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No part of this document may be reproduced, stored in retrieval system or transmitted by

any means, electronic, mechanical, photocopying, recording or otherwise, without written
permission from Tri-Star Technologies.

2. SAFETY

This chapter briefly describes safety issues associated with M100LFG-TT-A 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-A
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-A 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-A 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

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Содержание M100LFG-TT-A

Страница 1: ...S MANUAL M100LFG TT A Tri Star Technologies Laser Wire Marker Rev 4 4 June 2014 Tri Star Technologies 2201 Rosecrans Ave El Segundo CA 90245 USA Tel 310 536 0444 Fax 310 536 9322 www tri star technologies com ...

Страница 2: ...aser Cooling System 19 4 3 Beam Scanning System 20 4 4 Wire Pulling Mechanism and Coiling Pan 21 4 5 Operator Work Station 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 35 9 2 Default Font 36 9 2 Offsets 37 9 3 Parameters 38 9 4 Scanner Settings 39 9 5 Laser Parameters and Energy Offset Screens 41 9 6 Import ...

Страница 3: ...ored in retrieval system or transmitted by any means electronic mechanical photocopying recording or otherwise without written permission from Tri Star Technologies 11 Laser shipping instruction 54 12 Electrical Diagrams 57 13 List of Appendices 579 ...

Страница 4: ... language barcode 3 of 9 and some other symbols Special symbols and foreign languages may be supported per user request The M100LFG TT A 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 ...

Страница 5: ...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 regi...

Страница 6: ...TER ED RAD IATION CLASS IV LASER PRODUCT Max Output Energy mJ 0 1 Max Output Power W 2 1 Wavelength nm 355 CLASS IV LASER PRODUCT Certification Label T h isL a s e rM a rk e r m a n u fa c tu re db yT ri S ta rT e c h n o lo g ie s 2 2 0 1R o s e c r a n sA v e E lS e g u n d o C A 9 0 2 4 5 c o m p lie sw ith2 1C F R s u b c h a p te rJ a tth ed a teo fm a n u fa c tu r in g Interlock Label L a s...

Страница 7: ...quartz etc Three major control measures to reduce the concentration of air contaminants are exhaust ventilation respiratory protection and isolation of the process To operate the M100LFG TT A in a safe manner Permit only authorized personnel to operate the laser Ensure that all personnel wear adequate eye protection during laser maintenance Install appropriate signs and labels at site of laser ope...

Страница 8: ...ssed air connections and nozzles It is dangerous to touch current carrying parts For service and maintenance purposes housings and covers may be removed only when the machine is stopped and main power is switched off There is potential danger of being cut in the area around the blades Always turn off the machine before working on the cutting head or blades There is potential danger of being pinche...

Страница 9: ...centration of additives and usually does not exceed 25 m Very short laser pulses 10ns prevent regular heat exchange between the additives and surrounding 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...

Страница 10: ...60 White PTFE Tape wrap Good BMS 13 60 Green PTFE Tape wrap Marginal M22759 05 06 08 White Extruded PTFE Poor M22759 07 White Extruded PTFE Marginal M22759 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 ...

Страница 11: ...written permission from Tri Star Technologies Fig 3 1 UV Laser Marking on TiO2 doped ETFE insulation before 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 A scanning beam system ...

Страница 12: ... means electronic mechanical photocopying recording or otherwise without written permission from Tri Star Technologies 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 15 m laser fluence is 1J cm2 ...

Страница 13: ...ritten permission from Tri Star Technologies Fig 3 3 UV Laser Marking on TiO2 doped PTFE insulation before 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 A scanning beam system ...

Страница 14: ...means electronic mechanical photocopying recording or otherwise without written permission from Tri Star Technologies 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 8 m laser fluence is 0 8J cm2 ...

Страница 15: ...d Coiling Pan 5 Operator Work Station 6 Wire pre feed optional Warning M 100LFG TT A contains 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 A In proper operational condition all laser radiation is completely enclosed inside the cabinet in compliance with laser safety standards ANSI...

Страница 16: ...n consists of a laptop computer It is connected to the main cabinet through I O ports The M100LFG TT A 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 A System Specifications Laser wavelength 355 nm Laser average p...

Страница 17: ...n the frame inside the cabinet Fig 4 2 The connection cables run from the laser to the power supply and to PLC The air cooling heat exchanger is attached to the bottom of the laser base plate The heat exchanger has thermo conductive layer and fan to maintain the stable laser output Optical system is 3X telescope It provides the laser beam shape is necessary for marking Laser Power supplies Laser c...

Страница 18: ...nic mechanical photocopying recording or otherwise without written permission from Tri Star Technologies The laser is externally controlled by the PLC and scanner board All laser parameters are downloaded from the computer Warning Do not press any buttons on the laser unless instructed by authorized personnel ...

Страница 19: ...fan for use with the laser head The auxiliary fan attached to the heatsink is controlled through the laser A temperature sensor inside the housing continuously measures the base plate temperature and its feedback is part of an active servo loop that is used to set the fan speed The laser system provides the drive current for all of the active components inside of the laser head including the therm...

Страница 20: ...quire any alignments Scanner is powered by the separate 15VDC power supply The board is connected to the scanner 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 5 B...

Страница 21: ...its the machine and is automatically coiled for easy handling The wire enters from the inlet guide on the left wall of the cabinet continues through the straightener goes through the wire marking window to the pulling mechanism and then through the wire guide cutter and exit tube into the coiling pan Fig 4 6 Additional set of guides is provided for the thick wires Standard system handles the wires...

Страница 22: ...Standard pressure is set around 30 psi however it can vary depending on the wire gauge and mechanical properties of the insulation Belts can be easily removed from the pulleys and replaced by loosening belt tension rollers Fig 4 7 Pressure regulators and Electrical panel PLC controls the movements of pulling belts by supplying pulses of appropriate frequency to the stepping motor drivers It pulls ...

Страница 23: ...cks and laser scanner malfunctions Fig 4 7 shows all major electrical components Optional motorized prefeed is mounted on a separate cart on the left side of the laser marker It consists of the spool shaft connected to the AC motor two pairs of wire pulleys on a dancer shaft top and bottom limit switches and speed regulator When the wire starts moving the bottom pulleys move up and the motor spins...

Страница 24: ...be configured to the customer s specifications The operator can input information using a keyboard memory stick LAN etc In the marker mode computer has Ethernet connection with PLC RS 232 Serial connection with Laser and regular USB to USB connection with ScanAlone board White start and Red Power off emergency stop buttons are conveniently located on the front panel of the cabinet When powered and...

Страница 25: ...ing belts and through the wire guide into the cutting block Fig 4 6 5 Make sure that the wire is in the middle of the pulling belts and close the belts using the toggle switch 6 Gently pull the wire back from the left side of the cabinet and tight the straightener 7 Use air pressure regulator on the back of the cabinet to adjust the belts pressure if necessary 8 Close the door Wire marking 1 From ...

Страница 26: ...ean dry free of contaminants oil and water Air pressure 5 5 7 atm 80 100psi Upon receiving the system remove it from the box and visually inspect for damage The system is carefully packed at the Tri Star s manufacturing facility If any damage is noted file a claim with the carrier Assemble the system as follows 1 Set M100LFG TT A laser wire marker on a firm bench or table 2 Assembly the prefeed if...

Страница 27: ... necessary Inspect compressed air filters monthly drain excessive moisture Inspect I O cables and power cords for damage and loose fit Basic malfunctions are listed in the following table Problems Causes Solutions Power ON light is not illuminated Line cord is not connected Main power switch on the back of the cabinet is not on Offset Alignment problem see above Laser does not switch into the powe...

Страница 28: ... in the M100LFG TT A are available and may be ordered To obtain spare replacement parts address order or inquiry to TRI STAR TECHNOLOGIES 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 A model and serial number b Part number of part if known c Description of part including function a...

Страница 29: ... short menu for editing deleting and running the wire Double click opens the wire editing window To select 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 ...

Страница 30: ...pens the edit window for the wire highlighted in the wire grid Copy Wire copies the selected wire to the 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 r...

Страница 31: ...leading and trailing spaces are also taken into account The last message will only be printed if its width together with trailing end is smaller than the segment remainder SAVE button loads the edited wire into the current assembly wire grid Assembly Gauge selects the appropriate wire diameter for an accurate representation in the picture box blue strip Drawing Scale scales up or down the both mes...

Страница 32: ... the Line Spacing to 0 will remove all vertical lines leaving the contour only Contour checkbox is used to mark the outline of a character Refer to Chapter 10 2 for the details Vertical should be checked for marking along the wire Vertical tower mode allows printing a larger character as compare to the horizontal across the wire orientation That can significantly improve marking legibility especia...

Страница 33: ...e resumed from the point it was interrupted Laser ON OFF buttons turn laser on and off When the laser is turned off Laser is OFF label is visible When the laser is switched on and all alarms are cleared the label changes to Laser is Ready and RUN button becomes active Warming Up label appears when the laser is warming up The temperature stabilization progress is shown by a moving bar on the bottom...

Страница 34: ...o process the next wire Manual mode can be activated and deactivated any time during the production run Time shows the time it takes to mark a message when MARK button is triggered During the production PLC is constantly monitors basic system parameters and stops the process if any of the following malfunctions occur Laser Fault laser malfunction Wire Feed jammed wire prefeed malfunction Door Inte...

Страница 35: ...otherwise without written permission from Tri Star Technologies 9 1 Setup Setup tab defines basic control parameters 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 Setup tab ...

Страница 36: ...e version has limited number of fonts for printing the alpha numerical information in English including lower 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 b...

Страница 37: ...gth of the marking zone along the wire Angle defines the difference between X axis of the scanner and wire center line Make 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 or under the wire on piece of white paper as shown on Fig 4 3 4 Using the arrows move the beam to the center of the wire and to the right border o...

Страница 38: ...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 see p 9 2 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 Cut Time is the amount of ti...

Страница 39: ... Watts Laser Off Time is the maximum time the laser can be idle before turning the diode pump off Click the Save button to save all these values to the application Click the Cancel button to close the dialog box without saving any changes 9 4 Scanner Settings The following screen sets the scanner parameters Fig 9 10 Scanner parameters Mark Speed determines how fast the scanner moves when the laser...

Страница 40: ...od determines remote Q SW triggering frequency Frequency is factory set up for optimum laser performance Altering the frequency may change laser performance and marking 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 reinitial...

Страница 41: ...tive Fig 9 11 Laser Configuration and Energy Offset Laser ON OFF button turns the Q Switch on and off Temperature boxes display the current and set temperatures of the laser crystals and diode Arrow buttons are used to change the vlaues Save button saves the current setting Start Power Test moves the laser beam into the Beam Dump tube and turns the Q Switch on The button is disabled when laser dio...

Страница 42: ...y any means electronic mechanical photocopying recording or otherwise without written permission from Tri Star Technologies Laser Off turns the beam off Arrows move the beam into corresponding direction Save button saves the current setting Cancel closes the window without saving new values ...

Страница 43: ...NG GAP 20 8 Fig 9 12 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 ...

Страница 44: ...e section that has to be changed 2 Click Edit button to enter Edit Mode Column Number dropdown list will 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 Configu...

Страница 45: ...e Blue bar shows the message printed on the wire The bar code can be inserted in any section of the wire Fig 9 13 Barcode Barcode parameters are shown in Fig 9 14 Fig 9 14 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 betwe...

Страница 46: ...ronic mechanical photocopying recording or otherwise without written permission from Tri Star Technologies 9 8 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 15 About ...

Страница 47: ... of Wire Detector Printer Display state of Print Enable if Zebra Printer is attached to machine Disable if 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 fil...

Страница 48: ...o dimensional scanning beam technology to produce image on the wire Deflection mirrors scan the laser beam according to a specified pattern similarly to a hand writing process 200 mm objective focuses the beam on the wire surface Standard laser fires 50 000 shots per second leaving one 30 60 µm marking dot on the wire surface per shot The distance between the dots is completely programmable and de...

Страница 49: ...acter size The font selection is described in Subchapter 9 1 Generally larger characters provide better legibility especially for the wire insulations that produce a poor contrast under UV Laser exposure Printing along the wire vertical font allows bigger character sizes comparing to the regular marks across the wire Arial Vertical N font is specifically designed for marking on the small diameter ...

Страница 50: ...ibed 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 characters appear much darker when character outline is filled with properly spaced marking dots Filling the space and mak...

Страница 51: ...ve remove the front or top panel of the enclosure The objective lens focuses the beam on the wire Moving it up increases the dot size on the wire and reduces the incident density of the laser radiation Fluence Fluence is measured in Joules per square centimeter and defines the amount of energy applied to the unit of surface area during one laser pulse In most of the cases fluences less than 0 5J c...

Страница 52: ...ent may be reproduced stored in retrieval system or transmitted by any means electronic mechanical photocopying recording or otherwise without written permission from Tri Star Technologies Fig 10 3 Objective Objective position ...

Страница 53: ...eflon insulated wires has a grayish bluish color and cannot be as dark as on Tefzel insulation Fig 10 5 Fig 10 1 M100LFG TT A 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...

Страница 54: ...ut written permission from Tri Star Technologies 11 Laser shipping instruction Dismount the laser in the following order 1 Remove the side cover and disconnect the signal tower cable 2 Remove the top cover of the cabinet 3 Remove 2 optics protective cover screws and carefully remove the protective cover Optics protective cover Laser Optics protective cover screws ...

Страница 55: ... top of heat exchanger One is at the back side see picture above and two ones are at the front of the laser 6 Take the laser out from the frame and set it on a solid table 7 Pack the laser head in the moisture tight envelope 8 Ship the laser in the original shipping container to Tri Star Technologies 2201 Rosecrans Ave El Segundo CA 90245 USA Laser Power cable Laser RS 232 Laser Analog control Hea...

Страница 56: ...c mechanical photocopying recording or otherwise without written permission from Tri Star Technologies To set the laser back into the working position follow the instruction in the reverse order There are 3 dowel pins on the heat exchanger and new laser will be installed in the same position without realignment ...

Страница 57: ...s document may be reproduced stored in retrieval system or transmitted by any means electronic mechanical photocopying recording or otherwise without written permission from Tri Star Technologies 12 Electrical diagrams ...

Страница 58: ... part of this document may be reproduced stored in retrieval system or transmitted by any means electronic mechanical photocopying recording or otherwise without written permission from Tri Star Technologies ...

Страница 59: ...d stored in retrieval system or transmitted by any means electronic mechanical photocopying recording or otherwise without written permission from Tri Star Technologies 13 List of Appendices A Laser Manual B Scanner Manual C ScanaloneCard Manual ...

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