Apollo 4 Assembly Guide

Class 4 laser radiation

The Apollo 4 contains a Class 4 fiber laser (max output 1500 W, continuous wave, 1064–1080 nm). The beam is invisible, and direct or scattered radiation can cause permanent blindness and severe burns.

To avoid injury, always adhere to the following precautions:

• Wear laser eyewear OD 8+ at 1064–1080 nm whenever the laser is on. Ordinary safety glasses give no protection.
• The enclosure does not block laser radiation. Keep all panels in place and never defeat or remove the safety switches.
• Turn off the laser source before retrieving parts or servicing the nozzle or lens. Never look into the nozzle.
• Set up a designated laser area with a warning sign at each entrance, and alert bystanders before cutting.
• Wear gloves and clothing that cover your skin.

Electric shock and arc flash

The Apollo 4 and its water chiller run on 220–240 VAC. Electric shock or an arc flash can cause severe burns or death, and capacitors hold dangerous voltage after power is off.

To avoid injury, always adhere to the following precautions:

• Never touch live wires, terminals or components. Never work on energized equipment.
• Only qualified persons may open the electronics box. Lock out power first.
• Wait at least 5 minutes after power off, then verify zero voltage before touching components.
• The chiller has its own 18 A supply. Lock it out separately before servicing.

Fire

Sparks, molten slag and hot parts from laser cutting can ignite nearby flammable materials. Oxygen assist gas makes materials burn faster.

To avoid injury, always adhere to the following precautions:

• Never leave the machine unattended while cutting.
• Keep slag and scrap cleared from the cutting bed and slag tray.
• Never operate near flammable materials and never cut containers that have held fuel or any flammable substance.
• Always keep a fire extinguisher near the machine.
• Aluminum and titanium dust is combustible. Empty the dust collector regularly and use one rated for combustible metal dust.

Gas explosion

Pressurized oxygen and nitrogen can burst fittings and cause an explosion or fire, resulting in severe burns or death. Nitrogen can displace oxygen and cause suffocation. Oxygen makes oil and grease ignite easily.

To avoid injury, always adhere to the following precautions:

• Use clean, dry, industrial-grade gas and a regulator rated for each gas. Never exceed O2 80 PSI (5.5 bar) or N2 190 PSI (13.1 bar).
• Connect each gas only to its labeled inlet, and keep oxygen fittings, lines and hands free of oil and grease.
• Secure gas cylinders upright with a chain or bracket, away from heat and sparks.
• Close the supply valves when not in use and bleed the lines before disconnecting anything.
• Check for leaks with leak-detection solution.

Hazardous fumes and ventilation

Laser cutting produces fumes and fine metal dust that can cause respiratory irritation, lung damage or metal fume fever. Ventilation is always required.

To avoid injury, always adhere to the following precautions:

• Run fume extraction for every cut, especially aluminum, stainless steel, brass, copper and galvanized or coated metals.
• Connect the fume extractor before cutting and vent it outdoors. Never cut with the blower off or the enclosure open.
• Never cut material coated with paint, oil, grease or solvents, or PVC and other plastics containing chlorine.
• Check the Safety Data Sheet (SDS) for each material to learn what fumes it produces.
• If ventilation is poor, use an air-supplied respirator.

Pinch and crush points

The gantry and cutting head move quickly and with force and can start moving without warning whenever the machine is powered.

To avoid injury, always adhere to the following precautions:

• Keep hands clear of the moving gantry and never reach into its path while the machine is powered.
• Lock out power before servicing, cleaning or adjusting anything in the cutting area.
• During assembly, keep hands out of crush points and watch for pinch points at nested flanges, hinges and attachment areas.
• Use two people to lift and position heavy panels and assemblies.

Hot surfaces

Cut parts, slats, slag and surfaces in the cutting area stay hot enough to cause severe burns after cutting.

To avoid injury, always adhere to the following precautions:

• Always assume metal on or in the machine is hot enough to cause severe burns.
• Allow parts, slats and surfaces to cool before handling.
• Never handle hot metal with bare hands. Use heat-resistant gloves or tongs.

Lockout / tagout

A machine that is only switched off can be restarted by someone else. Before servicing, cleaning or repairing the Apollo 4, lock out all three energy sources:

1. Tell anyone affected, stop the machine normally and turn off the laser source.
2. Turn off or unplug E-1 and E-2 and apply your lock and tag to each.
3. Close the G-1 gas valves, apply a valve lockout and tag, and bleed the lines.
4. Wait 5 minutes, then verify: the machine will not start, the chiller is off and the gas gauges read 0 PSI.
5. When work is complete, reinstall all guards and panels, then remove locks and tags.

Do not enter the cutting area

The gantry can move without warning whenever the machine is powered and can crush or trap you. Nitrogen assist gas can collect in the cutting area and cause unconsciousness or death without warning. Oxygen assist gas makes clothing and hair burn easily.

• Never climb into, crawl into or lean your body inside the cutting area.
• Retrieve parts and scrap from outside the machine using a hook, tongs or other reach tool.
• If a part cannot be reached, lock out all energy sources before reaching in.