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Schilling Marking Systems GmbH

In Grubenäcker 1 DE-78532 Tuttlingen

+49 (0)7461 9472-0

+49 (0)7461 9472-20

[email protected]

www.schilling-marking.de

MegaLight

Installation

Technical modifications reserved

15

Edition 2004

IINDICATOR LED

FAN

HOUR METER

MULTILINGUAL DISPLAY

Picture 4: system rear panel: external indicators

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Summary of Contents for Megalight

Page 1: ...oc Marking Systems GmbH Megalight Marking Laser G Ge en ne er ra al l M Ma an nu ua al l Schilling Marking Systems GmbH In Grubenaecker 1 DE 78532 Tuttlingen Germany Tel 49 0 7461 9472 0 Fax 49 0 7461 9472 28 www schilling marking com info schilling marking com Edition 20 03 2004 ...

Page 2: ... system The Manual has been written in compliance with the requirements of EC directive 98 37 and subsequent modifications and integrations and is intended to supply a qualified installer with instructions for Conformity Shipping Use instructions Use contraindications Installation Commissioning Use Adjustments Maintenance Repair if necessary Training instructions Technical specifications Specifica...

Page 3: ...that created them Reference is made to them for editorial reasons only Microsoft MS MS DOS Windows 98 Windows NT Windows 2000 Windows XP Visual Basic PowerPoint Microsoft Press are registered trademarks or trademarks of Microsoft Corporation in the United States and in other countries TrueType is a registered trademark of Apple Computer Inc N B Schilling Marking Systems GmbH shall not be held liab...

Page 4: ...ser diode pg 18 Peltier cell pg 18 Aiming laser diode pg 19 Display pg 19 Laser resonator pg 19 Engraving scanner head pg 20 Objective lens pg 21 CHAPTER 2 INSTALLATION and START UP pg 22 Preliminary installation notes pg 22 Installation procedure pg 23 Environmental requirements pg 23 1 Connection to the mains pg 23 2 Connections pg 24 DSP board installation pg 24 Connectors pg 25 Electrical conn...

Page 5: ...ations pg 42 Environmental and installation specifications pg 42 Laser Source Specifications pg 42 Mechanical specifications pg 43 O E M device standard equipment pg 43 Separately supplied parts pg 43 MARKER device standard equipment pg 43 Possible field of adjustment pg 44 Warning labels and their positioning pg 45 Detailed label description pg 49 Mechanical drawings pg 51 APPENDIX B WIRING DIAGR...

Page 6: ...s voltage or powerful enough to constitute an electrical risk This symbol must appear on the finished machine as well at the electrical risk area LASER WARNING this symbol indicates the danger of exposure to visible or invisible laser radiation This symbol must appear on the finished machine as well at the optical risk area FIRE WARNING this symbol indicates the danger of a fire when processing fl...

Page 7: ... energy for power 1W 1 joule second mJ millijoule one thousandth of a joule µ J microJoule a millionth of a joule DO Optical Density the exponential to the power of 10 of optical radiation absorption for laser protection glasses NOHD Nominal ocular hazard distance λ Symbol for wavelength λ in nm α Symbol for the divergence of the laser beam α in mrad V ac Rsm value of the alternate voltage in Volt...

Page 8: ...device make sure you have suitable goggles for protection against scattered radiation Even with goggles it is possible to damage your vision by viewing direct laser radiation Avoid viewing direct radiation WARNING Before continuing with installation make sure that the environment is suitable for the intended use In particular make sure there are no openings windows or other towards the outside whi...

Page 9: ...he Antishock Wave label applied to detect any bumping during shipment is intact If not return to the sender WARNING Before starting unpacking operations carefully read the instructions on attached to the packing regarding handling the device N B Keep the packing it needs to be used if the device is reshipped In addition avoid exposing the device to rain cold excessive heat and or humidity During s...

Page 10: ...so do not direct the laser beam on flammable material The interaction of the laser beam with the material causes the formation of fumes and vapours which may be harmful or toxic It is advisable to use appropriate suction devices to eliminate fumes and filter fumes before releasing them into the air Use warnings Megalight is a Laser device able to emit class 2M visible radiation aiming red beam and...

Page 11: ...omponents required to create the Marker set up can be supplied separately as an option Engraving scanner head Interfacing electronic boards and engraving software Windows based A Personal Computer with Monitor keyboard and mouse All engraving operations can be managed with the Smartist 4 software program the minimum Personal Computer requirements and Software operating instruction are provided in ...

Page 12: ... of the device highlights the main system components composed of a power supply rack which generates Pump radiation at 808 nm optical fibre which transports the pump radiation to the Resonator Resonator which converts the 808 nm continuous radiation to pulsed radiation at 1064 nm engraving head scanner which aims and deflects the laser beam on the engraving surface Picture 2 Laser MegaLight Layout...

Page 13: ...ght Installation Technical modifications reserved 13 Edition 2004 The following figure shows the system layout diagram AC D C POWER SUPPLY DIODE LASER λ 808 nm CW DRIVER DIODE LASER OPTICAL FIBER I O BOARD λ 1064 nm pulsed Max 5W LASER RESONATOR RED DIODE PILOT BEAM SCANNING HEAD External A C Supply λ 635 nm CW Max 3mW RACK Picture 3 System layout of MegaLight ...

Page 14: ...g the laser diode Input Output board Radiators for heat dissipation via forced ventilation completely separated from the electrical part The front indicator panel is aimed at the Operator of the Megalight laser device and includes the following elements Multilingual display for displaying alarm messages and indications Three color LEDs indicating the device operating status POWER ON green LASER IN...

Page 15: ...lingen 49 0 7461 9472 0 49 0 7461 9472 20 info schilling marking de www schilling marking de MegaLight Installation Technical modifications reserved 15 Edition 2004 IINDICATOR LED FAN HOUR METER MULTILINGUAL DISPLAY Picture 4 system rear panel external indicators ...

Page 16: ... T 4 Galvo Supply connector sub D 9 p male for Scanner Head power 5 Internal Interlock Connector DIN 3 p male for connection to an external emergency interlocks circuit 6 Aiming Beam connector SMB female for connecting the red aiming diode 7 Command Box connector sub D 25 p female for connection to an external command box 8 P C connector sub D 9 p female for connecting the device to the DSp2 conta...

Page 17: ...e www schilling marking de MegaLight Installation Technical modifications reserved 17 Edition 2004 Picture 5 Rear management panel external connectors 2 MAIN SWITCH 3 PROTECTION FUSES 1 SOCKET MAINS SUPPLY 4 GALVO SUPPLY 5 EXTERNAL INTERLOCK 8 PC 10 OPTICAL FIBER 12 FAN 1 6 AIMING BEAM 9 SLAVE OUT 11 R F 7 COMMAND BOX 12 FAN 2 ...

Page 18: ...he radio frequency driver board RFD providing the 15Vdc low voltage and the command signals for driving the Q switch not used in this version the current driver board the display the three color LED the hour meter the rear panel the fans the Peltier cells In addition the IOB board communicates with the DSP2 laser management board and creates the interface towards the outside Current driver board T...

Page 19: ... resonator The laser Resonator is basically composed of a pair of lenses able to gather the radiation pumped at 808nm output from the optical fibre and focalized inside the crystal of active material Nd YAG by a pair of aligned mirrors which act as an oscillator for the laser radiation at 1064nm and a Cr4 YAG which acts as a passive Q switch and is used to generate instantaneous high power laser i...

Page 20: ... he main path of the invisible radiation even if indirectly The architecture of the laser head created in this manner is used to obtain an output laser beam of a very high modal quality with high performance and very little heat to dissipate The connection for the optical fibre is located in the rear wall of the Resonator see Appendix A Technical Specifications Engraving scanner head DRIVER X axis...

Page 21: ...present outside of the Miniscanner type head see Appendix A Technical Specifications Scanner head power supply connector connector DB9 Galvo motor command connector connector DB25 Picture 8 Rear view of the Engraving Head with connectors Objective lens The objective lens can be fitted with different length lens Typically for the Miniscanner head Lens length mm 63 100 160 Work area mm x mm 35 x 35 ...

Page 22: ...en it can cause electric shock To avoid the electrical risk do not use connection wires plugs sockets or extension cords lacking a quality mark or which are not intact N B Before continuing with installation the device makes sure you have suitable goggles available for protection against scattered laser radiation Even with goggles it is possible to damage your vision by viewing direct laser radiat...

Page 23: ... positioned at less than 2m Longer wires and optical fibre can be supplied upon specific request Leave a free space of at least 10 cm in front of and behind the power supply box to ensure the necessary flow of cooling air Do not install the System in an excessively dirty area in the presence of dust oil chemicals fumes or excessive humidity Do not install the system in a place where the ambient te...

Page 24: ...ator and Engraving Head are already connected together and separately packaged from the Rack and Optical fibre The necessary wires interface DSP2 board to be installed in the PC Smartist4 engraving software and related manual are also in the packaging The System installation procedure involves the following phases Preparation of the Personal Computer P C and installation of the DSP2 board Mechanic...

Page 25: ...nnector of the rear Management Panel of the power supply box and the SMB socket located on the laser resonator body TS SUB D 9 Female socket socket wire length 3m connecting the GALVO SUPPLY connector of the rear Management Panel of the power supply box and the SUB D 9 pin Male connector located on the scanner head STS SUB D 25 pin Male plug plug wire length 3m connecting the 25 pole Female SUB D ...

Page 26: ...ment Panel of the power supply box and the SMB socket located on the laser head body Connect the TS cable between the GALVO SUPPLY connector 4 of the rear Management Panel of the power supply box and the SUB D 9 pin M connector on the scanner head Connect the STS wire between the SUB D 25 pole F connector of the DSP board and SUB D 25 pin F connector located on the Scanner Head Connect the PC wire...

Page 27: ...r detailed wiring and connection diagrams see Appendix B Wiring and connection diagrams Optical fiber connection The optical fibre is connected between the laser opening of the power supply box connector 10 OPTICAL FIBER and the optical fibre connector socket on the rear wall of the Resonator Picture 11 Optical Fibre Connection The procedure to connect the optical fibre to the rack is as follows 1...

Page 28: ...of the fibre connector 2 does not come into contact with any other surface WARNING The operation for inserting the fibre needs to be carried out very carefully Absolutely avoid letting the optical surface of the fibre connector come into contact with any other surface Contact of the fibre optical surface with any other surface may damage it 6 Make sure the mechanical supports 3 on the male female ...

Page 29: ... into contact with any other surface WARNING The operation for inserting the fibre needs to be carried out very carefully Absolutely avoid letting the optical surface of the fibre connector come into contact with any other surface Contact of the fibre optical surface with any other surface may damage it 7 Make sure the mechanical supports 3 on the male female connectors are in the correct position...

Page 30: ...e is enough free space in front of and behind the power supply box to ensure cooling air flow Make sure that the plug is correctly inserted Make sure all the electrical connection have been correctly effected Make sure the optical fibre is connected to the power supply box and Resonator Make sure the protective cover of the scanner head lens has been removed Make sure the optical path of the laser...

Page 31: ...ction diagrams Make sure that the following events occur ORANGE led on return to STANDBY condition The aiming red diode reappears at the beam N B once this hardware start up phase is finished the laser source is in the condition to accept the ENABLE command and pass from STANDBY to READY and ready to operate Start up procedure Software 1 Start the Personal Computer where the DSP2 board has been in...

Page 32: ...R opening the contact between pin 07 and 08 of the COMMAND BOX connector 7 located on the rear Management Panel of the power supply box see Appendix B Wiring and connection diagrams 2 Give the STOP command opening the contact between pin 04 and 12 of the COMMAND BOX connector 7 located on the rear Management Panel of the power supply box see Appendix B Wiring and connection diagrams 3 Exit the Sma...

Page 33: ...mance and tested as a safety device General use instructions for Class IV lasers The use of remote controls is also envisaged for Class IV lasers as well as starting with a key command existence of an emission warning availability of an attenuation shutter command positioning of controls outside the radiation access area and clearly visible appropriate warning labels The manufacturer of Megalight ...

Page 34: ... the laser beam with organic or inorganic compounds causes the formation of fumes and vapours which may be harmful or toxic N B Make sure the personnel assigned to using the System have read this manual and the Laser Safety Manual before using the engraving system Daily use by an Operator The Operator is required to carry out the following preliminary tests before each use of the laser device Make...

Page 35: ...om this time on the source is enabled for emitting laser radiation from the engraving head Be careful not to expose yourself to optical risk Turning off 1 Disable the ELECTRONIC SHUTTER using the STAND BY READY button and make sure the following events occur ORANGE led on STAND BY condition The aiming red diode appears on the beam 2 Give the STOP command and make sure the following events occur GR...

Page 36: ...ge Once the lens has been replaced the laser focus needs to be adjusted again Ordinary maintenance Ordinary maintenance performed by the Operator exclusively involves cleaning the protection glass of the lens and cleaning the area around the fans These operations must be carried out on a weekly basis Cleaning the lens protection glass Turn off the System WARNING Disconnect the device from the main...

Page 37: ...llowing unauthorized work carried out by unqualified personnel on Manufacturer supplied parts If it is necessary to recalibrate the system or replace or do maintenance work on live internal parts only use qualified personnel which is authorized by the Manufacturer or its legal representative For all Technical Assistance needs or extraordinary maintenance work it is possible to contact the Manufact...

Page 38: ...s to the internal parts of the electrical system Schilling Marking Systems GmbH shall not be held liable for work done on the live parts by unauthorized personnel WARNING Only qualified and authorized personnel are allowed access to the internal parts of the laser Resonator Schilling Marking Systems GmbH shall not be held liable for work done on the live parts by unauthorized personnel WARNING The...

Page 39: ...g of the external contact READY command present before START Turn the switch to OFF wait 10s and turn to ON 3 The laser does not go on Display in alarm Status led off Voltage protection tripped with presence of Alarm DC POWER FAULT Contact the Call Centre Check the external connections pin 7 8 of the Command Box connector 4 a The laser is not enabled Display in alarm Status led off Interlock enabl...

Page 40: ...ontact the Call Centre Make sure the cooling air circulates freely Make sure the fans are running correctly 8 b The laser stops emitting Display in alarm Status led Green Temperature protection tripped with presence of Alarm M S HIGH DIODE TEMP Make sure the radiator is clean Make sure the cooling air circulates freely Make sure the fans are running correctly 8 c The laser stops emitting Display i...

Page 41: ...atutory European Directives related to safety and the constructions provisions for industrial device specifically it is in conformance with the following European Community Directives 98 37 EEC Machinery Directive for the MARKER version with safety box 89 336 EEC Electromagnetic Compatibility for the O E M version 73 23 EEC Low voltage for the O E M version The main applied standards are listed be...

Page 42: ...Heat charge towards environment Max WC 80W Maximum internal temperature Dissipaters 60 C Operating type Continuous Acoustic emissions Max sound level 65dbA Laser Source Specifications Working laser Enabled medium Nd YAG Wave length 1064nm 5nm Diameter of the beam output by Beam Expander 5mm 1 e2 Divergence of the beam output by the Resonator 3mrad full angle Mode Beam quality TEM00 M2 1 2 full pow...

Page 43: ... Head Miniscanner model 72 5400 1 E08Yxyyzz 1 Head power supply wire TS 72 5500 1 Head signal wire STS 72 5510 1 PC connection wire 72 5515 1 Aiming Beam connection wire DL 72 5610 1 F theta lens 160mm 72 5430 1 1 DSP2 board for PCI bus 1 CD Rom Smartist4 1 Floppy disk Files ini 1 Resonator attachment bracket 1 Engraving head attachment plate MARKER device standard equipment N Component Code Seria...

Page 44: ...ode power supply current value When the range of the laser diode power supply current is established maximum value set by the manufacturer the progress of the power emitted at the Resonator output for the Megalight source is shown in the following graph normally there is laser action around 45 and 100 of the maximum power supply current value threshold 0 1 2 3 4 5 6 0 20 40 60 80 100 of current to...

Page 45: ...61 9472 20 info schilling marking de www schilling marking de MegaLight Installation Technical modifications reserved 45 Edition 2004 Warning Labels and their positioning Rack front panel LASER RADIATION AVOID EYE OR SKIN EXPOSURE TO DIRECT OR SCATTERED RADIATION CLASS IV LASER LASER EMISSION ...

Page 46: ... 78532 Tuttlingen 49 0 7461 9472 0 49 0 7461 9472 20 info schilling marking de www schilling marking de MegaLight Installation Technical modifications reserved 46 Edition 2004 Rack rear panel AVOID EXPOSURE LASER RADIATION IS EMITTED FROM THIS APERTURE ...

Page 47: ...72 0 Laser Nd YAG CLASS IV Wavelength Max CW output power Max pulse energy Pulse duration Max repetition rate 808 nm 20 W CW 1064 nm 5 W 250 µJ 13 ns 20 kHz INVISIBLE LASER RADIATION This Laser system complies with FDAperformance Standards for laser products except for deviations pursuant to Laser Notice N 50 dated July 26 2001 DANGER VISIBLE OR INVISIBLE LASER RADIATION WHEN OPEN AVOID EYE OR SKI...

Page 48: ...g marking de MegaLight Installation Technical modifications reserved 48 Edition 2004 Coupler Engraving Head DANGER VISIBLE OR INVISIBLE LASER RADIATION WHEN OPEN AVOID EYE OR SKIN EXPOSURE TO DIRECT OR SCATTERED RADIATION AVOID EXPOSURE LASER RADIATION IS EMITTED FROM THIS APERTURE AVOID EXPOSURE LASER RADIATION IS EMITTED FROM THIS APERTURE ...

Page 49: ... every OEM laser device preferably near label no 1 4 Optical Safety Label Location On every Class IV laser device near the aperture where laser radiation is emitted 5 Optical Safety Label Location On every guard panel which once removed allows access to the radiation Marking Systems GmbH Laser Nd YAG CLASS IV Wavelength Max CW output power Max pulse energy Pulse duration Max repetition rate 808 nm...

Page 50: ...s not turned off in the event of opening if the class of the aiming beam is 2M 8 Optical Warning Label Location Front power supply rack panel it indicates laser emission when the led is red 9 Electrical Safety Label Location Near the electrical sockets 10 Electrical Safety Label Location On every guard panel irremovable which once removed allows access to the radiation CAUTION EQUIPMENT SUPPLIED E...

Page 51: ...Edition 2004 11 General Warning Label Location On the OPTICAL FIBER connector of the power supply rack when the optical fiber is disconnected 12 Component identification plate Location On every removable Laser component 13 Device identification plate Location Upper panel of the power supply rack Mechanical drawings The following drawings show Overall mechanical view of the Resonator and Engraving ...

Page 52: ...rking Systems GmbH In Grubenäcker 1 DE 78532 Tuttlingen 49 0 7461 9472 0 49 0 7461 9472 20 info schilling marking de www schilling marking de MegaLight Installation Technical modifications reserved 52 Edition 2004 ...

Page 53: ...ee contact STOP LASER Contact open STOP 4 Potential free contact 12 return Potential free contact START Contact closed START 7 Potential free contact 8 return Potential free contact STAND BY READY Contact open STAND BY Contact closed READY Output Pin N Signal Description Status 18 H L logic POWER ON 0 Volt Laser power off 12 Volt Laser power on 19 0V GND GND reference for pin 18 20 H L logic _____...

Page 54: ... contact INTERLOCK Open contact Emergency Enabled 3 0 V GND N B If the emergency is enabled by opening the Interlock contact it cannot be reset Resetting is only possible by putting the main switch MS in the Open position O and then the closed positions I Galvo Supply Connector Pin N Signal Description Status 1 6 2 15 V NEGATIVE SUPPLY Negative power supply 15V 3 max 7 3 8 0 0 V COMMON Common 4 9 ...

Page 55: ... 5 6 7 8 10 11 12 13 14 n c Internal connections do not use P C Connector Pin N Signal Description Action 1 Analogy 0 10V POWER LEVEL Regulates Laser power 6 Not used in this version 2 H L logic PEN UP Up Engraving impulse emission 8 12 V EXTERNAL SUPPLY External Positive Power Supply 12V 50mA min 3 0 V COMMON 0V External power supply Signal common Aiming Beam Connector Pin N Signal Description St...

Page 56: ...n Wiring diagrams The Manufacturer agrees to supply upon request the circuit diagrams lists of component parts calibration instructions or other information useful for adequately qualified personnel to repair the parts of the device which the Manufacturer considers repairable The following diagrams are supplied Rack interface wiring diagram Interface signal timing diagram Laser command signal timi...

Page 57: ...nteined contact KEY SWITCH 4 12 0 I 7 2 2k U12C 8 SB3 Remote STAND BY READY potential free make contact 7 8 18 19 12V U25 20 21 TLP523 12V U23 12V U24 22 24 19 18 21 20 22 24 KA1 KA2 KA3 Laser POWER ON 12V 50mA active Power ON Laser NOT READY 12V 50mA active Laser not Ready Laser ENABLE 12V 50mA active shutter opened 12V 24V max 200mA NOT USED NOTE do not use others pins internally connected Use o...

Page 58: ...al Interlock Connector Ext Interlock Pin 1 2 Remote START Connector Command Box Pin 4 12 Remote STAND BY READY Connector Command Box Pin 7 8 Laser POWER ON Connector Command Box Pin 18 19 Laser NOT Ready Connector Command Box Pin 20 21 Laser ENABLE Beam Attenuation off Connector Command Box Pin 22 24 0 I KA2 KA1 KA3 0 I min 100ms 0 I 1s Allarm or Warning internally generated LASER OFF START LASER ...

Page 59: ...ng marking de www schilling marking de MegaLight Installation Technical modifications reserved 59 Edition 2004 Emergency STOP Stand By Ready Laser Emission Pen Up TTL IN Power Level ANALOG IN 0 10 V DIODE Current pumping power YAG output power Typ 100 ms Typ 1 sec Typ 10 ms Delay 200 µ s Delay 200 µ s Delay 800 mSec ...

Page 60: ...12V MAX500mA X2 2 X2 6 X2 1 X2 3 to RACK VIOLINO P C Connector DSP2 Board to Scanner Head Digital Analogic Converter X1 1 A0 B0 C0 D0 E0 F0 G0 H0 X1 2 X1 3 X1 4 X1 5 X1 6 X1 7 X1 8 X1 26 X1 27 X1 28 X1 29 X1 30 X1 31 X1 32 X1 33 X1 9 X1 11 X1 13 X1 15 X1 16 A0 B0 C0 D0 E0 F0 G0 H0 gnd gnd gnd gnd gnd X2 DSP Connector Sub D 9 pin Female X1 DSP Connector Mini D 50p F X1 10 gnd gnd gnd gnd gnd SP5V S...

Page 61: ...e Z 13 0V 25 4 7k E3 1 E3 2 E3 3 E3 4 E3 5 E3 6 19 20 21 22 4 15 18 5 6 17 2 Step X Dir X Dir Y Step Y 3 Step Z 16 Dir Z break x break y break z ext in a ext in b ext in c ext in d 23 ext out a E3 7 E3 8 E3 9 E3 10 A3 4 A3 7 A3 3 A3 6 A3 9 A3 1 A3 8 A3 5 A3 2 A3 10 pull up resistors 1 A4 1 A4 2 A4 3 1 2 3 A4 5 A4 4 10 8 A4 6 15 4 E4 1 E4 2 E4 3 E4 4 E4 5 E4 6 5 6 7 13 14 0V 12V 12 9 Laser END 2 La...

Page 62: ...t the end of its optical path Closing of the optical path up to the point of application and confinement of the reflected and scattered radiation in a specific opaque container applied to the radiation No crack or opening must make the radiation accessible for viewing N B If the optical fibre is greatly bent it does not comply with this provision However it should not be disconnect able without us...

Page 63: ...ith a manual command via an intentional manoeuvre effected by trained personnel with a key device Fit a key device which can be removed in the off position No possibility of starting without the key and activating it Removable key in the off position N B a resent modification to the standard permits considering a software password or badge as a key 7 An acoustic or luminous warning must signal the...

Page 64: ... See Warning labels The labels are positioned and have the form dimensions and description corresponding to the Standard provisions 12 All the warning labels required for class I must be present on the system Install the Laser class I warning labels No other label is necessary if label no 1 is usually put on 13 A warning label needs to be present on the interlocking panels doors Install warning la...

Page 65: ...n 2004 Note 3 For export to the United States the following warning needs to be applied NOTICE This laser component complies with FDA Performance Standards for Laser Products except for deviations pursuant to Laser Notice N 50 dated July 26 2001 since there is a difference not yet transposed by Federal regulations 21 CFR 1040 between the provisions of standard CEI 60825 and the provisions of these...

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