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Operations Manual - Control Laser Corporation

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1. or ERUIT LEG ERE Mage eL EE tL iude 8 3 Inspecting and Cleaning the Scan Mirrors c ccceeeeeeeeeeeeseteeeeeeees 8 3 www controllaser com 407 926 3500 iii ProWriter F20 Operations Manual Table of Contents Troubleshooting E 9 1 EEN a ele uera deemed Sensei ee ee 9 1 Material Suitability to Laser Marking esee A 1 Part NUMDGMS ET B 1 www controllaser com 407 926 3500 iv Preface Introduction This manual covers safety system specifications installation maintenance basic troubleshooting procedures and operations Diagrams and drawings will be included to assist in the description of components and layout of the ProWriter F20 in the Customer Services Manual WARNING It is extremely important to read and understand Chapter 1 Safety before attempting to operate the ProWriter F20 Laser Marking System Control Laser Corporation CLC welcomes suggestions for future editions of this manual Please send your comments to Attention Marketing Control Laser Corporation 2419 Lake Orange Drive Orlando Florida 32837 E mail clcsales controllaser com Please contact the Field Service department for information regarding the maintenance of the ProWriter F20 Phone 1 866 612 8619 Monday through Friday 8 00 a m to 5 00 p m EST Fax 407 926 3551 24 hours a day seven days a week E mail clcsales Q2 controllaser com For information about CLC visit our webs
2. Master Key Control 1 5 5 Emission Indicator sss 1 5 6 Beam Aitenuator ener nnns 1 6 7 Location of Controls sssssssssssseseeeeeeeneee nnns 1 6 8 Manual Reset uncta led en ed ies 1 9 9 Jeebelng eL Ec 1 9 10 Documentation riae dele SEENEN 1 10 Classification of Laser Functions ssssseeessesinesrresrresinsssrnssrnssrnssrnssrnssrns 1 10 ee EE EE 1 11 Use of Combustible Material 1 12 Safety Label Diagram iei EE ero rette etate dt a neun 1 13 407 926 3500 ProWriter F20 Operations Manual www controllaser com System Description 1 ain ettet EEEEEEEREASEEEREEE NEEN 2 1 SI zs sede seh caine abode den abet Seege e Ee gege 2 1 ee Ee e le 2 1 Control UNIT mE 2 3 Marking Head EE 2 3 System Design Dees 2 5 Marking Fields tr tert ect ce Etre ep te 2 6 Computer Architecture nnne nnns 2 6 yug 3 1 Lasar ele TEES 3 1 OV CIVICW 3 1 Optional Accessory Control Wem 3 1 System Startup Procedure tt 3 3 Hardware Status Monitor 3 4 Automatic Shutdown ssssssssssseseee eee enne nnne nennen 3 4 Restarting the System sese eene 3 4 Manual Shutdown PDrocedure enne 3 4 Emergency Shutdown Procedure sse 3 5 Installation EEN 4 1 Receipt and Inspection sssssssssssseseseeeneeen nennen 4 1 UMP ACKING eT 4 1 Space and Environmental Requirements sss 4 2 Electrical Requireme
3. The user is familiar with basic programming concepts The user is designing a program requiring programming commands www controllaser com 407 926 3500 5 3 ProWriter F20 Operations Manual Software Setup mL File Edit View Laser Marking Admin Utilities Window Options Help 2 Xx P e ld pi A fe L Ki Q E Load Ejsmuate Fe Lase Fiy Pause Fm Stop Ta Design View E cMD Editor Ex Run Time System f SAMPLE PROGRAM Status lSpecifies that all position and height values be in inches INCH 1 Current level 12 amperes CURRENT 12 18ets the writing speed SPEED 20 iSets the pulse frequency QSMODE 5 Exclamation Point Adds text such as comments and instructions that will not be marked or affect the program in any way 8 21 00 AM Syntax comments Parameters comments are user supplied reference text that will not be marked Example Figure 5 2c Command Editor System Organization The ProWriter F20 incorporates two types of part marking programs and three types of reference files into part marking programs See Figure 5 3 www controllaser com 407 926 3500 5 4 ProWriter F20 Operations Manual Software Setup Edit Edit Drawing Command N File w File X Visual Command Editor Editor Create Create Gave iSave aly Start Compile 111 Visual B Open Start nS Command Open CBJ LBJ FBJ Hi CB Rear Software Start Con
4. HPLC grade acetone or Reagent grade methanol residue after evaporation 1 ppm WARNING Both acetone and methanol are highly flammable Use extreme caution when using acetone or methanol to clean laser components A fire or explosion could occur if the laser beam is allowed to contact flammable or combustible materials Keep acetone and any other flammable or combustible materials away from the laser when the keyswitch is in the POWER ON position 8 Shake excess liquid from the swab Gently roll the moist swab across the glass allowing each side of the swab to touch the surface only once Discard the swab and repeat with a new swab Continue until the entire glass is clean Do not touch the surface with a dirty swab this re contaminates it Do not dip used swabs in the cleaning solution this contaminates the solution Use gentle pressure to remove dirt and oils Do not rub a dry swab against a dry surface or scratching might result Or Gently rub the wet lens tissue across the glass in a circular motion starting from the center of the glass and working slowly to the outer edges Do not stop after the circular motion is started or a haze will form Use a clean section of lens tissue for each stroke across the glass Use gentle pressure to remove dirt and oils Do not rub dry tissue against a dry surface or scratching might result 9 Inspect the protective window for foreign material burn marks and other damage The bes
5. If Necessary Turn Laser Off Check All Cables amp Connectors Running From Computer to Contact CLC Field Service Turn Laser Off Check Power Cable From Wall Outlet Into Computer Turn Laser Off Inspect Fuse 2 Replace Key Not Set to Computer On Position Turn Key to Computer On Position Computer Power Supply Malfunction www controllaser com Contact CLC Field Service 407 926 3500 9 3 ProWriter F20 Operations Manual Material Suitability for Laser Marking Material Image Contrast Carbon Resin Good Ceramics Bare Good Gold plated Good Lacquer coated Good Glass Poor Proprietary CLC Process Good Inconel Graphite Good Kovar gold plated Good Metallics Aluminum Anodized Excellent Bare Good Black oxide coated Excellent Brushed Good Cast Good Galvanized Good Painted Excellent Brass Bare Good Coated lacquer Good Bronze Good Cast Iron Good Cobalt Good Copper Bare Poor Nickel coated Good Germanium Good Gold Poor Silver Good Steel Cadmium coated Good Carbon steel Excellent Cast steel Good Chrome plated Good Hardened Good Nickel plated Excellent Oxide coated Good Spring steel Good www controllaser com A Appendix A Material Image Contrast Metallics Continued Stainless polished Stainless unpolished Steel alloy Stress proof steel Surgical steel Untreated steel Titanium PC Board Bare Coated fiber Fiber substrate Plastics ABS Acrylic Delrin DIP plastic Ep
6. dTa controllaser ProWriter F20 LASER MARKING SYSTEM www controllaser com Operations Manual 2419 Lake Orange Drive Orlando FL 32837 Telephone 407 926 3500 Fax 407 926 3590 www controllaser com www controllaser com Table of Contents xii me V Tui cefe 8 e MET V About This Publication sess vi Chapter SUMMAN cise n cheer tn hare Rape EES vi Document Conventions sssssssssssseeeneeeeen nennen vii PROVISIONS 2i idest ent ee eek ke cada aim ed eta ened vii Technical Support Directory esee ix Field Service lee TE ix Suppott e Vd e ix SUPPOML DY FAX qe ix free eine VE UE ix Support by Website A ix Service and Maintenance Programs D Advanced Maintenance Training Seminars sss x Product E re X Parts Bepalt iiie indie e edite ao iere dee NEE dd raf nada X Replacement and Spare POTIS cuoio d DRAK US DURUM NE NIU NE xi cri eee 1 1 Hecommiendalion EE 1 1 Laser Radiation Wavelenglth see 1 2 Recommended Density for Optical Eyewear suse 1 2 Laser Radiation Specifications esses 1 2 Responsibility of the Laser User 1 2 Performance Requirements sse enne 1 3 J Protective Housing sence eege deed NEE NES eer 1 3 2 Safety Interlocks 1 oi eee aa eaa 1 5 3 Remote Interlock Connector sss 1 5 4
7. dirty or damaged optics or it might be a sign of a more serious problem To test the power output hold a laser power probe in the beam s path while running the Power Output Test Program The program should be created in the Command Editor and www controllaser com 407 926 3500 8 1 ProWriter F20 Operations Manual Routine Maintenance saved with the cmd extension See Appendix B Part Numbers for laser power probe ordering information and information on the Maintenance tool kit Power Output Test Program AUTOSTART SETBIT 39 CLRSCR PRINT 9 10 Set current to 18 amps PRINT 10 10 Place power probe in beam path and press PRINT 11 10 ENTER to turn on the beam for test INPUT 6 PRINT 10 10 PRINT 11 10 CURRENT 18 WAIT 500 Q 21 CLRBIT 39 PRINT 10 10 The beam is on PRINT 11 10 Press ENTER to turn the beam off INPUT 99 SETBIT 39 CLRSCR PRINT 10 10 The beam is off PRINT 11 10 Before You Begin Put on laser safety goggles with an optical density OD as recommended on page 1 Turn the keyswitch to the Power On position WARNING Do not open the safety shutter unless all personnel in the operating area are wearing laser eyewear with an optical density OD as recommended on page 1 1 To test laser power output 1 In Laser Marking Studio LMS click on the Status tab to view the Status window Choose File gt Open from the Main menu The Open dialog box is displayed In the Fi
8. from Laser Institute of America LIA 13501 Ingenuity Drive Suite 128 Orlando FL 32826 3009 Telephone 407 380 1553 Fax 407 380 5588 www ANSI org EN 60825 is issued by the European Committee for Electrotechnical Standardization CENELEC as a safety standard for the manufacture and use of laser products in the European Union It is enforced individually by the government of each member country of the European Union For more information please use the address phone number and or web site below CENELEC 35 Rue de Stassartstraat B 1050 Brussels Belgium Tel 32 2 519 68 71 Fax 432 2 519 69 19 www cenelec org Performance Requirements 21 CFR and EN 60825 specify certain performance requirements features that must be incorporated into or provided with each laser product for radiation safety purposes These features with an explanation of their function in the ProWriter F20 are described in sections 1 10 in this chapter 1 Protective Housing The laser radiation emitted by a Class IV laser product must be contained within a protective housing at all points where access to radiation is not required during normal operation of the product in the performance of the function for which it was designed 21 CFR 1040 f 1 and EN 60825 4 2 Laser radiation generated by the ProWriter F20 originates in the controller and is delivered via an optical fiber to the marking head assembly shown in Figures 1 1 and 1 2 The m
9. is competent to administer first aid e When possible keep one hand away from the equipment to reduce the danger of current flowing through the body e Special measurement techniques are required for this system Ground references must be selected by a technician who has a complete understanding of the system operation and associated electronics Use of Combustible Material WARNING A fire or explosion could occur if the laser beam is allowed to contact flammable or combustible materials Care must be taken to ensure that such materials are kept away from any part of the laser beam path See Figures 1 1 and 1 2 www controllaser com 407 926 3500 1 12 ProWriter F20 Operations Manual Safety Label 1 and 2 are on both sides of the laser head Label 3 is located on top of laser head and on inside frame Lable 4 is located on side of laser cabinet 2 INVISIBLE amp VISIBLE RADIATION AVOID EYE OR SKIN EXPOSURE TO DIRECT OR SCATTERED RADIATION CLASS IV LASER PRODUCT MAX OUTPUT 1kW 20kZ 1060 nm and 1mW 660nm LASER RADIATION AVOID EYE OR SKIN EXPOSURE TO DIRECT OR SCATTERED RADIATION MAXIMUM OUTPUT 25w AVG 20kW PEAK PULSE DURATION 70 120 nsec WAVELENGTH 1055 1070nm 5mW cw Q660nm CLASS IV LASER PRODUCT 4 Control Loser 2418 LAKE ORANGE DRIVE ORLANDO FL 32817 CAUTION MODEL SERIAL VISIBLE AND CR INVISIBLE LASER RADIATION WHEN OPEN AVOID EYE OR SKIN EXPOSURE TO DATE MF
10. logo files characters within fonts and command sections within command files LENS N A Assigns the laser s XY millimeter scale value to variable 508 RCLOSE N A Closes the text file previously opened for reading by the ROPEN command READ N A Reads data from an open text file and assigns it to a variable ROPEN N A Opens a text file on the rear computer for reading STRIPPER STRIP Strips space characters from the left or right TCAT N A Adds one text string to another TLEFT N A Copies text from the left of a specified location in a source string and assigns it to a destination variable TLEN N A Determines the number of characters in a string and assigns the number to a variable TMID N A Extracts text from the middle of a string TRIGHT N A Copies specified number of characters from the end of the source string to the destination text buffer WCLOSE N A Closes text file previously opened for writing WOPEN N A Opens a text file on the rear computer for writing WRITE N A Writes data from a variable to an opened text file www controllaser com 407 926 3500 7 7 Routine Maintenancem Performing Inspection and Maintenance Only individuals who have read the safety chapter of this manual should perform routine inspection maintenance troubleshooting and repairs Proper safety precautions should always be followed when operating inspecting and repairing the laser A qualified technician should perform all troubleshooting and
11. original installation site Check the environmental requirements outlined on page 4 2 Space and Environmental Requirements During moving do not subject the laser system to vibration excessive cold or excessive heat The ProWriter F20 can be stored for up to 5 years The temperature of the storage area must be between 14 F to 140 F 10 C to 60 C www controllaser com 407 926 3500 4 6 Software Setup Overview Laser Marking Studio LMS is a Windows based software program Drop down menus pop up windows dialog boxes and toolboxes are provided to make navigation quick and simple Recommendation Users unfamiliar with the Windows operating system should consult a Windows manual to learn basic navigation techniques before working with LMS The LMS software contains three main screens Run Time Design View and Command Editor All three of these can be accessed by clicking on the tabs located at the top right corner of any screen see Figure 5 1 y Run Time CMD Editor EY Design View Figure 5 1 Window Tabs Both the Design View and Command Editor are capable of creating programs that satisfy basic part marking needs Each screen has a unique feature that makes it suitable for writing certain types of programs Run Time Run Time is used only for loading and marking programs It displays hardware status and the program s marking parameters Editing cannot be done in this window See Figur
12. received Report any discrepancies to both the carrier and CLC Field Service department 407 926 3550 5 Ensure all packing lists manuals drawings and accessory packages are removed from the packing material before it is stored It is recommended to retain all packing materials In the unlikely event the laser must be returned pack the laser or parts in a suitable container for shipping CLC is not responsible for any damage on returned laser or parts www controllaser com 407 926 3500 4 1 ProWriter F20 Operations Manual Installation The temperature where the laser is installed should not be less than 33 F 1 C or greater than 93 F 33 C non condensing humidity Space and Environmental Requirements The ProWriter F20 should be installed in an area as free as possible from the following e Contaminants such as dust and oil mist e Combustible and flammable materials such as explosive fumes and gases e Corrosives such as acid vapors e The system should not be subjected to high energy level radio frequency emissions such as a two way radio or broadcasting equipment CAUTION The infrared laser emissions might interfere with the infrared sensors of nearby equipment The floor or foundation where the laser is installed must be level and firm It must not be subjected to vibration or shock The temperature where the laser is installed should not be less than 33 F 1 C or greater than 93 F 33 C non condensi
13. the laser manufacturer The responsibility of the user is the safe use of the laser defined in ANSI Z136 1 the American National Standard for the Safe Use of Lasers and Section Three of EN 60825 Radiation safety of laser products equipment classification requirements and user s guide These standards require the user to appoint a Laser Safety Officer to oversee the use of this equipment This individual shall have the authority and responsibility to evaluate monitor and enforce the control of laser hazards See the appropriate standard ANSI 2136 1 in the United States of America and Section Three of EN 60825 in the European Union for the specific responsibilities of the Laser Safety Officer www controllaser com 407 926 3500 1 2 ProWriter F20 Operations Manual Safety ANSI Z136 1 is issued by the American National Standards Institute ANSI as a recommended safety guide for the use of laser products in the United States of America ANSI cannot enforce adherence to the guide However OSHA the Occupational Safety and Health Administration uses the guide as its inspection standard when it inspects workplaces that use lasers Therefore the guide carries the authority of the United States government It is recommended the procedures outlined in the guide be followed when operating the ProWriter F20 and the user contact local and state authorities to determine if any additional regulations may apply ANSI Z136 1 2000 may be ordered
14. 05 in 000010 in Linear Ring and Angular 407 926 3500 Depth of Field Range of In Focus 020 in 1 02 mm 040 in 1 02 mm 060 in 1 54 mm 2 1 ProWriter F20 Operations Manual Character Fonts Graphics Laser Controller Computer Marking controller Program Storage Video Display Diagnostics Wavelengths Infrared IR Laser Diode Wavelength Mechanical Control Unit Scanner Umbilical Length Environmental Operating Temperature Storage Temperature Relative Humidity Atmospheric Pressure Storage Life www controllaser com System Description True T ype fonts from Windows and special Laser Marking Studio LMS software fonts User programmable Imports raster and vector graphics For a complete listing refer to the LMS help tab IBM compatible Pentium Type 3 5 inch 1 4 MB floppy disk drive DVD CD RW drive hard drive USB ports Flat screen LCD 1024 x 768 resolution Self diagnosis operator viewable 1 062 nm nominal Visible red light at 660 nm 23 0 inch L x 17 5 inch W x 12 0 inch H 584 mm L x 445 mm W x 305 mm H 97 lbs 44 kg 8 5 inch L x 7 0 inch W x 7 0 inch H 216 mm L x 178 mm W x 178 mm H 710 Ibs 4 5 kg 4 9 ft 1 5 m standard 16 ft 4 9 m optional 33 F to 93 F 1 C to 33 C 14 F to 140 F 10 C to 60 C 10 to 95 non condensing O to 6 000 ft 760 to 604 mmHg 5 years 407 926 3500 2 2 ProWriter F
15. 1 Assy Lens 4 x 4 Flat Field IR 235025 2 Scanner Assy 12 mm 6 240 with XY Mount 234888 3 Cover Scan head 234796 www controllaser com 407 926 3500 B 5
16. 20 Operations Manual System Description Cooling Requirements Type of Cooling Forced air over heat sink Utilities Line Voltage 115 VAC 46 10 VAC standard 50 60 Hz 230 VAC 6 10 VAC standard 50 60 Hz optional Current Consumption 7 A typical 9 A max Normal Average Output 20 watts Control Unit The ProWriter F20 control unit contains computers drives controls and indicators as shown in Figures 1 3a and b in Chapter 1 Safety Power and laser umbilical connections are located at the rear of the control unit Marking Head The ProWriter F20 laser standard marking head configuration is shown in Figure 2 3 The laser beam emits downward www controllaser com 407 926 3500 2 3 ProWriter F20 Operations Manual System Description Emissions Indicator Cables SIDE VIEW Standard Beam Path Figure 2 3 Side View of Standard Marking Head Assembly www controllaser com 407 926 3500 2 4 ProWriter F20 Operations Manual System Description System Design X Axis Galvanometer i Y Axis E y p Galvanometer A Laser not shown for clarity k Flat Field S Focus Lens Figure 2 4 Post focus Beam steering Design The galvanometer head contains two scan mirrors each mounted on a high speed high accuracy galvanometer The galvanometers are mounted to provide independent beam motion on both the x and y axis of the marking field The laser beam first reflects off the x axis s
17. 26 3500 3 5 l d Installation z Receipt and Inspection The ProWriter F20 is thoroughly inspected and carefully packed before leaving Control Laser s Corporation CLC factory The carrier assumes responsibility for the unit s safe delivery Any claims for loss or damage sustained in transit must be made against the carrier Carefully inspect the shipment upon receipt prior to signing for the delivery e Ensure the container is in an upright position as marked by the container labels e Check the shock and tilt indicators on the system If one or more indicators are red inspect the system for damage Contact the carrier immediately Any damage loss or discrepancies discovered during unpacking should be reported to the carrier immediately Not immediately reporting damage or discrepancies of the shipment could result in the carrier refusing to honor a claim All claims should be confirmed in writing as required by the carrier For claim purposes it is recommended all packing material be retained WARNING Do not turn on the laser until the Safety and Installation chapters in this manual have been thoroughly read and understood and all installation requirements have been met Unpacking 1 Ensure the shipping containers are in the upright position as labeled 2 Cut and remove any bands or straps from the container 3 Carefully remove any packing material from the equipment 4 Check the packing list against the equipment
18. 34908 Power Detector Kit 1 Detector Power 1 064 4mv Coax Cable w BNC CONN 4 Test Adapter BNC FEMALE DUAL Banana Jack www controllaser com 407 926 3500 B 1 ProWriter F20 Operations Manual Appendix B Part Number D ription nti Heatsink Thermopile 234909 RF Dummy Load Kit 1 Load Dry RF Dummy Adapter Coax N FEMALE MALE BNC Coax Cable w BNC CONN A 234910 RF Watt Meter Kit 1 CONN BNC FEMALE Watt Meter Element 100W 234911 Water System Test Kit 1 Meter Water Flow Barb Fitting 1 NPT to v2 Tubing Nylobraid 1 2 ID X 1 8 W Clamp Hose 5 16 7 8 www controllaser com 407 926 3500 B 2 ProWriter F20 Operations Manual General Assembly Appendix B Item Description Part 1 Assy Controller 234834 2 Assy Computer 234872 3 Umbilical 234873 4 Assy Scan Head 234874 5 Enclosure Case 234804 www controllaser com 407 926 3500 B 3 ProWriter F20 Operations Manual Computer Assembly Appendix B Item Description Part 1 Monitor Flat Panel 17 in 234618 2 Keyboard Charcoal 234894 3 Mouse Charcoal 234895 4 Assy Computer 234872 5 PCB Assy APEX not shown 234410 www controllaser com 407 926 3500 ProWriter F20 Operations Manual Appendix B Scanner Assembly Enlarged Item Description Part 1 Assy Lens 12 x 12 Flat Field IR 234988 1 Assy Lens 6 x 6 Flat Field IR 234930
19. 50 Telephone 301 594 4654 www controllaser com 407 926 3500 1 1 ProWriter F20 Operations Manual Safety Laser Radiation Wavelength The ProWriter F20 emits infrared laser IR radiation at 1 062 nanometers nm and visible laser radiation laser pointer at 660 nanometers The IR laser poses the greatest risk of injury if the safety precautions in this manual are not followed The 660 nm radiation used as a locating beam the laser diode poses a less significant risk but still requires adherence to the safety precautions The specifications in the following chart are provided to assist the Laser Safety Officer see Responsibility of the Laser User below in evaluating the hazard potential of the laser These specifications represent the worst case potential for short term peak laser emission and should not be confused with the operational specifications given in Chapter 2 System Description Recommended Optical Density for Eyewear ProWriter F20 IR 6 ProWriter F20 laser pointer 4 Laser Radiation Specifications Specification IR Laser Pointer Wavelength 1 062 nm typ 660 nm Peak Power 20 kHz 10 kW n a Pulsewidth 100 ns typ n a CW Power 20W 0 5 mW Divergence lt 0 3mrad lt 0 3 mrad Beam Size 7 5 mm typ 1mm Responsibility of the Laser User The performance requirements described in paragraphs 1 9 are defined by the United States government and the European Union as the responsibility of
20. 612 8619 or clcesales controllaser com Product Warranty The Customer Service Manual explains the warranty covering the ProWriter F20 Parts Repair If a laser component fails contact Field Service immediately Most repairs can be accomplished within 24 48 hours upon receipt of the component Some power supply units may take additional time to replace repair because they may require outside vendor participation Before returning any parts to CLC for repair replacement contact Customer Service at 1 866 612 8619 You will be supplied with a Return Material Authorization RMA number used to track the part during repair and shipping Return all components to CLC by United Parcel Service UPS Federal Express or any local carrier that can track your package to Attention RMA number Control Laser Corporation 2419 Lake Orange Drive Orlando Florida 32837 www controllaser com 407 926 3500 X ProWriter F20 Operations Manual Technical Support Directory Replacement and Spare Parts In North America replacement and spare parts must be ordered directly through CLC Parts can be shipped overnight at the customer s request Spare part kits and test equipment kits are also available See Appendix B Part Numbers for current part numbers of available ProWriter F20 parts and test equipment To order parts or a current parts catalog contact Customer Service at Control Laser Attention Customer Service Control Laser Corp
21. D WW Assembled THIS PRODUCT CO ES WITH 2 SUBCHAPTER J DIRECT OR SCATTERED RADIATION Figure 1 4 ProWriter F20 Labels Check Customer Service manual for additional labels www controllaser com 407 926 3500 1 13 Overview System Description The ProWriter F20 is a general purpose industrial marking system It is designed to permanently mark a variety of materials including hardened metals ceramics carbides silicon and plastics It is capable of marking alphanumeric characters barcodes 2D matrices and graphics The system is computer controlled and is easily adaptable to manual semi automatic or fully automatic part handlers The ProWriter F20 consists of a control unit connected to the laser marking head assembly by an umbilical cord and fiber cable The control unit contains power supplies computer fiber laser source and power distribution boards For a general description of how industrial lasers work see Laser Basics in Chapter 3 System Function Specifications Performance Marking field 4 0 in Square 100 mm 6 0 in Square 150 mm 12 0 in Square 300 mm Positioning Speed Repeatability 4 0 in Square 100 mm 6 0 in Square 150 mm 12 0 in Square 300 mm Writing Modes www controllaser com Working Distance Effective Focal Length 6 42 in 163 mm 7 52 in 191 mm 13 78 in 350 mm 275 in s 7000 mm s 000003 in 0000
22. E RACK 16 BIT ASSEMBLY 232542 REV L DETAIL 232544 REV ase H 8 8 Figure 3 3 Optional I O Module NOTES 1 SCRIBE MOUNTING Tees AT A 5 PLACES 2 DRILL AND TAP EACH FOR 6 3 RIBBON CABLE CONNECTOR s PLUGGED INTO P14 The I O lines act as interfaces between the laser computer system and any peripheral devices There are 16 user programmable UO lines per module Eight lines are for input and eight for output A maximum of two I O modules per ProWriter F20 are allowed for a maximum total of 32 user programmable UO lines Peripheral devices are connected to the I O lines through Opto 22 modules The accessory I O modules should be installed on a workstation separate from the ProWriter F20 control unit Each I O line has a corresponding bit A bit can be in one of two states off binary code 0 or on binary code 1 When a bit is on its LED on the I O rack turns on when a bit is off the LED turns off The Opto 22 module defines the type of signal AC or DC and voltage range used to change the state of the bit On the first optional I O module the 16 corresponding I O bits are numbered 0 to 15 and are read from left to right In the ProWriter F20 programming language the UO lines are always identified using this numbering system The first eight I O bits 0 7 are input signals to the ProWriter F20 from outside devices and the last eight bits 8 15 are output signals from the ProWriter F20 to outside devices B
23. FT JL Left justifies text LINE N A Writes all text in straight lines MARKCCW lt lt Marks in a ring counterclockwise MARKCENTER M Marks in a ring centered MARKCW gt gt Marks in a ring clockwise METRIC N A Specifies measurement system in millimeters MILLS N A Specifies measurement system in mils MIRROR MI Marks all text or logos in mirror image NORMAL NOR Nullifies MIRROR command POSABS PA Defines absolute coordinates of the marking position and the center of the circle in Ring mode POSREL PR Defines position relative to position absolute RADIUS R Defines the radius of a circle for Ring mode writing REALEND N A Specifies subsequent logos be interpreted in non scalable real heights REALMODE N A Enables all fonts and logos be interpreted in non scalable real heights REALSTART N A Starts a block of included files in which the first file determines the scaling factor for subsequently included files www controllaser com 407 926 3500 7 4 RIGHT RING SCALEX SCALEY VERTICAL Command Command INSERT ABORT AUTOSTART BITF BRANCH BRANCHE BRANCHG BRANCHL BRANCHNE BRANCHNZ BRANCHZ CALL COMPARE COMPAREAH ENDLOOP GOSUB HALT www controllaser com ProWriter F20 Operations Manual JR N A VE N A AB N A BF BR BEQ BRG BRL BNE BNZ BRZ N A CMP CMPH EL GOS N A Software Commands Right justifies text Writes all text in circles Scales text and logo
24. Make sure the Emergency Stop switch is in the pulled out position 3 Insert the key into the keyswitch and turn to the Control On position Windows XP and the software application Laser Marking Studio LMS opens automatically and the status window displays Note Programs can be written at this point with the system in the Control On state 4 When ready to start marking turn the keyswitch to the Power On position Hardware Status Monitor The Hardware Status Monitor reports the status of hardware components to the operator If the software application is unable to read any hardware sensors the corresponding indicator will show Unknown See Figure 3 4 below www controllaser com 407 926 3500 3 3 ProWriter F20 Operations Manual System Function System Status e Communication Normal Laser Power Supply Normal Laser Temperature Normal Laser Back Reflection Normal Laser Master Oscillator Normal Shutter Open 29 System Power Supply Normal iu Cabinet Temperature Normal Scanner Power Supply Normal Figure 3 4 Hardware Status Monitor Automatic Shutdown When certain functions vital to laser operation fail the laser system s safety interlocks are triggered The power to the laser is turned off but the computer controls remain on The System Defaults Status dialog box will display and detail the fault or faults When automatic shutdown occurs see the Hardware Status Monitor and immediatel
25. Normal Laser Back Reflection Normal Laser Master OscillatorNormal s Laser Power Supply Shutter Open e Laser Temperature System Power Supply Normal e Shutter Cabinet Temperature Normal Scanner Power Supply Normal e System Power Supply When a function deteriorates the blue outline surrounding the status box changes to yellow and the Normal status changes to the appropriate indicator This state is referred to as the warning state When a function has failed the blue outline surrounding the status box changes to red and its indicator changes from Normal to Error This state is referred to as the fault state and the laser will not operate Warning and fault states may lead to operational difficulties damage to the system or automatic system shutdown Monitor the status indicators on a regular basis The troubleshooting procedures in this section are intended as guidelines only For step by step instructions on how to access inspect and replace components refer to the appropriate sections in Chapter 8 Routine Maintenance www controllaser com 407 926 3500 9 1 ProWriter F20 Operations Manual Fault General System Failure System Status Communication Normal eu Cabinet Temperature Normal Updated 11 22 54 AM Laser Will Not Lase System Status Communication Normal Ge Laser Back Reflection Normal Laser Master OscillatorNormal Shutte
26. ProWriter F20 Operations Manual Creating and Running a Part Marking Program Setting the correct GST parameters requires some trial and error See the GST command in the online manual for a list of GSTs and general tips regarding GST adjustment Other Parameters Duty Cycle not applicable Q Sync not applicable Skip Speed programmable moving velocity for long moves Reduces cycle time Marking Tips When setting process parameters consider the type of mark to be made and the material being marked Types of Marks Depending on the material a contrasting mark can be created using any one of three different techniques Each method is differentiated by the maximum temperature achieved on the material s surface e Surface Annealing Annealing creates a contrasting mark with very shallow material penetration The material surface is not disrupted and no engraving occurs The beam speed must be relatively slow because heat must be conducted into the material To avoid vaporizing the surface material the power must be relatively low and the Q switch value relatively high Surface Melting The material is heated to a molten state and is most frequently used on plastics to induce a color change This method is typically used to mark plastics with relatively fast speed and shallow marking depth High speed combined with relatively low power and Q switch rates creates this effect Material Vaporization Engraving Vaporiza
27. aintaining the ProWriter F20 including inspecting and cleaning the galvanometer mirrors and focusing lens assembly Chapter 9 Troubleshooting This chapter provides general instructions for troubleshooting the ProWriter F20 according to the laser status indicators Appendix A Material Suitability to Laser Marking This appendix lists the marking quality that can be achieved with the most common types of marking materials Appendix B Replacement Part Numbers This appendix contains the current part numbers for ordering additional parts Document Conventions Special graphics described below are used in this manual to emphasize certain types of information When paired with a CAUTION notice this emphasizes information about actions that might result in equipment damage When paired with a WARNING notice this emphasizes information that might result in personal injury Revisions If any changes occur after the printing of this manual a Revision Page will be included in the back of this manual www controllaser com 407 926 3500 vii Technical Support Directory Field Service Support A qualified maintenance technician should troubleshoot the laser system before contacting the Field Service department Attempting to isolate the source of the problem will make it easier for the field service technician to assist you Have the model name and serial number of the laser available when you contact Field Service This in
28. arameters for your specific type of mark s before shipping the system The following information is provided to understand how process parameters are determined and modified should your needs change after the initial purchase or if the user needs to develop his her own marking applications www controllaser com 407 926 3500 6 1 ProWriter F20 Operations Manual Creating and Running a Part Marking Program The ProWriter F20 provides the user with the following user adjustable means of controlling the characteristics of the laser mark Marking Speed e Duty Cycle Laser Output Power e Q Sync e Q switch pulse Frequency e Skip Speed Galvanometer Settling Time GST By adjusting these parameters the user can achieve the desired mark on a specific material Use the LMS programming commands to adjust the process parameters in the Command Editor LMS comes with set default values for process parameters If values for one or more of the parameters in the program are not specified the default settings are automatically applied when the program is marked For more information about default settings see the online manual or Viewing and Editing Default Settings in Chapter 5 Software Setup Note The preset or default values should only be used as a guide and only be adjusted based on the user s marking needs Marking Speed In laser marking the marking speed is an important variable in the thermal process and must be set to achie
29. are necessary for operation of the laser must be located so they can operate without exposure to laser radiation 21 CFR 1040 10 f 7 and EN 60825 4 8 All controls used to operate the ProWriter F20 are located in the control unit see Figures 1 3a and b The marking head assembly connects to the control unit by an umbilical cord allowing placement of the marking head assembly anywhere within the radius of the cord CAUTION The ProWriter F20 is a Class IV product or otherwise stated in your Customer Service Manual and should be operated in accordance with procedures in this manual ANSI Z136 1 EN 60825 1992 and local procedures issued by the Laser Safety Officer www controllaser com 407 926 3500 1 6 ProWriter F20 Operations Manual Safety Computer Display USB Ports Keyboard Mouse and pad not shown Floppy Disk Drive See Figure 1 3b DVD CD RW Figure 1 3a ProWriter F20 Control Unit Laser On Keyswitch Indicator Fuse Emergency Shutter pointer Stop Switch Switch Circuit Breaker Figure 1 3b ProWriter F20 Control Unit bottom half www controllaser com 407 926 3500 1 7 ProWriter F20 Operations Manual Safety Refer to Figures 1 3a and b for the location of the following controls 1 Emergency Stop Switch Press the Emergency Stop switch in to shut down the laser system The Emergency Stop switch turns off power to the laser The control system remains on Turn the sw
30. arking head assembly manipulates and focuses the laser beam at the workpiece Laser radiation is www controllaser com 407 926 3500 1 3 ProWriter F20 Operations Manual Safety completely contained within the enclosed marking head assembly except where it exits to impact the workpiece In the standard marking head assembly configuration Figure 1 1 Figure 1 2 laser radiation is emitted downward when mounted vertically The user can also mount the marking head assembly horizontally Emissions Indicator lt Lens FRONT END VIEW Standard Beam Path Figure 1 1 End View of Standard Marking Head Assembly Configuration Emissions Indicator ER Cables SIDE VIEW Standard Beam Path Figure 1 2 Side View of Standard Marking Head Assembly Configuration WARNING The ProWriter F20 marking head assembly contains no components requiring access during normal operation The laser should never be operated without its cover except during authorized service functions requiring access The ProWriter F20 is certified as a Class IV product or otherwise stated in your CUSTOMER SERVICE MANUAL Access to laser radiation is possible during operation and all personnel in the operating area must wear laser eyewear with an optical density OD as recommended on page 1 2 www controllaser com 407 926 3500 1 4 ProWriter F20 Operations Manual Safety 2 Safety Interlocks Any part of the protective hou
31. arking Laser Station To test the marking image at the Marking Laser station open and run the program with a part in place see Running a Program on page 6 8 for step by step instructions www controllaser com 407 926 3500 6 5 ProWriter F20 Operations Manual Creating and Running a Part Marking Program CAUTION Keep the safety shutter switch set to the CLOSE position at all times except when emission outside the laser marking head assembly is desired Do not open the safety shutter unless all personnel in the laser operating area are wearing laser eyewear with an optical density OD greater than 6 0 at 1 064 nm If the image does not mark as intended debug the program using the step or continuous method see Testing the Program Code Line By Line on page 6 7 Testing at a Remote Station Use the simulator to test the marking image at a remote station The simulator marks the image on the marking screen in the same size orientation and event order it would be marked by the laser It also runs the program exactly as it would run at the Marking Laser station displaying screen prompts and waiting for keyboard input if the program requires To test the marking image using the simulator see the Simulator sections in the online manual for either the Design View or Command Editor Note If the optional user programmable Input Output module accessory is installed and the program being tested requires interaction with
32. aser to stop operation when the workstation door s is open If the workstation has multiple doors each door must have a separate interlock switch and all must be wired in series Interlock switches used on access doors of workstations must be of the type so the switch contacts electrically open to break the interlock circuit Dual switches wired in a series may be used on each door to provide redundancy in the event of failure of one of the switches Means of defeating or overriding safety interlocks are not recommended To install interlock switches 1 Shut off the main electrical disconnect supplying power to the laser and appropriately tag and lock it out 2 Use 22 24 AWG two conductor jacketed cables appropriate to the environment Run the cables from the external interlock switch to connector INT Mount a normally open switch rated for 24 VDC 9 1 amp on the workstation Connect the wires to the interlock switches If multiple doors require interlock protection use a separate switch for each door and wire in series Wires are jumpered for class IV operation INT LEG RE It i lpp n ome 3 5 A HA L Figure 4 1 Laser Controller www controllaser com 407 926 3500 4 3 ProWriter F20 Operations Manual Installation Installing External Devices Basic HO Start Write An external signal from either a PLC or external power source via a normally open switch can be connected to the laser to begin marking of the currently load
33. ated on the C drive at c drive BCLC LMS LASERHl options txt Open the file and change IOIGNOR from 0 to 1 www controllaser com 407 926 3500 4 4 ProWriter F20 Operations Manual Installation LASER CONTROLLER External Power Supply 3 3 33 VDC Figure 4 2 External Switch Connection www controllaser com 407 926 3500 4 5 ProWriter F20 Operations Manual Installation Installing the Optional UO Module The user programmable input output lines are available as an optional accessory module purchased separately Many of the more sophisticated programming commands require this accessory There are 16 user programmable I O bits per module The first eight bits are dedicated for input and the other eight bits are dedicated for output For more information about I O modules see Optional Accessory Control Item in Chapter 3 System Function The I O module may be installed within a workstation 1 To locate the I O rack assembly at a greater distance such as in a workstation a round to flat type of ribbon cable is used for the interconnecting cable to be run through the conduit Figure 4 3 illustrates the I O board assembly layout 3260 1750 Wo WF 3 emt vH ce wn erc SEEEEEERE GEEAERKA D EN EE onto Loser Corpo rho EEEE nrc 1 r nasa Figure 4 3 Optional I O Module Moving and Storing the ProWriterTM F20 Confirm the system s power requirements can be met if moving the ProWriter F20 from the
34. ault value when the program is run Factory defaults also provide more efficient programming For example the default values for GST s Galvanometer Settling Times are designed to prevent marking inaccuracies such as overlapping corners in the majority of programs There is no need to specify or change GST settings in a program unless marking results are unsatisfactory Default settings for programs created in both the Design View and Command Editor are displayed by clicking on Options Customize in the Main menu The default settings can be edited to meet specific marking needs However default settings are not saved to the Ims Design View and cmd Command Editor files CAUTION Use extreme caution when editing the defaults Edits to the defaults are not saved to an individual file but to the Defaults window Default values in the Laser Defaults window might affect any cmd program run on the Marking Laser Avoid using custom default settings as a substitute for specifying control settings in a program After editing a field s in the Laser Defaults window click on OK to save the change The new default settings are saved in Ims exe settings www controllaser com 407 926 3500 5 8 Creating and Running a Part Marking Program Introduction Control Laser Corporation CLC recommends the user use the comments identifier command in all cmd programs written in the Command Editor to detail the function of each p
35. can mirror then off the y axis scan mirror Computer signals move the mirrors steering the laser beam as it moves across the marking surface The flat field lens assembly is the last optic the beam passes through before reaching the marking surface The lens assembly focuses the beam reducing its diameter and increasing its energy density The lens diameter has an equal corresponding marking field diameter The ProWriter F20 can be installed for manual semi automatic and fully automated operation www controllaser com 407 926 3500 2 5 ProWriter F20 Operations Manual System Description Marking Field The ProWriter F20 has three fixed marking field sizes available in 4 inch 6 inch and 12 inch square fields see Figure 2 5 Marking Head over the Marking field Y axis Figure 2 5 6 inch Marking Field with a Marking Head Assembly eon pre The marking field is defined as a Cartesian coordinate system The coordinate system origin is in the center of the marking field The X axis of the coordinate system is parallel with the long dimension of the laser marking head The Y axis is perpendicular to the long dimension of the marking head Computer Architecture The ProWriter F20 incorporates a Pentium class computer for the operator interface and program execution All part program access creation editing and operator input is performed on the system computer The system computer also executes part
36. d gaps at corners Every SPEED command in a program requires the GST command and its values be placed after it The faster the marking speed the larger the GST value must be CAUTION Clicking on Reset deletes any changes made to the Laser Default Parameters window GST parameter settings define both the type of beam movement where the delays must occur and the length of the beam delays There are eight types of GST values that control marking quality In the Design View GST settings are edited by clicking on the GST number This is located in the Process tab of the Properties Explorer Property Explorer Visual Process All Pre Event Post Event C Enable Override GST 3 us N Les e GST3 GSTI DELAY j Galvanometer setting Tine GST is a laser beam delay measured in micro seconds which uses 1 2 to synchronize the laser beam with the galvanometer s movement during stops starts and corners GST is used to solve the problems such as burn holes and gaps Through GST setting v Load Preset Process Parameters Save Double click on the GST value field to highlight the current value enter the new value and press lt Enter gt Use the Properties Help Window located to the right of the Properties Explorer for help on the clicked item GST values can also be changed in the Command Editor by typing in the GST number followed its value syntax GST value www controllaser com 407 926 3500 6 3
37. e 5 2a for a view of the Run Time screen Use the Run Time view when Running a program e Checking the cycle time while running a program Using the Counter function to count how many times a program has been run www controllaser com 407 926 3500 5 1 ProWriter F20 Operations Manual Software Setup File View Laser Marking Admin Utilities Options Help ny Load ic Lase Pause 8 Stop mal Design View E CMD Editor 3 y Run Time System Status Entire Job _ gt START Communication Normal LASER MARHING unn Laser Power Supply Normal Normal LO Lasci Temperature Normal Laser Back Reflection Normal Laser Master Oscillator Normal Shutter Open System Power Supply Normal Cabinet Temperature Normal Scanner Power Supply Normal Updated 12 09 19 PM GQ controllaser Successfully initialized Laser Marking Studio is Ready Figure 5 2a Run Time Design View Design View contains a drawing screen for design and editing of images and adding basic commands Programs are saved in the drawing Ims format Different program layers can be viewed and or marked at any given time Programs in the Ims format load and run from this window See Figure 5 2b for a view of the Design View screen Use Design View when Creating one or more simple graphics e The user is unfamiliar with basic programming concepts e The user is comfortable in an intuitive graphics bas
38. e acceptable marking results Color Dark colored materials absorb more laser light than light colored materials Other Marking Tips To achieve the deepest material penetration use high power low Q switch frequency and low marking speed To achieve a surface mark with shallow penetration and increased machine throughput use low power high Q switch frequency and high marking speed e Atany given power setting a slow pulse rate vaporizes more material than a high pulse rate To engrave metals use a low pulse rate To anneal metals use a high pulse rate For a list of common marking materials and their suitability to marking see Appendix A Material Suitability to Laser Marking Program Testing and Debugging The ProWriter F20 provides several ways to test part marking programs for accuracy The user can check their marking image results review the program code line by line or execute the program in real time for debugging purposes All testing methods can be performed either at the Marking Laser station or at a remote programming station At a remote station the simulator executes the program exactly as it would run at a Marking Laser station The simulator screen displays the marking image as it would be marked on a part except not in real time Testing the Marking Image Test the appearance of a marking image by either marking the program on a test piece or by running the program on the simulator at the M
39. e safety chapter of this manual Optional Accessory Control Item UO Module User Programmable eight Input and eight Output Modules The user programmable input output lines are available as an optional accessory module purchased separately for the ProWriter F20 Many of the more sophisticated ProWriter F20 programming commands require this accessory See Figure 3 3 www controllaser com 407 926 3500 3 1 ProWriter F20 Operations Manual 0000 System Function 610 www controllaser com g Ld 1A CHANNELS 0 1 uc ES 4 EL 6 7 8 9 0 n 12 M 13 ier ha pa gej GE Cei ere ehe eee eee eer eer eer mee ee ee eve eee E athe Te o Zi meooococoomooccocooo Noooo0000 No0o000000 V Re 1 3 3 7 8 TIAE 4 D Y 3 7 s 13 SET D MM Ze Mil Ze 1222 181 T82 TB3 TB4 ej ssf pss fle H bd DM 09 0 e o e Ooo DH Ze R e J Ze a S H E oe e e e o e e e e a LS 15 M Ze Oo Oo 8 o O O o O o o o o 8 o Q e la 2 E e 9 0 Satz Oh 90 0 e e e e e e 9 0 e e e e s H oe e e e oe 0 e e e e ME Ko KI K2 3 K4 K5 K6 K7 KB K KO pm K2 um KM a re e amp b e e e e CR SA e e e W e Cen e o H x J J LJ LJ LI J LJ L LI LI LI LJ LJ D D D 04 05 06 or Os o on on on ov ou ons A oec 1 gt i CC Control Laser Corpor ation D LEEILEXXXJ T n oz DIGTACVO MODUL
40. ecution until a start write signal is given RETURN RET Returns execution of a program RUN N A Runs a DOS command line statement from the rear computer TSTFAULTS TF Sets branch flag to true if faults occur and check faults are on TSTPOWER TP Sets branch flag to true if power does not reach level as programmed TSTSHUTTER TS Sets branch flag to true if shutter is closed during lasing process TSTWARNINGS N A Sets branch flag to true if warnings occur and check faults are on WAIT WT Delays program by a specified length of time Text Variable File Commands ACLOSE N A Closes a text file that has been opened for appending by AOPEN AOPEN N A Opens a file for appending APPEND N A Writes a line of text to end of a file ASSIGN ASN Assigns text or values to a variable BFSIZE BS Assigns the file size of a binary file to a variable BRCLOSE BRC Closes binary read file BREAD N A Reads binary number of bytes data from a file BROPEN BRO Opens binary file for reading BRSEEK BRS Positions number of bytes into binary file for reading BWCLOSE BWC Closes binary file for writing BWOPEN BWO Opens binary file for writing www controllaser com 407 926 3500 7 6 ProWriter F20 Operations Manual Software Commands BWRITE BW Writes number of bytes to a binary file BWSEEK BWS Positions number of bytes into binary file for writing CYCLETIME TIME Saves the time in milliseconds in text buffer DEF N A Defines variables within text files logos within
41. ed program each time a voltage is provided to the start write input Activating this switch in a continuous or intermittent manner during program execution may result in improper marking operation Refer to Start Write Connections for complete instructions Various methods exist to establish a start write connection e Use of programmable logic controller PLC e Use of an external power supply Write Complete When the laser completes marking the program a write complete signal equivalent to a contact closure is sent to the external equipment The write complete function output accommodates 3 33 DC voltage 1 ampere max and is polarity sensitive Start Write Connections Programmable Logic Controller PLC This method requires connecting a PLC to the rear of the computer at the start write connections Connect the output of the PLC to the input of the start write The PLC is programmed to provide 3 33 VDC input pulse between 100ms 250ms in duration After connecting the PLC the options txt file must be changed in the software The options txt file is located on the C drive at c drive BCLC LMS LASERHVl options txt Open the file and change IOIGNOR from 0 to 1 External Power Supply This method requires connecting an external power supply to the rear of the controller at the start write connections After connecting the power supply the options txt file must be changed in the software The options txt file is loc
42. ed programming environment www controllaser com 407 926 3500 5 2 ProWriter F20 Operations Manual Software Setup mE File Edit View Format Draw Laser Marking Admin Utilities Options Help mix J ew bal il o6 B Q x N Q Qa Q C s F5 simulate ic Lase fas Pause fim Stop D Sie OG A E El s a o e be 8 Design view cm Editor x Run Time System Job Explorer Status Mob Lasersob E C Circle Layer I Text Layer2 bal Rectangle Layer we Text Ring L kt Text Ring Cycle Time 00 00 00 711 CH Visual Process All PreEvent PostE vent B8 X Inch uj 0 Y Inch 0 Z Inch D 0 B 9 16 32 AM Angle Deg Color SS Eee KOR IO LZ LaserJob Layer DW Units Inch Field Size 6 2 6510 2 1094 This is the Property help Window to display the description and the acceptable value ranges for the selected property of the property window There may be images associated with the property description to give user a better idea on selected property Figure 5 2b Design View Command Editor Command Editor writes the programs and is saved and loaded in the command cmd format See Figure 5 2c for a view of the Command Editor screen Use the Command Editor when The program does not require graphics or graphics have already been created in a separate graphics program
43. eececeeecececeeeceaeseaeeeaeseaeeeeeeeeresereseeees 6 3 Galvanometer Settling Time GT 6 3 Other Parameters ioi ett ore dera eerte qu uk a edd Ya Etc Ru er dera 6 4 Marking Be 6 4 Types of Mare 2ogueekdeddeger dci dee Seege Le dd dne Rata Neser 6 4 Material Characteristics seen 6 4 Other Marking Tips eessssssssesseneneeeenennen nennen 6 5 Program Testing and Debugging eeeceeeeeeeceeeeeeeeeeeeeeeeeeeteeeaeeeeeneaeeees 6 5 Testing the Marking Image sseseesseeseeiessesrrrssresrnssrrnsrrnsnnsrrennne 6 5 Testing at a Remote Station sss 6 6 Testing with the I O Module Accessory s 6 6 Testing the Program Code Line Dv lime sess 6 7 Part Positioning iieri Gna rideo doxes d red ede Edu e gud rada 6 7 Running a Program event tra ree tt rn eiua x ce E ER ed RES 6 7 Marking Requirements sesi seak anaa KEES 6 8 Lasinga File RE 6 8 Software CommandS qe 7 1 Command Quick Reference Guide 7 1 Communications Commande sse 7 1 Marking Characteristic Commande sss 7 2 Marking Image Commande sss 7 2 Mathematical Commande 7 3 Position and Dimension Commande sse 7 4 Program Control Commande 7 5 Text Variable File Commande senes 7 6 Routine Maintenance sess etic cists nares tere ENEAEEEEeegbegih enced naeeenanenseaiees 8 1 Performing Inspection and Maintenance 8 1 Recommended Maintenance Gchedule eee 8 1 Testing Power Output 8 1 Optics Maintenance
44. en file a Choose File gt Open from the Main menu or press Ctrl lt O gt b Click on the file to be opened For the Run Time click on the down arrow next to Marking Job and click on the file to be opened Run file b Choose Job gt Start from the Main menu press F9 or click on in the top toolbar P START Another option Run Time only Click on under Marking Job Stop file Choose Job gt Stop from the Main menu press lt F10 gt or click on A in the top toolbar Another option Run Time only Click on P 5TOP under Marking Job www controllaser com 407 926 3500 6 8 ProWriter F20 Operations Manual Creating and Running a Part Marking Program Pause file Choose Job gt Pause from the Main menu or click on JU in the toolbar Another option Run Time only Click on PAUSE under Marking Job www controllaser com 407 926 3500 6 9 Software Commands The online manual contains detailed descriptions for creating and editing lasing programs using the Design View and Command Editor The following is a quick reference guide for commands This includes the type of command its abbreviation or shortened version if applicable and a brief description Please refer to the online manual for a further description and an example Command Quick Reference Guide Communications Commands P Command Enables comments to be added to a program CLRBIT CB Clears turns on a
45. following definitions apply Operation Consists of functions by which the product accomplishes its intended purpose These may include loading workpieces or documents and setting and manipulating external controls Maintenance Consists of functions performed by the user to assure performance These may include cleaning and replacement of expendables e Service Usually means repair Service may be performed by specially trained service personnel or by sophisticated users following instructions specifically indicated as service instructions Certain maintenance procedures will be considered service if they are infrequent complex or highly specialized The following chart lists the functions of operation maintenance and service associated with the ProWriter F20 described in this manual WARNING All personnel in the vicinity of the laser while it is in operation must follow all prescribed safety procedures and use appropriate safety equipment This includes wearing laser eyewear with an optical density OD as recommended on page 1 2 Failure to follow these instructions may result in the exposure of personnel to hazardous laser radiation www controllaser com 407 926 3500 1 10 ProWriter F20 Operations Manual Safety Classification of Laser Functions Function Operation of Laser Controls Cleaning Optics Replacemenis of Electrical Assemblies amp Components Replacement of Mechanical Components Replace
46. formation is located on the Data Sheet in the Customer Service Manual Support by Phone The Field Service department can be contacted at 1 866 612 8619 Monday through Friday 8 00 a m to 5 00 p m Eastern Time After 5 00 p m an answering service will take your message and notify a field service technician of your requirements by the next business day Support by Fax The Field Service department can be contacted by fax at 407 926 3551 24 hours a day including weekends Faxes received after business hours and on weekends will be responded to the next business day Support by E mail The Field Service department can be contacted by e mail at clcsales 2controllaser com Support by Website Visit our website at www controllaser com to learn more about Control Laser Corporation CLC our laser markers and engravers and various applications www controllaser com 407 926 3500 ix ProWriter F20 Operations Manual Technical Support Directory Service and Maintenance Programs The Field Service department offers several service and maintenance programs that provide expert on site support from factory representatives Programs may be purchased on a quarterly or annual basis Contact Field Service for details at 1 866 612 8619 or clcsales controllaser com Advanced Maintenance Training Seminars Advanced maintenance training seminars are held once a month at CLC Contact Field Service for enrollment information at 1 866
47. go MOVE MOV Moves beam without marking an image NEWDATE ND Assigns year day month and hours to text buffers T500 through T503 STDCHARS sc References standard character set VERSION N A Marks software version number and date Mathematical Commands ADD N A Performs the addition operation COS N A Calculates radian value for cosine of angle DIVIDE DIV Divides value of one variable by value of another HEXINC HEX Hexadecimal incrimination INCREMENT INC Adds to the value of a variable by a defined integer value INCREMENTD INCD Adds to the value of a variable by a defined decimal value MASKINC N A Increments to next alphanumeric value MULTIPLY MUL Multiplies two numeric values values may be assigned to variables SIN N A Calculates radian value for sine of angle SUBTRACT SUB Subtracts value of one variable from value of another TAN N A Calculates radian value for tangent of angle www controllaser com 407 926 3500 7 3 ProWriter F20 Operations Manual Software Commands Position and Dimension Commands ALIGNRUN N A Uses the laser diode to verify part marking image alignment ANGLE AO Writes all text at an angle CENTERED JC Centers text DIR N A Writes text at one of four 90 degree angles DRYRUN N A Marks a cmd program using the dry run laser diode instead of the laser beam HEIGHT H Defines the marking height of characters and logos HORIZONTAL HZ Writes text horizontally INCH N A Specifies measurement system in inches LE
48. isible Diode Alignment Laser system Users may select DRYRUN MODE or ALIGN RUN MODE Either may be operated with the interlock disabled e Shutter Open Opens shutter to allow the laser beam to pass through the galvo head e Shutter Closed Closes the shutter to block the laser beam from passing through the galvo head 8 Manual Reset A class IV or otherwise stated laser in your Customer Service Manual must contain a mechanism requiring a manual reset to resume lasing following interruption through the remote interlock connector or from the loss of main electrical power 21 CFR 1040 10 f 10 To restart the ProWriter F20 and resume lasing following shutdown through the remote interlock connector or the loss of main power 1 Turn the keyswitch to the Power Off position 2 Turn the keyswitch to the Control On position The computer and control circuits restart 3 Turn the keyswitch to the Power On position The power supply restarts and restarts the laser CAUTION Do not turn the keyswitch to the Power On position while a program is loading This may cause the laser to start at higher than normal levels This hard start may cause serious damage to the computer drivers and other key components 9 Labeling Labels must be affixed to each laser to identify the manufacturer certify compliance with 21 CFR and EN 60825 provide warnings to the user about the wavelength level and location of accessible la
49. it zero KO on the I O board is dedicated for start write input Each time a start write signal is sent the laser marks the currently loaded program Bit eight K8 is dedicated for write complete input Each time the laser finishes marking a program the K8 bit tells the external equipment the laser is finished marking Bits zero and eight cannot be used for any purpose other than start write and write complete respectively On the second optional I O module the 16 corresponding bits are numbered 16 to 31 and are read from left to right The first eight I O bits 16 23 are input signals to the ProWriter F20 from outside devices and the last eight bits 24 31 are output signals from the ProWriter F20 to outside devices The following commands interface with the user programmable I O lines 407 926 3500 3 2 ProWriter F20 Operations Manual System Function TSTBIT Forces the laser system to check the state of a user programmable bit input only CLRBIT Forces the laser system to clear turn on a user programmable bit input only SETBIT Forces the laser system to set turn off a user programmable bit output only For additional information on how to control the I O lines through program commands see the SETBIT CLRBIT and TSTBIT commands in the on line manual System Startup Procedure To start the ProWriter F20 1 On the control panel turn the safety shutter switch to the Close position 2
50. itch to the right to release the Emergency Stop switch following the directional arrows 2 Keyswitch The keyswitch has three positions Power Off Turns off all systems The key can be removed only in this position Control On Activates the laser s computer system and loads the ProWriter F20 software which can be operated in this mode e Power On Activates the laser s power supply and internal cooling system CAUTION Do not turn the keyswitch to the Power On position while a program is loading This may cause the laser to start at higher than normal levels This hard start may cause serious damage to the computer drivers and other key components CAUTION When the keyswitch is in the Power On position current is present and the system is capable of lasing 3 Power On Indicator Light illuminates to indicate that the system is capable of laser emission 4 Mouse and Mouse Pad 5 Floppy Disk Drive A 3 5 inch 1 4 megabyte floppy disk drive for program and data storage 6 DVD RW Drive 7 USB Ports 8 Computer Keyboard A standard keyboard is provided for laser software control and data entry www controllaser com 407 926 3500 1 8 ProWriter F20 Operations Manual Safety 9 Computer Display A flat screen LCD allows visual interaction with the laser s operating software 10 Shutter Pointer Switch The shutter pointer switch has three positions e Pointer Activates the ViDAL V
51. ite at www controllaser com www controllaser com 407 926 3500 V ProWriter F20 Operations Manual Preface About This Publication Chapter Summary Technical Support Directory This directory explains how to contact CLC for technical support by telephone fax and e mail how to order parts and how to return components for repair Information about technical support programs training classes and the CLC website are included Chapter 1 Safety This chapter describes how the ProWriter F20 fulfills the performance requirements established by the United States Title 21 Code of Federal Regulations Subchapter J 21 CFR and the European Standard EN 60825 1992 This chapter documents the users responsibility and safety precautions CAUTION All users should read and understand the safety chapter before attempting to operate the ProWriter F20 Chapter 2 System Description This chapter outlines specifications for the ProWriter F20 The following diagrams and descriptions are provided control unit marking head system design beam steering marking field computer architecture and system operation software Chapter 3 System Function This chapter provides diagrams and descriptions of the ProWriter F20 controls and step by step instructions for system startup and shutdown Chapter 4 Installation This chapter explains proper procedures for receiving inspecting and unpacking the ProWriter F20 Space environ
52. le Name field enter the name of the laser output test program Click on OK The file is automatically loaded Hold the laser power probe underneath the scanner head where the laser beam is emitted Do not place the probe on the marking surface where the beam is focused as this will damage the probe Instead hold the probe several inches away www controllaser com 407 926 3500 8 2 ProWriter F20 Operations Manual Routine Maintenance from the scanner head and above the marking surface so the unfocused beam touches the probe 5 Inthe main menu either click on Job then Start or press lt F9 gt The program is executed Follow all onscreen prompts 6 Take a reading after the power probe has stabilized Optics Maintenance Inspection and cleaning of the ProWriter F20 scan mirrors and protective window are necessary only if a drop in laser power output is detected during testing Inspecting and cleaning the scan mirrors requires opening the scanner head It is extremely important the scanner head which also contains the focusing lens remain as clean as possible WARNING Do not open the scanner head and expose the scan mirrors and lens to airborne contaminants unnecessarily especially if your work environment is heavily contaminated Inspecting and Cleaning the Protective Window Focusing Lens Assembly The focusing lens and the glass protective window are joined in a single assembly The protective window prevents the le
53. me inputs from variables operator input through CommScreens Communication Screens or Dialog messages and serial and parallel WO communications Help System To access the Help System Hele ea Q C 9 1 Inthe main menu click on Help FO n oo amp 2 Help opens in Internet Explorer LMS contains an extensive help system in the Command Editor that includes the following Full listing of all programming commands complete definitions and programming examples e A special cut and paste method for creating command line programs from the help system s programming examples www controllaser com 407 926 3500 5 6 ProWriter F20 Operations Manual Software Setup Making Selections Main Menu and Toolbar Run Time Design View and Command Editor have similar main menus and toolbars displayed at the top These windows also have separate menus and tools accessible only when working in that particular window Hardware Status Monitor A Hardware Status Monitor indicates the status of the hardware components of the laser system The Hardware Status Monitor is located on the left side of all three screens and informs the operator of component operating status and any malfunctions that may occur Please see Section 6 6 Hardware Status Monitor in the online manual for more information Communication Normal Laser Power Supply Normal Laser Temperature Normal Laser Back Reflection Normal Laser Master Oscilla
54. ment of Optical Components Troubleshooting amp Repair Testing Following Repair Optical Alignment Adjustment Programming Connections to Remote Interlock Connector Setup Fixture Alignment Test Marking following repair programming setup Classification Operation Maintenance Service Service Service Service Service Service Service Service Service Service Requires Lasing Yes No No No No See Note See Note Yes No No No Yes Note Some troubleshooting and testing functions will not require the laser to be lasing Electrical Safety www controllaser com 407 926 3500 Disconnect main power line s before working on any electrical equipment if it is not necessary for the equipment to be operating After disconnecting power wait at least five minutes for the capacitors to discharge through the bleeder resistors before touching any electrical equipment Do not short or ground the power supply output The power supply is not electrically isolated from the power line Protection against possible hazards require proper connection of the ground terminal on the power cable and an adequate external ground Check these connections at the time of installation and periodically thereafter ProWriter F20 Operations Manual Safety Never work on electrical equipment unless there is another person nearby who is knowledgeable of the operation and hazards of the equipment and who
55. mental and electrical requirements are described Step by step instructions for installing safety interlocks and connecting electrical lines are included Guidelines for moving and storing the system are also outlined Chapter 5 Software Setup This chapter describes the basic features of the Laser Marking Studio LMS An overview of LMS is provided as well as directions for navigating Other topics include setting passwords help system and accessing other applications Chapter 6 Creating and Running a Part Marking Program This chapter describes the main concepts involved in using the LMS software to create and run a part marking program It also describes how to set up a remote programming station and how to select the LMS editor that best meets your programming needs Setting process parameter values speed power and Q switch frequency are explained to achieve optimum marking quality This chapter also describes testing and debugging programs and provides step by step instructions for loading and running programs Chapter 7 Software Commands This chapter provides a Quick Reference Guide to all of the software programming commands For details on creating editing and lasing programs in the Visual and Command Editors please refer to the online manual www controllaser com 407 926 3500 vi ProWriter F20 Operations Manual Preface Chapter 8 Routine Maintenance This chapter contains step by step instructions for m
56. n I O bit requires the accessory I O board CLRSCR CLS Clears information from system s video display FLUSH N A Clears or empties data from serial port INPUT IN Enables keyboard input to be assigned directly to a variable ISDIGIT N A Checks to see if byte is digit KEYBOARD N A Specifies a period of time to wait for keyboard input from the operator LANIN N A Receives UDP data packets from LAN port 1071 LANOUT N A This command is for messaging and cycle time initiation Sends UDP data packets from LAN port 1072 of the TCP IP stack NETIN N A Receives data down the network cable and assigns it to text buffer N NETOUT N A Sends data through the network cable PRINT PRT Prints information on the system s video display READBITS N A Reads the state of the eight input bits on the accessory I O board SERIN SI Accepts serial data from any device attached to serial port 2 SERINB2AH SIH Serial in hex information to text buffer www controllaser com 407 926 3500 7 1 ProWriter F20 Operations Manual Software Commands SERINOUTAH2B SEROUT SERPARMS SETBIT TSTBIT WRITEBITS SOH Serial out hex information SO Allows the system to transmit serial data to any device attached to the serial ports N A Controls the setting up of serial ports 1 2 3 and 4 SB Sets turns off an I O bit requires the accessory I O board TB Tests the state of an I O bit requires the accessory I O board N A Writes the state of the eight input bit
57. n to allow a person to avoid exposure to laser radiation 21 CFR 1040 10 f 5 and EN 60825 4 6 There are two emission indicators on the ProWriter F20 one on the main control panel and a second on the laser marking head assembly Both indicators light when the keyswitch is turned to the CONTROL ON position indicating the laser is being activated The indicators remain on until the keyswitch is turned to the POWER OFF position The keyswitch must be turned to the POWER ON position to activate the power supply that activates after a few seconds delay www controllaser com 407 926 3500 1 5 ProWriter F20 Operations Manual Safety Figure 1 2 shows the emission indicator on the laser marking head assembly The emission indicator on the control panel is the POWER ON indicator see Figure 1 3 6 Beam Attenuator A beam attenuator safety shutter must be provided to enable the user to terminate lasing without turning off the master keyswitch or main power switch 21 CFR 1040 10 f 6 and EN 60825 4 7 The shutter terminates lasing by blocking the laser beam before it reaches the output optics The ProWriter F20 s safety shutter is located inside the sealed marking head assembly The shutter is actuated when the shutter switch located on the control panel is moved to the closed position The external interlocks connected to the remote interlock connector can also actuate the shutter 7 Location of Controls Controls which
58. nes which errors if any exist in the program When using the Marking Laser station the user must load the program to step debug it The user may choose to mark during the debugging process or he she can turn the safety shutter switch to the Close position to prevent marking To mark during the debugging process CLC recommends a PRINT and a PAUSE statement be added after each process is completed The user would then know if a process was completed such as drawing a circle by looking in the User Text and Bitmaps column on the Action Menu during simulation debugging Please note when the Action Menu pops up the user must click on Lase A sample program INCH Circle will be drawn in inches PR 1 971 0 7 Center coordinates of circle X 2 1 971 Y 2 0 7 CIRCLE 0 354 Radius of circle is 0 354 inches PRINT 1 1 Printed Circle Print Printed Circle after circle is drawn PAUSE Pause program CAUTION Never operate the laser without first reading Chapter 1 Safety Always follow the safety precautions prescribed in the Safety chapter when operating the Marking Laser System Part Positioning The ProWriter F20 is equipped with an internal visible diode alignment laser ViDAL operating at 660 nm This eye visible beam can be used for part location or to visibly trace the marking program The red beam may be safely viewed through the window of the workstation or viewed through the open door The operator does not need to
59. ng humidity IMPORTANT e Do not turn on the laser if there is any condensation on the output casing of either the laser head or the control unit Remove the condensation with clean warm air e Never place the unit in a location where excessive heat moisture or corrosive materials are present e If the system is moved into the working location from a cold environment leave the system for a few hours to warm up before installing it Electrical Requirements and Connections All ProWriter F20 s use a standard 115 VAC 6 10 50 60 Hz electrical plug connection or an optional 230 VAC 6 10 50 60 Hz Also refer to the electrical data tag on the system control unit cabinet to verify the input power requirements www controllaser com 407 926 3500 4 2 ProWriter F20 Operations Manual Installation Installing Remote Options The remote interlock connector on the ProWriter F20 allows connection of external interlock circuits or switches Installing Safety Shutter Interlock Note The following procedure is only used when the laser is integrated into a Class I II certified workstation Connections are provided to attach external interlock switches to the safety circuit controlling the shutter This feature allows the laser to be integrated into an enclosed workstation with the door s to the workstation protected by interlock switches wired into the safety circuit When properly configured the interlocks cause the l
60. ns from getting dirty Do not remove the protective window from the lens As long as the protective window is intact you should never have to clean the focusing lens Equipment and Supplies Optical Cleaning Kit from Field Service Procedure 1 Inspect the focusing lens and protective window by looking down through the open scanner assembly Do not unscrew the lens assembly 2 Remove dust dirt or other contaminants from the inner surface of the protective window with low pressure clean dry compressed air or nitrogen or brush the glass lightly with a dry camel hair optical brush 3 Carefully replace the top scanner head cover and tighten the screws If the protective window appeared dirty during inspection go to Step 4 If the protective window appeared clean during inspection the procedure is complete 4 Use a 8 flat head screwdriver to unscrew the quarter inch turn screws in the bottom plate of the scanner head www controllaser com 407 926 3500 8 3 ProWriter F20 Operations Manual Routine Maintenance 5 Carefully unscrew the lens assembly from the scanner assembly 6 Remove dust dirt or other contaminants from the outer surface of the protective window with low pressure clean dry compressed air or nitrogen or brush the glass lightly with a dry camel hair optical brush If further cleaning is necessary go to Step 7 otherwise the procedure is complete 7 Dip a clean cotton tipped swab or lens tissue in
61. nts and Connechons 4 2 Installing Remote Options 4 3 Installing Safety Shutter Interlock ccccccceseeeeseeeeeeeeeseeeeeeeeeeeeeteas 4 3 Installing External Devices AA 4 4 Installing the Optional l O Kn 4 6 Moving and Storing the ProWriter V F20 sessssseeenee 4 6 Software Setup ge 5 1 eu P 5 1 UNE M 5 1 Design VIW n 5 2 Command WE ue TEE 5 3 System COrganmtzatlon eene 5 4 Part Marking Programs sss 5 5 Reference Files sessi enne 5 5 Secondary Files enne enne 5 6 User ACCOUNIS iei aoreet ce ire Staat o Eu dade REA Lp dee 5 6 File Wi ZAt e 5 6 Help Systems d ieee nie ai iia ee 5 6 407 926 3500 Table of Contents ProWriter F20 Operations Manual Table of Contents Making Selections enne nens 5 7 Main Menu and Toolbar sse 5 7 Hardware Status Monitor 5 7 nom cq 5 7 Setting the Field Gtze A 5 7 Viewing and Editing Default Settings sse 5 7 Creating and Running a Part Marking Program 6 1 oni efe Se e D 6 1 Setting Up a Remote Programming Gtaiion eeen 6 1 Setting the Event Order 6 1 Setting Process Parameters AA 6 1 Marking Speed tte prre etu gd Gees 6 2 aol n 6 2 Q Switch Frequency cccccececece
62. oration 2419 Lake Orange Drive Orlando Florida 32837 Telephone 1 866 612 8619 Fax 407 926 3551 In Europe replacement and spare parts may be ordered through Excel Technology GmbH at Roenstgenstr 84 D 6100 Darmstadt Germany Telephone 49 6151 9380 0 Telex 49 6151 9380 25 See Appendix B Part Numbers for current part numbers www controllaser com 407 926 3500 xi Safety CAUTION Use of controls adjustments or performance of procedures other than those specified herein may result in exposure to hazardous radiation Recommendation Control Laser Corporation CLC recommends the Safety chapter be read thoroughly by all personnel before operating or performing maintenance on the ProWriter F20 Commitment Statement The contents in this manual are not specific to the specific ProWriter F20 you purchased See the Customer Service Manual for a complete listing of diagrams drawings labels and parts Compliance Statement The ProWriter F20 is certified by Control Laser Corporation as a Class IV product in accordance with Title 21 Code of Federal Regulations Subchapter J 21 CFR and European Standard EN 60825 1992 Check your customer service manual for specific classification of your laser Compliance may be verified by contacting Office of Compliance HFZ 312 Center for Devices and Radiological Health US Department of Health amp Human Services 2098 Gaither Road Rockville MD 208
63. oxy Lexan Lucite clear Lucite painted black Melamine Mylar w silver nitrate coating Nylon w glass fill Nylon Zytall PES poly ether sulfone Phenolic Plaskon Polycarbonate Polyethylene Polyurethane PVC Rynite Ryton Styrene Teflon Thermal reinforced resin Valox Vandar Rubber Wood 407 926 3500 Excellent Excellent Good Good Excellent Good Excellent Good Good Poor Excellent Good Poor Good Excellent Good Good Good Poor Good Good Good Excellent Good Good Excellent Good Good Excellent Good Poor Excellent Poor Good Good Good Poor Poor ProWriter F20 Operations Manual Appendix B D Part Numbers D Use the part numbers listed when ordering parts and test equipment Parts and equipment can be purchased individually or in kits Quantities refer to kit contents only For ordering information see the Technical Support Directory at the beginning of this manual Part Number Description nti 227380 LED 6 chip 585 nm T1 75 14 VAC 4 234866 Fuse 5X20 mm 1 0 Amp 4 234867 Fuse 5X20 mm 1 5 Amp 4 234868 Fuse 5X20 mm 2 5 Amp 4 234869 Fuse 5X20 mm 5 0 Amp 4 234888 Scanner Kit 12 mm 6240 1 234618 Fiber Optic System 1 234834 Assy Controller 1 234872 Assy Computer 1 234835 Assy Power Supply 1 Field Service Tool Kit 234899 Part Number Description nti 234643 Viewer IR Hand Held 1 234648 Safety Glasses Nylon Frame 1 234897 Tool Case Field Service 1 2
64. programs and controls the marking process www controllaser com 407 926 3500 2 6 System Function Laser Basics Overview Laser is an acronym for Light Amplification by Stimulated Emission of Radiation Simply stated the laser is a light amplifier Lasers amplify light by absorbing and emitting energy Absorption can be either electronic on the atomic level or rotational vibrational on the molecular level The emitted energy is a high intensity beam of laser light Lasers emit optical radiation which can be either invisible infrared or visible laser pointer diode light Optical radiation is referred to as non ionizing to distinguish it from ionizing radiation which is the type of radiation associated with X rays and gamma rays While overexposure to ionizing radiation such as frequent medical X rays may cause health problems the non ionizing radiation emitted by lasers do not pose similar health risks even with frequent and long term non direct exposure Direct exposure to optical radiation can however pose serious health hazards to the skin and eyes Lethal electrical hazards may also be present in all lasers A laser induced reaction on certain types of marking materials can release hazardous particles and gaseous products Review Chapter 1 Safety for instructions on how to avoid eye and skin injuries and electrical hazards Never operate or service the ProWriter F20 without following the safety procedures specified in th
65. r Open m System Power Supply Normal Cabinet Temperature Normal Scanner Power Supply Normal Updated 11 21 09 AM www controllaser com Troubleshooting WARNING A qualified maintenance person should perform all troubleshooting procedures Read the Safety and Routine Maintenance chapters of this manual before performing any troubleshooting procedures Follow all safety precautions described in the Routine Maintenance chapter s step by step procedures Potential Cause E Stop Depressed Loose Connection Fuse Blown Laser Power Supply Malfunction Fuse Blown Loose Connection Laser Power Supply Malfunction Action Reset E Stop to Run Position and Restart System Turn Laser Off Check All Cables amp Connectors Running From Computer to Laser Case Turn Laser Off Inspect Fuse 1 Replace If Necessary Contact CLC Field Service Turn Laser Off Inspect Fuse 3 Replace If Necessary Turn Laser Off Check All Cables amp Connectors Running From Computer to Laser Case Contact CLC Field Service 407 926 3500 9 2 ProWriter F20 Operations Manual Scanner Not Operating Fuse Blown System Status jj Communication Normal Loose Con nection Scanner Power Supply Malfunction PACTI Normal Shutter Open X Cabinet Temperature Normal Updated 11 19 16 AM Computer Will Not Start Loose Connection Fuse Blown Troubleshooting Turn Laser Off Inspect Fuse 4 and 5 Replace
66. repairs requiring specific electrical knowledge Contact Field Service for technical assistance information on ordering parts ordering maintenance tool kits and where to send parts for repair Recommended Maintenance Schedule Control Laser Corporation CLC recommends an established routine maintenance schedule be followed Performing the following simple inspection and cleaning procedures on a regular basis helps ensure optimal laser performance e Check the laser power output at the workpiece See Testing Power Output below for a test program lfadropin laser power output is detected inspect the scan mirrors and optics and clean as necessary See Optics Maintenance pg 8 3 for cleaning instructions The frequency of inspection and cleaning depends on the cleanliness of the worksite environment power level of the laser and the material being marked Evaluate the level of airborne and surface contaminants in the laser s environment and follow the appropriate maintenance guidelines in the following chart Monitor the laser s performance over time and adjust the maintenance schedule as required Inspection and Cleaning Schedule If using Low Power High Power 15 watts 15 watts Dirty Environment 15 30 Days 7 Days Clean Environment 90 Days 15 30 Days Testing Power Output Test the laser s power output to confirm that the laser is emitting the required level of power A drop in power output over time indicates
67. rogram section Companion cmd files can be created for lms programs written in the Design View and comments detailing the program can be included in the same manner The user should keep a written record that includes a printout of the program a description of the program s purpose and any drawings graphs and flowcharts used to develop the program Setting Up a Remote Programming Station Laser Marking Studio LMS may be installed on a desktop computer to establish a remote station for writing programs and saving valuable system production time Click on the LMS icon to write and edit programs in either the Design View or Command Editor Use the Simulator in either the Design View or Command Editor to test the program at the remote station see Simulator sections in the online manual for either the Design View or Command Editor for more information Setting the Event Order Elements of a marking design should be marked in the most logical sequence for the most efficient production time Production time is slowed when the laser makes frequent stops and starts and jumps back and forth across the marking field The Cycle Time function enables the user to time entire programs or sections of programs in hundredths of seconds By testing cycle times the user can arrange the program event order to achieve the fastest execution time possible Setting Process Parameters In most cases CLC technicians have determined the optimum process p
68. s in the X axis Scales s text and logos in the Y axis Writes all text vertically Program Control Commands Establishes a label name for a branch destination Executes a command only once after the file loads then ignores it Merges contents of one file with another file at compile time Terminates the execution of a command file Starts program immediately after loading Allows UO bits to come on when fault conditions occur during the lasing process requires the accessory I O board Transfers control to a label Branches if equal to a condition Branches if greater than a condition Branches if less than a condition Branches if not equal to a condition Branches if equal to a condition Branches if not equal to a condition Starts another command program Compares the value of a variable with either the value of another variable or a literal text string Compares a text buffer to a HEX value Marks end of program segment to be looped Transfers control to a sub program Terminates the command file but does not delete it from the system memory 407 926 3500 7 5 ProWriter F20 Operations Manual Software Commands INCLUDE N A Loads command text and logo files as well as character sets fonts to be referenced by subsequent command files LOADRUN N A Loads cbn version of a cmd file previously loaded to the rear computer through auto cbn LOOP LP Directs the system to repeat a sequence of commands PAUSE PS Suspends program ex
69. s on the accessory I O board Marking Characteristics Commands CURRENT CWMODE CWSUPPRESS GST LINEWIDTH POWER QSMODE SLANTF SPEED SPIRAL N A Specifies the amount of current to apply to the lamp CW Specifies continuous wave non pulsed beam N A Prevents excessive heat conduction from the first pulse N A Prevents marking irregularities such as gaps at corners W Marks line wider than the beam PWR Specifies required power output Q Specifies beam pulse rate N A Slants font S Specifies marking speed SP Oscillates marking beam to create wider line widths Marking Image Commands text BOX CIRCLE ADDBITMAP ALTCHARS ARC ARCCCW www controllaser com N A Marks text within quotes N A Provides easy method of drawing a box N A Provides easy method of drawing a circle ADBMP Adds bitmap graphic to hot screen AC References alternative character set A Marks an arc ACCW Lase subsequent arcs counterclockwise 407 926 3500 7 2 ProWriter F20 Operations Manual Software Commands ARCCW ACW Lase subsequent arcs clockwise BARCODE N A Lase a barcode or matrix in the marking field DATE N A Assigns current date and time information to variables T500 though T505 507 and 508 DELALLBITMAPS DABMP Deletes all user bitmaps DELBITMAP DBMP Deletes a bitmap graphic from a hot screen DRAW DW Marks a line EXPIRATIONDATE EXPIRE Assigns current date and time to variables T500 through T503 LOGO L References graphic or lo
70. ser radiation present and give precautions that should be taken to avoid exposure to the laser radiation 21 CFR 1040 10 g and EN 60825 5 Figure 1 4 at the end of the chapter illustrates the labels affixed to the ProWriter F20 in compliance with this requirement For a complete and accurate showing of labels check your Customer Service Manual www controllaser com 407 926 3500 1 9 ProWriter F20 Operations Manual Safety 10 Documentation Instructions must be provided that will enable the user to safely operate and maintain the laser 21 CFR 1040 10 h and EN 60825 6 1 It is recommended the Operations and Customer Service manuals be thoroughly studied by all personnel who have any responsibility for the laser prior to the laser s operation The Operations manual gives instructions for proper operation and maintenance of the ProWriter F20 The manual also provides warnings and cautions that must be observed by the user to prevent unnecessary exposure to laser radiation Classification of Laser Functions Laser products are classified according to the maximum level of laser radiation within human access during operation only Levels accessible only during maintenance or service do not affect the classification Therefore it is possible for class or class Il products to contain class IV lasers It is the responsibility of the manufacturer to determine whether specific functions are operation maintenance or service The
71. sing that must be opened removed or displaced during normal operation of the laser must be interlocked to prevent access to laser radiation 21 CFR 1040 10 f 2 and EN 60825 4 3 No interlocks are required It is not necessary to open or remove any part of the laser marking head assembly during normal operation 3 Remote Interlock Connector A Class IV laser must have a means to shut down the laser from a remote interlock 21 CFR 1040 10 f 3 and EN 60825 4 4 The remote interlock connector on the ProWriter F20 allows connection of external interlock circuits or switches for the control unit which can shutdown the laser See Chapter 4 Installation for installation instructions 4 Master Key Control Each Class IV laser must be provided with a keyswitch which will prevent operation of the laser when the key is removed The key must be removable only in the OFF position and must disable the laser when removed 21 CFR 1040 10 f 4 and EN 60825 4 5 The master key control for the ProWriter F20 is located on the main control panel see Figure 1 3 WARNING The master key to operate the ProWriter F20 should be given only to personnel authorized by the Laser Safety Officer The laser should never be left unattended while running or while the key is in the laser 5 Emission Indicator An emission indicator is required to provide visible signal during emission of laser radiation and sufficiently prior to emissio
72. t way to inspect the protective window is to hold it flat at eye level and look across the surface Using a magnifying glass while looking directly at the window also makes damage easier to see 10 If the protective window is not damaged attach the lens assembly back into the bottom of the scanner assembly Or If the window appears damaged contact Field Service for assistance www controllaser com 407 926 3500 8 4 ProWriter F20 Operations Manual Routine Maintenance Fuses The ProWriter F20 has five fuses attached to the control unit bottom that should be replaced annually There are four fuses in the rear of the unit and one in the front See Figure 8 1a and Figure 8 1b for details on the placement and power of the fuses Fuse F1 1 Amp STATUS CIRCUIT BREAKER E gt gt CONTROL e SUA Og 49 Figure 8 1a Front of Control Unit Bottom Fuses F4 and F5 1 5 Amp each Figure 8 1b Back of Control Unit Bottom Fuse F2 5 Amps 407 926 3500 8 5 Troubleshooting Overview System Status Communication Normal Updated 12 09 19 PM This chapter provides guidelines for troubleshooting the laser status indicators located in the System Status window on the computer screen see left The System Status indicators identify the current state of the following functions vital to laser system operation Laser Power Supply Normal e Communication Laser Temperature
73. the module see Testing with the I O Module Accessory below Testing with the LO Module Accessory If the optional user programmable I O module accessory is installed use the Input and Output Bit icons to simulate set and clear bits Click on a Bit icon to change the state of the bit red for set green for clear For example to test the following program click on the Bit seven icon so it displays green simulating a clear bit in this case an open door Load the program to the simulator The program should not mark the text until you click on the Bit seven icon so it displays red simulating a set bit or a closed door Example CURRENT 10 SPEED 10 QSMODE 5 POSABS 0 0 INCH HEIGHT 25 TEST DOOR SWITCH TSTBIT 7 BRANCHNE TEST DOOR SWITCH Mark this text HALT www controllaser com Current output 10 amps Speed 10 per second Q switch frequency 5 kHz Identify absolute XY coordinate Measure all units in inches Mark all subsequent text 25 high Do not mark if door is open Establish label Test state of bit 7 If door is open return to label If door is shut mark text Stop execution of program 407 926 3500 6 6 ProWriter F20 Operations Manual Creating and Running a Part Marking Program Testing the Program Code Line By Line Line by line testing of a program s code is referred to as step debugging In step debugging the user controls the pace of the review and determi
74. tion removes material This technique has the advantage of considerable speed Material is almost instantly vaporized with each pulse Vaporization can also be used to create a contrasting color effect by removing the top layer of a material coated with two contrasting colors Relatively high speed and power settings combined with relatively low Q switch settings create this effect Material Characteristics e Reflectivity Polished metals such as gold and brass require more power to mark due to the highly reflective surfaces Organic materials such as wood and paper are almost transparent and are not good marking material Absorption Temperature Curve Changes in temperature of a material varies with the percentage of heat absorbed Some materials may not be markable because the laser increases the material s surface temperature causing distortion of the material For example some plastics exhibit too high an increase in absorption to create an acceptable mark www controllaser com 407 926 3500 6 4 ProWriter F20 Operations Manual Creating and Running a Part Marking Program Example of distortion of a material Thermal Conductivity Highly conductive materials convey heat away from the point at which the laser is attempting to mark The laser parameters need to compensate for the material s attempt to heat sink itself Aluminum is a good example of a material that requires higher power and or slower marking speed to achiev
75. torNormal Shutter Open CH System Power Supply Normal Cabinet Temperature Normal Scanner Power Supply Normal Ai Updated 12 09 19 PM Hardware Status Monitor Hot Keys All program functions accessed by pointing and clicking the mouse also have a keyboard command or hot key The hot key command may be a single function key or a combination of keystrokes Hot keys where applicable are noted in the toolbar and some hot keys are only applicable in certain viewing windows Setting the Marking Field Size The proper marking field size for the laser is pre set at the factory The marking field size establishes the programming resolution and optimizes the operating system s specific imaging requirements www controllaser com 407 926 3500 5 7 ProWriter F20 Operations Manual Software Setup The Set Field utility is provided if the marking field size settings need changing Do not change the marking field size setting without first consulting a Control Laser Corporation technician Viewing and Editing Default Settings The ProWriter F20 has default factory settings for most major program controls The default settings are provided to ensure the required major controls i e power speed are always included in each program They are not intended to be optimum settings for all marking programs If one or more of these controls are not specified in a program the system automatically assigns the def
76. trol Center LASER Figure 5 3 System Organization Part Marking Programs e Drawing Ims files Drawing objects with attached parameters and standard program controls e Command cmd files Program command lines in the ASCII text format Includes both standard and extended program controls Reference Files Logo log files Graphic images originating from either bitmap or CAD files e Text txt files ASCII text files e Font fnt files Character font files www controllaser com 407 926 3500 5 5 ProWriter F20 Operations Manual Software Setup Secondary Files e Object cbj Ibj fbj files Compiler files associated with command logo and font files User Accounts LMS has three different user levels 1 Administrator full access to software including creating deleting and editing user accounts 2 Engineer full access to software except to user accounts 3 Operator may only run programs in the Run Time File Utilization Graphic images used in several different programs can be saved as independent logo files Logo files are incorporated into Ims Design View files using the Logo tool in the Toolbox and into command files using the INCLUDE command Alphanumeric text common to several command programs can be saved and referenced as separate text files Optional font files can be used in addition to the pre loaded character fonts During execution part marking programs accept real ti
77. ve the desired process results The marking speed is measured in either inches or millimeters per minute depending on the unit of measurement specified in the program For deep marking each point on the engraved line requires more pulses than shallow marking Beam speed must be reduced until the required depth is achieved For shallow marking the speed may be significantly increased Note When changing the marking speed also reset the galvanometer settling time GST Power The output power of the laser is adjusted by increasing or decreasing the electric current to the fiber As the current changes light output from the fiber and the intensity of laser amplification increases or decreases accordingly Using the Standard CURRENT Command The CURRENT command specifies how much power is applied to the fiber under nominal conditions WARNING N Do not attempt to exceed the laser s maximum current value www controllaser com 407 926 3500 6 2 ProWriter F20 Operations Manual Creating and Running a Part Marking Program Q Switched Frequency The laser beam is emitted in Q switched pulsed mode When writing programs in the Command Editor use the QSMODE command Galvanometer Settling Time GST Galvanometer Settling Time GST is a laser beam delay measured in microseconds that synchronizes the laser beam with the galvanometers movement during stops starts and corners GSTs can prevent irregularities such as burn holes an
78. wear laser safe eyewear when the diode pointer is used in this manner The DRYRUN command is used at the beginning of a part positioning program to turn on the dry run laser diode Part positioning programs should be designed to mark a pattern in a loop to produce a constant visible guide The loop can be limited to a set number of repetitions or it can be continuous See the DRYRUN command in Section 6 3 1 CMD Commands in the online manual for an example of a part positioning program with a continuous loop www controllaser com 407 926 3500 6 7 ProWriter F20 Operations Manual Creating and Running a Part Marking Program Running a Program To enter Laser mode choose Laser gt Modes gt Laser from the Main menu Laser will be checked This can be done either in the Run Time Design View or Command Editor Marking Requirements In order for the laser to mark a running program the following conditions must be met on the laser console The laser keyswitch must be in the Power On position The safety shutter switch must be in the Open position CAUTION Never operate the laser without first reading Chapter 1 Safety Always follow the safety precautions prescribed in the Safety chapter when operating the laser Lasing a File A Ims file is run from the Design View and a cmd file is run from the Command Editor The instructions below can be done using both screens and the Run Time unless otherwise noted Op
79. y contact a qualified maintenance technician Restarting the System When automatic shutdown occurs see the system log file Log dat for a record of the events leading to shutdown A qualified maintenance person should troubleshoot the cause of the shutdown See Chapter 9 Troubleshooting for troubleshooting guidelines After the problem has been corrected follow the instructions in System Startup Procedure in this chapter Manual Shutdown Procedure To shut down the ProWriter F20 system manually close the software and then exit Windows To exit LMS 1 Press Alt F4 or click on File gt Exit 2 Tur the safety shutter switch to the Close position To exit Windows 1 Click on at the bottom of the screen The Start menu displays www controllaser com 407 926 3500 3 4 ProWriter F20 Operations Manual System Function 2 Select Shut Down The Shut Down Windows dialog box displays 3 Click on Shut down the computer 4 Atthe confirmation prompt click on Yes Turn the keyswitch to the Power Off position when the computer shuts down automatically 5 Remove the key from the keyswitch Emergency Shutdown Procedure Press the red Emergency Stop switch on the front control panel The power to the laser is turned off but the computer controls remain on To release the Emergency Stop switch turn the switch to the right following the directional arrows and pull the switch up www controllaser com 407 9

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