ByAcademyDokument - Dot Cabeza Corte BIMO

ByAcademy
Technical Training
BIMO2 Cutting Head
Issued on: 08.2018
CuttingHead_BIMO2_en.docx © Bystronic Laser AG, 2018

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Technical Training
Contents
1 Design and function ............................................. 5

1.1 Beam path in the cutting head .................................... 6
1.2 Lower glass cover and glass cover drawer.................. 7
1.3 Upper glass cover ....................................................... 8
1.4 Cutting attachment ..................................................... 9
1.5 Cutting head cooling water connection ..................... 10
1.6 Glass cover monitoring ............................................. 11
2 Machine - and technology options ..................... 12
2.1 CutControl ................................................................ 12
2.2 Power Cut Fiber ........................................................ 12
2.3 Detection Eye ........................................................... 12
3 Commissioning .................................................. 14
3.1 ByVision ................................................................... 14
3.1.1 Checking the hardware configuration values.................... 14
3.1.2 Checking the coefficients on the cutting head .................. 16
3.2 ByVision Cutting ....................................................... 17
3.2.1 Defining cutting head type/checking the coefficient values 17
3.3 Determining the focal length reference setting ........ 18
3.3.1 Determining the focal position tolerance ......................... 18
3.3.2 Determining the lower limit ........................................... 20
3.3.3 Determining the upper limit .......................................... 20
3.3.4 Calculating the focal position ......................................... 20
3.3.5 Correcting the focal length reference setting ................... 21
3.3.6 Checking the reference setting ...................................... 21
3.3.7 Cutting series parts ...................................................... 21
4 Maintenance work ............................................. 22
4.1 Maintaining the cutting attachment .......................... 22
4.1.1 Removing the cutting attachment .................................. 22
4.1.2 Fitting the cutting attachment ....................................... 23
4.2 Replacing the nozzle body ........................................ 24
4.3 Maintaining the lower glass cover ............................ 25
4.3.1 Replacing the glass cover drawer ................................... 26
4.3.2 Removing the glass cover ............................................. 28
4.3.3 Cleaning case .............................................................. 29
4.3.4 Cleaning the glass cover ............................................... 30
4.3.5 Installing the glass cover .............................................. 32
4.4 Adjusting the glass cover monitoring ....................... 33
© Bystronic Laser AG, 2018 3

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5 Service work ...................................................... 34
5.1 Calibrating the FJB box ............................................. 34
5.1.1 Zero calibration (above calibration plate) ........................ 37
5.1.2 Upper-position calibration ............................................. 39
5.1.3 Lower-position calibration ............................................. 40
5.1.4 Diagnostics on the FJB-Box ........................................... 41
5.2 Removing/installing the cutting head from Z-axis.... 42
5.2.1 Removing/connecting the optical fiber cable .................... 46
5.2.2 Cleaning the glass quartz.............................................. 48
5.3 Checking the seals at the QBH connector ................. 49
6 Procedure in case of cutting problems ............... 50
6.1 Testing the collimation optics drive unit ................... 51
6.1.1 Voltage measurements at the motor connector................ 52
6.2 Fault analysis on cutting head with alignment laser . 53
6.2.1 Lower glass cover test .................................................. 53
6.2.2 Upper glass cover test .................................................. 54
6.2.3 Quartz test ................................................................. 55
6.3 Cutting head checklist .............................................. 56
4 CuttingHead_BIMO2_en.docx
1 Design and function
The cutting head should be viewed as a black box. It consists of various

components, including an optical fiber holder, collimation and focusing
lenses. The correct focal position is set automatically as per the relevant
cutting parameters with the use of the collimation optics drive unit.
D D
G
H
Fig. Cutting head without CutControl Fig. Cutting head with CutControl
A QBH connector
B Collimation optics drive unit
C CutControl
D Collimation optics
E Centering screw for nozzle centering X-direction
F Glass cover drawer
G Centering screw for nozzle centering Y-direction
H Cutting attachment
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Applications and focal lengths used
Laser source Machine Focal length [mm]
YLS 2000 BySprint Fiber 150
YLS 3000 BySprint Fiber & ByStar Fiber 150
1.1 Beam path in the cutting head

 The light exiting the working fiber forms a conical beam
 This beam hits the collimation lens and is reshaped into a parallel
beam.
 The focusing lens focuses the laser beam at the machining point
A B C D E F G
Fig. Route of beam in cutting head
A Working fiber
B Conical beam
C Upper glass cover
D Collimation optics
E Parallel beam
F Focusing lens
G Bottom glass cover
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1.2 Lower glass cover and glass cover drawer

The glass cover is located inside a cassette that can be easily and quickly
removed. It seals the chamber in front of the nozzle so that cutting gas
cannot get into the optical system.
The condition of the glass cover is monitored. If the glass cover is dirty,
broken or not fitted, the cutting process is stopped and an error message
is issued at the operating panel.
A
B
Fig. Cassette with glass cover drawer and glass cover
A Glass cover drawer

B Glass cover
Removing the glass cover drawer and cleaning the lower

glass cover are described from page 25, «Maintaining the
lower glass cover».

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1.3 Upper glass cover

The cutting head has an upper glass cover. It significantly reduces the
risk of collimation optics soiling.
The upper glass cover is not monitored. No alarm or warning signal is
output if the upper glass cover is soiled.
WARNING
Maintenance of the upper glass cover must be

performed by Bystronic technicians only; customers
must not touch the glass.
Fig. Cutting head with upper glass cover
A Glass
A cover drawer
B H10
B Torx screws
The cleaning procedure is identical to that of the lower

glass cover, see page 25, «Maintaining the lower glass
cover».
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1.4 Cutting attachment

The cutting gas, the air for nozzle cooling, and the electrical contacts for
the distance measurement and the glass cover sensor are routed through
the cutting head towards the cutting attachment. This means that it is
not necessary to disconnect cables at additional connection points if the
cutting attachment is removed for cleaning.
A B
D
C
Fig. Cutting attachment with nozzle Fig. View from above

body
A Cutting
A attachment
B Electrical
B contact for nozzle distance measurement (FJB-Box)
C Cutting
A gas bore holes
D Electrical
B contact for glass cover monitoring
E Location
A pin
Removal and maintenance of the cutting attachment are

described from page 22, «Maintaining the cutting
attachment».

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1.5 Cutting head cooling water connection
WARNING
Caution, danger of overheating!

Operation with the cutting head is only permissible if the
cooling system is connected. Functional disorders in the
cooling system lead to high temperatures in the cutting
head.
Optical fiber
Optical fiber connector
Cutting head
Optical fiber holder
Aperture above collimation optics
NOTICE
The cooling water consumers’ hose connections

must be connected in series so that it will be
possible to detect any clogging!
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1.6 Glass cover monitoring

The condition of the bottom glass cover and the presence of the cutting
attachment are monitored with the glass cover monitoring.
NOTICE
During normal operation, all LEDs light up, with the

exception of the green ‹Signal› LED. (This LED will light
up only once the laser beam is emitted through the
cutting head)
If a fault occurs, the corresponding LED will flash and
the cutting process will be stopped.
Fig. Glass cover monitoring
Description of LED
Red LED flashes Error Glass cover critically soiled
Yellow LED flashes Warning Glass cover soiled
Green LED Signal Laser beam being emitted through
illuminated cutting head
Red LED flashes Drawer Cutting attachment not installed or
glass cover not inserted
The setting options for glass cover monitoring are described

on page 33, «Adjusting the glass cover monitoring».

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2 Machine - and technology options
Depending on the specific machine and laser combination, certain options

may be included as standard and others are available as options.
2.1 CutControl
CutControl is used to measure the light emitted by the workpiece in order
to increase process reliability during laser cutting. Additional functions
consist of accurate edge detection (±0.15 mm) and full piercing cut
detection during piercing cuts.
Training document «01_04_CutControl_Fiber_Vxx_en»

describes the configuration, functions and areas of
application of CutControl in detail.
2.2 Power Cut Fiber

Power Cut is the name used for a special cutting method that makes it
possible to cut greater sheet thicknesses than those with conventional
cutting. Accordingly, Power Cut requires a specific process controller,
software, and parameter set, as well as special nozzles.
Training document
«01_04_PowerCut_Fiber_Crossjet_Vxx_en» describes
the operation and areas of application of Power Cut Fiber for
BySprint Fiber and ByStar Fiber in detail.
2.3 Detection Eye

The ‹Detection Eye› camera system on the cutting carriage detects the
exact position of the sheet on the machine, measuring the edges of the
sheet in a matter of seconds.
TI 15/21-1 Retrofitting Detection Eye on BySprint Fiber

UA 15/21-1 All BySprint Fiber machines delivered on or after
02/01/2015 can be retrofitted.
Detection Eye cannot be installed if delivered before
01.02.2015.
Training document «01_04_Dedection_Eye» describes
the operation and areas of application for BySprint Fiber
and ByStar Fiber in detail.
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List of TI's
TI 17/18 Air dryer for BIMO cutting head

The moisture inside the cutting attachment is
prevented by installing an air dryer.
TI 16/14 Repairing Cutting Attachment on BIMO2 V2

Internals components of the cutting attachment
(part No. 10055441) can get damaged (e.g. after
a collision, soiling), which can lead to capacitive
problems.
TI 15/28 Replacement FJB Cable

Cable FJB 01-04-01-0191 has been discontinued
and replaced with cable FJB 01-04-01-0192.
Because the connector of the new cable is
approx. 7 mm longer than the previous one, this
leads to a collision in the event a spare part is
used.
TI 15/17 Cleaning/replacing the glass cover on

BIMO2 cutting heads
Explains how to correctly handle and replace the
glass cover.
TI 14/22 BySprint Fiber Cutting Head

The glass cover detectors on the cutting heads
do not work reliably. This can lead to the
inserted glass cover drawer not being detected.
This, in turn, will result in production stopping.
In various cases, it was necessary to disable the
detector so that it would be possible to work
without the glass cover. This can, however, have
dire consequences as splashes can then hit the
focusing lens and damage the cutting head.
TI 14/04 Nozzle Adapter for BIMO2 and BIMO2 V2

Cutting Head on BySprint Fiber
The nozzle adapters with predetermined
breaking point introduced in CW45/2012 proved
to be too weak. The predetermined breaking
point sheared off even in the slightest of
collisions.

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3 Commissioning
3.1 ByVision
3.1.1 Checking the hardware configuration values

The minimum requirements for operating the BIMO2 are as follows:
 CNC software version ≥P8106B
 ByVision software version ≥P8006A
Fig. CNC and ByVision software versions
Configuration file version
Fig. Main ->Administration ->Configuration, hardware ->Configuration file version
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Configuration machine
Fig. Main->Administration->Configuration, hardware->Cutting head type Fiber
Cutting head type Fiber

BIMO = manual adjustment of focal position
BIMO2 = automatic adjustment of focal position
Configuration, laser controller
Fig. Main->Administration->Configuration, hardware->Controller type
Control type
1 ASS BTL 3000 with ByVision and CNC 96+
2 SSI Bylaser and BCL series
3 Fiber v1 YLS laser source
4 Fiber v2 FL laser source

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3.1.2 Checking the coefficients on the cutting head
1. Check the values for the three ‹a, b, c› coefficients on the cutting
head by consulting the values specified on the label.
Fig. View of cutting head label
2. Go to the MAIN ->Administration ->Hardware Configuration menu

and check the values for ‹Coefficient a, Coefficient b and Coefficient
c›; if necessary, enter the values specified on the label.
Fig. Checking coefficients a, b, c in ByVision
3. Save the values. These data are lost when changing the machine
configuration and must therefore be reloaded.
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3.2 ByVision Cutting
3.2.1 Defining cutting head type/checking the coefficient values
1. Go to the Administration ->Components ->Modules ->Cutting Head

menu and select the «BIMO2» option.
Fig. Setting the cutting head type in ByVision Cutting
2. Check the values for «a, b, c» coefficients on the cutting head by

consulting the values specified on the label (see previous page).
3. Go to the Administration ->Cutting Head ->Coefficients menu and

check the values for ‹Coefficient a, Coefficient b and Coefficient c›, if
necessary, enter the values specified on the label.
Fig. Checking coefficients a, b, c in ByVision Cutting

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3.3 Determining the focal length reference setting

Checklist and prerequisites for commissioning cutting
 The FJB box must have been calibrated
 The bottom and upper glass covers must have been checked and
cleaned or replaced if necessary
 Nozzle centering with HK10/NK10 must have been carried out

 Always label the test determination parts with the focal position
 Always cut series parts without interruption. (Begin the series again
from the start if there is an interruption and cut with a micro joint)
 If a parameter change is required in order to cut the acceptance parts,

overwrite and save the parameters.
3.3.1 Determining the focal position tolerance

Focal position reference setting (focal length reference setting)
compensates production tolerances in the configuration. To make the
reference setting of the focal position, it is necessary to determine the
focal position tolerance (upper & lower limit) by means of cutting tests.
E
Fig. Focal position tolerance and focal-position reference setting
A Upper limit
B Focal position reference setting
C Lower limit
D Focal position tolerance
E Sheet thickness
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1. Load cutting plan.

BySprint Fiber:
Load the cutting plan with the filename:
«Test_1.4301_N2_2mm.ncp», assign the original cutting
parameters, and install the corresponding nozzle.
ByStar Fiber:
Load the cutting plan with the filename
«Test_1.4301_N2_2mm_lang», assign the original cutting
parameters, and install the corresponding nozzle.
2. Set the focal length reference setting to the recommended value.
BySprint Fiber:
Go to the ->MAIN ->Administration ->configuration hardware view
and enter a value of -1.5 for ‹Focal length default setting›.
Fig. Setting in ByVision
ByStar Fiber:
Go to the Administration ->Cutting Head ->Coefficients menu and
enter a value of -1.5 for ‹Focal length default setting›.
Fig. Setting in ByVision Cutting

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3.3.2 Determining the lower limit
1. Cut a test part with the original cutting parameters.
2. Adjust the focal position in the cutting parameter downwards in

steps of 0.5mm until beading or burring occurs.
3. Adjust the focal position from the last setting in steps of 0.1mm
upwards until no beading or burring occurs anymore.
The bottom part with acceptable quality defines the lower

tolerance limit.
3.3.3 Determining the upper limit
1. Reset focal position in cutting parameter to original value.
2. Adjust the focal position in the cutting parameter upwards in steps

of 0.5mm until beading or burring occurs.
3. Adjust the focal position from the last setting in steps of 0.1mm
downwards until no beading or burring occurs anymore.
The top part with acceptable quality defines the upper tolerance
limit.
3.3.4 Calculating the focal position

The focal position is one third of the focus tolerance above the lower
limit.
Example:
Lower limit = 2.7mm; upper limit = 1.1mm
Focus tolerance: = 2.7 – 1.1 = 1.6

Focal position: = 2.7 – 0.533 = 2.167  round to 2.2
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3.3.5 Correcting the focal length reference setting
1. On the relevant user interface, correct the value in ‹Focal length

reference setting› as per the table below.
2. Based on the example, you would change the value for ‹Focal length
reference setting› from -1.5mm to -1.3mm.
Focal position Focal length reference setting
…..  ……
1.8  -1.7
1.9  -1.6
2.0  -1.5
2.1  -1.4
2.2  -1.3 (based on example)
2.3  -1.2
2.4  -1.1
2.5  -1.0
2.6  -0.9
2.7  -0.8
2.8  -0.7
2.9  -0.6
3.0  -0.5
3.1  -0.4
3.2  -0.3
..…  …….
3.3.6 Checking the reference setting
1. Load original parameters.
2. Cut one part with the focal position for the lower limit and one with
the upper limit. If none of the parts displays bead or burr formation,
focal position reference position has been calculated correctly.
3. Save the values.
3.3.7 Cutting series parts
1. Load the «Serie_1.4301_N2_2mm.ncp» cutting plan and the

original parameters.
2. Cut 6 parts in series and compare the cut quality.

All parts must look the same!

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4 Maintenance work
4.1 Maintaining the cutting attachment

The cutting attachment or some of its parts may be damaged if it hits the
support grate or any protruding parts. The nozzle body or the damaged
part must be replaced after any collision.
4.1.1 Removing the cutting attachment
1. Move axes to service position.
2. Undo threaded ring (B).
Fig. Undo cutting attachment
A Cutting
A attachment
B Threaded
B ring
3. Remove the cutting attachment.
After replacing the cutting attachment, you will need to

calibrate the FJB box. For more information, see page 34,
«Calibrating the FJB box»
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4.1.2 Fitting the cutting attachment
1. Check the cutting attachment and mounting on the cutting head for
cleanliness. Clean if necessary.
C D
Fig. Cutting attachment
C
Fig. Mounting on cutting head
A Locating pin
B O-ring
C Electrical contacts
D Location hole
2. Check that the electrical contacts are clean and in perfect condition.
If necessary clean the contacts or replace the cutting attachment.
3. Check that the O-ring is seated correctly and is in perfect condition.

Replace the O-ring if necessary.
4. Place the cutting attachment in position, making sure that the

locating pin is located correctly in the hole.
5. Press the cutting attachment against the cutting head and tighten
the threaded ring.
After fitting the cutting attachment, the laser beam must be

centered with respect to the nozzle.

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4.2 Replacing the nozzle body

The nozzle body may get damaged if it hits the support grate or any
protruding parts. Damaged nozzle bodies must be replaced.
C
B
D
E
Fig. Replacing a broken nozzle body
A Cutting attachment
B Threaded ring of nozzle body, broken off at the predetermined
breaking point
C Predetermined breaking point
D Nozzle body
E Tool for removing the broken-off nozzle body
F Tool for installing the nozzle body
If you install a modified nozzle body as a replacement, you

will need to calibrate the FJB box. For more information, see
page 34, «Calibrating the FJB box».
If you replace with an identical nozzle body, there is no need
for calibration.
After fitting the cutting attachment, the laser beam must be
centered with respect to the nozzle.
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4.3 Maintaining the lower glass cover

The condition of the bottom glass cover is monitored. If the glass cover is
soiled, a warning will be output on the operating terminal. If the glass
cover is broken or absent, the cutting process will be stopped and an
error message will be issued at the operating terminal.
The glass covers’ service life depends on how they are handled and on
the material that is being cut. A single incorrect pierce can result in
spatter that renders the glass cover unusable.
Improper handling when replacing the glass cover causes soiling of the
optical system (lens or collimation) that severely shortens the service life
of the cutting head.
NOTICE
 Smoking is strictly forbidden when working on the
cutting head.
 Never use compressed air. Contaminants in the

compressed air can get into the cutting head and dirty
the lens.
 Wear disposable gloves. See page 29, «Cleaning

case».
 Always hold the glass cover around its edge by your

fingers.
 Always clean and replace the glass cover in as clean a

place as possible (e.g. office area).
 New glass covers must always be inspected and

cleaned before installing them.
 Make sure to only use the cleaning agents in the

cleaning case (acetone and acetic acid) when cleaning
the glass cover.
 Do not leave the cleaned glass cover lying around

unprotected.
 Make sure that the glass cover drawer is clean and

ready for use in the cleaning case.
 Immediately insert the unpacked glass-cover drawer

into the cutting head.

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4.3.1 Replacing the glass cover drawer
1. Move axes to service position.
2. Open the safety door.
3. Wait for dust extraction system to run down (approx. 10 minutes).

As long as the dust extraction system is running, there is a lot of
cutting dust swirling around in the cutting room.
4. Clean the outside of the cutting head with a clean cloth. Never use
compressed air.
5. Open the safety cover.
Fig. Protective cover on cutting head
6. Clean the glass-cover drawer and surrounding area with a clean

cloth. In case of heavy soiling, use cotton buds and acetone. Never
use compressed air.
7. Place a clean cloth on the bellows. Place the packed glass-cover

drawer from the cleaning case on the cleaning cloth.
8. Put on disposable gloves.
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9. Remove glass cover drawer from cutting head.
Fig. Remove glass cover drawer from cutting head
10. Remove the glass cover drawer (A) from the storage case and hold
it upright in front of the opening. Remove the adhesive tape (B)
from both sides.
A B
Fig. Removing the adhesive tape from both sides of the glass cover drawer
11. Immediately insert the glass-cover drawer into the cutting head.
Make sure you fit it the right way up (arrow pointing upwards).
Fig. Correctly inserted glass cover drawer
12. Check correct interlocking of glass cover drawer, then close the
protective cover.

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4.3.2 Removing the glass cover
1. Place the glass-cover drawer on the cleaning cloth.
2. Remove the cover with the supplied Torx 20 angeld Allen key. Make
sure that no parts drop out or get lost in the process.
Fig. Removing the glass cover
3. Remove glass cover and position in the holder for cleaning.
4. Clean glass cover drawer and cover thoroughly with acetone.
5. Check that seals are in perfect condition. Replace any damaged

seals.
6. Cover the bottom surface of the glass-cover drawer (A) and the top
surface of the cover (B) with new adhesive tape. Use Permafix 9516
adhesive tape (C).
B
A
Fig. Covering surfaces of glass cover drawer
Do not jam the adhesive tape in the screw recesses. New glass
covers must always be inspected and cleaned before installing
them.
7. Clean the glass cover if it is dirty; see page 30 «Cleaning the

glass cover». Replace the glass cover if it is scratched or broken.
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4.3.3 Cleaning case
Fig. Cleaning case
A Cleaning instructions
B Semperguard Nitrile Comfort disposable gloves, EN374-2, EN374
C TX 20 Torx screwdriver
D Glass-cover drawer (packed in storage case)
E Permafix 9516 adhesive tape, width of 50mm
F Holder
G Glass covers
– 4 units for installation in the focusing lens’ glass-cover drawer
– 1 unit for installation in the collimation lens’ glass-cover drawer
H Acetone, 30ml bottle (with pipette)
I 80% acetic acid, 30ml bottle (with pipette)
J Air bulb
K Cotton buds ITW Texwipe TX761
L Lens cleaning paper 7 × 12cm (pack of 50 sheets)
M Cotton buds ITW Texwipe TX759B
N Assembly tool (for replacing glass cover in the collimating lens)
O Torch
P Alphalite cleaning cloth

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4.3.4 Cleaning the glass cover
1. Clean holder with acetone.
2. Place the glass cover in the holder.
Fig. Holder with glass cover placed in it
3. Use air bulb to blow off dirt from the glass cover (dry nitrogen is
also allowed). Never use a blow gun.
4. Place a lens wipe on the glass cover; then apply two to three drops
of acetone on it.
Fig. Lens wipe with two to three drops of acetone
5. Draw the lens wipe slowly and horizontally over the surface of the
glass cover, avoiding smears and leaving a dry clean surface.
(Smears lead to irregular absorption of the laser beam)
Fig. Drawing the lens wipe over the surface of the glass cover
6. The procedure can be repeated more than once. Use a fresh lens
wipe each time.
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7. Use cotton buds (ITW Texwipe TX759B) and acetic acid to clean the
surface of the glass cover if it is heavily soiled.
Take particular care when using this cleaning method. Apply
only light pressure.
8. Sprinkle acetic acid on a clean cotton bud and clean the glass cover
for no longer than 30 seconds, working from the center outwards in
circular movements. Only exert gentle pressure on the glass
surface.
Fig. Cleaning the glass cover with a cotton bud soaked in acetic acid
9. Finally, to remove any smears, clean the glass cover again using
lens wipes as described in step 2 and step 3.
Fig. Drawing the lens wipe over the surface of the glass cover
If cleaning with acetone and acetic acid is unsuccessful or if

burn marks are visible on the glass surface, the glass cover
will need to be replaced.

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4.3.5 Installing the glass cover
1. Make sure that the glass cover is clean in a cone of light. Holding it
only by its edges. If you see any soiling, repeat the cleaning
procedure.
Fig. Making sure the glass cover is clean
2. Insert glass cover in glass-cover drawer.
3. Fit the cover and fasten with the fixing screws. When tightening the
screws, make sure that the cover is seated correctly on the glass-
cover drawer and that the masking tape is not jammed in the screw
recesses.
Fig. Installing the glass cover
4. Immediately insert the fully assembled glass-cover drawer into its

storage case.
Fig. Inserting the glass-cover drawer into the storage case
5. Store the storage case with the prepared glass-cover drawer in the
cleaning case.
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4.4 Adjusting the glass cover monitoring

The glass cover monitoring (A) is located to the right of the cutting
carriage (BySprint Fiber) and can be accessed from the right side.
Fig. BySprint Fiber; glass cover monitoring with the cover removed
Fig. Switch for adjusting the sensitivity
A Mark (current switch position)

B Maximum sensitivity (switch position 1)
C Adjustment range
D Minimum permissible sensitivity (switch position 5)
The setting for the glass cover monitoring needs to be de-

termined starting from switch position 1. A cleaned or new
glass cover must be inserted in the cutting head for this
process. See page 28, «Removing the glass cover»
Change the switch position by just one increment or
decrement at a time. Turning towards position 5 will reduce
sensitivity. This causes the glass cover monitoring to react
only when the glass cover soiling is severe.

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5 Service work
5.1 Calibrating the FJB box
NOTICE
The FJB box is calibrated automatically for all laser sources

delivered after April 2016. (by means of software)
In the case of 2kW, 3kW and 4kW laser sources delivered
before 04/01/2016, the FJB box must be calibrated
manually if necessary. (BySprint Fiber and ByStar Fiber)
ByStar Fiber with ByVision Cutting:

With ByStar Fiber, it must also be defined in the menu «Administration
->Cutting head ->FJB-box automatic calibration» whether the
adjustment is carried out automatically (≥6kW) or whether it must be
carried out manually.
Fig. Automatic/non-automatic calibration of FJB box
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Reasons for manual calibration:
 if the ›calibrate nozzle‹ function cannot be performed correctly
 after replacing the cutting attachment (ceramic)
 after replacing the cutting head
B
A
Fig. View of BySprint Fiber cutting carriage from behind
A Cover
B FJB box
Fig. Buttons and LEDs on FJB box
A MAX button, calibration of upper position

B MIN button, calibration of lower position
C Status indicator, LED No. 1 to 16

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Preparation
NOTICE
Any error occurring during calibration is indicated

by flashing of LED no. 2 (error).
If this happens, the cause of the error needs to be
fixed. Then recalibrate from the beginning.
ByVision:
1.  Reference the axes
 Go to the ‹HAND› menu and enable the hand-held controller
ByVision Cutting:
 Use the upper left button to activate manual operation
2. Disable the «TOOL» button on the hand-held controller.
3. Open the safety door.
4. Install and center an HK 10 or NK 10/15 nozzle.
5. Unscrew the cover (A).
6. Close the safety door.
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5.1.1 Zero calibration (above calibration plate)
1. Using the hand-held controller, move the cutting head downwards

(Z– direction) and stop about 1mm before the calibration plate.
Fig. Cutting head lowered
A Tip of nozzle
B Calibration plate
ByVision:
2. While in front of the CNC cabinet, use the thumb wheel to lower the
cutting head until the CRASH LED on the CNC rack lights up. Then
raise the cutting head until the CRASH LED turns off.
The CRASH LED must not light up anymore!
A CNC rack
B CRASH LED
Fig. CNC rack
Read the value for the Z-axis on the user interface (HAND view) and
write it down (e.g., +11.87mm)
Fig. Current positions of axes

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ByVision Cutting:
 Lower the cutting head until the screen shows 0kHz [zero] on
the Frequency display
 Raise the cutting head a bit until the Frequency display shows a
value again
Fig. Machine manual operation
3. Open safety door and check position of Z-axis.
ByVision:
 Open the safety door and check the Z-axis position value.
When the safety door is opened, the cutting head may move
downwards. (Check the display)
 Monitor the CNC rack to make sure that the crash LED does
not light up. If the LED lights up, repeat the procedure
starting from step 2.
4. Press and hold the «MIN» and «MAX» buttons simultaneously for
about 3sec until LED No. 6 (Ready) turns off.
After releasing the MIN and MAX buttons, LED No. 15 (origin
calibration) starts to flash.
Fig. FJB box, buttons and LEDs
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5.1.2 Upper-position calibration
6. Using the hand-held controller, move the cutting head upwards.

(Direction Z+) Perform fine positioning using the thumb wheel.
The distance (D) between nozzle tip and calibration plate must equal
20mm. (The value on the display is the value from step 2 plus
20±0.1mm, e.g., 31.87mm)
D = 20±0.1mm
Fig. Upper position of Z-axis for the calibration
ByVision:
When the safety door is opened, the cutting head may come
down a few tenths of a millimeter. (Check the display)
 If so, adjust the value determined in step 6 upwards until it is
displayed after opening the safety door as well.
7. Press the «MAX» button until LED No. 15 goes out. (Upper-position
calibration)
The internal calibration process for the nozzle-distance measuring
module can take several seconds. During this time, the cutting head
must not be moved because otherwise the calibration is stopped.
Once internal calibration has finished, LED No. 16 starts to flash.

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5.1.3 Lower-position calibration
9. Using the hand-held controller, move the cutting head downwards.

(Z– direction) Perform fine positioning using the thumb wheel.
The distance (D) between nozzle tip and calibration plate must equal
0.10mm. (This means that the value on the display is 0.10mm
higher than the value in step 3, e.g., 11.97mm)
Fig. Lower position of Z-axis for the calibration
ByVision:
When the safety door is opened, the cutting head may come
down a few tenths of a millimeter. (Check the display)
 If so, adjust the value determined in step 9 upwards until it is
displayed after opening the safety door as well.
10. Press the «MIN» button until LED No. 16 goes out. (Lower-position
calibration)
The internal calibration process may take several seconds. During
this time, the cutting head must not be moved because otherwise
the calibration is stopped. Once internal calibration has finished, LED
No. 6 comes on. (ready)
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Final tasks
11. Reinstall the cover (A).
ByVision:
13.  Close the CNC control cabinet
 Move to reference point
14. Switch on capacitive sensing. Enable the «TOOL» button on the
hand-held controller.
15. Run the «Calibrate nozzle» function twice.
5.1.4 Diagnostics on the FJB-Box

The LEDs can be used for troubleshooting. The LEDs not described in the
table have no function and are therefore of no significance.
LED- Status when

LED Function
Color Illuminated Flashing
1 red
2 red Error indicator Error
3 yellow
4 yellow
5 yellow
6 yellow Ready Ready
7 yellow
8 yellow
9 red
10 red Short circuit between Contact
nozzle and cutting part
11 yellow
12 yellow
13 yellow
14 yellow
15 yellow Upper position Moving to the
calibration upper position
16 yellow Lower position Moving to the
calibration lower position

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5.2 Removing/installing the cutting head from Z-axis
CAUTION
Clean cutting head and surrounding area carefully.
Make sure that the surrounding area is clean and
free of dust. Even tiny amounts of soiling on the
optical fiber can damage the optical system!
Cooling water that gets inside the cutting head or

the optical fiber can damage the optical elements.
 Make sure that no dirt can get on the optical fiber
connector or the optical fiber
 Position cutting head horizontally to remove the optical

fiber. This reduces the risk of dirt falling into the optical
system or the QBH connector
 Only connect the optical fiber in a clean, dust-free

environment
 Before removing the plug, clean the optical fiber and

the surrounding area thoroughly
 Slowly and steadily pull the cap or plug off from the
QBH connector/the optical fiber so as not to attract any
dust
 Store the QBH connector cap and the optical fiber plug
in a clean, sealable plastic bag.
 Whenever disconnecting the optical fiber cable,

immediately seal it with the appropriate cap.
 Whenever disconnecting the QBH connector,

immediately seal it with the appropriate plug.
 Never touch parts of the optical system (glass quartz)

with your hands.
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1. 1Remove the covers to the left and right of the cutting head, as well
.as the collimation unit’s cover.
Fig. Remove covers (BySprint Fiber)
2. 2Switch off the machine and the cooling unit at the main
.power switch.
3. 3Carefully detach all connections from the cutting head: Route the
.cooling water hoses in such a way that no cooling water will be able
to get into the optical system or the QBH connector.
Fig. Detach connections from the cutting head (BySprint Fiber)

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4. 4
Open the Z-axis energy chain with a screwdriver.
.
Fig. Open energy chain on Z axis
5. 5
Unscrew cutting head using an Allen key (SW5).
.
Fig. Remove cutting head
6. 6Place the cutting head, with the working fiber, flat on a suitable
.base without twisting and without any mechanical stress.
Fig. Position for setting down cutting head with feeding fiber on BySprint Fiber
7. Remove the optical fiber cable, see page 46, «Removing the
optical fiber cable».
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8. Install the (new) cutting head.
9. Check/clean the glass quartz, see page 48, «Cleaning the glass
quartz».
10. Connect the optical fiber cable, see page 47, «Removing the
optical fiber cable».
11. Reconnect all connections on the cutting head. Connect cooling

water hoses in such a way that no cooling water can get into the
optical unit or the QBH plug.
12. Check the system for water leaks before installing the covers.
13. After finishing work on the optical cable/QBH plug, a new seal must
be affixed. The new seal must be noted together with the serial
number of the seal in the working report and in the logbook of the
machine.
See page 49, «Checking the seals at the QBH connector».
Cutting heads are always delivered without a CutControl module.

If necessary, the CutControl module must be removed from the
old head and installed on the new one.

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5.2.1 Removing/connecting the optical fiber cable
Removing the optical fiber cable
1. Unlock the QBH connector (A): Turn the screw ring (B)
counterclockwise, push it in, and turn it counterclockwise all the
way.
A B C
Fig. Screw closure QBH
QBH connector
Threaded ring
Plug
Optical fiber
Red dot on optical fiber
Red dot on QBH connector
Red dot on screw ring
Groove on optical fiber
2. Remove the cap from the optical fiber and the plug (C) from the
QBH connector.
G F E
H D
Fig. QBH connector - optical fiber
3. Check the glass quartz on the optical fiber and the QBH connector to
make sure it is clean and clean it if necessary.
See page 48, «Cleaning the glass quartz».
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Removing the optical fiber cable
1. Align the three red dots (E,F,G) on the optical fiber and the QBH
connector with each other so that the locking pin in the connector is
able to engage the groove (H) on the optical fiber.
2. Slowly push the optical fiber (D) all the way into the QBH connector
(A).
A D
Fig. Pushing the optical fiber into the QBH connector
3. Lock the QBH connector (A): Turn the screw ring (B) clockwise, pull
it out, and keep turning it clockwise all the way.
4. After removing, immediately protect the cutting head with the plug
and the optical fiber with the cap in order to prevent soiling.
Fig. Plug
Fig. Plug inside QBH connector
Store the plug and the cap in separate clean, sealable plastic
bags. The plug and the cap must be inserted/fitted every time
after removal.

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5.2.2 Cleaning the glass quartz
1. Wear latex gloves (natural latex, powder-free, EN 1041 + EN 980)
2. Place optical fiber on microscope stand and fasten. Set the distance
between the end of the glass quartz - beginning of the microscope
to 55mm.
55
Fig. Optical fiber secured on microscope stand
3. Touch the quartz surface with cotton bud to adjust depth of focus.
(Special cotton buds TX759B, product No. 10041316)
Fig. Cleaning the quartz on the optical fiber
4. Carefully clean the glass quartz with acetone. Change the incidence
of light so that possible cleaning residues are recognized.
Fig. View of glass quartz via microscope
5. Complete the rest of the assembly as specified on page 47,

«Removing the optical fiber cable».
6. After finishing work on the optical cable/QBH plug, a new seal must
be affixed. (see next page)
7. Check the system for water leaks before installing the covers.
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5.3 Checking the seals at the QBH connector

The processes for handling the BIMO2 cutting head have been improved
so as to almost completely eliminate any soiling resulting from improper
handling.
With machines before release 2/16, as part of a maintenance- or
service work, the seals must be added by affixing them to the QBH
connector and to the upper glass cover. (TI 16/23-1)
Starting with release 2/16, seals will be affixed to the QBH connector
and upper glass cover on all new machines prior to shipping.
Fig. Upper glass Fig. QBH connector Fig. Cross bar order-no.:
cover seal seal 10085280/10085281
NOTICE
 Customers are not allowed to remove the seals, as
doing so will void the warranty
 The seals may only be removed by certified Bystronic
technicians.
 After finishing work on the cutting head, a new seal
must be affixed.
 Date and initials must be written on the seals.
 If a new seal is affixed, it must be noted down in the
working report and in the machine log book together
with the serial number.
 The seals (order No. 10084907) are part of the
standard tools of every Bystronic technician
 The technician must check the seals when performing
any service work.

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6 Procedure in case of cutting problems
WARNING
The tests described below should not be conducted

before consulting with the responsible Bystronic
branch office.
NOTICE
Training document «02_09_YLS-Fiber_Laser_Vxx»

describes the procedure for testing the laser power.
The «Cutting head checklist» at the end of this section is

meant for an exercise and will be filled out during the
course.
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6.1 Testing the collimation optics drive unit

The LEDs light up in normal mode. If a fault occurs, the relevant LED
goes out and the cutting process stops.
Fig. Motor connector detail
Fig. Complete view of cutting head
Meaning of LEDs
Color State Meaning
illuminated Function of drive unit OK
Red
not illuminated Drive unit position or overcurrent error
illuminated Operating voltage present
Green
not illuminated Operating voltage not present

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6.1.1 Voltage measurements at the motor connector
150-mm cutting head, 0-mm nozzle clearance height
Voltage [VDC] Focal position
[mm]
0 15.6
0.5 14.6
1 13.5
1.5 12.4
2 11.4
2.5 10.3
3 9.2
3.5 8.2
4 7.1
4.5 6.0
5 5.0
5.5 3.9
6 2.8
6.5 1.7
7 0.7
7.5 -0.4
8 -1.5
8.5 -2.6
9 -3.7
9.5 -4.8
10 -5.8
Fig. Connector D10
Pin 4 Neutral conductor

Pin 5 Signal voltage
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Technical Training
6.2 Fault analysis on cutting head with alignment laser
6.2.1 Lower glass cover test
1. Perform «Load tables».
2. Turn off the lighting inside the cutting area.
3. Switch the laser to test mode.
4. Turn on the alignment laser in LaserNet.
5. Place a sheet of white paper under the nozzle at a distance of

approx. 300mm.
The red guide laser image must be round and clearly visible
without burn marks.
6. If there are any burn marks in the image, remove the bottom glass
cover.
Fig. Removing the bottom glass cover Fig. visible burn mark
7. Check the image again. If the same burn marks are still there, the
bottom glass cover is OK.
8. The next step is to carry out the «upper glass cover test».

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6.2.2 Upper glass cover test
1. Place a sheet of white paper under the nozzle at a distance of

approx. 300mm. The red pilot laser image must be round and
clearly visible without burn marks.
2. If there are any burn marks, remove the upper glass cover.
Fig. Removing the upper glass cover
Do not move the cutting head anymore after removing the

upper glass cover!
3. Check the image again. If the same burn marks are still there, the
upper glass cover is ok.
4. The next step is to perform the «quartz test».
5. After finishing work on the upper glass cover, a new seal with the
date and initials must be affixed. A note of this new seal must be
made in the working report and in the machine logbook together
with the seal serial number.
The shake test after a new installation at the customer’s site and
after replacing a cutting head will not be performed anymore.
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6.2.3 Quartz test
The upper glass cover must be installed in order to be able

to carry out the quartz test correctly.
1. Apply pressure to the fiber connector from one side, the image will
shift. Do not loosen the fiber connector!
Fig. If the burn mark remains in the Fig. If the burn mark moves in the
same place and the image shifts, same direction, the quartz is
the quartz is OK. not OK and needs to be
(->check the upper glass cover) cleaned.
2. Remove cutting head from Z-axis. See page 42,

«Removing/installing the cutting head from the Z-axis»
3. Disconnect optical fiber from cutting head.

See page 46, «Removing the optical fiber cable»
4. Check the quartz and clean it if necessary.

See page 48, «Cleaning the glass quartz»
5. Connect the optical fiber to the cutting head.

See page 47, «Removing the optical fiber cable».
6. After reconnecting the optical fiber, a new seal with the date and
initials must be affixed. A note of this new seal must be made in the
working report and in the machine logbook together with the seal
serial number.
See page 49, «Checking the seals at the QBH connector».

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6.3 Cutting head checklist
General information
Name: ………………………..
Material no.: ………………………..
Serial No.: ………………………..
Power kW: ………………………..
Laser emission time: ………………………..
Machine on time: ………………………..
Removal date: ………………………..
Installation date: ………………………..
Date: ………………………..
Person submitting
report: ………………………..
Description of fault
Cutting problems - burr formation
Material: ……………………………………..
Thickness: ……………………………………..
Mechanical damage:
Cutting attachment
Nozzle centering
Cutting head in general
Glass cover drawer
Cutting attachment insulating ring melted
Water leak
Other  (picture)
Electrical problems:
Capacitive height detection
Glass cover presence sensor
Glass cover sensor
Other  (picture)
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Cutting head condition

Coefficients A, B, and C checked:
Value A:……………… Value B:……………… Value C:………………
Calibration cutting as per training documentation:

Offset value: …………… Tolerance during calibration cutting:
……………
Glass cover monitoring rotary switch value:…………
Tests conducted
Upper glass cover:
Checked Yes No
Cleaned Yes No
Replaced Yes No
Bottom glass cover:

Checked Yes No
Cleaned Yes No
Replaced Yes No
Were glass covers replaced Yes No
before the return?
Checks
Quartz block checked:
Clean Soiled Cleaned
Calibration cutting carried out as per training documentation?

Yes No
Upper glass cover checked?

Clean Soiled Cleaned
QBH connector fiber holder, inside checked for abraded particles?

Yes No

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ByAcademyDokument - Dot Cabeza Corte BIMO

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ByAcademy

BIMO2 Cutting Head

Issued on: 08.2018

CuttingHead_BIMO2_en.docx © Bystronic Laser AG, 2018

1 Design and function ............................................. 5

© Bystronic Laser AG, 2018 3

The cutting head should be viewed as a black box. It consists of various

1.1 Beam path in the cutting head

1.2 Lower glass cover and glass cover drawer

Fig. Cassette with glass cover drawer and glass cover

A Glass cover drawer

Removing the glass cover drawer and cleaning the lower

© Bystronic Laser AG, 2018 7

1.3 Upper glass cover

Maintenance of the upper glass cover must be

Fig. Cutting head with upper glass cover

The cleaning procedure is identical to that of the lower

1.4 Cutting attachment

Fig. Cutting attachment with nozzle Fig. View from above

Removal and maintenance of the cutting attachment are

© Bystronic Laser AG, 2018 9

1.5 Cutting head cooling water connection

Caution, danger of overheating!

Aperture above collimation optics

The cooling water consumers’ hose connections

1.6 Glass cover monitoring

During normal operation, all LEDs light up, with the

Fig. Glass cover monitoring

The setting options for glass cover monitoring are described

© Bystronic Laser AG, 2018 11

2 Machine - and technology options

Depending on the specific machine and laser combination, certain options

Training document «01_04_CutControl_Fiber_Vxx_en»

2.2 Power Cut Fiber

2.3 Detection Eye

TI 15/21-1 Retrofitting Detection Eye on BySprint Fiber

TI 17/18 Air dryer for BIMO cutting head

TI 16/14 Repairing Cutting Attachment on BIMO2 V2

TI 15/28 Replacement FJB Cable

TI 15/17 Cleaning/replacing the glass cover on

TI 14/22 BySprint Fiber Cutting Head

TI 14/04 Nozzle Adapter for BIMO2 and BIMO2 V2

© Bystronic Laser AG, 2018 13

3.1.1 Checking the hardware configuration values

 ByVision software version ≥P8006A

Fig. CNC and ByVision software versions

Configuration file version

Fig. Main ->Administration ->Configuration, hardware ->Configuration file version

Fig. Main->Administration->Configuration, hardware->Cutting head type Fiber

Cutting head type Fiber

Configuration, laser controller

Fig. Main->Administration->Configuration, hardware->Controller type

© Bystronic Laser AG, 2018 15

Fig. View of cutting head label

2. Go to the MAIN ->Administration ->Hardware Configuration menu

Fig. Checking coefficients a, b, c in ByVision

3.2 ByVision Cutting

3.2.1 Defining cutting head type/checking the coefficient values

1. Go to the Administration ->Components ->Modules ->Cutting Head