Domino D620i Blue, D620i, D520i, D320i Red, D320i Blue Product Manual

...

Domino D-Series

Product Manual

Note: This manual L025317 is intended for use only with the

following D-Series laser coder models: D120i, D120i IP, D120i Blue, D120i Blue IP, D320i, D320i IP, D320i Blue, D320i Blue IP, D320i Red, D320i Red IP, D520i, D520i IP, D620i, D620i IP, D620i Blue, D620i Blue IP

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L025317 Issue 5 July 2014 (3)

WARNINGS: (1) As supplied, This coder is a class 4 laser

product. During operation, it will emit up to 120 watts of pulsed invisible laser radiation at a wavelength between 9 and 11 microns. Avoid eye or skin exposure to direct or scattered radiation.

(2) This coder must be fitted with class 1 laser

guarding to safeguard against accidental exposure to direct or scattered radiation before it is operated or made ready for use.

(3) Guidance on creating and fitting laser guarding

can be found in part 1 of the product manual.

(4) Use of controls or adjustments of performance

or procedures other than those specified in this manual may result in hazardous radiation exposure.

(5) The laser print head (D120 ip, D320 ip) is cooled

by compressed air. Air overpressure inside the laser print head is harmful and may lead to rupture of the cabinet.

(6) The maximum pressure for the compressed air

supplied into the print head is 4 bar. A pressure supply of 4 bar must not be exceeded at any time.

(7) The laser print head has two air outlets. Both

air outlets must be kept clear as blocked air outlets can cause an overpressure inside the cabinet and may lead to rupture (potential hazard). Please do not swap air inlet and outlet

(8) The length of the compressed air outlet hose

must not exceed 4 metres.

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DOMINO D-SERIES LASER CODER

WARNING: This is a Class 4 Laser using high power invisible

infrared light. A risk of personal injury or damage to equipment may result if proper safety precautions are not observed. Reading and understanding this manual is required before operating this laser system.

This manual, Domino Part No. L025317, has been produced for use in the maintenance and operation of the Domino D-Series Laser Coder, and to reinforce and complement any training program available with the product. It is not designed to replace any such training program.

All rights reserved. No part of this publication may be reproduced, stored on a retrieval system, or transmitted in any form, or by any means, electronic, mechanical, photocopying, recording or otherwise, without the prior permission of Domino Printing Sciences plc.

Domino Printing Sciences plc has a policy of continuous product improvement. The Company, therefore, reserves the right to modify the specification contained in this manual without notice.

For sales and service assistance please visit the following website and select “Contact Domino in your country” for local technical support:

http://www.domino-printing.com

Domino Printing Sciences plc

Bar Hill

Cambridge

CB23 8TU

United Kingdom

Tel: +44 1954 782551

Fax: +44 1954 782874

L025317 Issue 5 July 2014 (5)

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CONTENTS OF THE

EC DECLARATION OF CONFORMITY

(in accordance with ISO/IEC 17050-1)

No. L025317/4 Issuer’s name: Domino Laser GmbH, Germany Issuer’s Address: Fangdieckstrasse 75a, 22547 Hamburg / Germany Object of the declaration: D-Series laser marking system consisting of:

BCP7 controller, laser head and optional TouchPanel.

The object of the declaration described above is in conformity with the requirements of the following documents:

EN 61000-6-2:2005 Electromagnetic compatibility (EMC) - Part 62: Generic standards - Immunity for industrial environments.

EN 60825-1:2007 Safety of Laser Products.

EN 55011:2007 + A2:2007 Industrial scientific and medical (ISM) radio-frequency equipment - Electromagnetic disturbance characteristics - Limits and methods of measurement (IEC/CISPR 11:2003 + A1:2004, modified + A2:2006)

EN 60950-1:2006/A1:2010 Safety of Information Technology Equipment.

EN 61326-1:2006 Electrical equipment for measurement, control and laboratory use - EMC requirements - Part 1: General requirements (IEC 61326-1:2005)

EN 61010-1: 2010 Chapter 11 and 13 Safety requirements for electrical equipment for measurement, control and laboratory use Part 1: General requirements

EN ISO 13849-1:2008 Safety of machinery - Safety related parts of control systems - Part 1

2006/95/EC: Low Voltage Directive 2004/108/EC: EMC Directive 2011/65/EU: RoHS2 Directive

Additional Information

Compliance is dependent upon installation and use in accordance with the Product Manual supplied.

L025317 Issue 5 July 2014 (7)

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L025317 Issue 5 July 2014 (9)

CONTENTS OF THE EU DECLARATION OF INCORPORATION

(in accordance to the Directive 2006/42/EC on Machinery appendix II I.B for

partly completed machines)

No. L025317/4 Issuer‘s Name: Domino Laser GmbH Issuer‘s Address: Fangdieckstrasse 75a, 22547 Hamburg, Germany,

Person authorised to compile the relevant technical documentation, who must be established in the Community

Research & Development Department, Domino Laser GmbH

Object of the declaration: D-Series laser marking system consisting

of: BCP7 controller, laser head and optional TouchPanel.

The special technical documents corresponding to the machine have been created according to Appendix VII, part B.

It is expressly stated that the partly completed machine fulfills all the relevant provisions of the following EC directives.

2006/42/EU Directive 2006/42/EC of the European parliament

and of the Council of 17 May 2006 on machinery, and amending Directive 95/16/EC (recast)

2006/95/EU Directive 2006/95/EC of the European parliament

and of the Council of 12 December 2006 on the harmonisation of the laws of Member States relating to electrical equipment designed for use within certain voltage limits

2004/108/EU Directive 2004/108/EC of the European parliament

and of the Council of 15 December 2004 on the approximation of the laws of the Member States relating to electromagnetic compatibility and repealing Directive 89/336/EEC

2011/65/EU Directive 2011/65/EU of the European parliament

and of the Council of 8 June 2011 on the restriction of the use of certain hazardous substances in electrical and electronic equipment (recast)

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Published applied harmonized standards according to Article 7 (2)

EN 60204-1:2006-06 Safety of machinery - Electrical equipment of

machines. Part 1: General requirements.

EN 61000-6-2:2005 Electromagnetic compatibility (EMC) - Part 6-2:

Generic standards - Immunity for industrial

environments. EN 60825-1:2007 Safety of Laser Products. EN 55011:2007 + A2:2007

EN 60950-1:2006/ A1:2010 EN 61326-1:2006 Electrical equipment for measurement, control

EN 61010-1: 2010 Chapter 11 and 13

EN ISO 13849-1:2008 Safety of machinery - Safety related parts of

Industrial scientific and medical (ISM) radio-

frequency equipment - Electromagnetic

disturbance characteristics - Limits and

methods of measurement (IEC/CISPR 11:2003 +

A1:2004, modified + A2:2006)

Safety of Information Technology Equipment.

and laboratory use - EMC requirements - Part 1:

General requirements (IEC 61326-1:2005)

Safety requirements for electrical equipment for

measurement, control and laboratory use - Part

1: General requirements

control systems - Part 1

Published other applied technical standards and specifications

ÖNORM EN ISO 11252 2013 -12-01

We commit to transmit, in response to a reasoned request by the surveillanceauthorities, relevant documents on the partly completed machineryProperty rights of the manufacturer of the partly completed machinery remain unafeected.

Lasers and laser-related equipment - Laser

device - Minimum requirements for

documentation (ISO 11252:2013); German

version EN ISO 11252:2013

Important Note

The partly completed machinery must not be put into service until the final machinery into which it is to be incorporated has been declared in conformity with the provisions of this Directive, where appropriate;

L025317 Issue 5 July 2014 (11)

CERTIFICATION

Laser Controller D320i (BCP7) & Laser Controller D320i IP (BCP7) Approved by Certificate No.: CU72110452 01

Laser Controller D620i (BCP7) & Laser Controller D620i IP (BCP7) Approved by Certificate No.: CU72110452 02

Industrial laser for marking D120i; D120i IP; D120i BLUE; D120i BLUE IP; D320i; D320i IP; D320i

BLUE; D320i BLUE IP; D520i; D520i IP; D620i; D620i IP Approved by Certificate No.: CU72112124 01

Industrial laser for marking D320i RED; D320i RED IP Approved by Certificate No.: CU72112124 02

Industrial laser for marking D620i BLUE; D620i BLUE IP Approved by Certificate No.: CU72112124 03

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FCC NOTICE

PART 18 USERS MANUAL STATEMENT

This equipment has been tested and found to comply with the limits of ISM Equipment pursuant to Part 18 of the FCC Rules. These limits are designed to provide reasonable protection against harmful interference in a typical installation.

This equipment generates, uses and can radiate radio frequency energy and, if not installed and used in accordance with the instructions, may cause harmful interference to radio communication. However, there is no guarantee that interference will not occur in a particular installation. If this equipment does cause harmful interference to radio or television reception, which can be determined by turning the equipment off and on, the user is encouraged to try to correct the interference by one or more of the following measures:

• Re-orientate or relocate the receiving antenna

• Increase the separation between the equipment and receiver

• Connect the equipment into an outlet on a circuit different from that to which the receiver is connected

• Consult the dealer or an experienced radio/TV technician for help.

Any changes or modifications not expressly approved by the manufacturer could void the user's authority to operate the equipment.

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MICROSOFT’S EMBEDDED SYSTEMS END USER LICENSE AGREEMENT (“EULA”)

• You have acquired a device (“DEVICE”) that includes software licensed by Domino Printing Sciences plc from Microsoft Licensing Inc. or its affiliates (“MS”). Those installed software products of MS origin, as well as associated media, printed materials, and “online” or electronic documentation (“SOFTWARE”) are protected by international intellectual property laws and treaties. The SOFTWARE is licensed, not sold. All rights reserved.

• IF YOU DO NOT AGREE TO THIS END USER LICENSE AGREEMENT (“EULA”), DO NOT USE THE DEVICE OR COPY THE SOFTWARE. INSTEAD, PROMPTLY CONTACT DOMINO PRINTING SCIENCES PLC FOR INSTRUCTIONS ON RETURN OF THE UNUSED DEVICE(S) FOR A REFUND. ANY USE OF THE SOFTWARE, INCLUDING BUT NOT LIMITED TO USE ON THE DEVICE, WILL CONSTITUTE YOUR AGREEMENT TO THIS EULA (OR RATIFICATION OF ANY PREVIOUS CONSENT).

GRANT OF SOFTWARE LICENSE. This EULA grants you the following license:

• You may use the SOFTWARE only on the DEVICE

• NOT FAULT TOLERANT. THE SOFTWARE IS NOT FAULT TOLERANT. DOMINO PRINTING SCIENCES PLC HAS INDEPENDENTLY DETERMINED HOW TO USE THE SOFTWARE IN THE DEVICE, AND MS HAS RELIED UPON DOMINO PRINTING SCIENCES PLC TO CONDUCT SUFFICIENT TESTING TO DETERMINE THAT THE SOFTWARE IS SUITABLE FOR SUCH USE.

• NO WARRANTIES FOR THE SOFTWARE. THE SOFTWARE is

provided “AS IS” and with all faults. THE ENTIRE RISK AS TO SATISFACTORY QUALITY, PERFORMANCE, ACCURACY, AND EFFORT (INCLUDING LACK OF NEGLIGENCE) IS WITH YOU. ALSO, THERE IS NO WARRANTY AGAINST INTERFERENCE WITH YOUR ENJOYMENT OF THE SOFTWARE OR AGAINST INFRINGEMENT. IF YOU HAVE RECEIVED ANY WARRANTIES

REGARDING THE DEVICE OR THE SOFTWARE, THOSE WARRANTIES DO NOT ORIGINATE FROM, AND ARE NOT BINDING ON, MS.

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• Note on Java Support. The SOFTWARE may contain support for programs written in Java. Java technology is not fault tolerant and is not designed, manufactured, or intended for use or resale as online control equipment in hazardous environments requiring fail-safe performance, such as in the operation of nuclear facilities, aircraft navigation or communication systems, air traffic control, direct life support machines, or weapons systems, in which the failure of Java technology could lead directly to death, personal injury, or severe physical or environmental damage. Sun Microsystems, Inc. has contractually obligated MS to make this disclaimer.

• No Liability for Certain Damages. EXCEPT AS PROHIBITED BY LAW,

MS SHALL HAVE NO LIABILITY FOR ANY INDIRECT, SPECIAL, CONSEQUENTIAL OR INCIDENTAL DAMAGES ARISING FROM OR IN CONNECTION WITH THE USE OR PERFORMANCE OF THE SOFTWARE. THIS LIMITATION SHALL APPLY EVEN IF ANY REMEDY FAILS OF ITS ESSENTIAL PURPOSE. IN NO EVENT SHALL MS BE LIABLE FOR ANY AMOUNT IN EXCESS OF U.S. TWO HUNDRED FIFTY DOLLARS (U.S.$250.00).

• Limitations on Reverse Engineering, Decompilation, and Disassembly. You may not reverse engineer, decompile, or

disassemble the SOFTWARE, except and only to the extent that such activity is expressly permitted by applicable law notwithstanding this limitation.

• SOFTWARE TRANSFER ALLOWED BUT WITH RESTRICTIONS. You may permanently transfer rights under this EULA only as part of a permanent sale or transfer of the Device, and only if the recipient agrees to this EULA. If the SOFTWARE is an upgrade, any transfer must also include all prior versions of the SOFTWARE.

EXPORT RESTRICTIONS. You acknowledge that SOFTWARE is of USorigin. You agree to comply with all applicable international and national laws that apply to the SOFTWARE, including the U.S. Export Administration Regulations, as well as end-user, end-use and country destination restrictions issued by U.S. and other governments. For additional information on exporting the SOFTWARE, see http://www.microsoft.com/ exporting/.

L025317 Issue 5 July 2014 (15)

LICENCE NOTES FOR DYNAMARK 3

Dynamark 3 uses code of the following projects:

• STLport (http://stlport.sourceforge.net)

• Boost (http://www.boost.org)

• libSigC++ (http://libsigc.sourceforge.net)

• FreeType (http://www.freetype.org)

• zlib (http://www.zlib.net)

• dxflib (http://www.ribbonsoft.com/de/about-dxflib)

• SQLite (http://www.sqlite.org)

• Lua (http://www.lua.org)

• FreeImage (http://freeimage.sourceforge.net)

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LIABILITIES AND WARRANTIES

Warranty and liability rights for personal or material damages are precluded, if they are caused by one of the following:

• Non-designated use of the laser marking system.

• The use of consumer-electronics (e.g. PDAs or Mobiles) as user interface for the marking laser systems is not recommended nor supported.

• Unauthorized installation or configuration of software on the controller.

• Unauthorized execution or configuration of programs on operating system level. On integration of the laser marking system into a TCP / IP network the Domino Laser GmbH excludes liability for all damages that are caused by attacks on the controller (like viruses, worms). The laser marking systems are built for integration in a secure industry network.

• Improper installation, commissioning, operating, and maintaining of the laser marking system.

• Operating the equipment with defective safety installations, or improperly installed or inoperable safety and protective devices.

• Non-compliance with the instructions of the operating manual regarding transport, storage, installation, commissioning, repairs, or maintenance of the laser marking system.

• Opening the laser unit.

• Unauthorised structural modifications to the laser marking system.

• Unauthorised modifications of the beam and laser parameters.

• Inadequate monitoring of components. (Refer to PART 5

MAINTENANCE AND FAULT FINDING)

• Disasters, war, and acts of God.

L025317 Issue 5 July 2014 (17)

CONTENTS

PART 1 HEALTH & SAFETY

PART 2 INSTALLATION INSTRUCTIONS

PART 3 OPERATION

PART 4 TECHNICAL REFERENCE

PART 5 MAINTENANCE AND FAULT FINDING

APPENDIX A MARKING FONTS

APPENDIX B BARCODES

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AMENDMENT RECORD

Amendment Date

All Parts at Issue 1 November 2010

All Parts at Issue 2 May 2011

All Parts at Issue 3 August 2012

All Parts at Issue 4 June 2013

All Parts at Issue 5 July 2014

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PART 1 : HEALTH & SAFETY

CONTENTS

Page

GENERAL ............................................................................................. 1-3

DESIGNATED USE ............................................................................... 1-4

SAFETY SYMBOLS .............................................................................. 1-6

SPECIFIC DANGERS ............................................................................ 1-7

Electrical Energy .............................................................................. 1-7

Compressed Air ............................................................................... 1-7

Water Cooling .................................................................................. 1-7

Laser Radiation ................................................................................ 1-8

Harmful Dusts and Vapours ............................................................. 1-9

Lenses .............................................................................................. 1-9

Scan Head Mirrors ........................................................................... 1-9

Noise ................................................................................................ 1-10

Crushing ........................................................................................... 1-10

Laser Marking Process .................................................................... 1-10

GUARDING ........................................................................................... 1-11

Access Guards ................................................................................. 1-11

Visor Guards .................................................................................... 1-11

Beam Stop Guard ............................................................................ 1-12

Materials .......................................................................................... 1-12

Interlock Switches ............................................................................ 1-13

Emergency Off ................................................................................. 1-13

Guarding Labels ............................................................................... 1-13

Specific Precautions During Maintenance or Repair Work .............. 1-14

SYSTEM NAMING CONVENTIONS ...................................................... 1-15

Complete system (laser and controller) ........................................... 1-15

Laser ................................................................................................ 1-16

Controller ......................................................................................... 1-17

LASER WARNING AND INFORMATION SIGNS ................................... 1-18

Technical data (D) ........................................................................ 1-19

Location of Controller signs ............................................................. 1-20

Controller rear side (E) ................................................................. 1-20

Location of Laser signs .................................................................... 1-21

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HEALTH & SAFETY

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HEALTH & SAFETY

GENERAL

The D-Series laser marking systems are designed and built in accordance with international standards and other technical specifications, which are to be observed. The equipment conforms to current technology and approved safety requirements.

Domino D-Series Laser marking systems are produced by Domino Laser GmbH Germany. For Sales and support contact Domino.

This safety standard, however, can only be achieved if all intended and required measures have been taken and are constantly observed. It is part of the operator’s duties to plan these measures and check their continuing implementation.

The D-Series laser marking systems have been developed and designed for fully automated marking of packaging materials and products by use of laser radiation.

The user must ensure that:

• The laser system is only made ready for use after it has been installed and guarded to Class 1 laser safety standards (EN60825), see

“HEALTH & SAFETY” on page 1-1.

• The equipment is only to be used for its intended purpose, see

“DESIGNATED USE” on page 1-4.

• The equipment is only operated in a good, serviceable condition, and that all safety installations are regularly checked for their serviceability.

• Personal protective goggles for maintenance and repair personnel are required and made available.

• Only suitable and approved tools and equipment are used.

• This Product Manual is complete and in a legible condition at the equipment location at all times.

• The valid rules and laws regarding accident prevention are available and observed.

• Only sufficiently qualified and authorised personnel shall operate, maintain, and repair the laser marking system.

• These personnel are regularly instructed in all matters concerning appropriate labour safety and environmental protection, and that they are familiar with the operating manual, particularly the safety instructions contained herein.

• Any safety and warning signs on the laser marking system must not be removed and must remain in a readable condition.

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HEALTH & SAFETY

DESIGNATED USE

The D-Series laser marking system is exclusively designated for fully automated marking of packaging materials and products by laser radiation.

If the laser marking system is used for improper purposes, all liability claims will be refused.

The technical specifications listed in “TECHNICAL REFERENCE” Part 4 must be observed and complied with at all times.

The manufacturer will not be liable for any material or personal damages resulting from non-designated usage.

The laser marking system must only be operated by authorised and specifically trained personnel who are familiar with and observe the procedures within this manual.

It is strongly recommended to carry out a risk assessment regarding laser printer integration according to EN ISO13849 and EN ISO11553. Potential hazards resulting from laser material processing machines are reported in EN ISO11553 including hazards from laser material processing (e.g. dusts, emissions, fires or explosion) and other potential hazards.

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HEALTH & SAFETY

Before turning the laser equipment on, check and ensure that:

• The laser system has been installed and guarded to Class 1 laser safety standards (EN60825), see “HEALTH & SAFETY” on page 1-1

• Only authorised personnel should be present within the operating area of the laser marking system.

For IP-rated print heads with compressed air cooling only, check and ensure that:

• The compressed air supplied to the printhead does not exceed a pressure of 4 bar.

• Both air outlets are kept clear.

• Air inlet and outlet are fitted correctly.

Before starting any production

• Check the laser marking system for any visible damage. Ensure that it is only operated in “best possible” condition Discovered defects must be eliminated immediately.

• Check and ensure that material or other objects not required for the production are removed from the operating area of the laser marking system.

• Check and ensure the flawless functioning of all safety devices.

All valid rules and laws for accident prevention are to be observed.

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HEALTH & SAFETY

SAFETY SYMBOLS

In this manual the following safety symbols have been used to alert the reader to the text of the safety instruction next to it.

This manual provides specific safety instructions for the operation of the laser marking system. These instructions exist for:

• Personnel

• Products and machines

•The environment.

WARNING: Indicates danger to life and health if the

instructions are not observed.

CAUTION: Indicates a risk of material damage if the instructions

are not observed.

WARNING: Indicates a danger from harmful dusts and

vapours.

WARNING: Indicates a danger from dangerous laser

radiation.

WARNING: Indicates a danger from dangerous electrical

voltage.

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HEALTH & SAFETY

SPECIFIC DANGERS

Electrical Energy

In the D-Series laser marking system, the maximum operating voltage is the connected mains voltage, which can pose a hazard to health. The mains voltage to be maintained is shown on the name plate.

Work on live components must only be performed by authorised personnel. In the case of a defective power supply, operation of the laser marking

system is to be stopped immediately and is only to be repaired by authorised personnel.

Keep the control unit closed at all times. Only expressly authorised personnel are permitted to open the control unit.

Compressed Air

The laser print head is cooled by compressed air (D120i IP65, D320i IP65). Air overpressure inside the laser print head is harmful and may lead to rupture of the cabinet.

The maximum pressure for the compressed air supplied into the print head is 4 bar. A pressure supply of 4 bar must not be exceeded at any time. The compressed air has to be free of oil, Class 1.7.2 of ISO8573.

The laser print head has two air outlets. Both air outlets must be kept clear as blocked air outlets can cause an overpressure inside the cabinet and may lead to rupture (potential hazard). Please do not swap air inlet and outlet.

The outer diameter of the outlet hose must be 12 mm. The length of the compressed air outlet hose must not exceed 4 metres!

Note: Contact Domino before disconnecting the silencer or

connecting a hose to the air outlet 2 at the laser.. If two hoses are used for the compressed air outlet these have to be placed in different positions for safety reasons.One event must not block both hoses.

Water Cooling

Handle the glycol based coolant with care. For more details see the safety data sheet of the coolant.

As a guide, avoid skin contact with the coolant. Always wear protective gloves and safety goggles when working with the coolant.

In case of:

• skin contact - remove the coolant by washing with water.

• eye contact - remove by washing with water and seek medical help immediately.

• swallowing - seek medical help immediately.

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HEALTH & SAFETY

Refer to the specific Safety Data Sheet supplied with the coolant for further information.

Only a water cooler with an empty tank is allowed to be shipped. Refer to the Water Chiller manual for the procedure to empty the tank.

Laser Radiation

Laser radiation can pose a risk to eyes and skin. The danger is not only posed by direct laser radiation, but also by scattered radiation and reflections from the work piece or the packaging machine. The degree of injury depends on the duration of the effect, the power and the wavelength of the laser.

Lasers and their installations are classified into seven laser protection classes, depending on their potential danger. Class 1 is the safest and Class 4 is potentially the most harmful. These classes are defined in detail in EN60825 Part 1 and are summarised below:

Class 1 The accessible laser radiation may be visible or invisible and is

harmless.

Class 1M The accessible laser radiation may be visible or invisible and is

harmless, provided additional optical instruments are not used.

Class 2 The accessible laser radiation is visible and is harmless for

accidental exposure to eyes for periods of less than 0.25 seconds.

Class 2M The accessible laser radiation is visible and is harmless for

accidental exposure to eyes for periods of less than 0.25 seconds, provided additional optical instruments are not used.

Class 3R The accessible laser radiation may be visible or invisible. It is

potentially harmful to eyes.

Class 3B The accessible laser radiation may be visible or invisible. Direct

radiation is harmful to the eyes and skin although diffuse radiation (reflected from a matt surface) is harmless.

Class 4 The accessible laser radiation may be visible or invisible. Direct

and diffuse radiation is extremely harmful to eyes and skin and can pose a fire risk if projected onto combustible materials.

The D-Series laser marking systems, taken by themselves, are Class 4 and must not be used until suitable, interlocked guarding is fitted to achieve a Class 1 laser installation that physically prevents access to the laser radiation or automatically disables the laser when access is required to the marking area (for cleaning or maintenance, etc.).

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HEALTH & SAFETY

Harmful Dusts and Vapours

When radiating materials by means of a laser, harmful dusts and vapours can be produced. The user is responsible for appropriate measures, e.g. an exhaust system, to reduce such harmful dusts and vapours to a level that complies with the allowed maximum concentration of pollutants at the work place.

Lenses

Germanium and Zinc Selenide lenses are used in the D-Series laser system. Lenses must not be touched. If the lens has been soiled, it must be thoroughly cleaned (see “CLEANING

THE LENS” on page 5-3) before any operation.

The lens is not water resistant and must therefore only be cleaned with Isopropyl Alcohol. Dry the lens using cotton swabs (Q-tips), ensuring the surface of the lens is not scratched.

The lens has to be protected with a cover against splash water when cleaning the system.

Scan Head Mirrors

Never touch the mirrors of the scan head. The mirrors are inside the scan head and there is a small risk of touching

them when cleaning the lens. The mirrors for the i-Tech 15 scan head are made of Beryllium. When the mirrors have been touched accidentally wash hands thoroughly

with water and soap. Fumes and dust from Beryllium metal can be hazardous if inhaled. Carefully clean the mirrors if the have been accidentally touched.

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HEALTH & SAFETY

Noise

All systems emit during operation a noise level lower than 80dB(A), Therefore no personal protective equipment against noise is needed.

Crushing

There is a crushing hazard during installation and operation due to:

• Product moving along the laser head.

• Products moving into and out of protective housing.

• Doors and maintenance openings of protective housings.

Especially prevent the risk of squeezing.

Laser Marking Process

Potential fire risks could result from examples as listed below. This list is not considered to be complete. Local conditions must be considered as well.

• Printing on not specified material (e.g. easily inflammable or explosive materials).

• Invalid parameter settings (e.g. very low mark speed).

• Invalid parameter settings due to corrupted print data.

• Printing constantly on the same product (e.g. no product movement caused by various reasons).

• Inflammable gases or materials inside the working area.

In printing mode the laser beam is controlled by software which must be considered as part of the risk assessment.

Note: Install a fire detector near the laser to monitor the marking

process.

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HEALTH & SAFETY

Substrate

Laser Beam Path

Access Guard

Laser Head

Lens

Substrate

Laser Beam Path

Access/Visor Guard

Laser Head

Lens

Scattered Radiation

GUARDING

The following type of guarding, using the recommended materials and construction techniques, is required to achieve a safe installation.

WARNING: Never install a laser in such a way that the lens

points to a door or in the direction of an operator.

Access Guards

Access guards are required to prevent direct human access to the laser beam. In practice, this requires full guarding of the area between, and including, the laser output lens and the area to be marked on the substrate.

Note: Guarding is required behind the substrate to prevent access to

the laser beam when the substrate is removed, or following accidental burn through of the substrate.

Visor Guards

Visor guards are required to prevent the escape of scattered radiation. Often the access guarding can be designed to perform this function without the need of an extra guard.

WARNING: Visor guards have to be installed at a minimum

distance of four times the focus distance to the laser beam.

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HEALTH & SAFETY

Substrate

Laser Beam Path

Access Guard

Laser Head

Lens

Beam Stop

Beam Stop Guard

A beam stop guard is required for applications where guarding material is fitted within 100mm of the laser lens focal plane. The beam stop is to prevent burn through of the guard should the laser be repeatedly operated without the substrate in position. The beam stop must be capable of absorbing the full output power of the laser for a period of eight hours and be large enough to cover the complete laser marking field area.

Materials

All guard materials must be opaque to 9 to 11 micron wavelength laser light produced by the CO through guard is required Makrolon® 099 from Bayer AG may be used.

laser. Guards may be metallic, however if a see-

A metallic guard with low reflectivity must be used. The housing must be orientated in a way that no laser light is reflected back to the laser as the reflected light may damage the laser.

The thickness of the guard material depends on the mechanical strength required for stable housings, and the amount of ‘burn through’ anticipated. For the purpose of adequate mechanical rigidity and laser safety, a thickness of at least six millimetres for 10W 30W laser systems and a thickness of at least eight millimetres for 60W laser systems is recommended. To ensure laser safety a greater thickness of the guard material may be required.

Housings made from Makrolon® 099 must be installed within a minimum distance of the laser lens of:

• 4 times the focus distance for 10W and 30W systems.

• 5 times the focus distance for 60W systems.

These distances are important to eliminate mirror reflection from any surrounding parts.

In a fault condition, these materials withstand the laser beam for a limited time before the beam burns through. The laser must therefore be monitored to avoid a risk of fire.

A ceramic or metal plate may be used as a beam stop. A greater thickness is required to achieve an “eight hour burn through” requirement.

Guidance regarding laser guards can be found in EN60825-Part 4.

1-12 L025317 Issue 5 July 2014

HEALTH & SAFETY

Interlock Switches

Interlock switches must be fitted to all access guards preventing access to the laser output lens and marking area that can be opened without the use of access tools.

Interlock switches must be wired into the laser control circuit so that the laser beam is disabled when the guard is removed.

Emergency Off

Integrate the laser into the emergency off circuit of the machine into which the laser is integrated. Install an emergency off push button near the laser marking systems which turns off the laser. Connect the emergency off push button via the interlock circuit to the controller.

Guarding Labels

Domino recommend that the following information is prominently displayed on the guard:

WARNING: Class 4 laser is enclosed in a Class 1 enclosure.

Operation of the system with safety guards removed may result in hazardous exposure to laser radiation.

These labels are supplied with the laser system. Additional labels are available from Domino Printing Sciences plc as part of the Guarding Labels Kit, Part Number L007628.

L025317 Issue 5 July 2014 1-13

HEALTH & SAFETY

Specific Precautions During Maintenance or Repair Work

D-Series laser marking systems are Class 4. In order to eliminate any danger to the operators, and in accordance with

the conditions of laser protection Class 1, the laser beam must always be kept inside suitable guarding.

During maintenance or checks, laser radiation dangerous to persons can become directly accessible. Persons within the dangerous work area must undertake protective measures. Of particular importance is:

• Always wear protective goggles approved in the user’s country whilst working

• Never look directly into the Laser beam (not even, when wearing protective goggles)

• Never expose skin to laser radiation

• Never insert flammable materials into the radiation beam

Laser protective goggles, approved for the respective intended purpose can be ordered from Domino (pt. No. L007761).

1-14 L025317 Issue 5 July 2014

HEALTH & SAFETY

D X YY i XX YYYY XXXX

D-Series

Product Family

1 = 10 Watt laser 3 = 30 Watt laser 6 = 60 Watt laser

20 = second

controller generation

i = i-Tech

Standard BCP7 =

air cooled laser, standard controller IP65 IP55 BCP7 = compressed air cooled laser (10W, 30W), water cooled laser (60W) IP55 controller IP65 Standard BCP7 = compressed air cooled laser (10W, 30W), water cooled laser (60W) standard controller

= wavelength 10.6 μm

BLUE = wavelength 9.3 μm RED = wavelength 10.2 μm

10 = i-Tech 10 mm scan head 15 = i-Tech 15 mm scan head

SYSTEM NAMING CONVENTIONS

Complete system (laser and controller)

Examples:

D120i 10 STANDARD BCP7

10W laser head, 10.6μm, i-Tech 10mm scan head, fan cooled, standard BCP7 controller

D120i 10 BLUE IP65 STANDARD BCP7

10W laser head, 9.3μm, i-Tech 10mm scan head, IP65, compressed air cooled, standard BCP7 controller

D320i 10 BLUE IP65 IP55 BCP7

30W laser head, 9.3μm, i-Tech 10mm scan head, IP65, compressed air cooled, IP55 BCP7 controller

D320i 10 BLUE IP65 STANDARD BCP7

30W laser head, 9.3μm, i-Tech 10mm scan head, IP65, compressed air cooled, standard BCP7 controller

D320i 10 RED IP65 STANDARD BCP7

30W laser head, 10.2μm, i-Tech 10mm scan head, IP65, compressed air cooled, standard BCP7 controller

D620i 10 IP65 STANDARD BCP7

60W laser head, 10.6μm, i-Tech 10mm scan head, water cooled, standard BCP7 controller

L025317 Issue 5 July 2014 1-15

HEALTH & SAFETY

D X YY i YYYY XX

D-Series

Product Family

1 = 10 Watt laser 3 = 30 Watt laser 6 = 60 Watt laser

20 = second

controller generation

i = i-Tech

= air cooled laser IP = compressed air cooled laser

(10 W and 30 W) IP = water cooled laser (60 W)

= wavelength 10.6 μm

BLUE = wavelength 9.3 μm RED = wavelength 10.2 μm

Laser

D120i 10W laser head, i-Tech scan head, 10.6μm, fan cooled

D120i IP 10W laser head, i-Tech scan head, 10.6μm, IP65, compressed air cooled

D120i BLUE 10W Laser head, i-Tech scan head, 9.3μm, fan cooled

D120i BLUE IP 10W Laser head, i-Tech scan head, 9.3μm, IP65, compressed air cooled

D320i 30W laser head, i-Tech scan head, 10.6μm, fan cooled

D320i IP 30W laser head, i-Tech scan head, 10.6μm, IP65, compressed air cooled

D320i BLUE 30W Laser head, i-Tech scan head, 9.3μm, fan cooled

D320i BLUE IP 30W Laser head, i-Tech scan head 9.3μm, IP65, compressed air cooled

D320i RED 30W Laser head, i-Tech scan head, 10.2μm, fan cooled

D320i RED IP 30W Laser head, i-Tech scan head, 10.2μm, compressed air cooled

D520i

55W laser head, i-Tech scan head, 10.6μm, fan cooled

1-16 L025317 Issue 5 July 2014

HEALTH & SAFETY

D X YY i XX

D-Series

Product Family

3 = 10 ,30 Watt laser 6 = 60 Watt laser

20 = secon

controller generation

i = i-Tech

= IP43

IP = IP55

D520i IP 55W laser head, i-Tech scan head, 10.6μm, IP65, water cooled

D620i 60W laser head, i-Tech scan head, 10.6μm, fan cooled

D620i IP 60W laser head, i-Tech scan head, 10.6μm, IP65, water cooled

D620i BLUE 60W Laser head, i-Tech scan head, 9.3μm, fan cooled

D620i BLUE IP 60W Laser head, i-Tech scan head 9.3μm, IP65, water cooled

Controller

D320i

10W or 30W laser, IP43 controller

D320i IP

10W or 30W laser, IP55 controller

D620i

55W or 60W laser, IP43 controller

D620i IP

55W or 60W laser, IP55 controller

L025317 Issue 5 July 2014 1-17

HEALTH & SAFETY

Laser warning sign (A)

Laser class 4 warning label (B)

Radiation from output lens (C)

LASER WARNING AND INFORMATION SIGNS

Warning signs are located at specific points on the laser marking system. They correspond to the afore mentioned standards and specify the potential hazards and the required safety measures.

These warnings, additional information signs and their locations on the laser marking system are shown in the following illustrations.

Check their presence and readability regularly.

1-18 L025317 Issue 5 July 2014

Controller branding (example) (E)

Technical data (D)

Technical data for D120i Blue and D120i Blue IP

Technical data for D320i and D320i IP

Technical data for D320i Blue and D320i Blue IP

Technical data for D120i and D120i IP

Technical data for D620i and D620i IP

Technical data for D320i Red and D320i Red IP

Technical data for D620i Blue and D620i Blue IP

HEALTH & SAFETY

L025317 Issue 5 July 2014 1-19

HEALTH & SAFETY

Location of Controller signs

Controller rear side (E)

1-20 L025317 Issue 5 July 2014

HEALTH & SAFETY

D-Series

10 and 30 Watt heads

Location of Laser signs

L025317 Issue 5 July 2014 1-21

HEALTH & SAFETY

THIS PAGE INTENTIONALLY LEFT BLANK

1-22 L025317 Issue 5 July 2014

PART 2 : INSTALLATION INSTRUCTIONS

CONTENTS

Page

UNPACKING AND INVENTORY ........................................................... 2-3

ASSEMBLY ........................................................................................... 2-3

Environmental and Storage Conditions ........................................... 2-3

Handling the Equipment .................................................................. 2-3

Laser Head Assembly ...................................................................... 2-4

Scanner Fields and Distances ..................................................... 2-5

Removal of the transport locking device ..................................... 2-6

Control Unit ...................................................................................... 2-7

Power supply ............................................................................... 2-7

Installing the Main Cable: Controller to Laser .................................. 2-8

TOUCHPANEL INSTALLATION ............................................................ 2-11

ELECTRICAL CONNECTIONS ............................................................. 2-13

Connecting Laser Head Cable to X11 ............................................. 2-15

USB 1.1 Port .................................................................................... 2-15

Ethernet connections ....................................................................... 2-15

X2 Connector Schematic - Beacons ............................................... 2-16

X3 Connector Schematic - Product Detector .................................. 2-18

X6 Connector Schematic - Shaft Encoder ....................................... 2-18

X4 Connector Schematic - Machine Control ................................... 2-20

The Compile OK Signal ............................................................... 2-23

X7 Connector Schematic - Fume Extraction ................................... 2-26

X23 Connector Schematic - RS232 COM1 ..................................... 2-28

X28 Connector Schematic - Air Chiller Control ............................... 2-30

X58 Connector Schematic - Power Extension ................................ 2-32

X59 Connector Schematic - Ethernet 2 - Remote Panel Interface .. 2-33

SAFETY OF THE LASER SYSTEM ....................................................... 2-35

X29 Connector ................................................................................. 2-36

Timing .............................................................................................. 2-38

Typical installation faults .................................................................. 2-39

CONNECTOR OVERVIEW .................................................................... 2-40

COMPRESSED AIR CONNECTION, LENS .......................................... 2-41

COMPRESSED AIR CONNECTION ...................................................... 2-42

COOLING D120i IP D320i IP ................................................................ 2-42

L025317 Issue 5 July 2014 2-1

INSTALLATION INSTRUCTIONS

Connection of Compressed Air to the Laser ................................... 2-43

AIR FLOW SETTINGS .......................................................................... 2-44

Air Flow without Air Chiller .............................................................. 2-44

D120i .......................................................................................... 2-44

D320i .......................................................................................... 2-45

Air Flow without Air Chiller .............................................................. 2-46

D120i .......................................................................................... 2-46

D320i .......................................................................................... 2-47

COOLING THE i-TECH 15 SCAN HEAD .............................................. 2-48

Air Flow Settings for the i-Tech 15 Scan Head ............................... 2-49

WATER COOLING D620i ..................................................................... 2-50

FUME EXTRACTION SYSTEM ............................................................. 2-51

GUARDING .......................................................................................... 2-52

INITIAL OPERATION ............................................................................ 2-52

INITIAL SETUP WIZARD ...................................................................... 2-53

POSITIONING CODE ON THE PRODUCT ........................................... 2-54

Achieving Maximum Line Speed ..................................................... 2-56

Making marks longer than one field size ......................................... 2-59

RapidScan Technology ................................................................... 2-59

Product Distance and Print Start - Ignore Distance ........................ 2-61

2-2 L025317 Issue 5 July 2014

INSTALLATION INSTRUCTIONS

UNPACKING AND INVENTORY

Prior to and while unpacking the control unit and laser assembly, visually check for damage that has occurred during transportation, in particular; loose parts, dents, scratches and missing parts.

ASSEMBLY

CAUTION: The assembly, i.e. the mounting and the

installation of the laser marking system must only be performed by personnel qualified for this task and in accordance with the valid regulations and safety instructions.

Before assembly, check the laser head and control unit for visible damage. Refer to PART 1 : “HEALTH & SAFETY” . The installation of the laser marking system has to comply to IEC 60825-1.

Environmental and Storage Conditions

The following conditions are necessary for operation and storage of the laser marking system:

Temperature +5°C to +40°C 90% max relative humidity - non-condensing

The controller is capable of operating within the International Protection Code IP43, which provides dust protection and protection from splashing water. To protect the installation from more severe conditions, extra measures must be taken.

CAUTION: To ensure IP43 protection always close the USB

connection with the cap supplied.

Handling the Equipment

The equipment must be handled appropriately and carefully. The laser head must not be held by the scanner head or by the supply lines. The control unit is to be specifically protected during assembly.

L025317 Issue 5 July 2014 2-3

INSTALLATION INSTRUCTIONS

Scanner Head

Lens

Object to be Marked

working distance

Laser Head Assembly

The laser head must be mounted correctly on the support profile provided for this purpose (depending on the laser system used).

A mechanical de-coupler must be provided to prevent damage to the laser head, or its mounting, during shock or shaking motions of the packaging machine.

The lens opening must be centred vertically over the text field of the object to be marked.

Correct laser marking is only possible when the surface of the object is at the focal point of the lens.

The working distance is measured from the lower surface of the scanner to the top surface of the marking product.

2-4 L025317 Issue 5 July 2014

INSTALLATION INSTRUCTIONS

Scanner Fields and Distances

i-tech 10mm Scanner

Focal Length

Maximum

Field

Usable

Field

80 +/- 32 +/- 29 70 100 +/- 38 +/- 34 90 120 +/- 47 +/- 42 108 150 +/- 56.5 +/- 51 138 200 +/- 75.5 +/- 68 187 250 +/- 99.5 +/- 90 243

i-tech 15mm Scanner

Focal Length

Maximum

Field

Usable

Field

250 270 x 260 200 x 254 246 325 360 x 344 262 x 334 326 450 485 x 467 356 x 452 427

All values in millimetres. All values may fluctuate up to 5%.

Working

Distance

Working

Distance

L025317 Issue 5 July 2014 2-5

INSTALLATION INSTRUCTIONS

The marking field of the i-Tech 15 scanner is rectangular and not a square. The orientation is shown in the graphic below.

Notes: (1) For mark on the fly installations, orientate the field such that the

long field side (X-axis is in the same orientation as the product

direction.

(2) RapidScan orientations are not available for the i-Tech 15

scanner.

Removal of the transport locking device

CAUTION: The beam output lens is protected by a

transport locking and dust protection cap to prevent damage or external soiling that will cause a reduction in laser performance. Remove this device without fail before operation.

2-6 L025317 Issue 5 July 2014

INSTALLATION INSTRUCTIONS

Control Unit

CAUTION: Do not expose the control unit to any vibrations.

The control unit must be installed on a stable base. The control unit has three internal blow-out fuses. The operation voltage is 90V to 264V at 47Hz to 63Hz. Two fuses (F1 and F2) for the input AC power

• F1 for the protected phase and

• F2 for the neutral line.

Fuse F3 protects the neutral line of the safety relay.

Note: The phase line of the safety relay is protected internally by the

laser power supply unit.

The control unit needs at least 80mm free space on all sides for proper ventilation.

Power supply

The mains supply is provided by a 5m mains cable, which is connected to the control unit via a four-pole plug. It may be necessary to install a suitable AC mains plug to the loose end of the cable, connected as follows:

Green/Yellow Ground/Earth Black 2 Neutral Black 1 Live

The equipment specifications, listed on the name plate (voltage, frequency, power consumption) are to be observed under all circumstances. The correct fusing is to be made external to the laser system

The mains power connection must always be easily accessible during operation in order to quickly remove the power from the laser system when required.

The control unit contains the electrical components necessary for distribution of the correct voltages to the laser head.

The mains power AC line needs to be fused by

• a 16A fuse at 230V operating voltage,

• a 20A at 110V operating voltage. Use a quick fuse or a circuit beaker characteristic B/C. Connecting the protective earth of the laser marking system to the

packaging machine earth rail prevents a ground loop.

L025317 Issue 5 July 2014 2-7

INSTALLATION INSTRUCTIONS

Installing the Main Cable: Controller to Laser

Controller front view without main cable

Main cable with IP seal

Open the controller and insert the main cable into the controller

2-8 L025317 Issue 5 July 2014

Lock the flange

Main Cable Connectors

Overview

INSTALLATION INSTRUCTIONS

View to the main cable connectors inside the controller front

L025317 Issue 5 July 2014 2-9

INSTALLATION INSTRUCTIONS

20 Pin IDC Connector

Power

Connector

Cable management for the 20 pin IDC connector

Cable management for the power connector

Close the controller cabinet. Controller with main cable fitted

2-10 L025317 Issue 5 July 2014

INSTALLATION INSTRUCTIONS

AC Mains supply via mains

socket

Power supply via BCP7

controller (X59)

AC On/Off

Switch

TOUCHPANEL INSTALLATION

The installation must be carried out by trained technicians only.

Two supply voltages are provided for the TouchPanel which can be operated individually or in parallel:

Power supply of the TouchPanel

• Mains supply via the main socket. Only use the Domino power

cord: A free accessible power socket must be installed nearby the TouchPanel. Extension cables must not be used to connect the TouchPanel to mains power. The built-in power supply may be switched via the AC On/Off switch of the TouchPanel.

• Power supply via the X59 ethernet connector of the BCP7

controller: Only use the Domino X59 cables with 5m (Domino part number L015211) or 10m (Domino part number L015212) length to connect the TouchPanel to the BCP7 controller. Only these cables ensure the 24V DC power supply of the TouchPanel. The power supply of the TouchPanel fused with 2.5A inside the BCP7 controller. This power supply may only switched off with the BCP7 controller On/ Off switch.

L025317 Issue 5 July 2014 2-11

INSTALLATION INSTRUCTIONS

Disconnect the mains power in the event of TouchPanel failure. Ensure that both the Mains and BCP7 connection is removed.

The power supply to the internal power supply of the TouchPanel depends on if

• a BCP7 controller is connected via Ethernet to the TouchPanel and/or

• the AC mains supply of the TouchPanel is used.

Both power connections may be used in parallel.

2-12 L025317 Issue 5 July 2014

INSTALLATION INSTRUCTIONS

USB

Laser On/Off

Mains Power

X28

X29

Control Unit Electrical Connections

X58

X23

X59

Ethernet

On/Off

ELECTRICAL CONNECTIONS

The following cables are part of the delivered package:

• Mains connection cable

• Connector plug to the machine control (X4) Type: 12-pole cable

socket, solder connection, strain relief PG11

• USB and Ethernet Connections

• Connector plugs for X23, X59, X7, X28, X3, X6, X4, X2, X29, X58

X23 RS232 COM1 X59 Ethernet 2: Remote Panel Interface

(pre-configured 192.168.57.2, 255.255.255.0) USB USB 1.1 Port Ethernet Ethernet Connection

(192.168.58.2, 255.255.255.0) X7 Fume Extractor X28 Air / Chiller Control X3 Photocell/Product Detector X6 Quadrature Shaft Encoder X4 Machine Control X2 Beacons X29 Interlock X58 Power Extension

L025317 Issue 5 July 2014 2-13

INSTALLATION INSTRUCTIONS

Mains Power

Mains Power to

controller

X12

X11

Note: To prevent incorrect connections, different male and female

connectors have been installed and clearly marked (X...). When connecting the cables, ensure that plugs are correctly aligned to prevent damage to the pins.

Connections for D620i

The lower controller cabinets contains the laser power supplies for the 60 W laser.

X12 Safety Extension 1 - do not disconnect the

factory fitted connector to X58

X11 Safety Extension 2 - do not connect anything

here

2-14 L025317 Issue 5 July 2014

INSTALLATION INSTRUCTIONS

Connecting Laser Head Cable to X11

The flange socket (X11) on the laser head is located on the front panel. If the groove on the flange socket is not properly aligned, the cable should

be turned, not the plug. Twists in the cable are to be avoided by properly routing the cable.

USB 1.1 Port

The USB 1.1 ports are located on the top right hand side of the front of the control unit.

Ethernet connections

There are two Ethernet connections. Ethernet 1 connection is pre-configured for access via the IP address 192.168.58.2 / subnet mask

255.255.255.0. The connector is a RJ45 Bulgin connector. Ethernet 2 connection (X59) is pre-configured for plug and play connection

of the optional Touchpanel. The IP address is 192.168.57.2 / subnet mask

255.255.255.0.

L025317 Issue 5 July 2014 2-15

INSTALLATION INSTRUCTIONS

X2 Connector Schematic - Beacons

2-16 L025317 Issue 5 July 2014

INSTALLATION INSTRUCTIONS

The D-Series laser marking system offers a DC beacon interface for 24V Domino standard beacons with 4 colours.

Connector Type:

• IEC 60130-9 Type 5 way female

Mating Cable Connector (IP67 Types):

• Lumberg: 033205-1

Pin description

• Pin 1 BLUE - Blue Lamp +24V Output

• Pin 2 AMBER - Amber Lamp +24V Output

• Pin 3 GREEN - Green Lamp +24V Output

• Pin 4 RED - Red Lamp +24V Output

• Pin 5 GND - Floating Ground

Outputs

Voltage: 24V floating, max. current 170 mA The beacon indicators are in a solid state as described below:

• Green - printer is printing or ready to print.

• Red - there is a fault, printer has stopped.

• Amber - printer requires attention - a warning is displayed but printer is printing.

• Blue - software loaded - printer is not ready

If there is a critical error the red and blue indicators are on. If the LEDs directly on the laser (see Chapter 3 - Indicator lamps) are not

observable due to installation reasons a red LED has to be connected to X2: Pin3 to show laser readiness or laser activity.

L025317 Issue 5 July 2014 2-17

PNP NPN

+ Supply + Supply

0V 0V

100

Laser - Controller Customer

(12V)

Source

24V

to the other connectors

floating

PD inputEnc A inputEnc B input

+ Supply + Supply

0V 0V

Input mode

Encoder

PNP

Differential

Input mode

Encoder

X3 / X6 solder side

(Standard)

Sum Load max 500mA together with X7

2.7mA

1002.7mA

INSTALLATION INSTRUCTIONS

X3 Connector Schematic - Product Detector

X6 Connector Schematic - Shaft Encoder

In order to use the shaft encoder as a print-go source ensure that pins 3 and 4 are connected.

In this configuration no additional

product detector should be connected.

2-18 L025317 Issue 5 July 2014

INSTALLATION INSTRUCTIONS

The product detect interface offers NPN or PNP standard wiring. Different types of product detect sensors (optical, magnetic, etc.) can be connected to this input. A shaft encoder may be connected here.

Connector Type:

• IEC 60130-9 Type 08 way female

Mating Cable Connector (IP67 Types):

• Lumberg: 033208-1

Pin description

• Pin 1 +24VF - 24V floating, max 120mA

• Pin 2 GNDF - Floating Ground

• Pin 3 PD+ - Product Detect positive input

• Pin 4 PD- - Product Detect negative input

• Pin 5 CHA+ - Encoder Channel A positive input

• Pin 6 CHA- - Encoder Channel A negative input

• Pin 7 CHB+ - Encoder Channel B positive input

• Pin 8 CHB- - Encoder Channel B negative input

All input circuits contain opto couplers. The input range is 10-30V, (NPN, PNP, RS422 differential) at an input

impedance of 2 kOhm. The maximum pulse frequency of CHA and CHB is 120 kHz The minimum pulse length of the PD input is 10 micro seconds. The maximum current for X3, X6, X7 and X21 (optional user port) is 0.5A. In

case of an over-current an automatic resettable fuse protects the system.

The Shaft Encoder input is directly connected in parallel with the Product Detect Interface. For this reason the electrical specification is identical as well.

For the same reason, the standard encoder cable has no “Z” connection in order not to get signal collision with the product detector. If needed e.g. in labeller applications, the isolated leads may be soldered to the scheduled pins, or a fully connected cable (Z- version) may be ordered.

Three different types of shaft encoders can be connected:

•NPN-types,

•PNP-types

• Differential types.

L025317 Issue 5 July 2014 2-19

INSTALLATION INSTRUCTIONS

D D

C C

B B

A A

Date Name Date Name

Ind. Chan.No. Changing Processed Reviewed

Title:

Project:

No.: 190010

X4 Machine Interface from DIB 1.53

D-Com Interface Documentation

D_Com_plugs_X4_MA-1_06-190010e.SchDoc

Date

14.05.14 HK

File:

Version: e06 Page of Size: A411

D-22547 Hamburg Germany

Sator Laser GmbH

Fangdieckstraße 75a

Domino Group

Laser - Controller

Customer

PSU

24V

---

to the other Connectors

OPTOKO

LASER_START

4k4

R120

VDR: CT1210K25K/VDR25V

2 4

U24

AQV112KLA

2 4

U25

AQV112KLA

2 4

U26

AQV112KLA

R123

R126

floating

OPTOKO

Logic Input

MARK_CONTROL

Logic Input

PRINT_GO

Logic Input

PROG_IN

Logic Input

PRINTER_READY

Logic Output

PRINTER_BUSY

Logic Output

COMPILE_OK

Logic Output

Input

Output

PLC

Output

PLC

Output

PLC

Output

PLC

Input

PLC

Input

PLC

X4 female plug solder side

(DC60V/0,5A)

2 4

U10

AQV112KLA

R39

X4M

Logic Output

Input

PLC

4k4

D F D

X4 Connector Schematic - Machine Control

history box 13.11.12 HK

1.01 A: Plug pinout added 29.10.08 HK

1.02 B: "Project Run" renamed to "Laser Start". Input Resitances added 29.04.09 SW c03: Add output X4M 21.09..12 HK d04: corr. input resistors 22.10.12 HK d05 corr footer address; complete e05: corr. diodes at dig. inputs 14.05.14 HK

omino Laser GmbH angdieckstraße 75a

-22547 Hamburg Germany © Domino Laser GmbH

2-20 L025317 Issue 5 July 2014

INSTALLATION INSTRUCTIONS

The machine interface delivers inputs and outputs to control the print process and provides status information. It can be used to communicate with a PLC or to harness external NPN or PNP type control elements.

Connector Type:

• IEC 60130-9 12 way male

Mating Cable Connector (IP67 Types):

• Lumberg: 032212

Pin description

Pin A +24VF - 24V floating This pin offers 24V floating. The maximum current for X4 and X28 is 0.5A. In

case of an over-current an automatic resettable fuse protects the system.

Pin B GNDF - Floating Ground.

Pin C INP_COM - This pin is defined as common pin for all inputs.

Pin D LASER_START - Mark enable input. A logic high level on this pin puts the system into print mode and resets

error messages. The laser is enabled.

Note: This input internally works in parallel to the other (X29 and X59)

Laser Start Inputs. Thus, applying of constant voltage at this pin will suppress edges coming from the other Laser Start Inputs.

Pin E MARK_CTRL - Mark inhibit / release input A logic high or low level at this input enables or disables the Print_Go signal delivered by pin F of the X4, pin 2 of X29 or pin3/4 of X3. The active level

can be selected by software.

Pin F PRINT_GO - Print Start input A rising or falling edge at this input starts the print. The active level can be

selected by software.

Pin G PROG_IN - Programmable Input This input is prepared for future use. Pin H OUT_+COM - Positive common

L025317 Issue 5 July 2014 2-21

INSTALLATION INSTRUCTIONS

This pin offers the positive supply input of all output opto couplers. Pin J PRINTER_READY - Laser Ready to Print DC output This output opto coupler is switched on when the printer is ready to print. In

multi head systems this pin shows the logical “AND” result of all Printer_Ready signals in the chain.

Pin K PRINTER BUSY - Print busy DC output This output opto coupler is switched on while the print is processed. In

multi head systems this pin shows the logical “OR” result of all Printer_Busy signals in the chain.

Pin L COMPILE_OK - Compile ok DC output This output opto coupler is switched on when the compilation of the next

print data is finished. In multi head systems this pin shows the logical “AND” result of all Compile_OK signals in the chain.

Pin M NC - Not connected

Inputs: 10-30V, NPN, PNP Input Impedance: 1 kOhm

Outputs

Solid State Relays max. Voltage: 50V max. Current X4 and X28 : 0.5A

2-22 L025317 Issue 5 July 2014

INSTALLATION INSTRUCTIONS

The Compile OK Signal

The sequence of the Compile OK signal normally follows the ready signal. The Compile OK signal goes into high state together with or later than the ready signal - depending on the compile time of the current printing message.

There are only two cases where the CPI signal goes into low state and the RDY signal stay at high state.

Buffer Empty

The CPI signal goes low as the buffer runs empty. An error message will occur if a print is triggered with an empty buffer. Normal printing carries on if the buffer is filled with data before the next triggered print.

Lock DSP Data on Change

It is possible to use the CPI signal to detect when changes to the message have been processed. As reaction to these changes, Dynamark first lowers the CPI output and raises it again when the changes have been processed so that they are included in the next print. Note that Dynamark does not prevent marking, so print triggered while the CPI output is low will not raise a fault but only print the old data. These external changes are typically triggered via the Dynamark 4 Remote Interface or user ports.

Changes that can be used to lower the CPI output:

• activating a changed message from the editor

• SETTEXT via Dynamark 4 Remote Interface

• SETDATA via Dynamark 4 Remote Interface

• SETVAR via Dynamark 4 Remote Interface

• counter increment via user input

• text select via user input

L025317 Issue 5 July 2014 2-23

INSTALLATION INSTRUCTIONS

Changes that will not lower the CPI output:

• BUFFERDATA via QuickStep Interface

• conditional printing via user input

• counter increment via print start

• date/time text elements

Note: Changes via the QuickStep Interface have in common that they

trigger MSG 26 (“data change complete”, see SETMSG) and that they can be used as part of a transaction in order to process multiple changes as one (see BEGINTRANS, EXECTRANS).

In order to activate this feature, it is necessary to set a flag in the configuration.

By default, this flag is not set and the CPI output remains high even while applying these changes.

The CPI signal will now be low as long as compilation on the DSP is forced by external modifications.

When using both options (Buffermode and “bLockDSPDataOnChange” Flag=1) both will influence the CPI signal.

2-24 L025317 Issue 5 July 2014

INSTALLATION INSTRUCTIONS

How to set the Flag to Lock the DSP

This should only be done by service technicians or special trained users. To set this flag l

•Login as service

•Go to Home > Settings > Advanced > > Configuration Files.

• Select “Ultramark”.

• Select “Compiler” and the value “bLockDSPDataOnChange”.

• Set “bLockDSPDataOnChange” to 1.

L025317 Issue 5 July 2014 2-25

INSTALLATION INSTRUCTIONS

vak OK

Filter OK

com

out

Logic Input

Relay

with

Laser - Controller Customer

Exauster

with

Exauster

Filter

GND

(12V)

Source

24V

to the other connector s

Sum Load max 500mA

Input Vac uum OK

Input Filter OK

X7 female plug solder side

Output Exhauster ON

vak OK

Filter OK

com

out

4k4

together with X3 and X6

X7 Connector Schematic - Fume Extraction

2-26 L025317 Issue 5 July 2014

INSTALLATION INSTRUCTIONS

The drawing shows two different ways to connect a fume extraction system:

• with relay

• logic input.

Connector Type:

• IEC 60130-9 Type 6 way male

Mating Cable Connector (IP67 Types):

• Lumberg: 032206

Pin description

Pin 1 VAC_OK - Extraction system running input A correctly running extraction system delivers a high level signal at this pin. Input Impedance: 1kOhm, Input range 10-30V

Pin 2 GNDF - Floating Ground

Pin 3 FILTER_OK - IN Filter clean input A clean filter delivers a high level at this pin. Input Impedance: 1kOhm, Input range 10-30V

Pin 4 VAC_ON_+COM - Solid State Relay - Vacuum ON - Relay positive Common

Pin 5 VAC_ON_NO - Solid State Relay- Vacuum ON - DC This output is used to switch on the Vacuum system by a solid state relay. (max. Voltage: 50V, maximum current for X3/X6 and X7 is 0.5A. In case of

an overcurrent an automatic resetable fuse protects the system).

Pin 6 +24VF- 24V floating This pin can be used to drive the chiller control relay (pin 4) or to supply the

feedback signals (maximum current for X3 and X6 and X7 and X21 (optional user port) is 0.5A. In case of an overcurrent an automatic resetable fuse protects the system).

L025317 Issue 5 July 2014 2-27

INSTALLATION INSTRUCTIONS

X23 Connector Schematic - RS232 COM1

2-28 L025317 Issue 5 July 2014

INSTALLATION INSTRUCTIONS

Connector Type:

• IEC 60130-9 Type 8 way male

Mating Cable Connector (IP67 Types):

• Lumberg: 032208-1

Pin description

• Pin 1 DCD - Data Carrier Detect

• Pin 2 TXD - Transmit Data

• Pin 3 RXD - Receive Data

• Pin 4 DSR - Data Set Ready

• Pin 5 GND - Ground

• Pin 6 DTR - Data Terminal Ready

• Pin 7 CTS - Clear To Send

• Pin 8 RTS - Request To Send

L025317 Issue 5 July 2014 2-29

INSTALLATION INSTRUCTIONS

X28 Connector Schematic - Air Chiller Control

Laser - Controller Customer

Airkit/ Chiller switching ON

to the other connector s

24V

(12V)

Source

Sum Load max 500mA

together with X4

LogicRelay

Outpu t Air/Chille r ON

Input Air OK

Input Chiller OK

4k4

GND

Air OK respectively water level O

Chiller OK

4k4

X28 plug solder side

2-30 L025317 Issue 5 July 2014

INSTALLATION INSTRUCTIONS

Connector Type:

• IEC 60130-9 Type 6 way female

Mating Cable Connector (IP67 Types):

• Lumberg: 033206

Pin description

Pin 1 AIR_OK - Air_OK or Water_Level_OK input A correctly running air system delivers a high level signal at this pin. Input Impedance: 1kOhm; Input range 10-30V

Pin 2 GNDF - Floating Ground

Pin 3 CHILLER_OK - Chiller OK input A correctly running chiller delivers a high level signal at this pin. Input Impedance: 1kOhm; Input range 10-30V

Pin 4 CHILLER_AIR_ON _+COM) Chiller/Air control relay positive common pin

Pin 5 CHILLER_AIR_ON_NO Chiller/Air control relay normally open pin This output is used to switch on the Chiller/Air by a solid state relay. (Maximum Voltage: 50V, maximum current for X4 and X28 is 0.5A. In case

of overcurrent an automatic resetable fuse protects the system).

Pin 6 +24V Floating This pin can be used to drive the chiller control relay (pin 4) or to supply the

feedback signals (maximum current for X4 and X28 is 0.5A). In case of overcurrent an automatic resetable fuse protects the system.

L025317 Issue 5 July 2014 2-31

INSTALLATION INSTRUCTIONS

X58 Connector Schematic - Power Extension

Only needed to connect the power extension box for 60 Watt systems. Do not connect anything else to this connector.

2-32 L025317 Issue 5 July 2014

INSTALLATION INSTRUCTIONS

X59 Connector Schematic - Ethernet 2 - Remote Panel Interface

L025317 Issue 5 July 2014 2-33

INSTALLATION INSTRUCTIONS

The second Ethernet interface is used for a remote panel pre-configured to the IP address 192.168.57.2 / subnet mask 255.255.255.0.

A Laser Start Input can be connected for laser start by means of a mechanical switch against floating GND (between pin 7 and pin 2).

Connector Type:

• IEC 60130-9 Type 7 way female

Mating Cable Connector (IP67 Types):

• Lumberg: 033207

Pin description

• Pin 1 +24VF - 24V floating. This pin can be used to drive a remote panel with 24V at 1.5A

• Pin 2 GNDF - Floating Ground

• Pin 3 TX+ - Transmit +

• Pin 4 TX- - Transmit -

• Pin 5 RX+ - Receive +

• Pin 6 RX- - Receive -

• Pin 7 LSTART_INP - static Laser Start Input. By applying voltage to this input the laser may be started; including enabling of the printer. Input level 10-30V; input impedance: 2 kOhm, referenced to Pin 2 GNDF Floating Ground. The voltage available at pin 1 may be used.

Note: This input internally works in parallel to the other (X4 and X29)

Laser Start Inputs. Thus, applying of constant voltage at this pin will suppress edges coming from the other Laser Start Inputs.

If in a multiple head system the install option “Laser On level sensitive” is activated, this input can only be used for the first controller next to the machine (“primary”) as Laser Start Input.

Applying of constant voltage at this pin of a “secondary” controller of a multiple head system would disturb the internal communication between the controllers and would lead to malfunction.

WARNING: Attention: this connector does not offer a “laser

switch off” input.

2-34 L025317 Issue 5 July 2014

INSTALLATION INSTRUCTIONS

SAFETY OF THE LASER SYSTEM

The safety of a laser guarding is ensured by interlock doors which must be equipped with interlock switches which are observed by a certified safety relay.

The former standard EN 954 Part 1 classified the safety of machines into five categories: B, 1, 2, 3, and 4.

According to the risk analysis of Domino Laser GmbH for laser coding systems safety category 2 had to be reached. An eclectically single circuit connection was sufficient for the safety doors when using the safety relay “PNOZ-S4”.

EN 954 has been replaced by EN 13849.

Since the beginning of 2012 the risk analysis has to be done according to the standard EN 13849. This standard distinguishes between different performance levels: a, b, c, d, and e. A risk analysis according to this standard leads to the result that performance level d has to be reached. Therefore a two circuit connection is needed to the safety relay as it has been needed for category 3.

This means that the laser system has to be connected by a double circuit connection to double switches of the safety door. This double switch needs to have forcibly guided contacts of the type “normally closed”.

When using this double circuit connection operation with or without crosswire short detection is possible.

Cross-wire short detection means that the safety relay detects a short between the two circuits. A short may be produced by damaging an interlock cable, e.g. by a vehicle in a factory hall.

Without cross-wire short detection performance level d is reached. With cross-wire short detection performance level e is reached.

The functionality cross-wire short detection is activated on the Pilz safety relay. Cross-wire short detection is switched off when using the setting “Cat 2/3”. It is active when using the setting “Cat 4”.

The setting of the category has to match the wiring at the safety relay.

L025317 Issue 5 July 2014 2-35

X29 Connector

INSTALLATION INSTRUCTIONS

Performance Level select

PL _d

In2+ In2-

24V

PSU

N.C.

Opto Coupler

8 7 6 5

1 2 3 4

High speed opto driver

Printer Ready Output

PG/ Trigger Input

High speed opto coupler

Laser start Input

mode

---

Laser - Controller

Pilz PNOZ S4

24V Source current limited

PL _e

IL1 input

IL2 input

A1 A2

100 mA 50R

S11

S12

S21

GND

S22

to the other Connectors

X29 female plug solder side

Customer

Selection wheel on SR

needs to be turned

The installation of Performance-Level _c is no more permitted since the new safety rules of 2012!

PL_cPL_d PL_e

Printer Ready

Print Go

Laser Start

2-36 L025317 Issue 5 July 2014

INSTALLATION INSTRUCTIONS

PCB Connector Type:

• IEC 60130-9 Type 7 way male

Mating Cable Connector (IP67 Types):

• Lumberg : 0322 07

Pin description

• Pin 1: L1_SOURCE - Positive Interlock Source / +24V floating. This pin delivers a current limited 24V source and can only be used to drive Pin 2, Pin 3 and Pin 7 of this connector.

• Pin 2: PRINT_GO - Print Start Input. For external “print go” this pin can be driven with 24V delivered by pin 1.

• Pin 3: IL1_INP - positive Interlock1 Input. This pin is used as input for the first interlock loop in the CAT2-4 modes.

• Pin 4: L2_GND - GND pin interlock loop 2

• Pin 5: IL2_INP - Negative Interlock2 Input. This pin is used as input for the second interlock loop.

• Pin 6: Printer Ready Output. This output opto driver is switched on when the printer is ready to print. In multi head systems this pin (at the “primary” controller only available) shows the logical “AND” results of all “Printer Ready” signals in the chain. This output opto driver is protected with an auto-resetting fuse with a current limit of 100 mA. The output voltage is +24V floating. The appropriate GND is delivered on pin 4. In multi head systems this pin (at the “secondary” controllers) are automatically switched to a serial mode to handle the internal communication between the controllers.

• Pin 7: EXT_LSTART_IN - External Laser Start Input. The laser can be switched on by placing a pushbutton or a switch between pin1 (current limited 24V) and pin 7 (External Laser Start In). This input is internally working in parallel to the other (X4 and X59) Laser Start Inputs. Thus, applying of constant voltage at this pin will suppress edges coming from the other Laser Start Inputs.

The PILZ safety relay has a small selection wheel on the enclosure to select CAT2/3 or CAT4.

L025317 Issue 5 July 2014 2-37

INSTALLATION INSTRUCTIONS

Timing

The next picture shows the general E-Stop Relay timing:

2-38 L025317 Issue 5 July 2014

INSTALLATION INSTRUCTIONS

Typical installation faults

The interlock door has to be equipped with double switches to reach the requested safety level.

If one switch fails the other switch will ensure safety level. Bot h interlock circuits have to be connected to the same safety door. A typical installation fault when interlock circuit 1 is only connected to

safety door 1 and interlock circuit is only connected to safety door 2.

L025317 Issue 5 July 2014 2-39

INSTALLATION INSTRUCTIONS

H H

G G

F F

E E

D D

C C

B B

A A

Date Name Date Name

Ind. Chan.No. Changing Processed Reviewed

Title:

Project:

No.: 124714

BCP7 Electrical Connections

Valid up to SCI 2.10

bcp7_electrical_connections-1_06-124714a.SchDoc

Date

24.06.14 PKU

File:

Version: a06 Page of Size:A311

D-22547 Hamburg Germany

Domino Laser GmbH Fangdieckstraße 75a

A 1.00 created 28.02.12 PKU A 1.01 X4 Description 23.10.12 PKU A 1.02 added : values of the input resistors 25.10.12 PKU A 1.03 add : mains power connection 110V / 230V 15.01.13 PKU A 1.04 without Cat2, new:Cat3=PL_d; Cat4=PL_e (Performance-Level...) 26.03.13 MAU a05: Including Interlock X69 (shutter /fiber laser version) 13.02.14 HK/PKU a06 change externe signal designation / remove interne s.d. 24.06.14 PKU

\\DEMK-DC1\group\Sator\R&D\Private\Elektronics\design\systems\bcp\bcp7\docu\bcp7_electrical_connections

1 2 3 4 5 6 7

X29

Laser Start

Print Go

Interlock X29

L1_SOURCE PRINT_GO IL1_INP

PRINTER READY OUTPUT EXT_LSTART_IN

Printer Ready

4 5 6

WH BN GN YE GY PK BU

PL_d PL_e

A B C D E F G H J K L M

1 2 3 4 5 6 7 8

100R

PD input

Enc A input

Enc B input

In order to use the shaft encoder as a print-go source ensure that pins 3

and 4 are connected.

WARNING: In this configuration no additional

product detector should be connected.

LASER_START

4K4

MARK_CONTROL

4K4

PRINT GO

4K4

PROG IN

4K4

PRINTER_READY

PRINTER_BUSY

COMPILE_OK

Logic Input

Logic Output

DCinputs: 10-30V/Rin 2,2K

DC outputs max 24V /max 500mA

Machine Interface X4

+-PLC

Output

+-PLC

Output

+-PLC

Output

+-PLC

Output

+-PLC

Input

+-PLC

Input

+-PLC

Input

INP_COM LASER_START MARK_CTRL PRINT_GO PROG_IN OUT_+COM PRINTER_READY PRINTER_BUSY COMPILE_OK NC

+ Supply 0V

Z Z

PNP

Encoder

Input mode

Differential (Standard)

Encoder

Input mode

2 3 4 5 6 7 8

Shaft Encoder Input X6

Product Detect Interface X3

PNP + Supply 0V Q

1 2 3 4

NPN + Supply 0V

1 2 3 4

PD+ Product Detect positiv input

+24V floating, max 120mA GNDF - floating Ground

CustomerBCP7 Controller

GND

+24V

GND

+24V

1 2 3 4 5

Logic Output

GND

+24V

BLUE (+24V output)

Beacon Interface X2

Blue

Amber

Green

Red

1 2 3 4 5 6

X28

4K4Input Air OK

4K4Input Chiller OK

Output Air/Chiller ON

AIR_OK

CHILLER_OK CHILLER_AIR_ON_+COM

Air/Chiller Control X28

1 2 3 4 5 6

4K4Input Vacuum OK

4K4Input Filter OK

Output Exhauster ON

VAC_OK

FILTER_OK VAC_ON_+COM VAC_ON_NO

Exhauster with Relay

Exhauster with Logic Input

GND

3 4 5 6

Vacuum Control X7

GND

1 2 3 4 5 6 7 8

X23

RTS - Request to Send

CTS - Clear to Send

DTR - Data Terminal Ready

GND - Ground

DSR - Data Set Ready

RXD - Receive Data

TXD - Transmit Data

DCD - Data Carrier Detect

RS232 Interface X23

Pilz PNOZ S4

PL_ePL_d

mode

In2+ In2-

WH BN GN YE GY PK BU RD BK VT

GY-PK RD-BU

X58 is only suitable for controller interconnection. X58 is needed to connect the power extension box for D620i systems. Do not connect anything else to this connector!

X4M_OUT

Logic Output

Depends on Dynamark options! Default Air/Chiller Control X28

Laser ON = Air ON

Laser ON = Chiller ON

Air OK respectively water level OK!

Chiller OK!

The main cable controller to laser is available in two versions:

Main cable BCP7 Cheetah / Harting-plug

Main cable BCP7 Cheetah / Toughcon-plug

100R1K

Ethernet 2 (Remote Panel Interface) X59

1 2 3 4 5 6 7

X59

TX+_Transmit+ TX-_Transmit-

RX+_Receive+ RX-_ReceiveLSTART_INP

Remote Panel

Power Input

for future application

S11

S12 S21 S22

Pilz PNOZ S4

A2A1

Printer Ready Output

N.C.

Laser start Input

PG/ Trigger Input

Opto Coupler

GND

+24V

4K4

2K2

ETH Control

GND

+24V

TX+ TXRX+ RX-

4K7

Logic Input

1 2 3 4 5 PE

GN/YE

RD BK

EXT_L_PWR+ EXT_L_PWR-

1 2

Molex MiniFit SR-2

AC Power line (110/230V)

Harting HAN 3A/5

(

)

BUBNN

BUBN2B

DIB-X5

Sabre-3

PE Housing

PE Chassis

EXT_L_PWR

L-out

N-outPEL-in

N-in

GN/YE GN/YE

GN/YE

1 2 3 4 5 6 7

X69

Laser Start

IL1_SOURCE +24V

IL1_INP

EXTERNAL LASER START INPUT

4 5 6

WH BN GN YE GY PK BU

PL_e

Pilz PNOZ S4

PL_ePL_d

mode

In2+ In2-

Pilz mm0p Programmed with shutter feedback verification

Safety 1 source

Safety 1 feedback

PSU 24V

431

PC357N2TJ00F

Filter / input ref.1.6V /

start logic / driver

R71 20k

R72 3k3

Case GND

Via X68 to:

BCP7 / X29

(floating system)

To laser and board supply

X29X68

BCP7 ControllerFb-Laser Extension Box

DLG: 122383

Connect this cable for the shutter function

Door lock output

X24

BCP7 ControllerFb-Laser Extension Box

DLG: 122384

Install this cable for the fiber laser internal data connection.

L2_GND IL2_INP

DOOR LOCK OUTPUT

IL2 (a) IL2 (b)

GND / PE

+-PLC

Output

Laser Start

Door lock (optional)

Interlock X69 (shutter /fiber laser version)

2.10 3.00

PD- Product Detect negativ input

PD+ Product Detect positiv input

+24V floating, max 120mA GNDF - floating Ground

PD- Product Detect negativ input

CHA+ Encoder Channel A positiv input

CHB+ Encoder Channel B positiv input

CHA- Encoder Channel A negativ input

CHB- Encoder Channel B negativ input

+24V floating GNDF - floating Ground

GNDF - floating Ground

+24V floating

GNDF - floating Ground

CHILLER_AIR_ON_NO

+24V floating

GNDF - floating Ground

AMBER (+24V output) GREEN (+24V output)

RED(+24V output)

+24V floating GNDF - floating Ground

CONNECTOR OVERVIEW

2-40 L025317 Issue 5 July 2014

600V/16A

INSTALLATION INSTRUCTIONS

Compressed air connector at scanner head

(use the connector on the left or on the right side of the scanner head)

COMPRESSED AIR CONNECTION, LENS

The scanner head can be equipped with a connection for compressed air. Compressed air keeps the objective lens of the free from dust. It requires a 6mm diameter hose.

To fit the compressed air hose:

• Push the sleeve nut over the hose

• Push the hose onto the air connector and tighten the sleeve nut.

Only clean and dry compressed air, free of oil, should be used, to avoid damage to the lens.

D120i, D320i and D620i

L025317 Issue 5 July 2014 2-41

INSTALLATION INSTRUCTIONS

Air Solenoid Cable

Connector to D-Series

Controller

10mm or 3/8"

OD Tubing

D-Series Air Filtration Kit, Part Number EPP002300

Pressure Regulator

In-Line Filters

Push-In

Connector

12mm OD

Tubing to Laser

Push-In

Connector

Notes: (1) Check that thread tape is applied prior to assembly.

(2) Minimum 58 psi/4 bar factory air supply needed to operate

the kit

(3) Maximum pressure is 10 bar.

COMPRESSED AIR CONNECTION

COOLING D120i IP D320i IP

The laser head is equipped with a connection for compressed air to cool the laser.

An optional air installation kit, for treating factory air that is to be supplied to the laser head, is available. The air kit includes an air filter, regulator, coalescing filter, a control solenoid and cable, fittings, and 12 meters of 12mm tubing.

CAUTION: Only clean compressed air, free of oil, to Class 1.7.2

of ISO8573 should be used to avoid damage to the lens and laser tube.

2-42 L025317 Issue 5 July 2014

INSTALLATION INSTRUCTIONS

Air Outlet 1 to connect

hose

Air Outlet 2 with silencer

Air Inlet

Safety valve

Connection of Compressed Air to the Laser

WARNING: Operating air pressure is 4 bar!

Connect the hose from the air installation kit to the laser compressed air inlet.

A safety valve is at the air inlet. It opens if the air flow at the inlet exceeds 450lpm.

For safety reasons there are two separate outlets for compressed air. To one of them a silencer is connected (Air Outlet 2). A hose is connected to the other one (Air Outlet 1). The end of this hose has to be installed in a way that it does not get blocked at any time or that water may infiltrate into the hose. Please check the outlets for blocking and dirt on a regular monthly basis. Blocked outlets may damage the laser!

One may check the function of the safety valve upon installation. Turn the line pressure up to 3,5 bar to 4,5 bar until the safety valve opens. Reduce the pressure by 01, bar to ensure the correct air flow. Please note that air pressure is only applied to the safety valve if the switch valve inside the laser head is open. If it is closed there is no air flow through the laser head.

Both air outlets must be kept clear. Only one silencer has to be installed to the air outlets. Do not use silencers on both air outlets. Do not swap inlets and outlets for compressed air.

Check the silencer for dirt once a year. Remove the stainless steel housing to check the silencer.

Minimum inner diameter of the outlet hose must be 12 mm. The length of the outlet hose must not exceed 4 metres.

L025317 Issue 5 July 2014 2-43

INSTALLATION INSTRUCTIONS

D120i Ambient temperature (in °C) vs. maximum mark duty cycle (in %)

depending on airflow (in LPM)

Without air chiller

AIR FLOW SETTINGS

The air flow through the laser head and thereby the consumption of compressed air is controlled by an internal switch valve.

In order to reach the specified cooling capacity the line pressure before the laser head must be set to approximately 3.5 bar. This results in an air flow of 400 litres per minute if the switch valve is open.

In order to prevent the laser from damage the switch valve opens for 60 seconds each time the marking system is set to its “Ready” state. After this sequence the switch valve opens every 10 seconds. Check and re-adjust the line pressure during the first off cycles after the initial 60 seconds cooling period. The flow control mechanism monitors the temperature of the laser source and adjusts the length of the periods where the switch valve is open. If the laser is running cold, the air flow is engaged for 1 second. Once the laser heats up this period gets longer until the open state would last for more than 9 seconds. At this point the valve will stop switching and remains open.

Air Flow without Air Chiller

D120i

These are examples of typical air flows for the D120i.

2-44 L025317 Issue 5 July 2014

INSTALLATION INSTRUCTIONS

D320i Ambient temperature (in °C) vs. maximum mark duty cycle (in %)

depending on airflow (in LPM)

Without air chiller

D320i

These are examples of typical air flows for the D320i.

L025317 Issue 5 July 2014 2-45

INSTALLATION INSTRUCTIONS

D120i Ambient temperature(in°C) vs. maximum mark duty cycle (in %)

depending on airflow (in LPM)

With air chiller

Air Flow without Air Chiller

If the ambient air temperature exceed 30°C and the duty cycle is higher than 50% an air chiller should be used.

D120i

All curves are recorded with the original D-Series air kit. The maximum hose length when an air chiller is used is 4 meters from the chiller to the laser head. In this case the air kit is installed between air chiller and laser head. An air chiller type SMC (Model: IDFA8E) has been used as reference.The actual pressure depends on the installed length of the hose.

2-46 L025317 Issue 5 July 2014

INSTALLATION INSTRUCTIONS

D320i Ambient temperature (in °C) vs. maximum mark duty cycle (in %)

depending on airflow (in LPM)

With air chiller

D320i

L025317 Issue 5 July 2014 2-47

INSTALLATION INSTRUCTIONS

Inlet for compressed

air for cooling

Air out for

compressed air for

cooling

Connect silencers

when in use

To Air Supply

(8mm (shown)

or 12mm

hose)

Throttle valve

COOLING THE i-TECH 15 SCAN HEAD

The i-Tech 15 is an extremely fast scan head with relatively large and fast mirrors. This allows for superior performance in applications where a large marking field is required.

In order to ensure reliable operation of the scan head at high temperatures and/or high duty cycles the scan head may need additional cooling. To avoid interruptions in the manufacturing processes we strongly recommend a careful evaluation of the given conditions. The table on the next page provides information about when to use additional compressed air cooling in typical marking applications.

The Mark Duty Cycle (MDC) may be calculated using this formula:

• Duty Cycle (%) = (mark time (ms) x product rate (products/s)/ 10

• Example e.g. for a message of 50ms mark time printing 4 prints per second. The duty cycle is 50 x 4 / 10 = 20% in this example.

Operating pressure is 4 bar.

To cool the scan head, connect the compressed air to the inlet and the silencers to the air outlets.

2-48 L025317 Issue 5 July 2014

INSTALLATION INSTRUCTIONS

Air Flow Settings for the i-Tech 15 Scan Head

The components from air kit L015288 are used to connect the compressed air cooling and to install the silencers.

We recommend using the Domino standard air kit EPP002300, especially if you are not sure about the available air quality or line pressure.

The settings for the throttle valve are given for a line pressure of 4 bar using the Domino air kit. In the first step the throttle valve is completely closed no air flow through the scan head. In order to set the correct air flow open the valve by turning the knob. The number of turns needed is given in the table below.

Turns Air f lo w

l/min 525 850

9.5 75

The following table shows the air flow to adjust depending on the ambient temperature and the mark duty cycle (MDC).

Ambient

temperature

Without

cooling

With cooling

MDC MDC Airflow

25°C 100% 100% 0 l/min 30°C 90% 100% 25 l/min 35°C 75% 100% 50 l/min 40°C 60% 100% 75 l/min

L025317 Issue 5 July 2014 2-49

INSTALLATION INSTRUCTIONS

Main cable from controller to laser

Water in

Compressed air in

Compressed air out 2 with silencer

Water out

Compressed air out 1 with hose (12mm outer diameter)

WATER COOLING D620i

The water chiller and compressed air must be connected to the laser. To avoid damage to the laser tube, only clean compressed air free of oil, to Class 1.7.2 of ISO8573 should be used. The compressed air is used to prevent too high humidity values inside the laser module. Therefore to prevent water condensation inside the laser module.

Adjust the pressure of the compressed air between 2.5 and 3 bar. This equals an air flow rate of 20 litres per minute. The water chiller is operated by the controller via the X28 connector. Also switching on and off is done via this connection.

See the water chiller manual for more details. Coolant may be ordered from Domino. The coolant has to be exchanged at least every two years.

Note: Contact Domino before disconnecting the silencer or

connecting a hose to the air outlet 2 at the laser. If two hoses are used for the compressed air outlet these have to be placed in different positions for safety reasons.

2-50 L025317 Issue 5 July 2014

INSTALLATION INSTRUCTIONS

Both air outlets must be kept clear. Only one silencer has to be installed to the air outlets. Do not use silencers on both air outlets. Do not swap inlets and outlets for compressed air.

The outer diameter of the outlet hose must be 12 mm. The length of the outlet hose must not exceed 10 metres.

CAUTION: Follow the safety guideline of chapter 1 regarding

water cooling.

Note: It is possible to operate an air kit and a water chiller in parallel.

Both are activated via X28. For details see the water chiller manual.

FUME EXTRACTION SYSTEM

Domino recommend installing the DPX500, DPX1000, DPX1500 or the DPX2000 fume extraction and purifier system. These are designed to protect personnel from hazardous dust and fumes that may be produced by the laser marking process.

The DPX1000 is a general purpose fume extraction system that removes particulates. The DPX2000 fume extraction system has an additional filter and a chemical pad to remove odours and toxic gases. The DPX500, DPX1000, DPX1500 and DPX2000 will be equipped with a connector for the Domino D-Series Laser System.

WARNING: When printing onto PVC material, the DPX2000

Extractor should be used due to the toxic and corrosive gases expelled during the process.

For details, see the manual included with the Fume Extraction system.

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INSTALLATION INSTRUCTIONS

GUARDING

Guarding must be installed surrounding the laser head marking area in order to achieve a Class 1 installation of this Class 4 laser system (See

“Access Guards”).

INITIAL OPERATION

WARNINGS: (1) Initial Operation of the laser

marking system must only be performed by qualified personnel and in accordance with all valid regulations and safety instructions.

(2) Refer also to PART 1 : “HEALTH &

SAFETY” .

CAUTION: When the controller unit has been switched on,

electrical connections must not be connected or disconnected.

(1) At the control panel, release the On/Off button by turning it clockwise.

Wait until the BOOT READY indicator has illuminated. (refer also to

“QUICKSTEP INTERFACE” on page 3-15).

(2) The QuickStep software will start automatically. After approximately

20 to 40 seconds the QuickStep user interface will be displayed on the touch panel (refer also to “QUICKSTEP INTERFACE” on page 3-

15).

(3) Check the following:

(i) Ventilation fans on the sides of the controller unit are running. (ii) The PRINTER READY indicator on the controller unit is

illuminated.

(iii) The fume extraction system has started, and no faults are

displayed.

If the laser marking unit is equipped with a compressed air connection, the compressed air system should be turned on.

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INSTALLATION INSTRUCTIONS

INITIAL SETUP WIZARD

This procedure is for trained personnel only. When logged in with a password for the supervisor user level, this initial setup wizard will not be available to the operator.

The initial setup Wizard is the simple way to configure the printer.

Note: System settings can only be changed after entering the

administrator password, which is only known by employees authorised to carry out this level of change. This manual is intended for supervisor level and does not cover installation.

(1) Home screen to login. (2) Select Home > Settings > Initial Setup Wizard

Note: Setup procedure should be completed by a trained service

technician.

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INSTALLATION INSTRUCTIONS

Mark Window on Product

Direction of

Tra vel

Product

Detector

POSITIONING CODE ON THE PRODUCT

The position of the code on the product depends on two factors:

(1) The location of the product detector (print-go), relative to the mark

window on the product; and

(2) The ‘Encoder Delay’ setting in the software.

The D-Series laser can start marking as soon as the print-go signal is received. In most situations, the mark can be moved on the product by moving the product detector upstream or downstream (i.e. triggering the marking process to start earlier or later).

By moving the product detector in the opposite direction to the direction of travel, the print is triggered earlier, and the mark moves further to the left within the Mark Window. By moving the product detector with the direction of travel, the print is triggered later and so the mark moves to the right of the Mark Window.

In some instances, it is not possible to relocate the product detector. The D-Series includes a feature called ‘Encoder Delay’, that allows the coder to wait a defined number of encoder pulses before starting the marking process. Since the encoder is measuring the distance that the product has travelled, this allows the print-go signal to be delayed by a known and userdefined distance of product travel.

Note that the encoder delay can only be used to make the marking start later. In the example above, this would move the mark to the right within the mark window.

In the example above, if the detector is upstream (before) the laser head, the print would be triggered too early to print in the mark window, so the encoder delay would be used to locate the print in the correct position.

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INSTALLATION INSTRUCTIONS

Encoder Delay = 0,

unused

Encoder Delay in use, delaying the marking process and moving the code, without changing the location of the sensor or print head

The encoder delay can be set on a message-by-message basis, which allows a single product detector location to be used for multiple sizes of product or to allow different code locations on products of the same size.

To set the encoder delay login as administrator and navigate to:

Home > Settings > Production Line Setup > Line Movement > Encoder Setup

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INSTALLATION INSTRUCTIONS

Product movement direction

Product

Marking field on product

Marking area

Example for Marking on the Fly without an extended field

Achieving Maximum Line Speed

The D-Series includes a feature to extend the marking field when a moving product is marked as it moves past the print head. This feature is used to achieve maximum line speed.

Marking mode has to be configured for “Mark on the Fly”. Adjust the marking mode via: Home > Settings > Production Line Setup >

Line Movement > Setup Line Movement

Normally the first object in the direction of movement of a message is marked when it has entered the marking area below the laser lens.

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INSTALLATION INSTRUCTIONS

Marking area

Product

Marking field on product

Product movement direction

Example of a setup message to be marked.

Marking starts when the marking field of the product is moved into the marking area of the laser.

To achieve maximum line speed, the field can be extended behind the marking direction. The marking starts when the object enters the marking area.

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INSTALLATION INSTRUCTIONS

Marking area

Product

Marking field on product

Product movement direction

To extend the marking field move the object in the opposite direction to the movement outside the marking field (see dotted line of the field borders).

Marking starts as the product marking field enters the marking area.

Note: Moving the mark on the screen, whether in the real or extended

fields, can move the mark on the product. First set the ideal position of the mark on the screen, then adjust the product detector (print go) or change the encoder delay to set the actual mark position onto the product.

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Domino D620i Blue, D620i, D520i, D320i Red, D320i Blue Product Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Domino D-Series

PART 1 : HEALTH & SAFETY

PART 2 : INSTALLATION INSTRUCTIONS