2.7 Electrical Grounding and Noise
The capacitive sensing circuitry contained in the
FiberCUT™ cutting head measures minute
changes in electrical capacitance between the
tip and earth-ground to determine tip-to-part
standoff distance. In order for this circuit to
function properly the part and the cutting head
need to be connected to a good earth ground.
2.8 Control Box Mounting
The important things to consider when mounting
the control box are:
 Clearance to attach connectors
 Clearance to open the control box door
 Standard cable length is 15 meters

 Ideally the ground should be established  Easy access for maintenance.

from a ground rod, approximately 2 meters
in length driven into the ground located near
the base of the robot.
 A large gauge (1.6mm diameter or larger)
ground wire should be run from the ground
rod to the part.
 Run a separate wire from the ground rod to
the mount of the FiberCUT™ at the end of
the robot See Figure 7.
 Mounting such that debris from the process
is not directed at the controller box.
 Mounting in an area where there are no
water leaks or oils from hydraulic presses.
The control box mounting pattern is illustrated in
Figure 8.
 Mounting screw heads are located inside the
control box.

Figure 7

Electrical noise can create sensing issues.

Large electric motors, arc welders and other
devices may be a source of significant electrical
Figure 8
noise. In order to eliminate this noise it may be
necessary to connect a ground wire to the
chassis of any such device near the process.

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 The control box door clearance dimensions are
The control box mounting clearance envelope
illustrated in Figure 10.
dimensions are illustrated in Figure 9.

Figure 10

Figure 9

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3 Installation – Electrical 3.2 Customer Interface (P2)
PIN NAME DESCRIPTION
INPUTS
Height Select Bit 1
P2-1 Input-1 (HS1)
(LSB)
P2-2 Input-2 (HS2) Height Select Bit 2
Height Select Bit 3
P2-3 Input-3 (HS3)
(MSB)
P2-4 Input-4 (COT) Teach/Center of Travel
Input-5
P2-5 Motion Inhibit/Hold
(HOLD)
P2-6 Input-6 (TSB) Tip Select Bit
P2-7 Input-7 (AIE) Analog Input Enable
P2-8 Input-8 (RST) Reset
Input
Figure 11 P2-9 Common (IN- Input Common
COM)
3.1 Power (P1) P2-10 ANALOG-IN Stand-off Height Select
ANALOG-
P2-11 Analog Ground
 Specifications: 85 to 264VAC, 50/60Hz, GND
6A OUTPUTS
ANALOG- Configurable Output
P2-12
OUT Voltage
Output-1 (IN-
P2-13 In-Position
POS)
Output-2
P2-14 Retracted Position
(RET-POS)
Output-3
P2-15 Tip Touch
(Tip Touch)
Output-4
P2-16 Crash/Fault Active
(Crash)
Output-5
P2-17 Status Code 1 (LSB)
(STAT1)
Output-6
P2-18 Status Code 2
(STAT2)
Output-7
Figure 12 P2-19 Status Code 3
(STAT3)
Output-8
Power to the FiberCUT™ controller is connected P2-20 Status Code 4 (MSB)
(STAT4)
using P1 (4-pin connector) on the bottom left Output
side of the control box. A power cord is included +V-Sourcing, 0V-
P2-21 Common
with the system, however alteration of this Sinking
(OUT-COM)
connection may be preferred based on specific P2-22 N/C N/C
installation requirements. Crash Interlock Relay
P2-23 INT1
N/O, 60V, .5A Max
PIN DESCRIPTION Crash Interlock Relay
1 Hot P2-24 INT2
N/O, 60V, .5A Max
2 Neutral
Ground Ground

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 3.3.2 Teach / Center of Travel (COT)
The COT input sets the head in the fixed
center of travel position. When teaching
the motion system path, it is preferable to
have the FiberCUT™ head in the COT
position.
 At the COT position, the label on the
telescoping tube will have half of the
Figure 13 green section exposed. See Figure
14.
3.3 Digital Inputs
 Specifications: 5 to 24VDC, 10mA at
24V
The inputs are configurable for connection to
either sourcing or sinking outputs depending on
the connection made to the input common.

3.3.1 Height Select Bits (HS1 – HS3)

The three discrete height select bits
activate seven standoff heights. When all
height select bits are off, the head will
return to its retracted position.

Note: The height select bits are only

operative if the analog input enable
(AIE) is off.

The • symbol indicates ON.

STANDOFF
HS1 HS2 HS3
HEIGHT
• 0.5mm
• 0.75mm
• • 1.0mm
• 1.25mm
• • 1.5mm
• • 1.75mm
• • • 2.0mm Figure 14
Head Retracted
 COT has precedence over HS1, HS2
and HS3.

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 3.3.3 Programmable Retract Position
The FiberCUT™ controller has the ability
to position the head at seven different
retracted positions. To enable this feature,
click the check box for Prog. Retract
Positions in the Preferences of
FiberCUT™ Monitor. See Section 5.12.
Once enabled, this feature can be
activated by simultaneously activating the
COT (Center of Travel) and a combination
of Height Select Bits.
The • symbol indicates ON.
PROG. RETRACT
HS1 HS2 HS3
POSITION
-8.5mm (COT)
• -7.5mm
• -6.5mm
• • -5.5mm
• -4.5mm
• • -3.5mm
• • -2.5mm
• • • -1.5mm
When the head has reached the
programmable retract position, the RET-
POS (Retracted Position) output will
become active. This feature can reduce
cycle time by minimizing the amount of
travel that the head has to move in-
between cuts.
Note: The FiberCUT™ controller does
not perform a height sensor
calibration when using this feature.
3.3.4 Motion Inhibit (HOLD)
The HOLD input holds the head at the
current position regardless of the
measured standoff height.
 HOLD is useful when the cutting path
must start in a location that is not over
the work piece.
PLMNL0215 REV. C Effective Date: 01/08/16
 HOLD has precedence over HS1,
HS2, HS3 and COT.
 See Section 4.3 for more details.
3.3.5 Tip Select Bit (TSB)
The TSB input allowed selection of the
type of tip installed on the head in early
controller versions. This functionality is
replaced by the FiberCUT™ Controller
Firmware Update PC software. The tip
select bit should remain off unless
otherwise instructed. See Section 5.4 for
more information.
3.3.6 Analog Input Enable (AIE)
 When AIE is active, the standoff
height will be controlled by ANALOG-
IN.
 With AIE inactive, the standoff height
is set by HS1, HS2 and HS3.
 If AIE, HS1, HS2 and HS3 are off, the
head will retract unless COT or HOLD
is active.
3.3.7 Reset/Servo Disable (RST)
 RST allows the head to be reset if a
fault occurs.
 When RST is activated, the Crash
output will be active and the
FiberCUT™ will fully extend. Once
RST is deactivated, the FiberCUT™
will fully retract and recalibrate. If RST
is held active, the FiberCUT™ servo
motor will be disabled and the head
will fully extend.
3.3.8 Input Common (IN-COM)
 Connect +V to IN-COM when the
inputs are connected to sinking (active
low) outputs.
 Connect 0V to IN-COM when
connecting to sourcing (active high)
outputs.
9 FiberCUT™ RAc Operation Manual
 3.4 Analog Inputs
3.4.1 Analog Input (ANALOG-IN,
ANALOG-GND)
 0 to 5VDC (input range)
 Selects standoff height. Working
range is 1V to 4V (1V=>0.5mm;
4V=>2.0mm).
3.4.2 Analog Output (ANALOG-OUT)
 0 to 5VDC
 There are 5 different output options
available. See Section 5.12 for setting
the preferences.
1. HSU Voltage:
A non-linear voltage that
represents the stand-off distance
between the tip and work piece.
2. Linear Pot Voltage:
A linear voltage that represents
the physical position of the
FiberCUT™ drives mechanism.
3. Electronics Temperature:
A voltage indicating the
approximate temperature of the
electronics contained in the head
(°C = V x 10).
4. Collimator/Mirror Block
Temperature:
A voltage indicating the
approximate temperature of
(1) The FiberCUT™ ST collimator
OR
(2) The FiberCUT™ RA or RAc
mirror block
(°C = V x 10).
5. Focus Lens/Nozzle Assembly
Temperature:
A voltage indicating the
approximate temperature of the
FiberCUT™ nozzle area – cover
glass and focus lens. (°C = V x
10).
 The temperature reading is
NOT for the nozzle assembly
alone.
PLMNL0215 REV. C Effective Date: 01/08/16
3.5 Digital Outputs
 Specifications: 5 to 24VDC, 250mA per
output
 All outputs are configurable for sourcing
or sinking depending on the connection
made to OUT-COM.
3.5.1 In-Position (IN-POS)
IN-POS indicates that the tip is within
range of the selected standoff height.
Typically IN-POS provides a handshake
back to the motion system that the tip
has reached the part and is ready to
begin processing.
3.5.2 Retracted Position (RET-POS)
RET-POS indicates that the head is at
the retracted position. Typically RET-
POS provides feedback to the motion
system that the head is parked at the
retracted position.
3.5.3 Tip Touch (TIP-TOUCH)
The TIP-TOUCH signal indicates that
the tip has electrically contacted the part
or object. This can occur during normal
processing and does not produce a
fault.
3.5.4 Crash/Fault (CRASH)
CRASH indicates that the head is
currently in a crash or fault condition.
Check the STAT1 – STAT4 for
information about the crash.
3.5.5 Output Common (OUT-COM)
 Connect +V to OUT-COM for sourcing
(active high) outputs
 Connect 0V to OUT-COM for sinking
(active low) outputs.
10 FiberCUT™ RAc Operation Manual
 3.5.6 Fault Code Status Bits

STATUS
* Automatic Sleep Mode
STAT1 STAT2 STAT3 STAT4
CODE  While in sleep mode the
No Fault FiberCUT™ will disable its servo

• 1: Head Not motor and the head will fully

Extended extend. All of the status bits
(STAT1, STAT2, STAT3 and
• 2: Hit Retract
Limit STAT4) will be active but the crash
output will remain inactive
• • 3: Calibration
Fault indicating that the FiberCUT™ has
entered sleep mode.
• 4: Extending
Watchdog  Set up automatic sleep mode

• • 5: Retract
Watchdog
according to Section 5.12.

6:
• • Temperature
Watchdog
3.5.7 Crash Interlock Relay (INT1,
INT2)
7: Overtemp.
 Solid State Relay Rating: 500mA at
• • • Focus Lens
and Nozzle
0-60VDC, 0-48VAC
Assembly  A solid-state relay opens to indicate
• 8: Overtemp.
Collimator
a fault or crash condition on the
cutting head.
9: Overtemp.
• • Head
Electronics
10:
• • Temperature
Error

• • • 11: Not
Centered
12: Failed To
• • Reach
Extend Limit
13: Height
• • • Sensor
Position Error

• • • 14: Hold
Position Error
15: Failed To

• • • • Retract

*
The • symbol indicates ON.

PLMNL0215 REV. C Effective Date: 01/08/16 11 FiberCUT™ RAc Operation Manual

 3.6 Interface Example
The interface allows control and feedback of all the FiberCUT™ operations.

Interface
Figure 15

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 3.7 Ethernet Interface (P3)
The Ethernet port provides a means of
interfacing to the FiberCUT™ controller with all
of the capabilities of the discrete I/O with the
addition of fault descriptions. Connect the
Ethernet port (P3) to your motion system using a
crossover or null modem Ethernet cable, or to a
network hub by a straight through Ethernet
cable. The controller has been assigned the IP
Address 169.254.99.12. A standard Windows
Telnet session can connect to the controller.
See Figure 16.
Note: The commands and
inquiries interact directly with the
program running on the LM/Galil
controller. Unintentional alteration
of the program may result if
improper instructions are given.
Care should be taken that the
commands to the controller are
accurate.
(Refer to Galil RIO-47IXO User
Manual for additional
information.)
Figure 16
PLMNL0215 REV. C Effective Date: 01/08/16
3.7.1 Simulating Inputs (i1 – i8)
The variables i1 – i8 are used to simulate
the discrete inputs by assigning the
variables a value of 1 or 0.
Examples:
i1=0; i2=0; i3=1 - Sets the standoff height
to 1.25mm.
i5=1 - Turns on motion inhibit.
i5=0 - Turns off motion inhibit.
3.7.2 Simulate Analog Input (anlg)
The variable anlg is used to simulate the
external analog input by assigning values
to the variable using the same rules as the
external analog input. The standoff height
is set with a value of 1 – 4, which gives a
corresponding standoff value of 0.5mm to
2.0mm.
Examples:
i7=1 - Activates external analog input.
anlg=2.5 - Sets the standoff height to
1.25mm.
13 FiberCUT™ RAc Operation Manual
 3.7.3 Output Status (MG @OUT[n])
The status of any of the discrete outputs
can be inquired by sending the MG
@OUT[n] command where n indicates the
output in question from 0 to 15. A
response of: 1.0000 indicates that the
output is on while a response of: 0.0000
indicates that the output is off. Using n
values from 0-7 correspond with outputs
1-8.
Examples:
MG @OUT[0] - Inquire the status of IN-
POS.
: 1.0000 – IN-POS is active.
MG @OUT[13] - Inquire the status of the
crash interlock
: 0.0000 - Interlock is open.
3.7.4 Temperature Status (MG tmp1,
tmp2, tmp3)
The status of the three temperature
sensors inside the head can be inquired
using this command. The returned value is
in degrees Celsius. The three
temperatures (tmp1, tmp2, tmp3)
correspond to sensors located on the
turning mirror block, nozzle assembly and
the head electronics respectively.
Examples:
MG tmp1, tmp2, tmp3 - Inquire the status
of all 3 temperatures.
: 25.3245 28.6532 33.2313 -Temperature
of sensors.
MG tmp2 - Inquire temperature of the
nozzle.
: 35.2834 - Temperature is 35.2834 deg.
C.
PLMNL0215 REV. C Effective Date: 01/08/16
3.7.5 Inquire Analog Height Sense (MG
@AN[1])
The value of the analog tip height sense
signal can be monitored by the command
MG @AN[1]. The value given back is a
highly non-linear value from 0 to 5
indicating a tip standoff height of 0 to
~10mm.
Examples:
MG @AN[1] - Inquire the analog standoff
value.
: 3.2134 - Tip has ~1mm standoff.
3.7.6 Inquire Analog Head Position (MG
@AN[2])
The value of the analog position feedback
from fully extended (~0) to fully retracted
(~5).
Examples:
MG @AN[2] - Inquire the analog head
position.
: 2.5872 - Reply indicating head is near
center.
3.7.7 Unsolicited Fault Status
When a fault occurs, the controller sends
a description of the fault. This action is
triggered by the fault, thus no inquiries are
required.
Examples:
2: Hit Retract Limit.
7: Overtemp Mirror.
11: Not Centered.
14 FiberCUT™ RAc Operation Manual
 3.8 Head-Control Cable (P4)
3.9 Remote I/O Options
A straight through 14-conductor cable
(PLCAB0489) connects the FiberCUT™ The remote I/O option in the FiberCUT™
head to the controller. See Figure 17. This controller simplifies the hardware
cable should be routed away from high integration into the laser processing cell.
power and high voltage wires to prevent Instead of using the discrete I/O
interference. connections in the customer I/O connector,
the integration can consist of a relatively
This cable is a high-flex cable designed for simple cable. Four different protocols are
robotic applications, but minimizing the available to support most industrial
amount of movement and flexing that the networks.
cable is exposed to can increase the life of
the cable.  Device configuration files (EDS or
GSD) and supplemental manuals are
available for download from the
FiberCUT™ Updates web page:
http://www.lasermech.com/fibercutupdates.asp

 All remote I/O options include the

digital inputs and digital outputs shown
below.
Digital Inputs Digital Outputs
BIT 7 RESET BIT 7 STAT4
Figure 17 BIT 6 AIE BIT 6 STAT3
BIT 5 TSB BIT 5 STAT2
BIT 4 HOLD BIT 4 STAT1
BIT 3 COT BIT 3 CRASH
BIT 2 HS3 BIT 2 TIP-TOUCH
BIT 1 HS2 BIT 1 RET-POS
BIT 0 HS1 BIT 0 IN-POS

 Some controllers also include analog

voltage and temperature readings for
monitoring purposes. Voltages are
reported as 12-bit numbers, where 0-
4095 = 0-5V. Temperatures are
reported as hundredths of degrees
Celsius, where 0-7000 = 0.00-70.00°C.
The (4) sections that follow provide
specific data mappings for each
controller configuration.

PLMNL0215 REV. C Effective Date: 01/08/16 15 FiberCUT™ RAc Operation Manual

 3.9.1 EtherNet/IP PLCSA0046 Configuration
The connection to the EtherNet/IP The FiberCUT™ controller with an
uses an RJ45 jack in the FiberCUT™ external power switch consists of a
controller. The EtherNet/IP should not HMS Industrial Networks Anybus IC
be confused with the computer EIP module and Interconnect Board.
Ethernet interface used for
The IP Address is set using the rotary
FiberCUT™ Monitor. See Figure 18.
switches S1 (x10) and S2 (x1) on the
Interconnect Board to addresses
ranging from 192.168.1.1-
192.168.1.99 on Subnet
255.255.255.0. Selecting a value of 00
allows the IP Address to be configured
using Fieldbus Settings on the
™
Preferences page of FiberCUT
Monitor and is set to DHCP by default.
See Section 5.12.
PARAMETER VALUE
Input Size (Bytes) 11
Output Size (Bytes) 1
Figure 18 Configuration Size (Bytes) 0
PLCSA0023 Configuration Input Instance 100
Output Instance 150
The FiberCUT™ controller without an Configuration Instance 1
external power switch consists of an I/O Data Type SINT
Allen Bradley 1734-AENT Point I/O
module.
BYTE DESCRIPTION
The IP Address is set using the
INPUTS
switches on the module or software
1 Digital Outputs
provided by Allen Bradley. Refer to
2-3 Analog Height Sense
Allen Bradley Publication ENET-
UM001N-EN-P for more information. 4-5 Analog Head Position
6-7 Nozzle Temperature
PARAMETER VALUE 8-9 Mirror Block Temperature
Input Size (Bytes) 11 10-11 Electronics Temperature
Output Size (Bytes) 3 OUTPUTS
Configuration Size (Bytes) 0 1 Digital Inputs
Input Instance 101
Output Instance 100
Configuration Instance 102
I/O Data Type SINT

BYTE DESCRIPTION
INPUTS
1-10 Not Used
11 Digital Outputs
OUTPUTS
1 Not Used
2 Digital Inputs
3 Not Used

PLMNL0215 REV. C Effective Date: 01/08/16 16 FiberCUT™ RAc Operation Manual

 3.9.2 DeviceNet
The connection to the DeviceNet I/O
uses a 5-pin micro connector located
in the bottom corner of the control
box. See Figure 19.
PLCSA0044 Configuration
The FiberCUT™ controller with an
external power switch consists of a
HMS Industrial Networks Anybus IC
DEV module and Interconnect Board.
The Node Address is set using the
rotary switches S1 (x10) and S2 (x1)
on the Interconnect Board to
addresses ranging from 01-63.
Selecting a value of 00 allows the
Node Address to be configured using
Fieldbus Settings on the Preferences
page of FiberCUT™ Monitor. See
Section 5.12.

Figure 19 A termination resistor is fitted on the

Interconnect Board and is controlled
PLCSA0015 Configuration using switch S5.
The FiberCUT™ controller without an  If this device is the last node in the
external power switch consists of an system, then S5 should be ON.
Allen Bradley 1734-ADN Point I/O
module that is preconfigured to  If this device is not the last node in
appear on Node 12. Refer to Allen the system, it is necessary to
Bradley Publication 1734-UM002C- switch S5 to OFF.
EN-P for more information on PARAMETER VALUE
configuring the module. Input Size (Bytes) 11
A termination resistor is fitted on the Output Size (Bytes) 1
terminal block of the I/O module in the Baud Rate 125K
FiberCUT™ controller. (S5 on new
controllers).
BYTE DESCRIPTION
 If this device is the last node in the INPUTS
system, then the terminating 1 Digital Outputs
resistor remains in place. 2-3 Analog Height Sense
 If this device is not the last node in 4-5 Analog Head Position
the system, it is necessary to 6-7 Nozzle Temperature
remove this resistor. 8-9 Mirror Block Temperature
10-11 Electronics Temperature
PARAMETER VALUE OUTPUTS
Input Size (Bytes) 4 1 Digital Inputs
Output Size (Bytes) 3
Baud Rate 125K

BYTE DESCRIPTION
INPUTS
1-3 Not Used
4 Digital Outputs
OUTPUTS
1-2 Not Used
3 Digital Inputs

PLMNL0215 REV. C Effective Date: 01/08/16 17 FiberCUT™ RAc Operation Manual


3.9.3 Profibus
The connection to the Profibus I/O
uses a 5-pin micro connector located
on the bottom of the control box. See
Figure 20.
Figure 20
PLCSA0017 Configuration
The FiberCUT™ controller without an
external power switch consists of an
Allen Bradley 1734-APB Point I/O
module that is preconfigured to
appear on Node 12. Refer to Allen
Bradley Publication 1734-UM005B-
EN-P for more information on
configuring the module.
A termination switch is located on the
9-pin connector of the Profibus
module. The FiberCUT™ controller is
shipped with this switch in the OFF
position.
 If this device is the last node in the
system, then the termination
switch remains OFF.
 If this device is not the last node in
the system, it is necessary to turn
the terminating switch ON.
PARAMETER VALUE
Input Size (Bytes) 1
Output Size (Bytes) 1
MODULE
SLOT DESCRIPTION
TYPE
1 Digital Inputs 1734-OB8
2 Digital Outputs 1734-IB8
PLMNL0215 REV. C Effective Date: 01/08/16
PLCSA0044 Configuration
The FiberCUT™ controller with an
external power switch consists of a
HMS Industrial Networks Anybus IC
PDP module and Interconnect Board.
The Node Address are set using the
rotary switches S1 (x10) and S2 (x1)
on the Interconnect Board to
addresses ranging from 01-99.
Selecting a value of 00 allows the
Node Address to be configured up to
126 using Fieldbus Settings on the
Preferences page of FiberCUT™
Monitor. See Section 5.12.
A termination switch is located on the
Interconnect Board labeled S5. The
FiberCUT™ controller is shipped with
this switch in the OFF position.
 If this device is the last node in the
system, then the termination
switch remains OFF.
 If this device is not the last node in
the system, it is necessary to turn
the terminating switch ON.
PARAMETER VALUE
Input Size (Bytes) 11
Output Size (Bytes) 1
MODULE
SLOT DESCRIPTION
TYPE
1 Digital Inputs Output 1 byte
2 Digital Outputs Input 1 byte
3 Analog Height Sense Input 2 byte
4 Analog Head Position Input 2 byte
5 Nozzle Temperature Input 2 byte
6 Mirror Block Temperature Input 2 byte
7 Electronics Temperature Input 2 byte
18 FiberCUT™ RAc Operation Manual
 3.9.4 PROFINET MODULE
SLOT DESCRIPTION
TYPE
The connection to PROFINET uses an
Output
RJ45 jack located in the FiberCUT™ 1 Digital Inputs
001 byte
controller. The PROFINET jack should
Input
not be confused with the computer 2 Digital Outputs
001 byte
Ethernet interface used for
FiberCUT™ Monitor. See Figure 21. Input
3 Analog Height Sense
002 bytes
Input
4 Analog Head Position
002 bytes
Input
5 Nozzle Temperature
002 bytes
Mirror Block Input
6
Temperature 002 bytes
Electronics Input
7
Temperature 002 bytes

Figure 21

The FiberCUT™ controller consists of

a HMS Industrial Networks Anybus IC
PRT module and Interconnect Board.
The customer must configure the
PROFINET Master to recognize this
slave device and map the data
correctly. Consult your system
manufacturer for specific instructions
on how to configure slave devices.
Object Name: Anybus-IC PRT / RT
Standard
Default Device Name: ABIC-PRT

PLMNL0215 REV. C Effective Date: 01/08/16 19 FiberCUT™ RAc Operation Manual

4 Operation
4.1 Power Up
Prior to applying power to the controller verify:
1. The head is connected to the control
with the head-control cable.
2. The remote interface to the head is
connected and powered on.
3. The head is mounted securely with the
nozzle pointed down.
4. The head must be allowed to fully
extend prior to applying power. This is
essential.
After power is applied, the controller:
1. Establishes all of the head positions,
such as center-position and retract-
position, based on the fully extended
position.
2. Then commands the head to go to the
retracted position.
 Make sure the head is positioned
away from any objects.
3. Once retracted, calibrates the height
sensor.
 Do not touch the tip while the head
is retracting, as this affects the
calibration of the height sensor.
The power-up sequence takes a few seconds to
complete.
The head is now ready for operation.
4.2 Sequence of Operation
Warning: It is essential that the
robot monitor and verify proper
operation of the FiberCUT™ head.
Using the Crash, IN-POS, and RET-
POS signals during processing will
insure that the head is functioning
correctly. Failure to monitor these
signals may result in damage to the
laser system.
PLMNL0215 REV. C Effective Date: 01/08/16
1. Home Position
The COT input can be on or off depending
on the desired sequence. If you are
uncertain, leave COT on.
 Prior to moving from the home
position, it is preferable to command
the head to go to COT, if it is not
already at COT, followed by retract.
 This sequence recalibrates the height
sensor compensating for any
variations in temperature, humidity, tip
changes, or any other changes that
may have occurred.
 If COT is activated (on), automatic
sleep mode is deactivated (off).
It is recommended that FiberCUT™ is
not left idle for extended periods of
time. Doing so may degrade the life of
the motor.
 FiberCUT™ controller software
SW0012 Rev 22 or greater includes a
way of powering off the motor by
holding the Reset input active.
o The robot controller should
activate Reset if the head is idle
for more than 10 minutes.
o While Reset is active the
FiberCUT™ head will fully extend
and the controller will indicate a
crash condition.
o When the robot deactivates
Reset, the FiberCUT™ head will
fully retract and clear the crash
condition.
20 FiberCUT™ RAc Operation Manual
  Sleep Mode is an alternative method
of powering off the motor is included
in SW0012 Rev 25 or greater and
FiberCUT™ Monitor 1.6.2 or greater.
o If the FiberCUT™ will be idle for
an extended period of time (>10
minutes), it is recommended to
place it in sleep mode. In sleep
mode, the servo motor will be
turned off and the head will fully
extend.
5. At End of Cut
 Turn off the beam, retract the head by
deactivating HS1, HS2 and HS3 and
turn off the assist gas.
 Return to step 2 (Rapid Positioning) to
move to the next feature to be cut.
OR
 Return to step 1 (Home Position)
when the part is complete.

These actions help increase the Summary Chart

life of the servo motor.
Steps for a cut MUST be performed in the sequence
listed below.
o To activate the automatic sleep
timer, set the Preferences
according to Section 5.12. FiberCUT™ OTHER
STEP HEAD
INPUTS SETTINGS
o The FiberCUT™ will only enter
Retracted HS1 OFF NA
Sleep Mode when no inputs are
HS2 OFF
active and there are no HS3 OFF
obstructions near the tip. 01 AIE OFF
HOME HOLD OFF
OR OR
2. Rapid Positioning
Clearance is maximized by keeping the COT * COT ON/OFF NA
head in the retracted position while it is HS1 OFF
moving to a feature to be processed. HS2 OFF
02 Wait for
Verify RET-POS is active prior to moving. HS3 OFF
RAPID Retracted RET ON
AIE OFF
POSITIONING POS
3. At Start Position HOLD OFF
Activate the assist gas and select a COT OFF
standoff height by activating a Assist ON
03 START
combination of HS1, HS2 and HS3. HS1 ON/OFF Gas
Ready to
HS2 ON/OFF Wait for
(See Note Cut
4. Processing HS3 ON/OFF IN ON
Below)
Processing (turning the beam on) should POS
begin when the IN-POS signal has been 04
Cutting NA Beam ON
received from the FiberCUT™ controller. PROCESSING
Beam OFF
HS1 OFF
 This signal insures that the head is Assist OFF
HS2 OFF
properly sensing on the part. 05 Gas
Retracted HS3 OFF
END OF CUT Wait for
AIE OFF
RET ON
HOLD OFF
POS

* When COT is activated (ON), automatic sleep

mode is deactivated (OFF).

PLMNL0215 REV. C Effective Date: 01/08/16 21 FiberCUT™ RAc Operation Manual

 4.3 Special Cases
4.3.1 Starting Off the Part
There may be times when the cut needs
to start off the edge of the part. If the
FiberCUT™ head is commanded to
activate height sensing without a part
present, the head will reach the extended
limit and issue a crash command to the
motion system.
The following sequence can be
implemented to prevent this crash
condition.
1. Position the head so that it is located
above the part, about 10mm away
from the edge. That positioning
ensures enough surface for sensing.
2. Activate the HS1, HS2 and/or HS3 to
begin sensing on the part.
3. After the IN-POS signal actives, lock
the head by activating HOLD.
4. Move the head off the edge of the
part.
5. Begin the laser processing by
activating the assist gas and turning
the beam on. Allow at least 1 second
for pressurization.
6. Turn off HOLD shortly after the head
has moved onto the surface of the
material.
7. Continue to process as normal.
Note: It may be necessary to end the cut in a
similar method by activating HOLD prior to
moving off of the part. Be sure to retract the
head prior to moving to the next cut feature.
PLMNL0215 REV. C Effective Date: 01/08/16
4.4 Centering the Laser through the
Tip
It is essential to any laser process that the beam
be centered in the gas jet tip. It is the customer’s
responsibility to center the laser beam in the gas
jet tip.
4.4.1 Centering the Beam in the Tip
Orifice
1. Verify that the high power beam is
disabled.
2. Put a piece of translucent tape on the
end of the gas jet tip.
3. Turn on the laser’s internal red
pointing beam and observe the
position of the beam on the tape. If the
beam is not centered in the tip orifice,
proceed to step 4.
Do not look directly into the red
beam.
Visually locating the beam
inside the tip orifice can be
difficult. Adequate lighting and
a magnifying glass are highly
recommended.
If necessary, Laser
Mechanisms offers an
alternative solution. See
Section 4.4.2, Centering the
Beam Using the Camera
System.
22 FiberCUT™ RAc Operation Manual
 Tip centering is accomplished by adjusting
the turning mirror. The turning mirror is
located inside the main body of the cutting
head.
4. To access the turning mirror, remove
the end cap by loosening its
captivated screws with a 3mm hex
wrench as illustrated in Figure 22.
Figure 22
5. Use a 1/8 inch hex wrench to turn the
mirror adjusting screws until the beam
is centered in the tip. See Figure 23.
Figure 23
PLMNL0215 REV. C Effective Date: 01/08/16
4.4.2 Centering the Beam Using the
Camera System
Laser Mechanisms’ camera system is an
aid in centering the beam in the tip orifice.
This method uses virtual images of the
beam and tip orifice on a computer screen
instead of visual inspection.
 See the chart below to determine the
appropriate camera system.
Camera System Tip Retainer
PLFXT0212 PLTRA0360
PLFXT0213 PLTRA0369 or PLTRA0417
To use it, you will need to supply a
computer and install the provided camera
software package (Digital Microscope
Suite).
1. Download the latest version of Digital
Microscope Suite software to the
computer that will be used to center the
laser in the tip orifice. See
http://lasermech.com/updates.asp
 A PDF copy of the Celestron®
Handheld Digital Microscope
Instruction Manual, with more details
on the features and use of the
microscope, is also available on the
website above.
23 FiberCUT™ RAc Operation Manual
  See Figure 24 for steps 2 and 3.  An image similar to Figure 25 will
appear.
2. Unthread the shroud (turn it
counterclockwise) to remove it from
the FiberCUT™ head.
3. Install the centering tool by threading
it (turning it clockwise) onto the
FiberCUT™ head in the location
where the shroud was.

Figure 25

 If the image appears blurry, adjust it

using the following (See Figure 26):

Figure 24 Always start with the lowest power

magnification (10X).
4. Insert the camera cable into a USB
port on the computer used to center
the beam in the tip orifice. a. Rotate the knob all the way to the left.
5. Start the software by double clicking b. Rotate the knob to the right until the
on desktop icon or the MicroCam2 image is clear.
icon in the Digital Microscope Suite
folder.
6. Turn on the laser’s internal red
pointing beam and observe the
position of the beam on the computer
screen.

PLMNL0215 REV. C Effective Date: 01/08/16 24 FiberCUT™ RAc Operation Manual

 Figure 26

7. If the beam is centered in the camera

and tip orifice, no further adjustment is
necessary.
8. If the beam is not centered in the
camera and tip orifice, adjust the
beam location according to the
following:
9. To access the turning mirror, remove
the end cap by loosening its captivated
screws with a 3mm hex wrench as
illustrated in Figure 22.
10. Use a 1/8 inch hex wrench to turn the
mirror adjusting screws until the beam
is centered in the tip. See Figure 23.

Some trial and error may be

necessary in order to center
the beam in the camera and
tip orifice.

11. Once the beam is centered in the tip

replace the cap. See Figure 22.

PLMNL0215 REV. C Effective Date: 01/08/16 25 FiberCUT™ RAc Operation Manual


4.5 Setting Focus to Tip Distance
This FiberCUT™ cutting head is available in four
different focal lengths (75mm, 100mm, 125mm,
and 150mm). It is equipped with an adjustable
focus lens cell, providing an infinitely adjustable
focus-to-tip setting.
The focus position must be customized in every
application in order to achieve the optimum cut.
 For mild steel applications, the focus is
generally set near the top of the material.
 For stainless steel and aluminum
applications, the focus is generally set near
the bottom of the material.
Figure 27 and Figure 28 show surfaces used to
measure the set up distance for each focal
length.
Figure 27
PLMNL0215 REV. C Effective Date: 01/08/16
Figure 29 (on the next page) shows the
nominal position of the lens holder for
each tip style with the focus distance
approximately 1mm outside the tip.
Note: If focus is adjusted too far from
the tip the beam may clip on the tip
orifice. Consider focus location, tip
orifice diameter and beam cone angle
when making this adjustment.
Note: Gas Jet tips and Tip Retaining
Assemblies are interchangeable. The
appearance of your system may be
slightly different, but all of the
dimensions in Figure 29 still provide
a good starting point.
Figure 28
26 FiberCUT™ RAc Operation Manual
 75mm Focal Length 100mm Focal Length

125mm Focal Length 125mm Focal Length 150mm Focal Length

Short Tip Long Tip

Figure 29

PLMNL0215 REV. C Effective Date: 01/08/16 27 FiberCUT™ RAc Operation Manual

  Adjusting the Focus Lens Position:
(see Figure 30).
1. Remove the tip assembly as outlined in
Section 6.2.
2. Verify that the lock nut is tight enough
so the lens holder is secured firmly in
position during operation, but can still
slide in and out of the collet assembly.
 If the lock nut tension is NOT set
properly, proceed to Adjusting the
Lens Holder Tension.
3. Slide the lens holder to the desired
location into or out of the collet
assembly.
 The 1mm scale on the side of the
lens holder can be used as a
reference to make the adjustment.
4. Measure and record the location of the
lens holder.
5. Make sure there is no debris on either
side of the focus lens.
6. See Section 6.2 to reinstall the tip
assembly on the head.
Figure 30
PLMNL0215 REV. C Effective Date: 01/08/16
 Adjusting the Lens Holder Tension:
(see Figure 31):
If the lock nut tension is NOT set properly:
1. Pull the lens holder to remove it from the
collet assembly.
 It is more efficient to tighten the lock nut
after removing the lens holder.
2. Tighten the lock nut and test the fit by
reinserting the lens holder.
 The lens holder should be secured
firmly in position during operation, but
can still slide in and out of the collet
assembly.
3. Repeat steps 1 and 2 until the lens holder is
secured firmly by the collet assembly.
 It is possible to over tighten the lock nut.
 It may be necessary to twist the lens
holder to move it in and out.
4. Go to step 3 of Adjusting the Focus Lens
Position.
Figure 31
28 FiberCUT™ RAc Operation Manual
5 FiberCUT™ Monitor
FiberCUT™ Monitor is a very useful tool for use with
your FiberCUT™ head. FiberCUT™ Monitor runs on 5.1 System Requirements
a standard PC and connects to the controller with an  Windows XP or later
Ethernet cable. It provides real time monitoring of
the tip standoff, head position, head temperatures  Screen Resolution:
and I/O of your FiberCUT™ on a single, easy-to-
– Standard View: Minimum 800 x 600
read screen. See Figure 32 and Figure 33.
– Multiple View: Minimum 1280 x 768
 Ethernet Port
5.2 Installation
Download the latest copy of FiberCUT™
Monitor and FiberCUT™ Controller
Firmware Update (FiberCUT™ Update) from
the FiberCUT™ Updates web page:
http://www.lasermech.com/fibercutupdates.asp
Once the compressed folders are
downloaded from the web site they only
need to be decompressed.
1. Right-click on each compressed
folder and select Extract All....
2. Follow the on-screen instructions to
complete the decompression
Figure 32 (extraction) of the compressed
Standard View Panel files.
 The FiberCUT™ update (SW0012)
folder will have a single executable
file.
 The FiberCUT™ Monitor folder will
have a single FiberCutMonitor.exe
file and a folder named
FiberCutMonitor Libs.
 It is important that the Libs folder
remain at the same location as
FiberCUT™ Monitor.
 The parent folder for these files can
be moved and copied as needed.
No license key is needed.

Figure 33
Multiple View Panel

PLMNL0215 REV. C Effective Date: 01/08/16 29 FiberCUT™ RAc Operation Manual

 5.3 Connecting
All communications between FiberCUT™
Monitor and the FiberCUT™ head are made
using an Ethernet cable. See Figure 34.
5.4 Firmware Update and
Configuration
Prior to using FiberCUT™ Monitor for the
first time, run FiberCUT™ Update
(SW0012) to load the latest firmware
version on the FiberCUT™ controller and to
configure the controls and graphical
displays to match your FiberCUT™ head.
See Figure 35.

Figure 34

 The FiberCUT™ controller can be directly

connected to a PC or multiple FiberCUT™
controllers can be connected to a PC using
an Ethernet Switch.
o Connecting the FiberCUT™ controller to
a wider network, which may include an
internet connection, is also possible.
This type of connection adds a level of
complexity due to the high level of
network traffic.
 FiberCUT™ controllers are set at the factory
to a static IP address of 169.254.99.12.
Typically it is necessary to set the IP
address of your PC to the same range as
the IP address of your FiberCUT™
controller.
o For example; to connect to the
FiberCUT™ controller at the default
address, set your PC to an address of
169.254.99.1 with a subnet mask of Figure 35
255.255.255.0. Refer to your Windows
documentation on how to set your IP
address.
 To connect to the FiberCUT™ controller,
select the IP address from the pull down
menu and press the connect button. Once a
connection is established, the display will
change to an image representing the
FiberCUT™ being used.

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 To run the FiberCUT™ Update 5.5 Manage Connections
(SW0012) software (see Figure 35):
To add, modify and rearrange IP addresses in
1. Launch the SW0012Rxx.exe FiberCUT™ Monitor, select the Manage
application. Connections… option under the Connections
Menu. The Manage Connections screen
 xx is the current revision number. appears. See Figure 36.
2. Enter the controller's IP address and
click Connect.
 If the IP address is unknown, click
Find to display all the controllers on
the network.
 An additional software installation
may be necessary to use the Find
feature. If that is the case, follow the
on screen instructions.
3. The updater will display the current
Model, Tip Assembly, and Tip
configuration assigned to the controller.
 Make any necessary changes then
click Update.
4. A message may appear that the
version is already installed. Figure 36

 If changes have been made to the 5.5.1 Add an Address

head configuration, click Yes to
continue. 1. Click the + button to create a new
entry with the default IP address.
 Otherwise, click No.
2. Modify the IP address to match the
5. A prompt will appear asking whether to address of the FiberCUT™.
save existing Preferences or use
default values. 3. Assign a name to the FiberCUT™
and add an optional description.
 Click on the appropriate selection to
4. Click Add & Test to verify the
begin updating
connection and save the address.
OR
 Click Cancel to stop the update  To add an address for a
process. FiberCUT™ that is currently offline,
click Add Without Testing instead.
6. Once the update is complete, the head
will reset.
 You are ready to exit this program
and launch FiberCUT™ Monitor.

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5.5.2 Modify an Address
To change the address only within
FiberCUT™ Monitor:
1. Click on the row of the address you
would like to change.
2. Modify the IP address as desired.
3. Click Modify & Test to verify the
connection and save the address.
 If the FiberCUT™ is currently offline,
click Modify Without Testing instead.
To rearrange the order of the addresses,
click on a row and drag it to the desired
position in the list.
You may also sort the addresses by
number, name, or description by clicking on
the appropriate header.
5.6 Temperature Displays
The Temperature Displays indicate three
different temperature readings in the
FiberCUT™ head. See Figure 37.

5.5.3 Reassign an Address

To change the address both on the
FiberCUT™ and within FiberCUT™
Monitor:
1. If the address of the FiberCUT™
you would like to reassign is not
currently listed within FiberCUT™
Monitor, add it by following the
procedure in Step 5.5.1.
2. Click on the row of the address you
would like to reassign.
3. Modify the IP address as desired.
4. Click on Reassign and confirm the
change.
 If the change is successful, the new
address will be saved.
Figure 37
These temperature readings are valuable
information that can indicate problems with
contaminated or damaged optics, or poorly
aligned fibers.
The temperature of the electronics is usually 5 to
10 degrees warmer than ambient temperature.
The FiberCUT™ controller will generate a
temperature fault when any of these readings
exceed the max temperature limit (45°C – 55°C).

5.5.4 Rearrange Addresses A fault will also be generated whenever the

readings are below 0°C.
The order of the addresses in the list is the
same as the order they appear in the 5.7 Position Display
Standard View drop-down list. See Figure
The Position Display indicates the physical
32.
position of the head within its travel. The
When using Multiple View, the order retracted position is zero with the negative
determines which panel has the address. direction toward the extended limit.
The first address appears on Panel 1, the
second address appears on Panel 2, and so
on. See Figure 33.
The first address is also used as the default
address when using FiberCUT™ Update.

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 5.8 Active Standoff Display
The Active Standoff Display indicates the
measured standoff distance as determined by
the capacitive height sensor.
Readings above 10mm are indicated as
>10.0mm.
Figure 38
When the head is not actively tracking a surface
(no standoff is selected) the message Height 5.12 Preferences
Sensing Disabled is displayed.
The Preferences button (see Figure 32 and
Otherwise, the selected standoff height is Figure 33) allows technicians to adjust certain
displayed. parameters on the FiberCUT™ controller. See
Figure 39.
5.9 Inputs
The eight inputs displayed indicate the real time
status of the command signals from the robot to
the FiberCUT™ controller. See Section 3 of this
document manual for a detailed description of
these signals.
5.10 Outputs
The eight output signals indicate the real time
status of the signals that are available to the
robot. See Section 3 of this document for a
detailed description of these signals.
IN POSITION – The head is positioned at the
proper standoff from the part.
RETRACTED – The head is in the fully retracted
position.
TIP TOUCH – The tip is making contact with the
part.
CRASH – A fault has occurred with the head.
STAT (1-4) – Four bits that together signify the
current fault code. Figure 39
5.11 Status Display / Fault Code This menu is password protected to prevent
History access by people who should not modify the
settings. To access the Settings window, enter
This indicates the current alarm status of the the password: cutsetup.
FiberCUT™. Any alarms that may occur while
FiberCUT™ Monitor is connected will be With the exception of Simulated Inputs, all
recorded in the Fault Code History. The history changes made are stored directly on the
can be cleared by clicking the Clear button. controller and not within FiberCUT™ Monitor.
This means each head maintains its own
The Clear button is located near the lower right settings, and changes made to the settings of
corner of either the Standard View Panel or the one head will not affect the operation of any of
Multiple View Panel. See Figure 32, Figure 33, your other heads.
and Figure 38.

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 Maximum Temperature – Sets the upper limit 5.13 Diagnostic View
for Electronics, Mirror/Collimator, and Nozzle
temperature. The thermometers within The Diagnostic view is provided to aid in
FiberCUT™ Monitor scale accordingly and troubleshooting faults. This mode records all
exceeding this temperature generates a fault. input and output data for two seconds before
and after a fault occurs. See Figure 40.
Extended Crash – When enabled, the CRASH
output actuates when the head is fully extended.  Data is only captured when the computer is
connected and the diagnostic software is
Inverted Crash – When enabled, the CRASH active.
output is open when there is a crash and closed
when there is no crash.
Enable PLTRA0417 – Enabled when tip retainer
assembly PLTRA0417 is used.
Prog. Retract Positions – Allows the retract
position to be set through a combination of the
Height Select Bits and Center Of Travel Bit (see
Section 3.3.1 Height Select Bits (HS1-HS3) for
more information).
Show Simulated Inputs – When checked, a
second set of inputs is displayed within
FiberCUT™ Monitor. These inputs are
designated by orange circles and may be set
and cleared by clicking on them. The input seen
by the FiberCUT™ is the OR value of the Actual
Input and Simulated Input.
The Stand Off and Servo and
Terminal tabs contain advanced
settings that should only be
adjusted under the direction of a Figure 40
Laser Mechanisms technician. Diagnostic View Panel
Sleep Mode – If the head is inactive for the
indicated length of time (use the up/down arrows to To begin watching for a fault:
set the length of time, see Figure 39), the servo 1. Click Start and once the Status reads
motor will turn off and the head will fully extend. Ready, data collection will trigger on the
Analog Output – HSU Voltage is the typical next change of state of the CRASH bit.
output. Other options include Linear Pot Voltage, 2. Full data can then be saved to a .csv file by
Electronics Temperature, Collimator/Mirror Block clicking Save.
Temperature, or Nozzle Temperature. See the
drop down menu shown in Figure 39.  The Status will change to Triggered once a
fault is detected, and data will appear on the
Fieldbus Settings (If Equipped) – Depending graph showing the output voltage of the
on the controller model, an additional button height sensor and linear potentiometer after
may appear to allow configuration of the Remote approximately two seconds.
I/O Node or IP Address. See Section 3.9 for
more details.  If necessary, data collection can also be
triggered manually by clicking Trigger.

PLMNL0215 REV. C Effective Date: 01/08/16 34 FiberCUT™ RAc Operation Manual

6 Service
Regular maintenance is required for the
FiberCUT™ Head. The operating environment
has a critical impact on the frequency of
maintenance procedures. Consult your Laser
Mechanisms representative for guidance.
6.1 Replacing Gas Jet Nozzle Tip
6.1.1 Step 1
a. Unscrew the tip from the tip retainer
by turning it counterclockwise.
6.1.2 Step 2 (See Figure 42)
a. For PLTRA0360 and PLTRA0369: Figure 42
Check the condition of the O-ring and
replace it if necessary. Stretch the O- 6.1.3 Step 3 (See Figure 41)
ring over the tip retainer boss. a. Thread in a new tip finger tight until it
seats solidly (do not use pliers).
OR
6.1.4 Step 4
b. For PLTRA0417: a. Update the tip selection and
Check the condition of the isolator and recalibrate according to Section 5.4.
replace if necessary.
Available Tip Retainers and Tips

Figure 41
See Appendix E Recommended User-Serviceable
Parts List for nozzle part numbers.

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 6.2 Tip Assembly Removal and
Reinstallation
The tip assembly must be removed to service
the focusing optics. See Figure 43.
To remove the tip assembly:
6.2.1 Step 1
a. To remove the tip assembly from the
head, unscrew the shroud from the tip
assembly to expose the mounting
screws.
It may feel stiff because of the seal.
b. Unbolt the tip assembly using a 3mm
hex wrench.
The screws are captive.
c. Unplug the SMB connector by firmly
grasping it between thumb and
forefinger and pulling straight off of the
tip assembly.
Figure 43
PLMNL0215 REV. C Effective Date: 01/08/16
6.2.2 Step 2
To reinstall the tip assembly on the head:
a. Push the SMB connector over the
male SMB connection on the tip
assembly by firmly grasping the
connector between thumb and
forefinger and pushing it straight on.
Verify that the (2) O-rings are properly
located inside the housing.
If the SMB cable has accidentally
retracted into the head, compress the Z-
slide until the cable reappears.
Warning: If the SMB connector is not
attached, the system will not work.
b. Reattach the tip assembly using a
3mm hex wrench.
c. Thread on the protective shroud.
d. Center the laser beam in the tip
according to Section 4.4.
36 FiberCUT™ RAc Operation Manual
 6.3 Cleaning Optics
Optics are very sensitive to dust and
debris. It is extremely important to
take every possible precaution to
ensure the optics remain pristine.
 Clean optics in a dust free air-conditioned room.
 Before opening any part of the head, clean off
the dust and/or process debris using an exterior
cleaning towel (PLTLS0023) or equivalent.
 ALWAYS handle optics by their edges, never
touch the optical surfaces.
 ALWAYS wear powder free gloves or finger cots
when handling optics and optics holders.
 Inspect the optics with high power illumination,
such as Laser Mechanisms pen light (part
number PLTLS0021) under 2X magnification.
The following instructions are provided as a
guide only. Laser Mechanisms Inc. cannot be
held responsible for any damage to optics
resulting from improper cleaning or handling.
Cleaning instructions supplied by the optics
manufacturer should always be followed.
1. Wash hands with soap to remove all oils,
and then put on powder free gloves or finger
cots.
2. Hold the optic by its edges and blow any
dust off with low-pressure dry nitrogen
(2 to 5 PSI) or air from a blow bulb.
DO NOT USE AN AIR COMPRESSOR.
PLMNL0215 REV. C Effective Date: 01/08/16
3. Soak a clean lens tissue (PLOCK0014 –
®
Texwipe Absorband Wipes – or equivalent)
with acetone or reagent grade isopropyl
alcohol.
4. With the soaked lens tissue wipe the optic in
one direction.
5. Repeat steps 3 and 4 three times using a
clean lens tissue.
6. Inspect the optic. If there is any dust on it or
it appears cloudy repeat steps 2 through 5. If
it is clean, proceed to step 7.
7. While holding the optic by its edges place a
clean piece of lens tissue over the optic, and
then apply a few drops of Tech Spec lens
cleaner or reagent grade isopropyl alcohol to
the lens tissue.
8. Drag the lens tissue off the surface of the
optic in one direction.
9. Repeat step 7 and 8 three times.
10. Rotate the optic 90° and repeat steps 7 and
8 three times.
11. Inspect the optic to make sure that it is
clean.
12. Turn the optic over onto a clean lens tissue
and repeat steps 2 through 11 to clean the
other side.
37 FiberCUT™ RAc Operation Manual

6.4 Changing the Cover Glass
Before opening any part of the
head, clean off the dust and/or
process debris using an exterior
cleaning towel (PLTLS0023) or
equivalent.
The cover glass can be changed while the head
is mounted to the robot.
Always wear powder free gloves or
finger cots when handling optics and
optics holders.
6.4.1 Step 1 (See Figure 44)
a. Unscrew the shroud from the tip
assembly to expose the cover glass
holder.
It may feel stiff because of the seal.
b. Pull the cover glass holder out of the
tip retainer assembly.
It may be necessary to use the 3mm
hex wrench to help pull out the cover
glass holder.
Figure 44
PLMNL0215 REV. C Effective Date: 01/08/16
6.4.2 Step 2 (See Figure 45)
a. Remove the cover glass from the
holder by applying pressure with your
fingers to the surface of the cover
glass, opposite the seal.
 The seal and cover glass will pop out.
 Save the seal.
Figure 45
6.4.3 Step 3
a. Install the new cover glass by placing
it into the holder. See Figure 45.
6.4.4 Step 4
a. Press the Teflon seal into the holder
to retain the cover glass.
Replace the existing seal with a new
one if it appears damaged.
b. Reinsert the cover slide holder into the
tip assembly.
Verify that the orientation of the cover
slide holder is correct. See Figure 44.
38 FiberCUT™ RAc Operation Manual
 6.5 Changing the Focusing Lens
Optics
To change the focusing lens, the tip assembly
must be removed and relocated to a clean dry
area. Individual optics may be cleaned
(according to Section 6.3) or replaced.
6.5.1 Step 1
a. Remove the tip assembly as outlined
in Step 6.2.1.
6.5.2 Step 2 Figure 46
a. Measure and record the position of
the lens holder as shown in Section 6.5.4 Step 4
4.5.  Blow the dust off of the optics using
canned gas or clean nitrogen.
See Figure 46 for steps 3-6.
6.5.3 Step 3 a. Insert a new lens and spacer into the
a. Using PLLIT0028, unthread the lens lens cartridge as shown in Figure 47.
retainer nut as shown in Figure 47. It is critical the lens and spacers are
inserted as shown.
b. Hand-tighten the retainer nut using
Before opening any part of the head, PLLIT0028. Over-tightening the nut
clean off the dust and/or process will cause the lens to distort.
debris using an exterior cleaning
towel (PLTLS0023) or equivalent.

Always wear powder free gloves or

finger cots when handling optics and
optic holders.

 Inspect the optics with high power

illumination, such as Laser
Mechanisms pen light (part number
PLTLS0021) under 5X magnification.

b. Carefully remove the lenses and note

the orientation of the lenses, spacers, Figure 47
and seal rings.
6.5.5 Step 5
a. Measure the position of lens holder to
confirm it has not moved.
b. Reinstall the tip assembly as outlined
in Step 6.2.2.
6.5.6 Step 6
a. Perform the tip alignment procedure
according to Section 4.4.

PLMNL0215 REV. C Effective Date: 01/08/16 39 FiberCUT™ RAc Operation Manual

 6.6.2 Step 2
6.6 Removing the Cutting Head from a. Unbolt head using 5mm hex wrench
the End of the Robot as shown in Figure 48.

To perform most service procedures, it is

necessary to remove the cutting head form the Take care to note orientation of
end of the robot. Remove the head when cutting head.
cleanliness is important, especially if the
procedure involves optic maintenance.
 Take the cutting head to a clean area to b. Separate the head from the mount
insure unwanted dust and debris do not until the alignment pins are
contaminate optics and other critical parts of disengaged.
the head.
 Wipe the head clean of any foreign matter
prior to removal from the robot.
6.6.1 Step 1
a. Remove the fiber optic cable from the
cutting head.
Special attention must be
given to the fiber optic
cable.
Care must be taken to
insure dirt and debris do
not contaminate the glass
block at the end of the fiber.

Damage will occur if:

Figure 48

 The output is not covered

with manufacturer’s cap.
 The fiber input is not
protected by the provided
dust cover.
b. Turn off the water supply and
disconnect the water fittings.
c. Remove the purge air and assist gas
lines.
d. Disconnect the control wire.
e. Leave the robot mount plate and
crash protection in place.

PLMNL0215 REV. C Effective Date: 01/08/16 40 FiberCUT™ RAc Operation Manual

 6.7 Fiber Collimator Assembly
Removal and Reinstallation
The collimator assembly must be removed to
replace the turning mirror and collimator optics.
To remove the Collimator assembly:
6.7.1 Step 1
a. Remove cutting head from robot. See
Section 6.6.
In order to keep out debris, it is
recommended to move the head to a
horizontal orientation.
6.7.2 Step 2
a. Unbolt the fiber collimator assembly
from mount by loosening the (4)
screws with a 3mm wrench. See
Figure 49.
Figure 49
PLMNL0215 REV. C Effective Date: 01/08/16
b. To remove the fiber collimator
assembly from the cutting head, use
steady pressure to unseat it from the
o-ring seal.
 The plate is dowel-pinned in place,
so pull it straight out.
 Verify that the o-rings come out with
the assembly and do not remain in
the head.
To reinstall the collimator:
6.7.3 Step 3
a. Reinstall the fiber collimator assembly
from the cutting head by reversing the
steps followed in 6.7.1 – 6.7.2.
Take special note not to snag, pinch
or tangle any wires inside the head
during reinstallation.
41 FiberCUT™ RAc Operation Manual
 6.8 Turning Mirror Removal and
Reinstallation
The turning mirror is located in the fiber
collimator assembly. See Figure 50.

Before opening any part of the head,

clean off the dust and/or process
debris using an exterior cleaning
towel (PLTLS0023) or equivalent.

Always wear powder free gloves or

finger cots when handling optics and
optic holders. Figure 50

6.8.3 Step 3
6.8.1 Step 1
a. Remove the fiber collimator assembly
from the cutting head. See Section
6.7.
6.8.2 Step 2
a. Remove the mirror cap using a 3mm
hex wrench.
 The screws are not captivated.
 The mirror should remain in the cap
as you remove it from the body.
a. Remove the mirror from the cap by
putting a bent wire hook into the slot
and gently applying pressure from the
underside of the mirror. See Figure
51.
 The heat sink spring should remain in
the mirror cap.
If the heat sink spring sticks to the
back of the mirror, remove it from the
mirror and return it to the deeper of
the two pockets.

b. Separate the cap from the collimator

assembly until the alignment pins are
disengaged.
 Note the correct orientation for
disassembly in Figure 50.

Figure 51

PLMNL0215 REV. C Effective Date: 01/08/16 42 FiberCUT™ RAc Operation Manual

 6.8.4 Step 4
a. Put a small amount of thermo
compound (PLTHC0001) on the heat
sink spring located in mirror cap.
 Select only the approved Laser
Mechanisms’ mirror part number
PLTRG0041.
 DO NOT SUBSTITUTE – The
thickness and coating of the mirror are
critical.
b. Place the mirror inside of the mirror
cap with the coated side up.
6.8.5 Step 5
a. Install the cap onto the fiber collimator
assembly by carefully sliding it over
the dowel pins.
b. Replace and tighten the cap screws
using a 3mm wrench.
PLMNL0215 REV. C Effective Date: 01/08/16
6.9 Changing the Collimating Lens
Cartridge or Optics
The recommended procedure is to change the
entire collimating lens cartridge; the fiber
collimator must be removed from the cutting
head.
6.9.1 Step 1
a. Remove fiber collimator assembly
from cutting head. See Section 6.7.
6.9.2 Step 2 (See Figure 52)
a. Loosen the clamp screw with a 3mm
hex wrench.
b. Unthread the fiber input connector
from the fiber input body.
Figure 52
43 FiberCUT™ RAc Operation Manual
 6.9.3 Step 3 (See Figure 53)
a. Unthread the cartridge retainer nuts
using a spanner wrench (PLLIT0028).
b. Slide the lens cartridge out of the fiber
input body.
 Note the orientation of the lens
cartridge for reassembly.
Figure 53
6.9.4 Step 4 (See Figure 53)
a. Slide a new lens cartridge into the
fiber input body.
 Verify the orientation of the lens
cartridge for reassembly.
b. Rethread the cartridge retainer nuts
using a spanner wrench (PLLIT0028).
6.9.5 Step 5
a. Reinstall the fiber collimator assembly
by reversing the steps in Section 6.7.
6.9.6 Step 6
b. Perform the tip alignment procedure
according to Section 4.4.
PLMNL0215 REV. C Effective Date: 01/08/16
6.10 Changing the Collimating Lens
Optics
Laser Mechanisms recommends
purchasing the complete lens cell
and returning any defective cell
for refurbishment.
The optics MUST be loaded in the
orientation shown in Figure 54
and Figure 55. Failure to follow
these guidelines can result in
damage to all optical elements,
including the fiber.
As an alternate procedure, individual optics may
be cleaned (according to Section 6.3) or
replaced.
Follow the instructions in steps 6.9.1, Step 1
through 6.9.3, Step 3, then:
Alternate 6.10.4 Step 4
a. Using PLLIT0028, unthread the lens
retaining nut as shown in Figure 54.
Before opening any part of the head,
clean off the dust and/or process
debris using an exterior cleaning
towel (PLTLS0023) or equivalent.
Always wear powder free gloves or
finger cots when handling optics and
optic holders.
44 FiberCUT™ RAc Operation Manual
  Inspect the optics with high power
illumination, such as Laser
Mechanisms pen light (part number
PLTLS0021) under 5X magnification.

b. Carefully remove the lenses and note

the orientation of the lenses, spacers,
and seal rings.

Figure 54

Alternate 6.10.5 Step 5

 Blow the dust off of the optics using
canned gas or clean nitrogen.

a. Insert new lenses and spacers into the

lens cartridge as shown in Figure 55.
 It is critical that the lenses and
spacers are inserted as shown.
Figure 55
b. Hand-tighten the retainer nut using
PLLIT0028. Alternate 6.10.6 Step 6
 Over-tightening the nut will cause the a. Reinstall the fiber collimator assembly
lens to distort. by reversing steps followed in Section
6.7.

PLMNL0215 REV. C Effective Date: 01/08/16 45 FiberCUT™ RAc Operation Manual

 6.11 Motor Removal and e. Unplug ONLY the 2 conductor motor
Reinstallation wire connected to the height sense
card. See Figure 57.
The following procedures refer to motor part
number PLMOT0022.
To remove the motor:
6.11.1 Step 1 (see Figure 56)
a. Remove the cutting head. See Section
6.6.
b. Move the cutting head to a clean
environment to prevent contamination
of the optics.
c. Unscrew and remove the nut holding
the height sense card (HSU) onto the
motor cover box.
d. Loosen the (4) captive M4 bolts and
remove the motor cover box. Set the
motor cover box aside.
Figure 57

6.11.2 Step 2 (see Figure 58)

a. Inside the motor compartment,
remove the (4) M3 socket head cap
screws that hold the motor onto the
housing.
b. Lift up on the moving head slide to lift
the actuator follower block off of the
motor cam arm.
c. Remove the motor assembly from the
housing.

Figure 56

Figure 58

PLMNL0215 REV. C Effective Date: 01/08/16 46 FiberCUT™ RAc Operation Manual

 6.11.3 Step 3 (see Figure 59)
a. Loosen, but DO NOT REMOVE, the
clamp bolt from the clamp arm.
b. Loosen, but DO NOT REMOVE, the
cam arm set screw.
c. Pull the cam arm off of the motor
shaft.
d. Remove the (3) M2.5 bolts that hold
the motor onto the assembly plate.
e. Remove the motor from the assembly
plate.
Figure 59
To reinstall the motor:
6.11.4 Step 4
For steps a-c, see Figure 60.
a. Insert the new motor into the
assembly plate.
 Orient the wires out of the motor in the
5 o’clock position as shown.
b. Turn the FiberCUT™ head and verify
that the threaded holes on the shaft
side of the motor are aligned with the
holes in the housing. Rotate the motor
to align the holes as necessary.
c. Reinstall the (3) M2.5 socket head cap
screws previously removed in step
6.11.3 Step 3.
PLMNL0215 REV. C Effective Date: 01/08/16
If a screw falls into the body of
the FiberCUT™ head, retrieve
it by removing the lower part of
the housing body. Remove it by
unthreading it or turning it
counterclockwise).
Figure 60
For steps d-f, see Figure 61.
d. Push the motor cam arm onto the
motor shaft.
 The cam arm should be flush with
the end of the motor shaft.
 Take care that the flat on the motor
shaft is in line with the set screw.
 It may be necessary to slightly
loosen (turn counterclockwise) the
cam arm set screw. Use a 2 mm
hex wrench.
e. Tighten (turn clockwise) the cam arm
set screw. Use a 2 mm hex wrench.
 The cam arm set screw should
contact the flat of the new motor
shaft.
47 FiberCUT™ RAc Operation Manual
 f. Then, reinstall the clamp bolt. Use a
2.5 mm hex wrench.

Figure 61 Figure 62

g. Push the moving head up and reinstall

the motor assembly into the housing
using the (4) M3 socket head cap
screws removed in step 6.11.2, Step
2. See Figure 62.
 Insert the cam arm under the
follower dowel
 The cam arm must be oriented as
shown in Figure 62.

PLMNL0215 REV. C Effective Date: 01/08/16 48 FiberCUT™ RAc Operation Manual

 6.11.5 Step 5
a. Connect the 2 conductor motor wire to
the height sense (HSU) card. See
Figure 57.
For steps b and c, see Figure 63.
b. Attach the motor housing box using
the (4) captive M4 bolts.
c. Reattach the fiber and communication
cables. See Section 6.6.
d. Turn the power back on to the
FiberCUT™ head. See Section 6.6.
Figure 63
PLMNL0215 REV. C Effective Date: 01/08/16
6.12 Dust Seal Removal and
Reinstallation
To remove the manifold seal:
6.12.1 Step 1 (see Figure 64)
a. Remove the 4 M4 screws and the dust
cover.
b. Use an appropriate tool to peel the
manifold seal off of the shroud.
Figure 64
49 FiberCUT™ RAc Operation Manual
 To reinstall the dust seal:
6.12.2 Step 2 (see Figure 65)

Figure 65

a. Verify that the bottom of the cover,

especially the lip area, is clean.
b. Press the manifold seal (part number
PLMSR0031) against the cover along
the lip until the entire seal is pressed
against the inside of the cover.
 No adhesive is used to install the
seal.
 There is a “smooth” side and a
“fuzzy” side to the seal. The
“smooth” side is pressed against the
lip area of the shroud. The “fuzzy”
side creates a dust barrier between
the main body and the shroud.
 The ends of the seal, cut at a 45°
angle, must meet together without
any gaps.
 An appropriate sharp tool may be
helpful.

PLMNL0215 REV. C Effective Date: 01/08/16 50 FiberCUT™ RAc Operation Manual

7 Specifications

CUTTING HEAD
Power Rating .............................................................................................................................. up to 4 kW
Focusing Lens (Effective Focal Length) ................................................ 75mm, 104 mm, 130 mm, 150 mm
Focusing Lens (Diameter) ................................................................................................................. 28 mm
Clear Aperture ................................................................................................................................... 25 mm
Nozzle Tip .......................................................................................................................... Various Shapes
Assist Gas Pressure ............................................................................................................... up to 20 BAR
Gas .................................................................................................................................... Female 1/8 NPT
Water Ports ........................................................................................................... 6 mm tube to M5 fittings
Weight ................................................................................................................................................ 3.2 kg
Height (Center Of Travel) ........................................................................................................ 304, 333 mm
Slide Travel .................................................................................................................................... ±8.5 mm
Max. Travel Speed .................................................................................................................. 175 mm/sec.
Standoff Distance Range (1 mm Recommended) .......................................................... 0.5 mm to 2.0 mm

COLLIMATOR
Effective Focal Length (Doublet, Fused Silica) .................................................................. 78 mm, 102 mm
Recollimating Lens (Diameter) .......................................................................................................... 28 mm
Clear Aperture ................................................................................................................................... 25 mm
Fiber Socket (Others Available On Request) .................................... QBH, HCL-8, LLK-B, QD, LCA, PIPA

CONTROL BOX
Sealed Enclosure ............................................................................... 380 mm L x 300 mm W x 160 mm H
Single Interconnect Cable ................................................................................................... up to 15 m long
Number of Standoff Settings ...................................................................................................................... 7
Electrical Supply ........................................................................................ 85-264 VAC, 1-Phase,47-63 Hz
Interface Inputs ................................................................ 5-24 VDC, 2.2 kΩ impedance, optically isolated
Interface Outputs ................................................ 12-24 VDC, 150 mA max., sink/source, optically isolated

Specifications are subject to change without notice.

PLMNL0215 REV. C Effective Date: 01/08/16 51 FiberCUT™ RAc Operation Manual

8 Troubleshooting
Most of the faults can be cleared by moving the head away from any objects, turning off all of the I/O’s, followed
by resetting the head by activating the RST input for ~0.1sec.
In some cases just activating RST for ~0.1sec will also clear the fault.

SYMPTOM CAUSE REMEDY

Crash interlock is not
satisfied (INT1 and INT2)
Fault:
1: Head Not Extended
Fault:
2: Hit Retract Limit
Fault:
3: Calibration Fault
Fault:
4: Extending Watchdog
Fault:
5: Retract Watchdog
Fault:
6: Temperature Watchdog
Fault:
7: Overtemp, Mirror
8: Overtemp, Focus Lens &
Nozzle Assembly
9: Overtemp, Head
Electronics
The head has reached the
extended or retracted limit while
sensing.
Head has had a fault or crash.
Power is not turned on to the
controller.
Something is preventing the head
from fully extending.
The head has collided with an
object causing the head to reach
the retract limit.
The controller has not received the
proper response from the height
sensor.
The motor is being told to extend
continuously.
The motor is being told to retract
continuously.
The controller is not getting the
proper response from the head
electronics.
One or more optics have failed.
The tip is not centered.
Insufficient water-cooling.
Turn off HS1, HS2, HS3, AIE and HOLD
inputs to place the head in retracted
position mode.
Reset head.
Check power and all connections to the
controller and head.
When the controller is first powered up,
the head must be able to fully extend.
Jog the head away from the object and
then turn power on to the controller.
Jog the head away from the object and
reset.
The tip may be shorted or the sense
cable may be broken. Replace the
nozzle or sense cable.
An object is touching the head
preventing it from extending. Move the
head away from the object.
The drive system has failed. Replace the
motor or drive mechanisms.
An object is touching the head
preventing it from retracting. Move the
head away from the object.
The drive system has failed. Replace the
motor or drive mechanisms.
Replace the head-control cable or head
electronics module.
Inspect all optics and fiber, replace as
needed.
Check tip centering. The tip may need to
be replaced.
Make sure proper water temperature
and flow are maintained to the head.

PLMNL0215 REV. C Effective Date: 01/08/16 52 FiberCUT™ RAc Operation Manual

 SYMPTOM CAUSE
Fault:
Sensor failure in head.
10: Temperature Error
Fault: Collision with the head while COT is
11: Not Centered active.
Fault: Collision with the head while in
12: Hit Limit While Retracted retracted position.
Head is failing to sense properly on
the part.
Fault:
13: Height Sensor (HS)
Position Error The height sensor failed to calibrate
properly on the previous retract.
Or head is chattering on the
part.
The head is trying to sense the
edge or corner of the part.
Improper tip is selected.
Fault: Collision with the head while HOLD
14: Hold Position Error is active.
Fault: An object is preventing the head
15: Failed To Retract from fully retracting.
PLMNL0215 REV. C Effective Date: 01/08/16 53
REMEDY
Check the temperature sensors in the
head for broken wires or shorts.
An object is touching the head
preventing it from reaching position.
Move the head away from the object.
Jog the head away from the object and
reset.
An object is touching the head
preventing it from reaching position.
Move the head away from the object.
The internal sensor cable is not
connected. Remove the tip assembly
and reattach the internal SMB
connector.
Prior to sensing on the part, place the
head in COT followed by a Retract. This
recalibrates the height sensor. Do not
touch the tip while the head is retracting.
In order to sense accurately, the tip must
see a relatively flat surface. Edges may
not provide adequate surface area.
Selecting a higher standoff may resolve
this issue.
Make sure the Tip Select input matches
the corresponding tip being used.
An object is touching the head
preventing it from reaching position.
Move the head away from the object.
Inspect the head for objects that may be
interfering with the motion. The
obstruction may be internal.
FiberCUT™ RAc Operation Manual
9 Appendix A – Coolant Specifications
The cooling manifolds are designed to be operated on either a closed-loop cooling system or facility tap water.
For either type of system the requirements in the table below must be met.

1.6 liter/minute @ 2 BAR

Minimum Flow Rate
minimum
Inlet Pressure 170 to 520 kPa
Inlet Temperature ≥room temperature / >dew point
Hardness (Equivalent to CaCO3) <250mg/liter
pH 6 to 8
Particulate Size <200 microns in diameter

10 Appendix B – Assist Gas Specifications

Impurities in the assist gas such as hydrocarbons (THC) and moisture (H 2O) can damage optics, cause power
fluctuations and result in inconsistent cuts. See the table below for recommended assist gas specifications.

GAS PURITY MAX H2O ppm MAX THC ppm

Oxygen 99.8% <5 ppm <1 ppm
Nitrogen 99.998% <5 ppm <1 ppm
Argon 99.998% <5 ppm <1 ppm
Helium 99.998% <5 ppm <1 ppm

Impurities can also be picked up in the supply lines. Non-metallic materials can allow oxygen and moisture to
permeate the system and can be a source of dust and hydrocarbons. Stainless steel lines and fittings are
recommended. Use filters that remove particles down to .01 microns and purifiers that guard against oil or water
from getting into the optical system.
Regulators with a stainless steel diaphragm are recommended. Industrial regulators can aspirate air and the
neoprene diaphragm can be a source of hydrocarbons.

11 Appendix C – Beam Delivery Purging

The beam delivery system must be purged with clean, dry air {specification to meet or exceed ISO 8573.1:2001
Class 1.5.2}; Solids <100 particles per cubic meter of 0.1-0.5 µm size, and <1 particle per cubic meter of 0.5-0.1
µm; Water dewpoint <+7º C; Oil <0.1 mg per cubic meter. Purge flow rate is 1400 liters/hr (50 SCFH) @ 20 kPa.
A self-regenerating desiccant air dryer filter unit (PLKIT0188) is available as an option from Laser Mechanisms.

PLMNL0215 REV. C Effective Date: 01/08/16 54 FiberCUT™ RAc Operation Manual

12 Appendix D – Fiber End Types

Fiber End Type Sample Image

HLC or QBH

QD or LLK-D

LCA

Q5 or LLK-B

PLMNL0215 REV. C Effective Date: 01/08/16 55 FiberCUT™ RAc Operation Manual

13 Appendix E – Recommended User-Serviceable Parts List
For recommended user-serviceable spare parts, please call Laser Mechanisms at (248) 474-9480. If your head
requires service beyond the instructions outlined in this manual, please contact Laser Mechanisms for further
assistance.

ITEM PART # DESCRIPTION

FIBER INTERFACE ASSEMBLY
1 Fiber Interface Assembly (Contact Laser Mechanisms)
2 PLFTG0081 Tube Fitting
3 PLTRG0041 Total Reflective Mirror
4 PLHSK0003 Heat Sink Spring
COLLIMATOR FIXED LENS HOLDER 75mm BFL
5 PLFLH0243 Collimator Fixed Lens Holder 75mm BFL (Complete Assembly)
6 PLYFS0013 Collimating Lens For PLFLH0243
7 PLLSR0002 Lens Seal Ring
8 PLLBR0002 Lens Backup Ring
9 PLLBR0005 Lens Backup Ring
10 PLLRN0026 Lens Retainer Nut
COLLIMATOR FIXED LENS HOLDER 100mm BFL
11 PLFLH0229 Collimator Fixed Lens Holder 100mm BFL (Complete Assembly)
12 PLYFS0007 Collimating Lens For PLFLH0229
7 PLLSR0002 Lens Seal Ring
8 PLLBR0002 Lens Backup Ring
10 PLLRN0026 Lens Retainer Nut
CABLES
13 PLCAB0489 Controller Interface Cable
14 PLCAB0487 Sensor Cable
ADJUSTABLE LENS HOLDER 100mm BFL
15 PLALH0137 Adjustable Lens Holder 100mm FL (Complete Assembly)
10 PLLRN0026 Lens Retainer Nut
8 PLLBR0002 Lens Backup Ring
7 PLLSR0002 Lens Seal Ring
16 PLYFS0012 Lens 100mm BFL
ADJUSTABLE LENS HOLDER 125mm BFL
17 PLALH0138 Adjustable Lens Holder 125mm FL (Complete Assembly)
10 PLLRN0026 Lens Retainer Nut
8 PLLBR0002 Lens Backup Ring
7 PLLSR0002 Lens Seal Ring
18 PLYFS0016 Lens 125mm BFL
COVER GLASS HOLDER
19 PLFLH0123 Fixed Lens Holder
20 PLLCG0034 Lens Cover Glass
21 PLMSR0017 Manifold Seal Ring
TIP RETAINER ASSEMBLIES
22 PLTRA0360 Tip Retainer Assembly 100mm FL
23 PLTRA0369 Tip Retainer Assembly 125mm FL
24 PLTRA0417 Tip Retainer Assembly 125mm FL – Narrow Profile

PLMNL0215 REV. C Effective Date: 01/08/16 56 FiberCUT™ RAc Operation Manual

 ITEM PART # DESCRIPTION
SCREWS
25 PLSCR0034 Custom Socket Head Cap Screw
O-RINGS
26 PLORG0017 O-ring
ISOLATORS
27 PLISR0033 Tip Isolator
NOZZLES
28 PLGJT0623 Slim Style Tip 1.5mm Orifice
29 PLGJT0522 Blunt Style Tip 1.2mm Orifice
30 PLGJT0608 Blunt Style Tip 1.5mm Orifice
31 PLGJT0563 Narrow Style Tip 1.2mm Orifice
32 PLGJT0682 Narrow Style Tip 1.5mm Orifice
33 PLGJT0711 Tight Access Style Tip 1.5mm Orifice
34 PLGJT0226 TRA0417 Style Tip 1.0 mm Orifice
35 PLGJT0227 TRA0417 Style Tip 1.2mm Orifice
36 PLGJT0172 TRA0417 Style Tip 1.5mm Orifice
37 PLGJT0173 TRA0417 Style Tip 2.0mm Orifice
38 PLGJT0523 TRA0417 Style Tip 2.5mm Orifice
SEALS
39 PLMSR0031 Manifold Seal Ring
TOOLS
PLLIT0028 Lens Insertion Tool
PLTHC0001 Thermo Compound

PLMNL0215 REV. C Effective Date: 01/08/16 57 FiberCUT™ RAc Operation Manual

 Figure 66

PLMNL0215 REV. C Effective Date: 01/08/16 58 FiberCUT™ RAc Operation Manual

14 Glossary
Assist Gas
Any gas that is applied to the working point
on the material to assist the laser process
(also referred to as cover gas or shield gas).

CFN
Cold Formed Nozzle

Cover Gas
(See Assist Gas)

FL
Focal Length

HSU
Height Sensing Unit

I/O
Inputs(s) and Output(s)

PSI
Pounds per Square Inch

SHCS
Socket Head Cap Screw

SMA
Sub-Miniature-A 50 ohm connector with a
threaded coupling interface.

Shield Gas
(See Assist Gas)

TRA
Tip Retainer Assembly

PLMNL0215 REV. C Effective Date: 01/08/16 59 FiberCUT™ RAc Operation Manual

 Laser Mechanisms, Inc.
25325 Regency Drive • Novi, Michigan 48375 USA
Phone: (248) 474-9480 • Fax: (248) 474-9277
In Europe: Phone: +32(0)92 18 70 70 • Fax: +32(0)92 18 70 79
Web: www.lasermech.com • E-Mail: info@lasermech.com