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SH-series Marking Head Operation Manual

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1. 48 diagonal Max degrees NNI 15 28 14 13 focuse Scanning Aperture mm 15 Input Beam Diameter at Le mm 3 4 50 Q switched ON Continuous Input Power W Settling Time Full Field ms Full Amplitude Drive Freq Hz 130 Field Distortion 0 196 Relative to Drive Voltage 28 30VDC 3 A maximum For input beam diameters lt 3mm use optional suffix 4 5 6 7 5 and 10 after SH 1 SH6 250Y to indicate larger beam expansion ratio Consult Synrad for larger input beam diameters Corresponds to typical engraving results SH Series Marking Head Operation and Service Manual 2 2 Physical Features The physical features of the Marking Head are shown in Figure 2 1 Page 8 and Figure 2 2 Page 9 and are described in the following paragraphs 2 2 1 Electronics Cover A removable cover to provide access to the internal electronics 2 2 2 Y Axis Galvo Cover A removable cover that provides access to the Y Axis galvo 2 2 3 Expanding Mirror Mount Externally mounted assembly that retains the internal expanding mirror A number of different beam expanders are available to allow users to optimize Marking Head performance for a variety of marking and cutting applications 2 2 4 Focusing Lens Externally mounted lens that focuses the laser beam for marking and cutting applications A number of lens options are available in a variety of focal lengths to provide different field
2. 551 TABLE 5 1 NOMINAL FOCAL LENGTH FIELD SIZE RELATIONSHIP TABLE 6 1 DADIO M ARKING HEAD INTERCONNECT WIRING e TABLE 6 2 CIO DDA06 M ARKING HEAD INTERCONNECT WIRING TABLE 7 1 CLEANING MATERIALS 9 TABLE 7 2 SELECTION OF CLEANING SOLVENT ccccsssssesessescescecescuecssesenececsecaesscnecaesecaeseaeceeseaeseeaeeaeeeesenaeeeeaeneeeee SH Series Marking Head Operation and Service Manual 1 Introduction Laser based marking and cutting systems are typically characterized in terms of speed and accuracy Conventional systems employ a type of motion control system that requires movement of either the laser or the work surface both of which have mass and therefore inertia These dynamics significantly limit acceleration deceleration rates and positional resolution The ideal solution is to provide a method which requires movement of that component of the system with the least amount of mass the laser beam Since the laser beam has no practical mass potential limitations on speed and accuracy are imposed only by the method used to move the laser beam 1 1 Synrad SH Series Marking Head At Synrad we have used our technical expertise to design and manufacture the SH Series a unique Marking Head that provides a high performance low cost beam control solution for a wide range of marking and cutting applications refer to Table 1 1 for a summary of the SH Series featur
3. D A Card performance and operating requirements 6 1 1 Scientific Solutions DADIO Card The DADIO Card available from Scientific Solutions is depicted in Figure 6 1 Page 25 showing required switch and jumper settings SW and SW2 set the base address of the card to 330H 816 decimal SW2 8 is set to select simultaneous updating of the D A outputs JPR2 sets DACO to 0 10 VDC output for laser power control JPR4 and JPR5 are set to configure DAC2 and DAC3 outputs for 10 VDC to control the x and y axes of the Marking Head If you purchased the D A board from Synrad the analog input cable used between the Marking Head and the DADIO card is supplied with the Marking Head Otherwise the cable should be fabricated in accordance with Figure 6 2 Page 26 with required pin wire assignments as shown in Table 6 1 Page 26 Figure 6 1 DADIO Switch Jumper Settings OFF OPEN 1 OFF orF 4 n js dg EN aiz Y x PCWER Bact DAGD Hi o Im JPR4 JUPAS PRE 25 SH Series Marking Head Operation and Service Manual Figure 6 2 DADIO Marking Head Interface Cable Table 6 1 DADIO Marking Head Interconnect Wiring SCIENTIFIC SOLUTIONS DADIO HEAD WIRE Nc NC EXTERNAL MODULATION 3 B NC 13 GROUND 4 4 NC GROUND L 5 ser NC NC NC GROUND WW can d 0 1OVDC or TTL F 8 NC XINPUT 10VDC CS 26 SH
4. Marking Head Operation and Service Manual 2 2 14 Analog Input Connector A DB9 connector that provides the interconnect for all required drive inputs to the Marking Head The pin assignments for the connector are provided in Table 2 2 Table 2 2 Analog Input Connector Pin Assignments PIN NUMBER SIGNAL NAME FUNCTION 1 External Modulation Connected to Ext Mod Out Refer to Para 2 2 15 2 3 4 5 Ground 6 Laser Power Control Connected to Power Control Output connector through 1 kQ resistor Refer to Para 2 2 13 Page 9 7 Laser Gate Control Connected to Gate Out connector through kQ resistor Refer to Para 2 2 10 Page 8 8 X Input DC input voltage to control the position of the X axis galvo 10VDC 9 Y Input DC input voltage to control the position of the Y axis galvo 10VDC 2 2 15 Ext Mod Out A BNC style connector that provides a control signal to the laser for external frequency modulation This is routed directly from Pin 1 of the analog input connector This output can be used to control power and frequency on CO2 and YAG lasers 2 2 16 X Output Connector A BNC style connector for the X Output signal This signal is a DC voltage that represents the true mechanical position of the X axis galvo 1 172 volts per degree of angular rotation over a range of 7 5 relative to the galvo zero position The actual output voltage differs from the associated input in that a correction factor is applied to compensate for op
5. Series Marking Head Operation and Service Manual 6 1 2 Computer Boards Inc ClIO DDA06 Card The CIO DDAO6 Card available from Computer Boards Inc is depicted in Figure 6 3 showing required switch and jumper settings The appropriate switch settings have been set at the factory if you purchased the board from Synrad The base address switch is set to 330H 816 decimal The Wait state is enabled as recommended by the manufacturer The gain switches for DAC2 and DAC3 are set for X 10V The gain switch for is set to 0 10V operation for laser power control If you purchased the D A board from Synrad the analog input cable used between the Marking Head and the CIO DDAO6 card is supplied with the Marking Head Otherwise the cable should be fabricated in accordance with Figure 6 4 Page 28 with required pin wire assignments as shown in Table 6 2 Page 28 Figure 6 3 CIO DDA06 Switch Jumper Settings OU gO E ur nnn Do nan hun c man Dun 029020 Bun S Eme 22 i BTh374 Hn HELL HH N G 6 2 ProLase Software ProLase is a PC based software application for controlling both the Marking Head and laser operation ProLase controls the Marking Head through a D A card installed in the PC ProLase is not provided with the Marking Head and must be obtained as a separate product from American Laserware refer to Appendix A Page 35 The following information shoul
6. and spot sizes for CO or YAG laser compatibility These lenses can be interchanged on the Marking Head by the user without any additional modifications 2 2 5 X Axis Galvo Cover A removable cover that provides access to the X Axis galvo 2 2 6 Power On LED A panel mounted LED for indicating Marking Head power is on Illumination of the LED typically lags power switch activation by approximately 2 seconds 2 2 7 Power Switch A panel mounted rocker switch for turning Marking Head power on and off 2 2 8 Y Output Connector BNC style connector for the Y Output signal This signal is a DC voltage that represents the true mechanical position of the Y axis galvo 1 172 volts per degree of angular rotation over a range of 7 5 relative to the galvo zero position The actual output voltage differs from the associated input in that a correction factor is applied to compensate for optical astigmatism This interconnect is an optional output provided for monitoring purposes and is not required for system operation SH Series Marking Head Operation and Service Manual Figure 2 1 Physical Features ELECTRORHMIC COVER Y AXIS GALI COVER EXPANDING MIRROR MOUNT POWER SWITCH POWER uci LED X AXIS GALVO COVER 2 2 9 Beam Entrance Aperture Entrance aperture for the laser beam Safe operation of the Marking Head requires installation of a beam enclosure tube between the exit aperture of the laser and the entrance aperture o
7. capable of providing the following signals to the Marking Head and laser controller X Input 1OVDC Y Input 1OVDC Laser power control 0 10VDC Synrad UC 1000 Laser on off gate TTL Synrad UC 1000 These boards are available from a variety of sources Refer to Appendix A Page 35 for possible suppliers 12 SH Series Marking Head Operation and Service Manual 2 3 7 Computer System Dependent on software requirements but minimum specifications are typically 33 MHz 386 DX PC 387 math co processor IMb RAM graphics For enhanced performance a 486DX based PC is recommended 2 3 8 Laser Marking Program CAD Software This software will provide the means to convert a CAD file to a format suitable for driving the Marking Head Refer to Appendix A Page 35 for recommended suppliers These software packages convert the images and text generated in commercial CAD packages such as AUTOCAD and CorelDRAW 6 into a suitable output for the Marking Head They also include software routines for control of the laser and offer outputs to other external devices such as work handlers and transport mechanisms These commercial drivers also have some onboard graphic and text capability for creation of images logos and alphanumerics 2 4 System Options The following options are available for configuring the Marking Head for a particular application For assistance in selecting the most suitable options or for more details on par
8. during operation could result in exposure to laser radiation Each of these labels is shown in Figure 1 1 The location of each is shown in Figure 1 2 Page 4 Figure 1 1 Laser Radiation Warning Labels DANGER AVOID EXPOSURE DANS ER 1 E In AUI GiB PE Invi sible lager radiatio om hio aure d director emitted from aperu hen open watered radiation Thi aperture EXPOSURE PROTECTIVE COVER APERTURE APERTURE WAAR IAS LABEL WARHIHG LABEL WARES LABEL There are two types of precautions that appear throughout the manual a WARNING and a CAUTION Any process or procedure that could result in exposure to laser radiation if not properly performed will be preceded by the following notation WARNING Any process or procedure that could result in damage to the Marking Head if not properly performed will be preceded by the following notation CAUTION A manufacturer s placard is also affixed to the Marking Head indicating date of manufacture model number and electrical power requirements The location of the manufacturer s placard is shown in Figure 1 3 Page 5 SH Series Marking Head Operation and Service Manual 1 2 Safety Requirements Continued Figure 1 2 Location of Warning Labels AMOD EXPOSURE nimia latar radiation DANG ER am ittad trom DANGER In ul dole cnr radiation aperture In ul dole radiation when open nr Ir
9. NNECTIONS E OPENS MAR MO ERIS 5 6 MARKING FIELD AND COORDINATE SYSTEME ene tenete tenete tenete tentent 21 5 7 SELEING WORKING DISTANGE 23 5 8 TURN ON CHECK QUT 23 5 9 CHANGING FOCUSING LENS is 24 6 OPERATION WITH PROLASE SOFTWARE AND SYNRAD LASERS 9924 444 25 6 1 PC MARKING HEAD D A INTERFACE 6 2 PROLASE SOFTWARE 6 3 SYNRAD LASER CONNECTIONS 7 MAINTENANCE AND SERVICE scsssssssssssssssssssssssssscscsssessssssssssssssssssesevssssssssnsssessssssssesavessesessessnsessssssssnseses 31 TAZDAAEX INSPECTIONS IRR TREE ERAI REPARARE RE 7 2 FOCUSING LENS CLEANING INSTRUCTIONS 8 RETURN FOR FACTORY 2 APPENDIX LIST 8 2 35 APPENDIX B SYNRAD SH SERIES MARKING HEAD MOUNTING KIT eee eee ee esten tensa ense sees 37 SH Series Marking Head Operation and Service Manual List of Figures FIGURE 1 1 LASER RADIATION WARNING LABELS esee esent entente teen tentent tenete tenete rennen ntes rens 3 FIGURE 1 2 LOCATION OF W ARNING LABELS ccssessssessesessesceecssescuecassecnescenecaesecnesaesecaesseaecasseea
10. NY POWER ON OO SUPPLY 20 30 DC MARKING HEAD CIN COMPUTER zaw SUPPLY Hag 0 8 1 2 GALLONS PER MINUTE LOSER DEB GATE PWR OUT OUT MARKING uico OUTPUT COMPUTER ANALOG INPUT CABLE WITH 30 SH Series Marking Head Operation and Service Manual 7 Maintenance and Service Other than the procedures described in the following paragraphs no other service is required or should be attempted 7 1 Daily Inspections 1 Ensure that power is off to the laser and the Marking Head WARNING Harmful laser radiation is emitted through the focusing lens Ensure power is off prior to inspecting the lens surface Remove the focusing lens cover 3 Visually inspect the exterior surface of the focusing lens for contaminants Perform the cleaning instructions specified in Para 7 2 as necessary 4 Visually inspect the Marking Head housing for loose panels or covers and tighten as necessary 5 Visually inspect the exterior of the Marking Head housing to ensure all warning labels are present refer to Para 1 2 Page 3 for label locations and types 7 2 Focusing Lens Cleaning Instructions 7 2 1 Precautions The following precautions should be followed at all times when performing the cleaning instructions described in this section Failure to follow these precautions may result in damage to the focusing lens The materials identified in P
11. SH SERIES MARKING HEAD OPERATION AND SERVICE MANUAL RELEASE v1 2 DATE 1 23 96 Synrad Inc 11816 North Creek Parkway N Bothell WA 98011 206 483 6100 email synrad aol com FAX 206 485 4882 In U S 1 800 SYNRADI SH Series Marking Head Operation and Service Manual TABLE OF CONTENTS 1 INTRODUCTION 1 1 1 SYNRAD SH SERIES MARKING HEAD cerent nne nennen eene tnn nnn en nete nter 1 1 2 SAFETY REQUIREMENT S 3 2 DESCRIPTION OF SH SERIES MARKING 2 6 2 1 TECHNICAL SPECIFICATIONS RP HER HORE EUREN ERAS PH S Ee IR end 6 2 2 PHYSICAL FEATURES terere esci ee a eere eb De E RO E ESL TORNA UE NAT e SX Ee ETE QURE eR 2 3 SYSTEM REQUIREMENTS 25 5 Cp 3 UNPACKING INITIAL INSPECT ION esee enano nea 14 4 SETUP REQUIREMENTS 15 Z MOUNTING E A e ME 15 42 ALIGNMENT EEA E E E EE Ei D iuter ee 17 5 OPERATING INSTRUCTIONS eese eee enne totos 20 STEGENER AL aree re ORAE EEUU RUBER 92 ANALOG nette eh RR OE AERE RIS ERATES MEER ohooh A EA EE Re Ee eS ERR S COMPUTER SORT WARE ERR ER RR RU DG 5 4 WORK SURFACE REQUIREMENTS S ELECTRICAL CO
12. acteristics refer to Para 4 1 Page 15 The alignment process requires the use of the supplied beam alignment tool This tool is inserted into either the entrance aperture or the aperture exposed by removing the expander mirror mount It is held securely in place by the outer springs When the beam alignment tool is inserted into either aperture the laser beam heats the screen producing 17 SH Series Marking Head Operation and Service Manual 4 2 Alignment Continued a glowing orange spot Proper alignment is achieved by precisely adjusting the position of the Marking Head or laser until the glowing spot is centered relative to the alignment hole Figure 4 4 Beam Alignment Tool SCR ALIGNMENT HOLE Verify that power to the laser is off Remove protective cap from beam input aperture 3 Remove the four mounting screws that secure the expander mirror mount assembly to the Marking Head housing 4 Place the expander mirror mount in a protective case CAUTION Ensure that expander mirror mount is not subjected to any physical shock when removed from the Marking Head housing Do not adjust the button head screws that secure the expander mirror to the mirror mount The expander mirror mount is an integral part of the internal optics of the Marking Head and is aligned at the factory Insert the beam alignment tool into beam entrance aperture of the Marking Head Make certain the tool is seated flush against t
13. al to the laser system that can accept the signals from the D A card in the computer These signals gate the laser on and off control output power and in the case of YAG lasers control the Q switch frequency To operate a Synrad laser with the SH Series Marking Head an external laser controller is required The Synrad UC 1000 Universal Controller has been designed to provide necessary control of the laser output from a remote source The UC 1000 requires 22VDC at 80mA from a wall plug transformer rectifier or laser supply 2 3 8 SH Series Marking Head Incorporates internal reflective beam expander x and y axis galvo scanners galvo drive cards distortion compensation card and flat field focusing lens Requires 28VDC operating voltage plus four input signals for laser and scanner control refer to Para 2 3 6 For operation with Synrad lasers one 28VDC power supply may be used to power both laser and Marking Head 2 3 4 Mounting Structure A means of mounting the Marking Head is required to maintain the alignment of the laser beam with the internal mirrors of the Marking Head 2 3 5 28VDC Power Supply Available from a variety of manufacturers these power supplies need to generate 6A at 28VDC for the Marking Head plus additional current capability for power requirement of the laser Refer to Appendix A Page 35 for recommended suppliers 2 3 6 Digital to Analog Drive Board D A drive board mounted in the computer system must be
14. ance MAREIHG HEAD RAUSING LEHS WORKING ae DISTAHCE SURFACE WERF FIECE ADJUSTABLE STAHD 5 8 Turn On Check Out 1 Verify that power is off to the laser and the Marking Head 2 Remove the focusing lens cover 3 Turn on power to the DC power supply 23 SH Series Marking Head Operation and Service Manual Turn On Check Out Continued Turn Marking Head power switch to on and listen for a series of clicking sounds from within the Marking Head Two of these are relays and the last is the sound of the galvo mirrors being positioned Place a material for marking on the work surface Use the laser marking program to run a standard test pattern at the required laser output power level Inspect the pattern marking on the work material to verify dimensions and clarity are consistent with test pattern 5 9 Changing Focusing Lens The Marking Head is designed to operate with either CO or YAG lasers at a variety of focal lengths by simply exchanging the focusing lens If the focusing lens is removed at any time place protective covers over the exterior of the focusing lens and the exposed focusing lens aperture Ensure power is off to the laser and the Marking Head While holding the lens assembly remove the three 48 socket head cap screws holding the lens assembly to the Marking Head housing Carefully remove the lens assembly from the aperture Install the focusing lens cover and place the focusin
15. and mark the product as it moves along the production line This marking on the fly makes the SH Series ideally suited for manufacturing applications with capacities of thousands of units per hour The laser marking program generates the required drive and control signals for both the Marking Head and the laser through the D A card Alphanumerics and simple drawings may be created within the laser marking program itself In addition standard graphics applications such as AUTOCAD6 and CorelDRAWe can be used to generate high quality graphics logos and text which can be easily read by the laser marking program to provide the required drive outputs to the Marking Head SH Series Marking Head Operation and Service Manual 1 2 Safety Requirements To prevent exposure to direct or scattered laser radiation follow all safety precautions specified throughout this manual Use of controls or adjustments or performance of procedures other than those specified herein may result in hazardous invisible radiation exposure Safe operation of the Marking Head also requires the user follow all precautions specified in the operator s manual provided by the manufacturer of the laser beam There are two types of warning labels affixed to the Marking Head Aperture warning labels identify all apertures through which the laser beam travels and from which exposure to laser radiation could occur Protective cover labels identify all covers or enclosures which if open
16. ara 7 2 2 Page 32 have been selected to prevent damage to the focusing lens Use of materials other than those listed is acceptable providing they meet or exceed the specified levels of quality or purity When performing cleaning of the focusing lens the lens paper must be held so that it just comes in contact with the surface of the lens Do not exert pressure on the surface being cleaned This may result in scratches to the surface of the lens 3l SH Series Marking Head Operation and Service Manual 7 2 2 Materials The materials required when cleaning the focusing lens are identified in Table 7 1 Table 7 1 Cleaning Materials Material Requirements Finger Cots Powder Free Air Bulb Clean air bulb Distilled Water N A Ethyl Alcohol Spectroscopic or Reagent Grade Acetone Spectroscopic or Reagent Grade Vinegar N A Lens Tissue Optical Quality 7 2 3 Passive Cleaning Passive cleaning of the focusing lens may be performed without removal of the lens from the Marking Head Passive cleaning involves the use of air to remove particulate contamination from the surface of the lens Using a clean air bulb hold the bulb at an angle to the lens and blow a stream of air at a glancing angle across the surface Repeat as necessary CAUTION Do not allow the nozzle of the air bulb to come in contact with the lens surface as this may damage the lens by scratching the surface 7 2 4 Aggressive Cleaning Aggressive cleaning of the lens involv
17. d be used to configure ProLase to recognize the D A card installed in the PC and to optimize marking system performance 6 2 1 Output Driver Select the appropriate output driver for the installed D A card DDA06 Computer Boards Inc DADIO Scientific Solutions 27 SH Series Marking Head Operation and Service Manual Figure 6 4 CIO DDA06 Marking Head Interface Cable Table 6 2 CIO DDA06 Marking Head Interconnect Wiring COMPUTER BOARDS DDA06 NC SHIELD NC GROUND 0 I0VDO LI 8 TTL 8 4 X INPUT 10 Y INPUT 10VDC 28 SH Series Marking Head Operation and Service Manual 6 2 2 Field Size Set the field size to the calibrated value inscribed on the focusing lens assembly shipped with the Marking Head If the focusing lens to be used was not calibrated with the Marking Head set the field size to a value that will produce marked geometry equal in size to the pattern geometry as displayed in ProLase 6 2 3 Device Corner Set the x and y axis values to equal the negative value of the field size divided by 2 6 2 4 Axis Correction Set A Corr and B Corr terms to zero The Synrad Marking Head does not require software corrections for optical distortion 6 2 5 Delays The following delays provide good performance with the Marking Head in terms of speed and quality Additional information on setting the delays is available in the ProLase manual Poly TC 0 0 sec Angle TC 0 9 sec Po
18. e 4 2 for an illustration of the planes of movement required for alignment Figure 4 2 Planes of Movement Required for Alignment S YAW ELEVATIOH HORIZONTAL The Marking Head is designed to allow mounting using either the bottom or front surfaces Six mounting holes are located on the bottom surface and eight are located on the front surface refer to Figure 4 3 Page 17 All mounting holes are reinforced with heli coil inserts that accept 8 32 screws with a maximum length of 3 16 inch 4 7 mm 16 SH Series Marking Head Operation and Service Manual 4 14 Mounting Continued CAUTION Do not mount the Marking Head directly to the laser housing without additional support The weight of the Marking Head may cause permanent damage to the laser housing or distort system alignment Figure 4 3 Location of Marking Head Mounting Holes 8 52 p 3616 MOUNTING HOLES 2 8 52 516 MOUNTING HOLES 851 BOTTOM SURFACE FRONT SURFACE 1 ALL DIMENSIONS ARE IN INCHES d a 0285 s s 4 2 Alignment Alignment of the Marking Head is achieved by adjusting the relative position of the Marking Head and the external laser until the laser beam passes through the center of both the entrance and the expanding mirror mount apertures This process referred to as bore sighting requires positional adjustments to either the laser or the Marking Head depending upon specific mounting char
19. emitied tum hic chin rre b director aparu hen open ca md radiaton EX POSURE SH Series Marking Head Operation and Service Manual 1 2 Safety Requirements Continued Figure 1 3 Location of Manufacturer s Placard and CE Compliance Label 112 1B Crash P hvmy Bothell im 82044 DB 405 8 100 Panu toire mo input Pave SH Series Marking Head Operation and Service Manual 2 Description of SH Series Marking Head 2 1 Technical Specifications Synrad s SH Series Marking Heads are available for both YAG and CO lasers with numerous interchangeable focusing lenses to provide a range of field sizes spot diameters and focal lengths A choice of beam expander ratios allows users to match perfectly their laser input beam to the SH Marking Head see Para 2 4 1 Page 13 for further details on selection of beam expanders The specification table refer to Table 2 1 provides technical information for Synrad s SH Series of Marking Heads with standard focusing lenses for both Y AG and CO lasers The specifications are based on a system with a 3x beam expander as recommended for operation with Synrad lasers Table 2 1 Specification Table 200C 125C 69C 172 550Y 250Y 125Y 110 70 38 95 305 138 69 Spoxsize a pepe ps 20 0 7 160 8 Working Distance 236 3 142 From Lens Mount mm Scan Angle degrees
20. ent focal length lenses The actual factory calibrated field size value and the factory calibrated working distance refer to Para 5 7 Page 23 is marked on each focusing lens Table 5 1 Nominal Focal Length Field Size Relationship Focal Length 200 mm 125 mm 69 mm Field Size 110 mm 70 mm 38 mm The field coordinate system used to determine spot location is shown in Figure 5 1 Page 22 and Figure 5 2 Page 22 When configuring the laser marking program for field size any correction terms used to compensate for optical distortion should be disabled 21 SH Series Marking Head Operation and Service Manual 5 6 Marking Field and Coordinate System Continued Figure 5 1 Field Coordinate System 10v 1 v 10 10 7 CENTER E p FIELD SEE tow 11571 10 10s Y FIELD SEE 5 Figure 5 2 Marking Field Relative to Marking Head 22 SH Series Marking Head Operation and Service Manual 5 7 Setting Working Distance The working distance and corresponding field size for a given focusing lens are identified on the focusing lens assembly The working distance is measured from the bottom of the focusing lens housing to the work surface refer to Figure 5 3 CAUTION When measuring the working distance between the lens housing and the work surface ensure that the exterior of the lens is not touched Any contact could result in scratching the lens surface Figure 5 3 Measurement of Working Dist
21. es and benefits Table 1 1 SH Series Features and Benefits FEATURES BENEFITS Large 15 mm Marking Aperture Smaller f for a given focal length produces smaller spot size providing greater resolution Single Pupil Optical System Zero distortion in the image plane Internal Distortion Compensation Automatic elimination of pin cushioning and barreling Reflective Internal Optical Design YAG or CO interchangeable by simply changing the final focusing lens Choice of Internal Expansion Ratio Optimize any manufacturer s YAG or CO laser for operation with the Marking Head Low Cost Implementation Requires only a PC CAD software laser marking program and D A card Programmable Galvos Suitable for a wide variety of production applications high volume low mix low volume high mix individual one off jobs SH Series Marking Head Operation and Service Manual 1 1 Synrad SH Series Marking Head Continued Control of the laser is accomplished using small lightweight mirrors attached to computer controlled galvanometer motors This provides a simple but effective method of positioning a focused laser beam in an X Y plane The combination of these scanning mirrors and additional optical components such as beam expanders and focusing lenses provides an ideal method for a wide range of writing cutting and marking applications The unique design of the internal optics of the Marking Head coupled with a single large exit p
22. es the use of solvents and requires that the focusing lens be removed from the Marking Head The appropriate solvent used for cleaning should be selected based on the type of contamination that exists on the surface of the lens Refer to Table 7 2 to select the appropriate cleaning solvent Table 7 2 Selection of Cleaning Solvent Solvent Classification Application Ethyl Alcohol Least Aggressive Initial Dust Cleaning Acetone Moderately Aggressive Oily residues Minor baked on plastics Vinegar Most Aggressive Baked on plastics Oxide build ups 32 SH Series Marking Head Operation and Service Manual 7 2 4 Aggressive Cleaning Continued Before starting the cleaning process read the entire procedure below to ensure that all required materials and tools are available The use of finger cots powder free is recommended to prevent contamination of the lens surface from skin oils In addition observe necessary safety precautions when handling solvents Remove the focusing lens from the Marking Head according to Para 5 9 Fold a clean lens tissue to a length equivalent to the radius of the focusing lens Saturate the lens tissue with the appropriate solvent as indicated in Table 7 2 Page 32 and shake tissue to remove excess 4 Place the folded edge of the tissue against the surface of the lens Slowly rotate the tissue around the center of the lens To prevent residues from being deposited on the surface of the lens the tissue must be
23. eseeseeaeseeseseeseeaeseesesaes 4 FIGURE 1 3 LOCATION OF MANUFACTURER S PLACARD AND CE COMPLIANCE LABEL 1 5 BIGURE2 PHYSICAE FEATURES FIGURE 222 PHYSICAE FEATURES UC DIR cua e EO FIGURE 2 3 LASER MARKING SYSTEM essent E ennt tente instet EE iaa FIGURE 4 1 TYPICAL MARKING HEAD MOUNTING pe FIGURE 4 2 PLANES OF MOVEMENT REQUIRED FOR ALIGNMENT FIGURE 4 3 LOCATION OF MARKING HEAD MOUNTING HOLES FIGURE 4 4 BEAM ALIGNMENT FIGURE 5 1 FIELD COORDINATE SYSTEM eese enne FIGURE 5 2 MARKING FIELD RELATIVE TO MARKING HEAD essent nnne tnter renean FIGURE 5 3 MEASUREMENT OF WORKING DISTANCE essent tnter FIGURE 6 1 DADIO SWITCH JUMPER SETTINGS ee FIGURE 6 2 DADIO M ARKING HEAD INTERFACE CABLE esee entente entente tenete rennen innen FIGURE 6 3 CIO DDA06 SWITCH JUMPER SETTINGS Ne FIGURE 6 4 CIO DDA06 M ARKING HEAD INTERFACE CABLE eese ener tenerent nnne ten FIGURE 6 5 UC 1000 INTERCONNECTION DIAGRAM enne rene List of Tables TABLE 1 1 SH SERIES FEATURES AND BENEFITS essent eene enne tne teen tente entente tentent nne tenens rens 1 TABLE 2 TSPEGIEICATION TABLE tr ERE ERE et en E Eee TABLE 2 2 ANALOG INPUT CONNECTOR PIN
24. eturn the Marking Head in the original packing material and shipping container Write the return authorization number on the outside of the shipping container 34 SH Series Marking Head Operation and Service Manual APPENDIX A List of Suppliers 35 SH Series Marking Head Operation and Service Manual D A Cards DADIO Card available from Scientific Solutions Inc 6225 Cochran Rd Solon OH 44139 Tel 216 349 4030 FAX 216 349 0851 CIO DDAO6 available from Computer Boards Inc 44 Wood Avenue Mansfield MA 02040 Tel 508 261 1123 FAX 508 261 1094 Software American Laserware ProLase 812B Eyrie Drive Oviedo FL 32765 407 366 2237 T F 407 366 3847 M Power Supply Lambda Electronics Inc 515 Broad Hollow Rd Melville NY 11747 Tel 800 LAMBDA 4 36 SH Series Marking Head Operation and Service Manual APPENDIX B Synrad SH Series Marking Head Mounting Kit Installation Adjustment Instructions 37
25. f the Marking Head 2 2 10 Gate Out Connector A BNC style connector that provides the gate control signal for turning the external laser on and off This signal is routed from pin 7 of the analog input connector to the Gate Out connector The characteristics of this output are determined by the requirements of the laser controller For use with a Synrad laser this connector provides a TTL output to drive Synrad s UC 1000 Universal Controller SH Series Marking Head Operation and Service Manual Figure 2 2 Physical Features Y XOUTPUT CONHECTOR A ADUTPUT BEAM ENTRANCE APERTURE EXT MD OUT GOH HECTOR POWER CONTROL OUTPUT GOHHEGTOR FUSE HOLDER FOWER IHPUT 2 2 11 Power Input Connector A panel mounted circular connector that provides 28 30VDC operating power to the Marking Head 2 2 12 Fuse Holder A panel mounted fuse holder The required fuse is rated at 28 VDC slow blow 2 2 13 Power Control Output Connector A BNC style connector that provides a DC voltage to control the power output level of the external laser This signal is routed from pin 6 of the analog input connector to the power level control connector The characteristics of this output are determined by the requirements of the laser controller For use with a Synrad laser this connector provides a 0 10VDC output to drive a Synrad UC 1000 Universal Controller SH Series
26. g lens airflow across the work surface should be provided at a rate sufficient to prevent smoke and debris from the cutting and marking process from settling on the lens 5 To provide orientation relative to the Marking Head the work surface should employ a method to allow repeatable X Y alignment and rotational adjustments 5 5 Electrical Connections Electrical setup of the Marking Head requires performing the interconnects described in the following procedure Also refer to Figure 6 5 Page 30 Verify that power is off for all system components 2 Connect the analog input cable between the Marking Head and the computer and tighten into place If you purchased a D A card from Synrad this cable is provided with your system The cable should be wired according to Table 2 2 Page 10 3 Attach BNC terminated cable between the PWR CTRL OUT connector on the back panel of the Marking Head and the laser controller ANV input on Synrad s UC 1000 Laser Controller 4 Attach BNC terminated cable between the GATE OUT connector on the back panel of the Marking Head and the laser controller GATE input on Synrad s UC 1000 Laser Controller 5 Attach the power cable between the PWR connector on the back panel of the Marking Head and the 28VDC power supply 5 6 Marking Field and Coordinate System The laser marking program must be configured for the field size of the Marking Head Table 5 1 specifies the nominal field size for three differ
27. g lens in a safe clean environment Remove the focusing lens cover from the exterior of the replacement lens Insert the replacement lens into the focusing lens aperture the orientation of the 3 hole pattern is not important Install and tighten the three 8 socket head cap screws into the focusing lens mounting assembly Reconfigure the laser marking program for the field size of the new lens Para 5 6 Page 21 and adjust for the new working distance Para 5 7 Page 23 24 SH Series Marking Head Operation and Service Manual 6 Operation With ProLase Software and Synrad Lasers Performance of the laser marking system is directly affected by properly configuring the marking program and the D A interface Although the Marking Head is designed to operate using a number of different software and D A interfaces information in the following paragraphs defines configuration details for ProLase software and D A boards from Scientific Solutions or Computer Boards Inc In addition details are provided to describe how the laser and Marking Head can be powered using the same DC supply and how to properly connect the Synrad UC 1000 Laser Controller 6 1 PC Marking Head D A Interface Two options for the D A interface card are the DADIO Card Scientific Solutions and the CIO DDAO6 Card Computer Boards Inc In addition to the following details the user should consult the associated manufacturer s manual for a complete description of
28. he Marking Head and is not cocked in the hole 6 Ensure laser output power is set to minimum 18 4 2 10 11 12 13 14 15 16 17 18 19 SH Series Marking Head Operation and Service Manual Alignment Continued Turn laser power on and gradually increase output until an orange glow just appears on the screen of the alignment tool WARNING Harmful laser radiation is emitted through the open expanding mirror mount aperture Adjust the relative horizontal and elevation of the Marking Head Laser installation until the orange spot is centered relative to the alignment hole in the screen Turn laser power off Move the beam alignment tool to the exit aperture exposed by removal of the expander mirror mount Make certain the tool is seated flush against the Marking Head and is not cocked in the hole Ensure laser output power is set to minimum Turn laser power on and gradually increase output until an orange glow just appears on the screen of the alignment tool WARNING Harmful laser radiation is emitted through the open expanding mirror mount aperture Adjust the relative angular positioning pitch and yaw of the Marking Head laser installation until the orange spot is centered relative to the alignment hole in the screen Turn laser power off Repeat Step 5 through Step 14 as required to achieve proper alignment After proper alignment has been verified secure the laser and Marking Head
29. in their aligned position Repeat Step 5 through Step 12 to verify alignment except adjustments are not required after securing Marking Head laser mounts Remove beam alignment tool Install the expander mirror into the exit aperture and secure with the four screws This completes laser Marking Head alignment No further alignment is required 19 SH Series Marking Head Operation and Service Manual 5 Operating Instructions 5 1 General Proper operation of the Marking Head laser system requires consideration of several configuration and performance aspects relating to the laser Marking Head and computer system Refer to Para 2 3 Page 11 for system component requirements 5 2 Analog Input Cable The analog input cable connects the Marking Head to the D A card The analog input cable is provided if you purchased a D A card from Synrad This cable must be terminated using a DB9 connector wired according to the pinout requirements specified in Table 2 2 Page 10 Connections at the other end of the cable are defined by the D A card Refer to Para 6 1 1 Page 25 if you are using a Scientific Solutions DADIO card and Para 6 1 2 Page 27 if you are using a Computer Boards Inc card 5 3 Computer Software Control of the Marking Head is accomplished using a 386 486 or Pentium based personal computer The selected software should provide the necessary drive signals to allow text and CAD geometry to be transferred from the compu
30. moved slowly CAUTION Do not exert pressure on the surface of the lens as this pressure may cause scratching of the lens by dislodged contaminants 5 For cases when acetone is used a follow up cleaning of the lens surface is required using ethyl alcohol Repeat Steps 2 through 4 using ethyl alcohol 6 For cases when vinegar is used a follow up cleaning of the lens surface is required using distilled water acetone and ethyl alcohol Repeat Steps 2 through 4 using distilled water acetone and ethyl alcohol in that order Examine the surface of the focusing lens to determine if any contaminants remain Repeat Steps 2 through 7 as required to remove all contaminants and deposits 7 2 5 Storage Store the Marking Head with the entrance aperture plug in place and the focusing lens cap installed Store in a dry room temperature environment 39 SH Series Marking Head Operation and Service Manual 8 Return for Factory Service In the event the Marking Head requires return for factory service Synrad must be contacted prior to shipment of the Marking Head for a return authorization number The return authorization number must be included on all shipping documentation included with the returned Marking Head The following information is required by Synrad to issue a return authorization number Name of Company Name of Individual requesting return of the Marking Head Model Number Serial Number Brief description of the fault R
31. rial Do not discard the shipping container or the foam packing since these are required if the Marking Head is ever returned to Synrad for factory service Inspect the Marking Head housing for any visible signs of shipping damage Verify that the beam entrance aperture and focusing lens protective covers are installed Also verify that all external labels and placards are attached to the housing refer to Para 1 2 Page 3 Contact Synrad if the Marking Head housing is damaged or if any of the required materials labels or placards are missing 14 SH Series Marking Head Operation and Service Manual 4 Setup Requirements 4 1 Mounting The Marking Head must be mounted in a manner that allows precise alignment of the laser to the beam expansion optics within the Marking Head and adjustment of the distance between the focusing lens and the work piece Although the Marking Head can be mounted in any orientation the same may not be true of the laser Check the manual provided with your laser for suggested mounting orientation If you also purchased the mounting kit for the Marking Head and laser refer to Appendix B Page 37 for specific installation mounting instructions WARNING When mounting the Marking Head with lasers from other manufacturers ensure the beam attenuator function is not adversely affected by the Marking Head or the mounting configuration Because a number of acceptable mounting orientations are possible the ac
32. sition TC 1 0 sec Endseg TC 1 1 sec Pos Res 004 GS Distance TC 0 DAC TC 0 0 sec PCX Run 0 0 sec 6 2 6 Laser Speed 30 inch sec or a value appropriate for the material being marked Power Set to a value appropriate for the material being marked Freq Not used 6 2 7 Power Calibration The software should be calibrated to match laser output Use a laser power meter for best resuts 6 3 Synrad Laser Connections 6 3 1 DC Power Supply The same 28VDC power supply used for the Synrad laser can also be used to power the Marking Head A power cable should be fabricated using a minimum of 14 AWG wire The cable should be terminated at one end with the power connector supplied with the Marking Head The other end should be connected directly to 28VDC power 29 SH Series Marking Head Operation and Service Manual 6 3 1 DC Power Supply Continued supply Verify that the power supply voltage is 28 30VDC Using a power supply that provides less than 28VDC may cause erratic performance of the Marking Head 6 3 2 UC 1000 Laser Controller The UC 1000 Laser Controller should be connected between the laser and the Marking Head as shown in Figure 6 5 BNC style connectors should be used to terminate cables connected between Marking Head GATE OUT and POWER CONTROL OUTPUT connectors and UC 1000 GATE INPUT and ANV analog voltage connectors respectively Figure 6 5 UC 1000 Interconnection Diagram NOTES 1000 SET TO A
33. ter to the Marking Head Information on recommended software vendors is provided in Appendix A Page 35 A copy of Synrad s EmmuLase software is included with the Marking Head EmmuLase allows you to use the Marking Head as a printer from windows based applications e g AutoCAD Corel Draw To install EmmuLase run A Mnstall from the File menu in Windows The EmmuLase Help menu provides additonal information Users may elect to develop software for specific applications However this will require an advanced understanding of software design and principles of Marking Head operation 5 4 Work Surface Requirements The work surface used for cutting or marking of material should meet the following requirements 1 To avoid laser reflections back into the Marking Head the marking surface should be non reflective Black anodized aluminum is recommended 2 To assure a uniform focused beam diameter over the entire marking field the surface should be flat and parallel to the Marking Head mounting surface Recommended ratings are a surface flatness of 0 001 inch per inch of work surface and parallelism of 0 01 inch 3 To accommodate material of different thickness and to optimize marking cutting performance the distance between the Marking Head and the work surface should be adjustable 20 SH Series Marking Head Operation and Service Manual 5 4 Work Surface Requirements Continued 4 To minimize contamination of the focusin
34. tical astigmatism This interconnect is an optional output provided for monitoring purposes and is not required for system operation 10 SH Series Marking Head Operation and Service Manual 2 3 System Requirements A complete laser marking system is shown in Figure 2 3 and consists of the following Laser CO or YAG System Laser Controller SH Series Marking Head Mounting Structure 28VDC Power Supply D A Board Computer System Laser Marking Program CAD Software Figure 2 3 Laser Marking System COMPUTER 3 Y STEM VMTH Lu d ER MUFREI NC PROGROM OND CAD a ATOL TOA M x CONVERSION 28wDCc POWER dl PPL A Wa Lo INPUTS HEAD EN 3 E3 133 EF CONTROLLER 2 3 1 Laser CO or YAG System Any manufacturer s laser can be configured with Synrad s marking heads provided that the maximum specified power levels are not exceeded and that the correct beam expander ratio is selected The laser should have the capability for remote power control and remote on off switching refer to Para 2 3 2 Page 12 11 SH Series Marking Head Operation and Service Manual 2 3 1 Laser CO or YAG System Continued Synrad lasers operate at 28 VDC input power The Marking Head can be powered off of the same 28VDC power supply 2 3 2 Laser Controller For any type of laser a control module must be provided in some lasers this may be integr
35. ticular options please contact the factory on our toll free number 1 800 SYNRADI 2 4 1 Beam Expanders To ensure optimum performance of Synrad s SH Marking Heads the input laser beam should be collimated and 10 to 15 mm in diameter To enable users to match the SH Marking Head to their lasers Synrad offer a choice of six beam expander ratios 3x 4x 5x 6x 7 5x and 10x For use with Synrad lasers users should specify 3x expander ratios 2 4 2 Mounting Platform Synrad can supply a complete mounting platform to accommodate a Synrad CO laser and Marking Head for easy mounting and alignment The mounting platform is provided with a beam enclosure tube 13 SH Series Marking Head Operation and Service Manual 3 Unpacking Initial Inspection Place the shipping container on a sturdy level surface and open the top of the box Verify that the following items are included in the container The SH Series Marking Head Orange protective covers over the beam entrance aperture and the focusing lens Operation and Service Manual Power Connector 2 BNC Terminated Interconnect Cables Orange Output Aperture Cap Beam Alignment Tool 4 each 8 screws EmmuLase Software Disk If a D A card was purchased from Synrad then the following is also included D A Card D A Software Disk D A User s Manual D A Calibration Tool Analog Input Cable Carefully remove the SH Series Marking Head from the container and remove the outer foam packing mate
36. tual orientation will depend on the unique requirements of the user Therefore the following information stresses important considerations independent of the actual orientation Also prior to mounting ensure that the selected mounting orientation will satisfy all work surface requirements specified in Para 5 4 Page 20 A typical mounting arrangement is shown in Figure 4 1 The Marking Head and laser are aligned horizontally on a common mounting surface There is adequate distance between the work surface and the focusing lens to accommodate material work pieces of different sizes Figure 4 1 Typical Marking Head Mounting BEAM ENCLOSURE TUEE ADJUSTABLE STAND MOUNTING STRUCTURE 15 SH Series Marking Head Operation and Service Manual 4 14 Mounting Continued The distance between the Marking Head and the laser should be adequate to install a beam enclosure tube The beam enclosure tube prevents exposure to laser radiation and prevents airborne contaminants from entering the Marking Head through the entrance aperture WARNING To prevent exposure to harmful laser radiation install a beam enclosure tube to fully enclose the laser beam as it travels between the output aperture of the laser and the entrance aperture of the Marking Head The internal optics have been pre aligned at the factory and do not require adjustment by the user It will be necessary however to align the laser to the Marking Head Refer to Figur
37. upil provide the fastest scan speeds while providing the smallest spot sizes over the entire scanned area The single pupil configuration operates without the astigmatism optical non linearity associated with other scanner designs The SH Series incorporates an internal beam expander with a variety of available expansion ratios to transform any input beam diameter into a beam large enough to fill the exit aperture This results in the smallest possible spot size for a given focal length lens improving system speed and resolution compared to conventional systems To ensure that the head is compatible with both Y AG and CO lasers all internal optics are of a reflective design with broadband coatings equally reflective at both 1 06 and 10 6 um This feature also allows the same head to be interchanged between Y AG and CO lasers by replacing only the final focusing lens Control electronics and distortion compensation are integrated into the compact head design and are easily accessible by removing the top cover Pin cushioning and barreling effects normally encountered with flat field marking systems are eliminated No further software correction for astigmatism is required Recent developments in software control and on line product monitoring have led to numerous applications in high speed manufacturing facilities The programmable nature of the galvanometers allows the scanning mirrors to be positioned in a way that allows the laser to track

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