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5 
 

2. SAFETY 

 
           This chapter briefly describes safety issues associated with M100LFG-TT/150 Laser 
Wire Marker and provides guidelines to operate the machine in a safe manner. 
 

WARNING !!! 

Only qualified personnel should have access to the machine.  

 
 

The user must be familiar with all technical aspects of the machine’s operation and have 

a good knowledge of the operating software. Service and maintenance of M100LFG-TT/150 
require proper technical training and understanding of potential hazards to which personnel may 
be exposed.  This manual is intended to be a supplement but not a replacement to this training. 
 

 

2.1 Hazards associated with laser equipment 

 
M100LFG-TT/150 contains internal and external interlocks to assure safe operating 

conditions. Normally the laser beam is completely enclosed within a cabinet. The laser shuts off 
automatically if any door or cover is open.  

 

Service work, performed by 

OEM,

 including installation and calibration procedures, may 

require access to the laser and other optical components. The unenclosed beam should be 
contained within a specified region by adequate control measures. Temporary control area may 
be required to prevent personnel in the vicinity of the laser or its emitted beams from radiation 
exposure. Consideration should be given to direct, reflected and scattered radiation. 

 

Warning !!!

 

M -100LFG-TT/150 contains CLASS IV High Power Laser.  

Direct beam contact or exposure to diffuse reflection is 

hazardous to the eyes and skin and can also be a fire hazard  

 

Warning !!!

 

All installation and maintenance procedures should be 

conducted by specially trained personnel 

 

Warning !!!

 

Always work in low power mode when dealing with open laser 

radiation     

 

 

Warning !!!

 

Always wear laser safety glasses when working with an open 

laser beam      

 

The invisible ultra-violet pulses of coherent light emitted from this laser are capable of 

inflicting permanent eye damage and total blindness. The beam can burn skin tissue and may 
cause ignition of chemicals on some common materials. If possible, perform laser work in a light 
tight room with safety interlocks. 

 

Summary of Contents for M100LFG-TT/150

Page 1: ...ANUAL M100LFG TT 150 Tri Star Technologies Laser Wire Marker Rev 1 0 October 2016 Tri Star Technologies 2201 Rosecrans Ave El Segundo CA 90245 USA Tel 310 536 0444 Fax 310 536 9322 www tri star technologies com ...

Page 2: ...n 24 5 Wire Processing 25 6 Installation 26 7 Maintenance and Troubleshooting 27 8 Spare Parts List 28 9 Software User Guide 29 9 1 Setup 36 9 2 Default Font 37 9 2 Offsets 38 9 3 Parameters 40 9 4 Scanner Settings 42 9 5 Laser Configuration 44 9 6 Energy Offset 46 9 6 Import Export 48 9 7 Barcodes 50 9 8 Calibration 51 9 9 About 53 10 Marking parameters 55 10 1 Laser Power 55 10 2 Scanner paramet...

Page 3: ...3 12 Mechanical Diagrams 63 13 Electrical Diagrams 66 14 List of Appendices 73 ...

Page 4: ... user request The M100LFG TT 150 is fully programmable The program routines include set up and adjustments of pulling and cutting processes laser and scanner parameters marking patterns etc When malfunctions occur the process stops automatically and specified error message appears on the screen A marking task consists of entering message separate space between the messages and cutting length for e...

Page 5: ...ration procedures may require access to the laser and other optical components The unenclosed beam should be contained within a specified region by adequate control measures Temporary control area may be required to prevent personnel in the vicinity of the laser or its emitted beams from radiation exposure Consideration should be given to direct reflected and scattered radiation Warning M 100LFG T...

Page 6: ...s may be generated when Class IV laser beams interacts with matter When the target irradiance reaches a given threshold 107 W cm2 target materials including plastics composites metals and tissues may liberate airborne contaminants such as metallic fumes and dust metallic oxide fumes chemical and gaseous vapours etc Some of the compounds include polycyclic aromatic hydrocarbons from poly methyl met...

Page 7: ... beam Hazards Associated with Laser Use LIA 1999 4 Guide for the Selection of Laser Eye Protection LIA 1996 5 OSHA Instruction Pub 8 1 7 6 IES 825 Radiation Safety of laser products Equipment Classification Requirements and User s Guide Laser Safety Guide Laser Institutes of America 2 2 Hazards associated with wire cutting equipment There are several potentially hazardous areas associated with cut...

Page 8: ...ng material and limit any structural and or chemical modifications only to the pigment particles themselves Titanium dioxide TiO2 is a white color pigment added to the wire insulation materials as well as to different formulations of paints coatings and plastics primarily for color changing purposes For industrial applications it is mostly produced as powder of white color submicron particles or s...

Page 9: ...759 09 10 11 12 20 21 22 23 28 29 30 31 White Extruded TFE Marginal M22759 16 17 18 19 White Extruded ETFE Good M22759 32 33 35 41 42 44 45 46 White Extruded XLETFE Very Good M22759 34 43 White Extruded XLETFE Excellent M22759 80 81 82 83 84 85 86 87 88 89 90 91 92 White PTFE Tape wrap Good M85485 5 6 9 10 Violet Extruded XLETFE Very Good M25038 White PTFE Tape wrap Poor M27500 SP2S23 White Extrud...

Page 10: ...e bottom and after top accelerated thermal aging 168hours at 200oC Wire diameter is 1 15 mm laser fluence is 1J cm2 Magnification is 15x and 65x Solid marking corresponds to M100L masking system Dot matrix marking corresponds to M100LFG TT 150 scanning beam system ...

Page 11: ...11 Fig 3 2 UV Laser marking penetration into TiO2 doped ETFE insulation at 65x and 500x magnification Wire diameter is 1 15 mm visible marking depth is 15µm laser fluence is 1J cm2 ...

Page 12: ... bottom and after top accelerated thermal aging 168hours at 310oC Wire diameter is 1 30 mm laser fluence is 0 8 J cm2 Magnification is 15x and 65x Solid marking corresponds to M100L masking system Dot matrix marking corresponds to M100LFG TT 150 scanning beam system ...

Page 13: ...13 Fig 3 4 UV Laser marking penetration into TiO2 doped PTFE insulation at 65x and 500x magnification Wire diameter is 1 30 mm visible marking depth is 8µm laser fluence is 0 8J cm2 ...

Page 14: ...a CLASS IV High Power Laser Direct beam contact or exposure to diffuse reflection is hazardous to the eyes and skin and can also be a fire hazard Fig4 1 M100LFG TT 150 In proper operational condition all laser radiation is completely enclosed inside the cabinet in compliance with laser safety standards ANSI Z136 1 1993 The system has a number of internal locking devices which automatically shut do...

Page 15: ...0LFG TT 150 prints messages on a wide variety of wires The message can contain any symbols in any font in any language in any size and orientation Consult factory for specific applications Standard system specification is listed below M100LFG TT 150 System Specifications Laser wavelength 355 nm Laser average power 6 W Pulse length 15nsec Nominal repetition rate 50 000 Hz Dot size 30 70µm depending...

Page 16: ...ental harmonic emitted in the Infra Red region of the spectrum 1064 nm is transformed into Ultra Violet wavelength of 355 nm by the optical frequency conversion system The detailed laser description is given in Appendix F Laser is mounted on the solid aluminum plate using two T nut screw on the front and one on the back of the laser head Fig 4 2 Laser Mounting Lock Screw Laser Head Lock Screw Lock...

Page 17: ...scope in front of the scanner and then focused on the wire 200mm objective after exiting the scan head Changing the base between telescope lenses or moving the objective up or down results in changing the focus distance and therefore applied fluence amount of energy per unit of target area delivered in one pulse of the incident beam Focusing the beam closer to the wire surface reduces the beam foo...

Page 18: ...ny information on the wire surface including logos pictures barcodes and alphanumeric messages Laser is equipped with locking key switch During the operation the key should be in ON position and laser shutter should be open The laser is externally controlled by the scanner board All laser parameters are downloaded from the computer Warning Do not press any buttons and or change any settings on the...

Page 19: ...n the water supply line Flow sensor output normally closed and chiller general fault signal are connected to the PLC If no flow is detected machine stops and Flow Fault message appears on the RUN screen If chiller malfunctions machine stops and Chiller Fault appears on the RUN screen Fig 4 7 flow sensor Warning Check the water level before operation Use distilled water only For detailed chiller de...

Page 20: ... laser Q SW control PLC 24VDC power supply and via USB cable to the computer Optimized for a high speed marking M100LFG software transforms the required printing information into the set of command downloaded into the Scanalone Board that controls both the scanner and the laser Fig 4 8 Beam Scanning System Detailed description of Scanner and Scanalone Board is given in Appendixes C and D respectiv...

Page 21: ...m goes inside the height adjustable wire channel to the pulling mechanism and then through the wire guide cutter and exit tube into the coiling pan Fig 4 9 Additional set of wire guides is provided for the thick wires Standard system handles the wires with up to 10mm diameter Fig 4 9 Pulling mechanism and coiling pan Coiling Motor Speed Regulator Pulling Toggle Switch Cutter Encoder Belt Tension R...

Page 22: ...nd laser scanner malfunctions Fig 4 7 shows all major electrical components Encoder belts move with the speed of wire producing the encoder pulses supplied directly to the scanner Scanalone board reads the encoder pulses and automatically corrects the marking for the current wire speed allowing message printing on the fly Optional motorized prefeed is mounted on a separate cart on the left side of...

Page 23: ...23 Fig 4 11 Motorized Prefeed Prefeed motor Speed Regulator Dancer Top Wire Pulleys Motor Shaft Limit Switch Wire Tail Grounding clip Bottom Wire Pulleys Prefeed motor controller ...

Page 24: ...ick LAN etc In the marker mode computer has Ethernet connection with PLC USB to Serial connection with Laser power supply and regular USB to USB connection with Scanalong board Yellow start and Red emergency stop buttons are conveniently located on the front panel of the cabinet When powered and connected to the air supply machine is completely ready for wire processing Fig 4 12 Fig 4 12 Operator ...

Page 25: ...he encoder belt toggle switch 7 Gently pull the wire back from the left side of the cabinet and tight the straightener 8 Use air pressure regulators on the back of the cabinet to adjust the belts pressure if necessary 9 Close the door Wire marking 1 From the main menu screen open a file with existing data or enter the new data following Software Guide Chapter 9 2 When starting a job for the first ...

Page 26: ... of the cabinet 4 Plug power cord to the outlet 5 Hook up compressed air supply 6 Connect dedicated computer and monitor 7 Open the top cover of the cabinet and set the laser in place as shown on Fig 4 2 8 Connect the utility module and water chiller 9 Connect the cables on the back of the laser head as shown on Figs 4 3 4 6 10 Fill the chiller with distilled water 11 Align the laser in the follow...

Page 27: ...ilot beam is detected on the wire Alignment problem Check the wire position Check the scanner offsets Trace the beam with a piece of paper starting from the objective Restart the system Consult the factory No beam at all Make sure that laser shutter is open and cooling temperature is 20C Check the front panel of the laser power supply for specific faults Restart the system Consult the factory Pilo...

Page 28: ... 2201 Rosecrans Ave El Segundo CA 90245 Telephone 310 536 0444 FAX 310 536 0201 E mail alex kerner tri starelectronics com Please supply the following a M100LFG TT 150 model and serial number b Part number of part if known c Description of part including function and location in M100LFG TT 150 d Quantity desired Consumable parts are listed below Wire pulling belts set TST TB 180XL075 NG ML TIMING ...

Page 29: ...t more than one wires from the job file press Shift and Left Click on the required wires in the grid To process selected wires open Commands tab from the menu bar Fig 9 2 and use Run Selected Wires option The processing window below the wire grid in the main menu defines marking parameters and switches the system into the Run mode Scaled up message for the selected segment of the wire appears in t...

Page 30: ...end of the list Delete Wire deletes the wire highlighted in the wire grid Delete Selected deletes the wires highlighted in the wire grid Printer Config opens label printer configuration for selected wire Run All opens the run screen for all the wires in the current task Run Selected opens the run screen for all the wires highlighted in the wire grid Wire Edit Each single wire can be split into 3 i...

Page 31: ... distance equals the sum of the gap the message width and the trailing space Message Width is displayed on the right side of the editing window Based on the width length and gap the program determines how many messages will be imprinted on the segment e g the message in segment 1 will be marked 3 times The leading and trailing spaces are also taken into account The last message will only be printe...

Page 32: ...n nearest characters in the message Increasing the spacing makes message longer Cut should be checked if cutting is required Units set length measurement units for entering the data Changing the units in the current job converts all the values Multi Line Spacing defines the vertical space in bits between the lines in multi line messages Assembly Length is the total length of all the wires in the a...

Page 33: ...any wire of this type in the all earlier saved assemblies Modified parameters for the None type wires will be saved for the current assembly only RUN button switch the system into operation mode Run Screen The Run screen is shown on Fig 9 5 On the left side is a list of all the wires in the current job A job may be run completely or partially by selecting a specific wire from which to begin The Ru...

Page 34: ...starts the motors in the manual mode MARK button prints currently selected message It allows marking a single message on a wire or any other substrate e g shrink tubing without engaging the wire pulling mechanism manual mode The message box can have up to 5 lines The length of the message is determined by the longest line The displayed time is a time required to print the entire message Marking pa...

Page 35: ...ps the process if any of the following malfunctions occur Laser Fault laser malfunction Wire Feed jammed wire prefeed malfunction Door Interlock front door is open during production process Air Low low air pressure Scanner Error lost communication with scanner Wire Slip Wire is not moving End Of Wire Wire is not present PLC Disconnected lost communication with PLC Warming Up Warm up sequence not c...

Page 36: ...rameters for the laser scanner PLC stepping motors and also import export and bar code options Detailed description is given in the following chapters In order to access the setup submenu press Ctrl Shift F12 on the keyboard Fig 9 6 Menu bar windows ...

Page 37: ...ower and upper case letters Some fonts have been expanded to allow printing in different languages For example ArialG has both English and Greek alphabet Select this font if the message on the wire requires special characters along with regular data Change the language in the windows language bar from English to Greek and vice versa depending on the characters that need to be printed Other fonts a...

Page 38: ...38 9 2 Offsets Offset screen is used for beam alignment It is not accessible in demo mode Fig 9 8 Offset Laser Beam footprint Laser Beam footprint ...

Page 39: ...e an alignment in the following order 1 Load 20 to 24 gauge wire 2 Turn on the laser 3 Observe low power beam footprint on the wire 4 Using the arrows move the beam to the left side of the wire channel as shown on Fig 9 8 5 Click Save button to save start mark position Every message will be printed starting from this position and farther to the right 6 Press the Test button The beam should jump to...

Page 40: ...be adjusted if cut length of the wires is different from the specified values Increasing the number will reduce the total wire length and vice versa Waste Wire is the space between start mark position and the cutting blades Wobble Delay is a time interval between stop the wire and start the marking signals Increasing the delay allows more time to settle down the wire vibrations in the marking zone...

Page 41: ...s of the PLC Printer IP Address and port relate to the optional label printers Warm Up Time is the amount of time after the diode is turned on before the laser is ready The diode turns on automatically when the machine powers up Conversion Factor is used to convert the analog input from the laser power meter to Watts Laser Off Time is the maximum time the laser can be idle before turning the diode...

Page 42: ...Smaller distance or higher resolution dpi makes message look darker On the other hand that takes longer to mark For the standard system the dots overlap if the speed is less than 500 bits ms Jump Speed determines how fast the scanner moves between the marking periods Various Delays and Edge Level are used to optimize a marking pattern Enable Z Axis is for marking within a 3D object Laser Mode spec...

Page 43: ...ing pattern Pulse Width 1 determines the duty cycle of the triggering signal Pulse width of 16ms for the laser period of 33ms corresponds to the 50 duty cycle Pulse Width 2 is only used for CO2 lasers Click the Save button to reinitialize the Scanner Click the Cancel button to close the window without saving Detailed description of the scanner parameters is given in Appendix C ...

Page 44: ...er Configuration Fig 4 22 shows LASER SETTING panel accessible from the HMI main screen Configurable Parameters o Epulse Hz defines the laser pulse energy during the marking process The appropriate pulse energy for each type of tablets is established during initial qualifications and set as Nominal Pulse Energy o Frequency Hz defines the laser repetition rate and the output power o Duration is mea...

Page 45: ...tected o Laser Power W displays the laser power measured during the last energy testing o Diode and Tower Temperatures are used for diagnostic purposes only Activate Deactivate Laser button turns the laser on off The action of the button is determined by the current state of the laser The status label reads Laser On when laser is activated and Laser Off when the laser is off Start Stop Energy Test...

Page 46: ...me The beam dump should be placed as far from the focus of the objective as possible Do not measure the laser power without objective and telescope in place Energy Offset screen is used to direct the beam into the beam dump during power measurement process Laser On turns the pilot beam on Laser Off turns the beam off Arrows move the beam into corresponding direction Save button saves the current s...

Page 47: ...ose the doors 6 Turn the laser on 7 Observe low power beam coming down from the objective 8 Adjust the beam position using the arrows on the offset screen so that it would path through the middle of the channel opening 9 Confirm that the beam enters the dump tube 10 Click save and close the program 11 Remove beam visualization papers 12 Switch to the Laser Parameters window 13 Click Start Power Te...

Page 48: ...NG GAP 20 8 Fig 9 13 shows Import Export configuration screens Message is the number of the text file column for the section messages Length is the number of the text file column for the section lengths Gap is the number of the text file column for the section gaps Leading Space is the number of the text file column for the leading space LS Default is used if Default Value is selected for Leading ...

Page 49: ...appear Select a column number from the dropdown list or select Default Value Set the Default Value in the text box to the right default value 3 Click Save to save changes to the section or Cancel to return to previous values 4 Click New to enter Edit Mode for a new section to the Import Configuration Enter column numbers or default values for Message Length and Gap and click Save to add the new se...

Page 50: ...Fig 9 15 Barcode Barcode parameters are shown in Fig 9 16 Fig 9 16 Barcode parameters Horizontal Scale defines the width of the barcode Vertical Scale defines the height of the barcode Line Spacing is the distance between vertical lines within the barcode Character Spacing is the distance between nearest barcode symbols Click the Save button to save new parameters to the application click Cancel b...

Page 51: ...h Angle compensates mechanical misalignment between the X axis of the scanner and wire center line Encoder Pulses is quadruple number of encoder pulses corresponding to the calibration length EncoderBPI is quadruple number of encoder pulses per inch Scale Factors are automatically calculated during the calibration procedure These parameters synchronize the scanner with the movement of the wire and...

Page 52: ... 6 Measure the length of the horizontal mark 7 Divide the number specified in the step 2 by the measured length and enter it into the Scanner resolution text box 8 Click save 9 Enter 3 in into calibration length text box 10 Press calibrate The marker pulls the wire for a specified length with the pull speed specified on the parameter screen and calculates the scale factors 11 Save and close 12 Run...

Page 53: ...3 9 9 About Clicking Help About opens the About screen The screen displays all parameters in the configuration file PLTDraw exe config that are specific to the system and cannot be changed Fig 9 19 About ...

Page 54: ...f machine doesn t have Zebra Printer Working Files Initial directory where wmj files are saved Import Files Initial directory where import files are read Log Files Directory where log files are saved Fonts Directory where font files are kept Application Settings Path of Application Settings file Bar Codes Path of Bar Codes file Import Configuration Path of Import configuration file Correction File...

Page 55: ...ower output As described in the following chapters when machine is properly set it will always produce the same marking contrast on the same types of wire Apparent contrast deterioration is usually associated with the loss of laser power The power may be recovered using the following procedures 1 Increasing E Pulse up to 50000 2 Changing the spot after preferably after 20000 hours 3 SHG auto tune ...

Page 56: ...rs and laser repetition rates That allows high resolution marking with print densities of up to 600dpi which is especially important for small diameter wires All scanner parameters are preset at the factory To change the dot density in the vertical direction access the scanner window Chapter 9 4 and adjust the Mark Speed Higher speed corresponds to a bigger spacing between the dots At the optimum ...

Page 57: ...ce between the vertical printing lines filling the contour of a character Fig 10 4C D Similar to the marking speed described above the optimum spacing should place the lines as close to each other as possible without overlapping Fig 10 4A shows the marking using the contour only While this is the most economical and the fastest print setting it may not be enough to provide a legible marking The ch...

Page 58: ...g 10 4 M100LFG TT 150 marking on the 12 gage BMS 13 48 wire using contour with different line spacing A Contour only B Line spacing 40 no contour C Line spacing 40 with contour D Line spacing 80 with contour ...

Page 59: ...r pulse In most of the cases fluences less than 0 5J cm2 will leave a poor or no mark on the wire surface On the other hand fluences in excess of 2J cm2 may damage the wire The system comes with factory preset objective Overtime as laser ages its output and therefore fluence decrease to the point when marking becomes not legible Moving down the objective shifts the beam focus closer to the wire su...

Page 60: ...g 10 6 M100LFG TT 150 marking on the BMS 13 48 Tefzel and 22759 86 Teflon Green offset marks with wire spec numbers are made during the wire manufacturing process and used as a reference only Laser markable wires commonly used in the aerospace industry are listed in the table 3 1 The contrast of a dot for a given type of wire stays the same for as long as laser output does not change The marking l...

Page 61: ...struction Dismount the laser in the following order 1 Remove the top cover and the cross bar Disconnect water and air hoses and cables from the back of the laser Cross bar Locking cap Lock Screw Lock Screw Back Holding Screw ...

Page 62: ... envelope 4 Pull out utility module from the holding brackets disconnect air hoses and laser power cable 5 Pack the utility module in the moisture tight envelope 6 Ship the laser utility module air hoses laser power cable and the key in the original shipping container to Tri Star Technologies 2201 Rosecrans Ave El Segundo CA 90245 USA To set the laser back into the working position follow the inst...

Page 63: ...63 12 Mechanical Diagrams ...

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Page 66: ...66 13 Electrical Diagrams ...

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Page 73: ...73 14 List of Appendices A Laser Manual B Cooler Manual C Scanner Manual D ScanaloneCard Manual ...

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