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VLS Service Manual - REV2015.04

Table of Contents

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Table of Contents

9V Battery Holder/Drawer .................................................................................................................... 75

Accessories 76

Air Assist Cone Alignment .................................................................................................................... 76
Air Track .............................................................................................................................................. 76
Air Assist Diffusers ............................................................................................................................... 77

#2 Mirror Diffuser .............................................................................................................................................

Beam Window Diffuser ....................................................................................................................................

Summary of Contents for VLS Series

Page 1: ...VLS Service Manual...

Page 2: ...libration 12 Cutting Table Calibration 13 Rotary Calibration 15 X Axis Arm Alignment Check and Adjustment Squaring 16 Adjustments 17 Laser Beam Check and Alignment 18 Z Axis Leveling 20 Setting the Ta...

Page 3: ...lex Board 70 Flex Cable 71 Thermal Sensor Com Board 71 Thermal Snap Switch 72 Power Supply Module 73 AC Power Inlet 74 Fuse 74 Front Door Latch 38 Front Door Latch Catch 39 Front Door Proximity Sensor...

Page 4: ...4 Table of Contents 9V Battery Holder Drawer 75 Accessories 76 Air Assist Cone Alignment 76 Air Track 76 Air Assist Diffusers 77 2 Mirror Diffuser 77 Beam Window Diffuser 77 Cutting Table Insert 78 Ro...

Page 5: ...orming VLS Service Procedures Safety When performing the procedures in this manual always be sure to read and understand the entire procedure before operating the machine Follow each step carefully Pa...

Page 6: ...ation Never operate the laser system without constant supervision of all cutting marking and engraving processes Exposure to the laser beam may cause ignition of combustible materials which can lead t...

Page 7: ...behavior Always plug the system into a properly grounded earthed outlet The power supply cord is the main disconnect device the equipment should be located close to an easily accessible power outlet...

Page 8: ...NOCULARS OR MICROSCOPES This device contains a visible Red Diode Pointer Class 2 to aid in positioning material to be cut or engraved DO NOT LOOK DIRECTLY INTO THE RED LASER BEAM OR USE A REFLECTIVE S...

Page 9: ...splay Properties select the Screen Saver tab Set the Screen saver to None 3 In the Monitor Power field select Power 4 Select the tab Power Schemes 5 From the Power Schemes tab in the Settings for Home...

Page 10: ...the symbol 10 Set all Sleep options to Never or OFF 11 Click Apply 12 Scroll to USB settings and click the symbol 13 Set all USB selective suspend settings to Disabled 14 Click Apply 15 Click OK to cl...

Page 11: ...19 Click Apply to save the changes 20 Click OK to exit Laser Power Upgrading The VLS3 60 VLS4 60 and VLS6 60 are capable of upgrading to a maximum of 60 watts When upgrading either system the VLS int...

Page 12: ...e surface of the table Out of Focus The table is to low Correct Focal Height NOTE If you are unable to focus to the surface of the Engraving Table due to the system preventing you from raising the tab...

Page 13: ...le Cutting Table Calibration NOTE Even with multiple lens kits calibration on the Cutting Table is only required for one of them the calculation will be done automatically for all other optics sizes a...

Page 14: ...o the System Tab Notice that the red CALIBRATE button for the Cutting Table box is activated 6 Click CALIBRATE The Calibrate dialog box will appear Adjustments and Settings 7 Accept the new Z height b...

Page 15: ...VLS 7 The rotary automatically rotates to indicate it is properly connected 8 Select the System tab in the UCP In the Rotary field click CALIBRATE Adjustments and Settings 9 The Rotary Calibration win...

Page 16: ...ge will re home automatically on exiting the window 16 Calibration is complete X Axis Arm Alignment Check and Adjustment Squaring 1 Power OFF the VLS and unplug it 2 Remove the 2 mirror cover 1 by rem...

Page 17: ...in the previous step 8 Push the arm into the approximate center of the engraving field With your left thumb and forefinger touch the two Y axis bearings and attempt to turn or rotate them NOTE You sho...

Page 18: ...mpared to the burn mark you will make in the following steps we recommend you make a burn mark for best results 4 Using the Focus Feature on the Viewer Tab of the UCP verify the position of the red di...

Page 19: ...tinue to modify the Power settings increasing in 1 increments for each attempt 17 With a burn mark now on the piece of tape keep the piece of tape on the focus carriage 18 Click on the lower right han...

Page 20: ...left hand corner of the table inside the rulers 4 Using the UP and DOWN arrow buttons either on the machine on the front keypad or in the UCP bring the Z axis table up 5 Using the appropriate Focus T...

Page 21: ...move the Z belt again as this will throw off the alignment and the procedure will need to be restarted Manually Setting the Table Height 6 Turn OFF the system and unplug it 7 Move the Focus Carriage...

Page 22: ...lowered 14 To adjust the Lower Left Hand Corner of the Table loosen the belt pulley Lockdown Screw This releases a clamping mechanism that attaches the Belt Pulley to the Lead Screw 15 Grasp and rotat...

Page 23: ...Tool ensure the 2 0 Lens Kit is installed in the focus carriage 2 Remove everything from the engraving table stage including any currently installed accessories Cutting Table Rotary or Pin Table 3 Wi...

Page 24: ...ing distance by two 12 This number is the distance to set the focus carriage from the engraving table 13 Slightly loosen the setscrew located on the base of the focus tool 14 Raise and or lower the sh...

Page 25: ...te Leave the Phillips head screws slightly loose 9 Clean the 3 Mirror and Focusing Lens if necessary 10 Carefully reinstall the Lens Kit using the thumbscrews removed earlier 11 Tighten the Phillips h...

Page 26: ...eave the Phillips head screws slightly loose 9 Clean the Focusing Lens and 3 Mirror if necessary 10 Carefully reinstall the Lens Kit using the thumbscrews removed earlier 11 Tighten the Phillips head...

Page 27: ...emove the optic 8 Attach the new Beam Shaper to the Front Cover Plate 9 Clean the 3 Mirror Focusing Lens and Beam Shaper if necessary 10 Reinstall the Lens Kit in the Focus Carriage Replace Beam Shape...

Page 28: ...backside of the mirror so be sure that you re install the mirror correctly 6 Once the mirror has been installed perform a Laser Beam Check and Alignment Replace Mirror 2 NOTE Be careful not to touch t...

Page 29: ...4 Carefully remove the Collimator and place in a safe location 5 With the Collimator uninstalled perform a Laser Beam Check and Alignment 6 Once the Laser Beam Check and Alignment is complete install...

Page 30: ...e fan grilles in place 5 Installation is opposite of removal 7 Using a 9 64 Allen wrench check to ensure the new Collimator has the correct gap The width of the Allen wrench is approximately the corre...

Page 31: ...of removal 12 Plug in and power ON the VLS Open and close the door Check to see if the door open light on the keypad turns on and off red flashing light when you open and close the cover Or check the...

Page 32: ...a resting position 7 Remove the two screws and two washers holding each of the cover latches in position 8 Installation is opposite of removal Rear Cover Latches and Cover Latch Catch VLS3 60 and VLS4...

Page 33: ...osite of removal Rear Cover Proximity Sensor Magnets 1 Power OFF and unplug the VLS 2 Open the rear cover by pulling the latches toward the back of the system or by pressing down on the button part of...

Page 34: ...n a soft flat sturdy surface such as a table covered with a cloth with the top side face down Top Door and Window NOTE Obtain assistance from 1 or 2 additional people when removing the top door 1 Make...

Page 35: ...g outward from the door 7 Locate the 12 window nuts and remove them with a needle nose pliers as shown Set the window nuts aside in a safe place 8 With the top door still on a flat surface carefully r...

Page 36: ...Store them in a safe location Remove the hinges 9 Installation is opposite of removal 10 Plug in and power ON the VLS Open and close the door Check to see if the door open light on the keypad turns on...

Page 37: ...ing light when you open and close the door Or check the UCP to see if the system is indicating that a door is open Hydraulic Pressure Cylinder NOTE Obtain assistance from 1 or 2 additional people when...

Page 38: ...VLS is turned OFF and unplugged 2 Slightly open the door giving the person assisting you something to hold on to 3 While one person holds the door remove the three screws holding each of the two VLS3...

Page 39: ...slightly sticking out 4 Plug in and power ON the VLS Open and close the door Check to see if the door open light on the keypad turns on and off red flashing light when you open and close the door Or c...

Page 40: ...ocation for the edges of the rulers Exhaust Plenum 1 Power ON the laser system and the UCP 2 Remove any material or accessories from the engraving table 3 Using the Z axis buttons on the keypad or UCP...

Page 41: ...ossible 2 Attach the back panel to the legs using the 4 socket head screws 4 locking washers and 4 flat washers 6 After the cut file has been run peel the outside masking layer off leaving the inside...

Page 42: ...n the door and the cart legs 6 Securely tighten all the screws 7 Disassembly is opposite of installation 3 With the assistance of another person place the system on top of the cart aligning the pins o...

Page 43: ...Secure the X axis Arm inside the system This is normally done by wrapping a rubber band around the arm and securing it to the Y axis Motor 2 Using strong shipping tape or rope secure the top and front...

Page 44: ...ecommended that you obtain the assistance of another person when replacing a caster on this system 1 Turn OFF and unplug the VLS 2 Place each caster in its locked position 3 Slightly lift the corner o...

Page 45: ...in position and slide the sensor in or out Retighten the screws and repeat Step 7 until complete Front Door Interlocks 1 Turn the VLS ON and move the table to its lowest position using the keypad or t...

Page 46: ...er Check to see if the door open light on the keypad turns on and off red flashing light when you open and close the cover Or check the UCP to see if the system is indicating that a door is open 8 If...

Page 47: ...not to lose or damage this washer The bearing itself has no orientation and can be installed with either surface against the carriage as long as all three are installed in the same direction 9 Install...

Page 48: ...direction 9 Slowly pull the other end of the old belt allowing the new belt to be pulled through the inside of the X axis arm Make sure that you do not twist the belt going through the rail The teeth...

Page 49: ...taple and discard the old belt 11 Re attach the belt clamp to the ends of the belt Make sure that the rounded side of the clamp faces inward Gently pull the belt through the clamp until the slack in t...

Page 50: ...elt as done in X Axis Belt Replacement 8 Replace the 2 Mirror Cover and screws X Axis Idler Pulley 1 Power OFF and unplug the VLS 2 Open the Top Door and bring the X axis Arm forward 3 Remove the 2 mi...

Page 51: ...amp and drive gear should be flush with each other 9 Once the gear and retaining clamp are in place Tighten the screw 10 Installation is opposite to removal once finished tension the belt according to...

Page 52: ...is Motor wire from the Upper Flex Board 12 Remove the 4 screws and washers that hold the motor to the motor bracket 13 Remove motor and set apart 14 Install the drive gear onto the new motor following...

Page 53: ...n the top 2 and bottom 2 of the support 5 Remove the 2 mirror cover 1 by removing the thumbscrew 2 sliding the cover to the right and then off the rail 6 Unscrew the two protruding screws on the left...

Page 54: ...tallation It is often easier to feed the belt through the X Axis rail prior to installing the end assemblies Ensure that you do not have a twist in the belt Failure to remove a twist will result in th...

Page 55: ...staple and discard the old belt 8 Insert the new Y axis Belt ends into the belt clamp with the belt teeth facing inward Pull the belt as tight as possible by hand NOTE For the next step you will need...

Page 56: ...il Place the end of the ruler against the middle of the Y axis arm inside the belt groove Hook the spring scale onto the middle of the belt and pull the scale until you reach 1 2 inch You should read...

Page 57: ...nd and pull the metal shaft 2 out with the other 9 Remove the drive gear and replace it with a new one 10 Follow the instructions of Y Axis Belts beginning at Step 5 to finish the installation Y Axis...

Page 58: ...s securing the motor to the Y Motor bracket 8 Installation is opposite of removal 9 Once the new motor is installed perform the X Axis Arm Alignment Check and Adjust Squaring Y Axis Bearings 1 Power O...

Page 59: ...Contents Y Axis Page 59 Y Axis Y Axis Rail This is not a field serviceable part as the Y axis rails have to be completely square for the system to function properly If the Y axis rail s need to be rep...

Page 60: ...ly loose 11 Place the small Z axis Belt onto the lead screw drive gear and the new Z axis Motor 12 Pull the motor to the right to re apply tension to the belt while tightening the 3 screws Do not over...

Page 61: ...he old belt off and slide it under the lead screw pulleys Z Axis Limit Switch 1 Turn ON the VLS and lower the engraving table all the way down by using either the keypad or the UCP 2 Power OFF and unp...

Page 62: ...4 socket head screws and 4 washers holding the left stage support in place 6 Using a permanent marker draw a square in the four cut outs behind the lead screws This step critical and will make the in...

Page 63: ...screws securing the Z Axis Stage Support and Table Support Right 7 Remove the 4 socket head screws 4 lock washers and 4 flat washers holding the Left Z Axis Assembly in place 8 Remove the Left Z Axis...

Page 64: ...ew from the assembly 4 Remove the top bearing block 8 Remove the 3 socket head screws 3 lock washers and 3 flat washers holding the Right Z Axis Assembly in place 9 Remove the Right Z Axis assembly fr...

Page 65: ...locate the proximity sensor and disconnect it from the wiring harness 5 Locate and remove the two screws holding the left hand side of the stage to the left stage support 5 Loosen the screw securing...

Page 66: ...e stage locate and remove the two screws and washers holding the right hand side of the stage to the right table support Set the screws aside 7 Lift the stage out of the system and set it in a safe lo...

Page 67: ...nt fork with the larger tab exposed to the outside Laser Source NOTICE Handle the laser with care Do not bump or jar it 1 Power OFF and unplug the VLS system 2 Open the rear cover by pulling the latch...

Page 68: ...m before continuing 7 With the laser at an angle make sure it is hanging correctly on the two laser supports while still seated on the alignment fork correctly 8 When rotating the laser down make sure...

Page 69: ...he protective backing from the new keypad and slowly apply it to the system making sure the connector goes to the inside of the system 7 Connect the keypad to the wiring harness 8 Installation is comp...

Page 70: ...plug the cable attached on the back of the board DO NOT pull on the Lower Flex Board because it is still attached to the VLS 7 Installation is opposite of removal Upper Flex Board 1 Power OFF and unpl...

Page 71: ...ermal sensor com board and slide the board out being careful not to damage the testing button 7 Installation is opposite of removal Flex Cable 1 Power OFF and unplug the VLS system 2 Open the Top Door...

Page 72: ...roperly Thermal Snap Switch NOTICE When installing the new Thermal Snap Switch do not apply excessive force when bending the Thermal Snap Switch s metal contacts 1 Power OFF and unplug the VLS system...

Page 73: ...nscrew the 4 Button Head Screws located underneath the right Rear Shelf Set the screws and washers aside 3 After removing the 4 Button Head Screws proceed to the left side of the VLS Located near the...

Page 74: ...fuse drawer 4 Installation is opposite of removal AC Power Inlet 1 Power OFF and unplug the VLS system 2 Remove the Power Supply module 3 Turn the power supply module over and set it on a safe flat s...

Page 75: ...e the laser and set it aside in a safe place 4 Follow the CPU procedure up to step 7 5 Disconnect the battery cable from the thermal sensor com board 6 Remove the mounting screws from the 9V Battery H...

Page 76: ...kets 9 Installation is opposite of removal Air Assist Cone Alignment 1 Complete the X Axis Arm Alignment and Adjustment Squaring 2 Complete Laser Beam Alignment 3 Power ON the VLS and start the UCP 4...

Page 77: ...ove the two screws securing the Fitting Block to the Beam Widow Protector 7 Unscrew the diffuser from the Fitting Block 8 Installation is opposite of removal Air Assist Diffusers 2 Mirror Diffuser 1 E...

Page 78: ...2 Set cutting table on a safe and level working surface 3 Remove the 8 screws holding the rulers and side braces of the cutting table in place and set aside 4 Remove the rulers and side braces 5 Caref...

Page 79: ...PCB board and set it aside 7 Remove the E Ring from the drive shaft Rotary Belt Motor 1 Remove the Rotary fixture from the system if installed and place on a flat working surface 2 Turn the rotary ov...

Page 80: ...the lowest point on the rear bracket to tension the belt 8 Remove the 5 screws securing the rear driver bracket to the front drive bracket 9 Firmly press the drive shaft out of the front drive bracke...

Page 81: ...rs securing the toggle clamp 6 Install new toggle clamp with the four screws and washers Rotary Clamp NOTE If you are using an extended rotary you will not have the tailstock cover in step 4 All other...

Page 82: ...ms correctly complete the installation If the clamp does not apply sufficient pressure to stop the tailstock from moving remove the tailstock from the rotary base 8 Slightly unscrew the clamp stopping...

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