BOCI BLT481 User manual

BLT481 Product Manual
Brilliant Optical Cutting Instrument
BOCI

BLT481 Product Manual
Document History
Number
Date
Version
01
2022/08/19
V1.1
Notice:
Thank you for choosing the BLT intelligent cutting head. This manual provides you with
important information such as product parameters, installation, and maintenance, so please
read this manual carefully before using the product. At the same time, in order to ensure the
safety of operation and the operation of the product in the best condition, please strictly follow
the precautions in the manual.
BOCI is constantly updating/upgrading products, so our company reserves the right to modify
the product models and descriptions in this manual without prior declaration.
Unauthorized disassembly of the product is strictly prohibited without the authorization of
BOCI Technology, otherwise the warranty will be invalid!
BOCI

BLT481 Product Manual
Table of contents
BLT481 Product Manual .................................................................................1
1. Product Description ....................................................................................1
1.1 Product View.......................................................................................................................................................... 1
1.2 Technical parameters............................................................................................................................................. 2
1.3 Meaning of LED indicator....................................................................................................................................... 3
2. Gas port......................................................................................................4
3. Water cooling interface ...............................................................................5
4. Electrical interface ......................................................................................6
4.1 Bus system ............................................................................................................................................................ 7
4.2 Non-bus systems ................................................................................................................................................... 8
5. Cutting head installation..............................................................................9
5.1 Preparation before operation ................................................................................................................................. 9
5.2 Specific operation process ................................................................................................................................... 10
5.2.1 Preparation of clean bench ........................................................................................................................ 10
5.2.2 The cutting head is placed in the clean workbench.................................................................................... 10
5.2.3 Clean and wipe the fiber interface of the cutting head ............................................................................... 11
5.2.4 Check the laser fiber end face ................................................................................................................... 11
5.2.5 Tear off the protective film/remove the protective cap ............................................................................... 11
5.2.6 Insert the laser fiber interface into the cutting head ................................................................................... 12
5.2.7 Wrap and seal............................................................................................................................................ 12
5.2.8 Mount the cutting head on the backplane .................................................................................................. 13
5.2.9 Installing the ceramic body and nozzle ...................................................................................................... 13
BOCI

BLT481 Product Manual
5.2.10 Beam centering........................................................................................................................................ 14
Appendix A - Care/Maintenance ...................................................................16
1.1 Schematic diagram of product structure............................................................................................................... 16
1.2 Replace the upper protective lens........................................................................................................................ 17
1.3 Replace the lower protective lens ........................................................................................................................ 18
Appendix B - Mechanical Dimensions...........................................................19
1.1 Cutting head installation size ............................................................................................................................... 19
BOCI

BLT481 Product Manual
1
1. Product Description
1.1 Product View
Product View (Structure and Interface Description)
1. Optical fiber interface; 9. Nozzle cooling air interface;
2. 1st Upper protective lens; 10. Cutting gas interface;
3. 2nd Upper protective lens; 11. Cooling water outlet;
4. Collimation unit; 12. Cooling water inlet;
5. Focusing unit; 13. Anti-collision screw;
6. 2nd Lower protective lens; 14. Ceramic body lock ring;
7. 1st Lower protective lens; 15. Ceramic body;
8. Working indicator; 16. Nozzle;
1
2
10
3
4
5
6
9
12
11
8
14
15
16
13
14
7
BOCI

BLT481 Product Manual
2
1.2 Technical parameters
Cutting head
BLT481
Laser wavelength:
1030-1090nm
Laser power:
≤30kW
Fiber interface:
Q+、QD、QBH、ADD
Spot magnification:
M=2.0
Focus adjustment range:
±50mm (optical ratio 1:2 100:200)
NA:
Max.0.13 at Fc100
Centering adjustment range:
±1.5mm
Focus acceleration:
7.5m/s²
Cutting gas interface:
ø10, maximum 25bar (2.5Mpa)
Nozzle cooling gas connection:
ø6, maximum 5bar (0.5Mpa)
Water cooling interface:
ø8, maximum 5bar (0.5Mpa), minimum flow 2.0l/min
Operating temperature:
5～55℃
storage temperature:
-25～+55 ℃
size:
404x122
weight:
About 5.5kg
Notice:
To avoid damage to the cutting head during storage and transportation, pay attention to the
following:
The cutting head should be stored within the allowable temperature and humidity range.

Avoid storage in and near magnetic fields such as permanent magnets or strong alternating
fields.
Avoid collision of the cutting head.
BOCI

BLT481 Product Manual
3
1.3 Meaning of LED indicator
icon
state
meaning
green
Power is normal.
red
Under-voltage alarm: insufficient electrical power.
not
bright
No power supply: There is no power supply, the connection cable is broken, and the
interface is loose.
icon
state
meaning
green
The system is operating normally.
red
Abnormal motor: The current consumption of the motor is too large, and the mechanical
components cannot run smoothly.
not
bright
The cable is broken, and the interface is loose.
icon
state
meaning
green
System communication is normal.
red
System communication is abnormal.
not
bright
The cable is broken, and the interface is loose.
icon
state
meaning
green
The readings of each sensor are normal.
red
There is an abnormal sensor reading.
not
bright
The cable is broken, and the interface is loose.
BOCI

BLT481 Product Manual
4
2. Gas interface
Installation connection: cutting gas 1, nozzle cooling gas 2
Notice:
The maximum pressure of cutting gas is 25bar (2.5Mpa).
The cutting gas quality shall meet the requirements of gas quality in accordance with ISO 8573-1:2010:
solid particles - class 2, water - class 4, oil - class 3. The purer the cutting gas, the longer the life of the
protective lens.
The cutting gas pipe diameter (outer diameter) is 10mm, and the nozzle cooling gas pipe diameter
(outer diameter) is 8mm.
Cutting gas
interface
Nozzle cooling gas
connection
BOCI

BLT481 Product Manual
5
3. Water cooling interface
Installation connection: water-cooled water inlet port 2A, water-cooled water outlet port 1A
Notice:
Deionized/distilled water (conductivity < 10 μS/cm) specified by the laser manufacturer is recommended.
Recommended cooling water setting value: cooling water pressure ≤5bar (0.5Mpa), water flow rate ≥2.0l/min.
Please refer to the dew point table to set the cooling water temperature to prevent condensation on the optical
components.
Dew point temperature at different temperature and humidity
Water cooling water
outlet
Water cooling water
inlet
BOCI

BLT481 Product Manual
6
4. Electrical Interface
PWE and aviation plug interface waterproof precautions:
1. PWE interface and air plug interface are equipped with dust plugs from the factory. If
the dust plug does not fall off, the protection level of IP64 can be achieved; at the same
time, when the PWE cable and the air plug cable are well connected, IP64 can also
be achieved;
2. After the dust plug is removed, the protection level of IP64 cannot be achieved. If it
encounters spraying or flushing at this time, it will cause water to enter the product
and affect the function;
3. Ensure that the water circuit is connected well, and the water pipe interface is
tightened before removing the dust plug to prevent the water pipe from accidentally
loosening and water rushing to the interface, causing the product to enter the water;
4. When adjusting the wiring, remove the dust plug for wiring. It is recommended to keep
the removed dust plug of the PWE interface. Install the dust-proof plug as soon as
possible after the stitches are removed to prevent accidental water ingress in the
transfer, water connection and other links.
BOCI

BLT481 Product Manual
7
4.1 Bus system
Hypcut
IPC
master
station
Slave Station
HyPanel
BCS210E
Power supply
220V AC
BLT421 cutting head installation wiring
diagram
Notice:
The above wiring operations should only be performed by trained
and professional personnel.
When the cutting head is connected to the BCS210E, the BCS210E
must be powered off.
PWE line
BOCI

BLT481 Product Manual
8
4.2 Non-bus systems
BCL4500A
Cypcut
IPC
master
station
Slaves
Station
Power
24VDC
Notice:
The above wiring operations should only be performed by trained and professional personnel.
When the cutting head is connected to the BCL4500A, the BCL4500A must be powered off.
PWE line
HC plug-in cable
BLT421 cutting head installation
wiring diagram
BOCI

BLT481 Product Manual
9
5. Cutting head installation
During the installation of the cutting head, dust or dirt may accidentally enter the cutting head, contaminate the optical lens,
and affect its normal functions. To prevent dust or dirt from entering the cutting head, please refer to the following methods
for the installation of the cutting head:
5.1 Preparation before operation
The following objects are required before operation:
Cutting head;
Clean workbench (clean workbench type: vertical purification; cleanliness level: ISO 5, 100; average wind speed ≥
0.4m/s);
Cleaning kit: strong light flashlight, absolute ethanol (or IPA), dust-free purification cotton swab, dust-free cloth,
compressed air dust removal tank (or air blower).
Cutting head
clean workbench
Flashlight Ethanol Dust-free cotton swab
dust-free cloth Compressed air dust removal tank
Purification Kit
Notice:
The above operations can only be carried out by personnel who have received
appropriate training and have professional knowledge.
In order to ensure the normal operation of the laser device and the safety of operators,
please be sure to follow the relevant operating instructions.
BOCI

BLT481 Product Manual
10
5.2 Specific operation process
5.2.1 Preparation of clean bench
Prepare the clean bench, start it up and ensure its functionality:
1. Check that the equipment is clean and qualified (checks the cleanliness of the dust particle counter ), and confirm
that the FFU purification unit is within the validity period (measure the average wind speed in the working area, when the
wind speed cannot reach 0.3m/s, the FFU purification unit must be replaced);
2. Check whether each switch is running normally, and check whether the fan is running normally;
3. It is strictly forbidden to install unnecessary items in the clean working area to ensure that the clean air flow is
not disturbed;
4. For clean workbenches that are newly installed or have not been used for a long time, please use a clean cloth
and anhydrous ethanol to wipe them clean before use;
During operation:
1. Turn on the power, and pull the glass sliding door of the clean workbench to the lowest position (leaving a gap
of about 10cm);
2. Start the fan, it is recommended to purify the clean table for about 30 minutes in advance;
3. Turn on the light source of the clean workbench.
5.2.2 The cutting head is placed in the clean workbench
Put the cutting head horizontally inside the clean workbench.
Clean table type: vertical
purification; cleanliness class: ISO
5, 100; average wind speed ≥
0.4m/s
Notice:
To prevent dust from contaminating the core area of the
cutting head, please ensure the integrity of the special
protective film/cap for the optical fiber interface before
plugging and unplugging the optical fiber.
BOCI

BLT481 Product Manual
11
5.2.3 Clean and wipe the fiber interface of the cutting head
Wipe the fiber interface of the cutting head with a clean cloth and anhydrous ethanol.
5.2.4 Check the laser fiber end face
Remove the protective cap of the laser fiber, and irradiate the end face of the fiber with a strong flashlight to observe
whether there is any pollution; if it is clean, you can directly insert the fiber;
Compatible interfaces: Trumpf LLK-Q, IPG HLC-8/LC-8
5.2.5 Tear off the protective film/remove the protective cap
Remove the special protective cap/protective plug for the optical fiber interface on the cutting head.
Check the fiber interface end face before insert
BOCI

BLT481 Product Manual
12
5.2.6 Insert the laser fiber interface into the cutting head
Align the fiber optic plug with the red dot, insert it into the unlocked fiber optic port, and ensure that it is inserted as far
as it will go. Rotate the lock cap until it tightly locked.
5.2.7 Wrap and seal
After inserting the optical fiber, wrap and seal the interface between the optical fiber and the cutting head with tape.
Tape wrap seal
Notice:
To achieve affective sealing, it is recommended to wrap the tape
at least three times for sealing.
lock
BOCI

BLT481 Product Manual
13
5.2.8 Mount the cutting head on the backplane
The cutting head can be installed on the Z-axis backplane of the machine tool through four screws A, B, C, and D.
When fixing the cutting head on the machine, it must be ensured that the cutting head is locked and there is no obvious
movement.
5.2.9 Installing the ceramic body and nozzle
Install the ceramic body and secure with the locking ring, then install the nozzle.
A
B
C
D
ceramic body
BOCI

BLT481 Product Manual
14
5.2.10 Beam centering
Adjust the XY centering knob to make the focal point in the center of the nozzle by low-power dotting.
Tape
Fail
Relative position of laser beam
pass
The conditioned laser beam
must be in the center of the
nozzle.
X/Y
adjustment
screw
BOCI

BLT481 Product Manual
15
Manual alignment operation:
1. Make sure the laser beam is turned off.
2. Place scotch tape under the nozzle.
3.
Click to trigger a low-power laser pulse and assess the position of the laser beam relative to the
nozzle through the penetration of the tape.
4. Adjust the X/Y centering screws to center the laser beam on the nozzle.
BOCI

BLT481 Product Manual
16
Appendix A - Care/Maintenance
1.1 Schematic diagram of product structure
Notice:
During the maintenance of cutting head accessories, dust or dirt may accidentally enter the cutting head and damage the product.
Please pay attention to keep it clean during maintenance and replacement of accessories;
The maintainable parts of different products will have different specifications. If you need to replace them, please contact your after-
sales service personnel for specific models;
Optical products have high quality requirements for maintainable accessories. Please ensure that the replacement and maintenance
accessories are original accessories. Otherwise, there may be potential safety hazards.
BOCI