Schilling Megalight User Manual

K:\Bedienungsanltg\Lasertechnik\BA-Erstellung\General Manual MegaLight_NEW_GB.doc

Megalight™

Marking Laser

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Schilling Marking Systems GmbH

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DE-78532 Tuttlingen Germany

Tel.: [phone]

Fax.: [phone]

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In Grubenaecker 1

Marking Systems GmbH

www.schilling-marking.com

[e-mail]

Edition: 20.03.2004

MegaLight Installation

Edition:

20/03/2004

Subject areas covered in the new edition

No. of pages
added or
modified

Foreword

Megalight™ is a Complex Component not intended to be marketed as a single commercial
unit but rather distributed exclusively as Original Equipment Manufacturer ( OEM) to qualified
Suppliers, Users, Installers who have the technical background in relation to the Safety
requirements which an Installed Laser System must possess to become a Laser Machine,
as defined by standard EN 12626 (ISO 11553).

The information contained in this manual is addressed to a qualified inst aller able to integrate
the device in a system, completing all the protection systems required by international
standards and local laws.

The following manual refers to the model Megalight™, in the two versions Marker and OEM,
i.e. relative to a Laser source which has been designed and developed as a single component
to be integrated in more complex systems to create a Laser engraving system.

The Manual has been written in compliance with the requirements of EC directive 98/37 and
subsequent modifications and integrations, and is intended to supply a qualified in staller with
instructions for:

Conformity
Shipping
Use instructions
Use contraindications
Installation
Commissioning
Use
Adjustments
Maintenance
Repair (if necessary)
Training instructions
Technical specifications
Specifications of accessories
Mechanical drawings
Wiring diagrams

The functions required from creating an engraving system must be supplied by an external
Personal Computer, with an appropriate Engraving Software installed on it.
The Marker version is supplied with an Engraving Head and Smartist 4 engraving software
with DAC 2 Hardware (Board for PCI bus and D/A converter) needed for creating the
engraving system. Installation and use instruction s for Smartist 4 are provided separately in a
specific manual called: Smartist 4 Manual.
The OEM version does not include the Engraving Head, Hardware and Engraving Software.
It is advisable to carefully read the laser safety instructions contained in this manual and to
refer to the separately provided Laser safety guide.
Make sure the system has not undergone damages from shipping when you receive it and
before installing it. If there are any signs of possible damage, contact the shipping company to
lodge a complaint and notify us at:

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MegaLight Installation

Schilling Marking Systems GmbH

In Grubenaecker 1

DE-78532 Tuttlingen - Germany

Tel.: [phone]

Fax: [phone]

eMail: volker.bartsch@schilling-markin g.com

The information contained in this document is subject to modification and review without prior
notification. All the names of the products referred to are registered trademarks belonging to
the companies that created them. Reference is made to them for editorial reasons only.
Microsoft, MS, MS-DOS, Windows 98, Windows NT, Windows 2000, Windows XP, Visual Basic,
PowerPoint, Microsoft Press, are registered trademarks or trademarks of Microsoft Corporation
in the United States and in other countries. TrueType is a registered trademark of Apple
Computer, Inc.

N.B.:
Schilling Marking Systems GmbH shall not be held liable for any damage or injury
arising from incorrect installation of its product by unqualified personnel and for
damage or injury resulting from on conforming use of the supplied equipment!

N.B.:
This product is intended to be incorporated in an O.E.M. laser system and requires
additional functions to make it in compliance with the specifications set forth in
21CFR 1040 or-60825. Class IV product.

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CONTENTS

Symbols related to equipment safety pg. 6
Definitions pg. 7
Main preliminary safety warnings pg. 8
Shipping pg. 9
Disposal pg. 9

CHAPTER 1: DESCRIPTION OF THE EQUIPMENT pg. 10
Intended Use pg. 10

Use contraindications pg. 10
Use warnings pg. 10
Composition pg. 11
Layout of the device pg. 12

Rack pg. 14
Description of the main electrical system components pg. 18

Main switch pg. 18
I/O board pg. 18
Current driver board pg. 18
Laser diode pg. 18
Peltier cell pg. 18
Aiming laser diode pg. 19
Display pg. 19

Laser resonator pg. 19
Engraving scanner head pg. 20

Objective lens pg. 21

CHAPTER 2: INSTALLATION and START-UP pg. 22
Preliminary installation notes pg. 22

Installation procedure pg. 23
Environmental requirements pg. 23

1. Connection to the mains pg. 23

2. Connections pg. 24

DSP board installation pg. 24
Connectors’ pg. 25
Electrical connections pg. 26
Optical Fibre Connection pg. 27
Preliminary commissioning (Safety instructions) pg. 30
Commissioning pg. 30
Start-up procedure (Hardware) pg. 30
Start-up procedure (Software) pg. 31
Shutting Down pg. 32

CHAPTER 3: USE and MAINTENANCE pg. 33
General use instructions for Class IV lasers pg. 33

Individual Protection Devices (IPD) pg. 34
Daily use by an Operator pg. 34
Turning on pg. 34
Turning off pg. 35
Replacing the lens pg. 35
Ordinary maintenance pg. 36

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Cleaning the lens protection glass pg. 36

Extraordinary maintenance pg. 37

TROUBLESHOOTING pg. 39

APPENDIX A: TECHNICAL SPECIFICATIONS pg. 41
System Specifications pg. 41

Identification pg. 41
Conformity pg. 41
Laser Source Classification pg. 41
Equipment electrical specifications pg. 42
Environmental and installation specifications pg. 42
Laser Source Specifications pg. 42
Mechanical specifications pg. 43
O.E.M. device standard equipment pg. 43
Separately supplied parts pg. 43
MARKER device standard equipment pg. 43

Possible field of adjustment pg. 44
Warning labels and their positioning pg. 45
Detailed label description pg. 49
Mechanical drawings pg. 51

APPENDIX B: WIRING DIAGRAMS pg. 53
Description of signals on connectors pg. 53

Command Box (CB) Connector pg. 53
External Interlock Connector pg. 54
Galvo Supply Connector pg. 54
Slave Out Connector pg. 54
P.C. Connector pg. 55
Aiming Beam Connector pg. 55
R.F. Connector pg. 56

Wiring diagrams pg. 56

APPENDIX C: Safety notes pg. 62

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SYMBOLS RELATED TO DEVICE SAFETY

Symbol Meaning

I

O

INDICATION: this symbol indicates that in this position the device
power switch is off

INDICATION: this symbol indicates that in this position the device
power switch is on

GENERIC WARNING: (caution, warning, danger): this symbol
indicates that the instructions regarding important manoeuvres or
maintenance operations need to be carefully read.

ELECTRICITY WARNING: this symbol indicates the presence of
associated dangerous voltage, or powerful enough to constitute an
electrical risk. This symbol must appear on the finished machine as
well, at the electrical risk area.

LASER WARNING: this symbol indicates the danger of exposure to
visible or invisible laser radiation. This symbol must appear on the
finished machine as well, at the optical risk area.

FIRE WARNING: this symbol indicates the danger of a fire when
processing flammable materials. For this reason it is necessary to
follow the instructions provided by the manufacturer when
commissioning the machine.

CONFORMITY: this symbol indicates that the device has been
produced in conformity with European Community directives.

READ THE WARNING: this symbol indicate s that it is obligatory to
read the important remarks in the manual before continuing

TEMPERATURE WARNING: this symbol indicates the presence of
high temperatures which may involve a risk of being burned

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Definitions

Term Definition

F

p

Symbol of impulse repetition frequency
Q Symbol of energy of one impulse
P

m

Symbol of the average power of a series of impulses
Hz Hertz, unit of measurement for frequency (1 Hz – 1 impulse/s)
J Joule, unit of measurement for energy
W Watt, unit of energy for power (1W = 1 joule/second)
mJ millijoule = one thousandth of a jou le
µ J microJoule = a millionth of a joule

DO

Optical Density, the exponential to the power of 10 of optical

radiation absorption for laser protection glasses
NOHD Nominal ocular hazard distance

λ
α

Symbol for wavelength (λ in nm)

Symbol for the divergence of the laser beam (α in mrad)
V ac Rsm value of the alternate voltage in Volts

Note for laser parameters

The energy related to a single laser impu lse is measured in microJoules. The average power of
a train of impulses is measured in Joules/second, or Watts. This average power (Watts) is
equal to the energy per impulse (Joules) multiplied by the impulse repetition frequency
(Hertz).

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Main Preliminary Safety Warnings

Before continuing with the installation of the device carefully read the following important
preliminary safety warnings.

WARNING:

The main laser radiation of Megalight™ is in Class IV. The free beam produced by a
Class IV laser source may represent a significant risk for the eyes and skin even
from a great distance!
The device is intended for use by instructed and informed personn el strictly within
an industrial plant!

N.B.:
Before continuing with installation of the device make sure you have suitable

goggles for protection against scattered radiation. Even with goggles, it is possible
to damage your vision by viewing direct laser radiation. Avoid viewing direct
radiation!

WARNING:
Before continuing with installation make sure that the environment is suitable

for the intended use. In particular make sure there are no openings (windows or
other) towards the outside which can let dangerous radiation leak out!

WARNING:
Install the laser on a stationary support. Unforeseen risks may be caused if the

device falls!

WARNING:
The intensity of this laser is sufficient to ignite flammable materia l. Do not aim the
laser beam at flammable material.

WARNING:

The interaction of the laser beam with the material causes the formation of fumes
and vapors, which may be harmful or toxic. It is advisable to eliminate the fumes
with a specific suction device and only release them to the air after they are
filtered.

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Shipping

Megalight™

must be shipped in its original packing to prevent it from undergoing bumping and

vibration. The packing has a device which is sensitive to excessive bumping which may
damage the internal parts.

WARNING:
After shipping and before starting unpacking operations make sure the
Antishock Wave label applied to detect any bumping during shipment, is intact,

If not, return to the sender.

WARNING:
Before starting unpacking operations carefully read the instructions on

attached to the packing regarding handling the device.

N.B.:

Keep the packing; it needs to be used if the device is reshipped.

In addition, avoid exposing the device to rain, cold, excessive heat and/or humidity.
During shipping do not expose the device to environmental conditions other than those liste d
below for more than 24 hours:

• ambient temperatures from - 5°C to + 55°C;

• relative humidity of 100% without condensation.

Disposal

No part of the device, including electronic, mechanical and optical, requires special precautio ns
for disposal.

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CHAPTER 1:

DESCRIPTION OF THE EQUIPMENT

Megalight™ is a Nd:YAG/passively Q-switched laser with wavelength equal to 1064nm,
maximum power equal to 6W (in continuous operation) and operating frequency equal to
25KHz, pumped by a laser diode at 808 nm and air-cooled. The pumped source is remote
controlled in relation to the laser head (Resonator) and is situated inside the rack. Coupling
between the pump diode and laser head is cone via Optical Fibre.

Intended Use

The device is designed and built for the application of engraving of non-flammable
metal and plastic materials. If the intended use of the source is changed, for example for

applications other than material processing, collateral risks may arise associated with the
interaction of laser radiation with the material.

Use contraindications

Do not subject materials other than those the device was designed for to Laser radiation.
The laser possesses intensity sufficient for igniting flammable material, so do not direct the
laser beam on flammable material. The interaction of the laser beam with the material
causes the formation of fumes and vapours, which may be harmful or toxic. It is advisable to
use appropriate suction devices to eliminate fumes and filter fumes before releasing
them into the air.

Use warnings

Megalight™ is a Laser device able to emit class 2M visible radiation (aiming red beam) and
a Class IV main invisible radiation (laser beam).
Visible lasers which are not able to damage the eye for momentary viewing but may represent
a danger if viewed through a magnifying class belonging the class 2M.
Class IV includes lasers which can produce risks, not only from direct or reflected radiation, but
also from scattered radiation! The main radiation is included in Class IV. The free beam
produced by these laser sources may represent a significant risk for the eyes even at a
substantial distance!
The device is intended for use by trained and informed personnel only within an industrial
plant!

The installer must put into eff ect all measures aimed at containing the radiation to make sure
that it is terminated at the end of its useful path. In addition, the final User (Operator) must be
informed of the risks from exposure to Laser radiation and must wear specific I.P.D. (individual
protection devices) including goggles that protect against radiation and are certified as such.

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Composition

The Megalight™ device in its basic “O.E.M.” version is composed of:

• A power supply Rack containing the pump laser diode

• A compact laser Resonator, designed to take up little room.

• A connection Optical fibre

The components required to create the “Marker” set-up can be supplied separately as an

option:

• Engraving scanner head

• Interfacing electronic boards and engraving software (Windows-based)

• A Personal Computer with Monitor, keyboard and mouse.

All engraving operations can be managed with the Smartist 4 software program.
(the minimum Personal Computer requirements and Software operating instruction are
provided in the Smartist4 Manual).

The pictures below show the composition of an engraving system and the Megalight™ with
Miniscanner model

MONITOR

MOUSE AND
KEYBOARD

PERSONAL
COMPUTER

LASER ENGRAVING
HEAD

LASER RACK

Picture 1: Megalight™ engraving laser system

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POWER SUPPLY
RACK

SCANNING HEAD OPTICAL FIBER

LASER RESONATOR

Picture 2: Laser MegaLight Layout

Device layout

The essential layout of the device highlights the main system components, composed of a
power supply rack which generates Pump radiation at 808 nm, optical fibre which
transports the pump radiation to the Resonator, Resonator which converts the 808 nm
continuous radiation to pulsed radiation at 1064 nm, engraving head scanner which aims and
deflects the laser beam on the engraving surface.

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λ

The following figure shows the system layout diagram.

OPTICAL
FIBER

DIODE LASER

λ=808 nm / CW

I/O BOARD

RACK

DRIVER
DIODE

LASER

LASER
RESONATOR

AC/ D.C
POWER

SUPPLY

RED DIODE
PILOT BEAM

=1064 nm/pulsed

Max.5W

Picture 3: System layout of MegaLight™

External
A.C. Supply

SCANNING HEAD

λ=635 nm/CW

Max.3mW

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Rack

The power supply box contains the following components:

• AC/DC Power supplies able to provide all the required service power supply

• Coupler for the pump laser diode with 808 nm wavelength.

• Current driver powering the laser diode.

• Input/Output board.

• Radiators for heat dissipation via forced ventilation completely separated from the

electrical part.

The front indicator panel is aimed at the Operator of the Megalight™ laser device and
includes the following elements:

• Multilingual display for displaying alarm messages and indications

• Three color LEDs indicating the device operating status

- POWER ON (green)

- LASER IN STAND BY (orange)

- LASER READY (red)

• Hour meter for recording the total activation time of the laser diode, making it
possible to monitor the life of the laser diode and plan maintenance work ahead of time.

• Fan for circulating radiator cooling air

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MULTILINGUAL DISPLAY

IINDICATOR LED

HOUR METER

FAN

Technical modifications reserved 15 Edition 2004

Picture 4: system rear panel: external indicators

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The rear management panel faces the side opposite the operator and inclu des the following
elements:

1 Socket for 230/110 Vac – 3/6A – 50/60Hz mains supply
2 Main switch to disconnect from the mains
3 Protection fuses (5x20mm, 6.3A/250V type T)
4 Galvo Supply connector (sub-D, 9 p., male) for Scanner Head power
5 Internal Interlock Connector (DIN, 3 p., male) for connection to an external

emergency interlocks circuit.

6 Aiming Beam connector (SMB, female) for connecting the red aiming diode.
7 Command Box connector (sub-D, 25 p., female) for connection to an external

command box.

8 P.C. connector (sub-D, 9 p., female) for connecting the device to the DSp2 contained

in the external Personal Computer.

9 Slave Out connector (sub-D, 15 p., female) (not used in this version).
10 Optical Fibre connector (D-80-LKA) for the optical fibre connection between the

Rack and Resonator.

11 R.F. connector (not used in this version).
12 Cooling fan

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2. MAIN SWITCH

MegaLight Installation

3. PROTECTION FUSES

1. SOCKET MAINS SUPPLY

4. GALVO SUPPLY

5. EXTERNAL INTERLOCK

8. PC

12. FAN 1

9. SLAVE OUT

6. AIMING BEAM

11. R.F.

7. COMMAND BOX

10. OPTICAL FIBER

12. FAN 2

Picture 5: Rear management panel: external connectors

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Description of the main electrical system components

Main switch

A line bipolar main switch (230/110Vac-10A) is contained in a filter with socket with double
fuse holder. It is located on the rear Management Panel and carries out th e following functions
at the same time:

• Power disconnection device

• Protection device against overloading and short circuits (up to 1500 A)

• Category 0 emergency device.

The main switch is normally used in turn on and turn off operations.

Input/Output board

The input/output Board IOB communicates with the various elements of the electrical system,
centralizing and sorting operational and management functions. The board IOB receives
voltage directly from main switch and interfaces w it h:

• the AC/DC service power supplies,

• the radio frequency driver board (RFD), providing the 15Vdc low voltage and the

command signals for driving the Q-switch (not used in this version)

• the current driver board

• the display

• the three color LED

• the hour meter

• the rear panel

• the fans

• the Peltier cells

In addition the IOB board communicates with the DSP2 laser management board and creates
the interface towards the outside.

Current driver board

The current driver board manages and controls the current which supplies the laser diode in a
closed circuit.

Laser diode

The power laser diode LD is contained in the Coupler. It is powered at low voltage (2-4 Vdc)
and medium-high current (up to 50A). Its operating temperature is detected by a temperature
sensor and adjusted so that it stays between 20°C and 30°C. The Laser Diode provides the
pump radiation at a 808nm wavelength, transported in Optical Fibre and necessary to supply
the Resonator (optical pumping).

Peltier cell

The Peltier cell is placed in direct contact with the base of the Coupler unit and is located
exactly below the power laser diode. It is supplied with 24Vdc voltage and transfers the
generated heat from the laser diode to be eliminated by the Dissipater.

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Aiming laser diode

The aiming diode laser with 635nm wavelength (v isible in red) is supplied at low voltage (2 .5­4Vdc) and is located in the Resonator unit. This visible radiation overlaps with the pow er laser
beam and makes it possible to indirectly view the optical path, as well as the operating field at
the output of the scanner head.

Display

Display provides the Operator with information on the status of the laser and is the first
diagnostic tool in the event of a fault

Laser resonator

RED DIODE PILOT
BEAM

λ=1064 nm
PULSED

+

λ=635 nm/CW

DICHROIC MIRROR

λ=808 nm CW

FOCUSING OPTICS

MIRROR HR@1064nm

EXIT COUPLING

BEAM EXPANDER

CRYSTAL Cr4+:YAG

CRYSTAL Nd:YAG

Picture 6: Laser Resonator

The laser Resonator is basically composed of a pair of lenses able to gather the radiation
pumped at 808nm output from the optical fibre and focalized inside the crystal of active
material (Nd:YAG) by a pair of aligned mirror s which act as an oscillator for the laser radiation
at 1064nm and a Cr4+:YAG, which acts as a passive Q-switch and is used to generate
instantaneous high power laser impulses suitable for engraving. T he final stage carried out a
beam-expander function: it increases the diameter of the output laser beam and improves the
collimation in order to be able to improve the focalization of the beam in a spot of reduced
dimensions, to obtain elevated irradiation on the engraving plane.

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The aiming red diode is also situated in the Resonator unit, returned by a dichroic mirror so
that it overlaps the laser beam exactly and can be used to learnt he main path of the invisible
radiation, even if indirectly. The architectu re of the laser head created in this manner is used
to obtain an output laser beam of a very high modal quality, with high performance and very
little heat to dissipate.

The connection for the optical fibre is located in the rear wall of the Resonator (see
Appendix A: Technical Specifications):

OPTICAL FIBER
CONNECTOR SOCKET

Engraving scanner head

DSP2 (PC)

Power supply

D/A
CONVERTER

GALVO
MOTORS X-Y

MIRRORS X-Y

DRIVER X-axis

DRIVER Y-axis

FOCUSING
LENS

Picture 7: Galvanometric scanning head to direct the laser beam

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Two tilt able mirrors are installed inside the engraving scanner head, moved by galvo-motors
and run by the DSP2 board installed in the P.C., which in turn interfaces with a digital analogy
converter D/A, also installed in the head.

Two connectors are present outside of the Miniscanner type head (see Appendix A: Technical
Specifications):

• Scanner head power supply connector (connector DB9)

• Galvo-motor command connector (connector DB25)

POWER SUPPLY ± 15V

GALVO-MOTOR COMMAND
SIGNALS

LENS

Picture 8: Rear view of the Engraving Head with connectors

Objective lens

The objective lens can be fitted with different length lens.
Typically, for the Miniscanner head:

Lens length (mm) 63 100 * 160
Work area (mm x mm) 35 x 35 60 x 60* 100 x 100
Work distance (mm) 1 73 ± 2 97 ± 2* 180±5

* available in the near future

1

from lens edge

For Scanlab head:

Lens length (mm) 100 160 254
Work area (mm x mm) 50 x 50 110 x 110 180 x 180
Work distance (mm) 1 98 ± 2 175 ± 5 285 ± 5

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MegaLight Installation

CHAPTER 2:

INSTALLATION and START-UP

Preliminary installation notes

This chapter discusses the subjects related to the installation procedure for the MEGALIGHT™
device and the tests to safely start it.
Installation must be effected by TRAINED AND QUALIFIED personnel because it
involves effecting electrical and optical tests which require a specific qualification.

Warning:

main standards regarding Class I laser devices containing Class IV sources.

before installing the device carefully read Appendix C, Safety Notes, related to the

WARNING:
The mains voltage is dangerous. If adequate precautions are not taken it can
cause electric shock! To avoid the electrical risk do not use connection wires,

plugs, sockets or extension cords lacking a quality mark or which are not intact.

N.B.:
Before continuing with installation the device makes sure you have suitable

goggles available for protection against scattered laser radiation. Even with
goggles, it is possible to damage your vision by viewing direct laser radiation!

WARNING:
Before continuing with installation make sure that the environment is suitable

for the intended use. In particular make sure there are no openings (windows or
other) towards the outside which can let dangerous radiation leak out!

WARNING:
Install the laser on a stationary support. Unforeseen risks may be caused if the

device falls!

WARNING:
Only use original wires, connectors and optical fibres. Wires with an incorrect
dimension of loose connections can cause an electrical shock or a fire.

WARNING:
Do not bend the optical fibre beyond the minimum radius indicated. Greatly

bending the fibre may cause unforeseen optical risk.

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Installation procedure

Environmental requirements

Before installing the Megalight™ engraving system, make sure that:

• The system is situated in a controlled area dedicated to laser processing.

• Until the system has been installed with all the safety devices and until it correct

operation has been tested, the installer must have the laser area guarded and not let
unauthorized personnel access the area.

• The System is positioned on a stationary surface with no vibration. In order to prevent
distortions in the engraving, install the head and the piece to be worked on the same
support, so that the piece is not subject to vibration during processing.

• To adequately house the wires and standard optical fibre equipped with the System
(max. length 3m), the power supply box and laser head must be positioned at less than
2m. Longer wires and optical fibre can be supplied upon specific request.

• Leave a free space of at least 10 cm in front of and behind the power supply box to
ensure the necessary flow of cooling air.

• Do not install the System in an excessively dirty area, in the presence of dust, oil,
chemicals, fumes or excessive humidity.

• Do not install the system in a place where the ambient temperature falls below 15 °C
or can rise above 35°C.

• Do not install the System in a place where the relative humidity often exceeds 80%.

• Do not install the System in a place with an altitude over 1500m.

(see Appendix A: Technical specifications)

Sudden and often variations in temperature can cause condensation on the surfaces of

N.B.:

the lens with the deposit of dust, which can damage optical parts.

1. Connection to the mains

The required mains is the Public mains protected and dimensioned with the following
requirements:

• Single phase voltage P+N+PE 90-240Vac (±10%)

• Mains frequency 50-60Hz

• Harmonic distortion <10%

• Interruptions <3ms

• Max absorbed power 400W

WARNING:
Do not work on the electrical part if you are not an expert!
Do not remove protection devices.
Do not replace the fuses with ones of another calibre and type.

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The wall socket for connection must be protected by a switch with 16A fuses able with their
high interruption power (normally 6000A) to interrupt the short circuit current of the mains.

N.B.:

The fuses inside the MEGALIGHT™ device are not able to directly interrupt the short
circuit current. If not adequately interrupted the short circuit current may

cause a fire!

2. Connections

The following procedure refers to the device in its “MARKER” set-up.
When they arrive the Resonator and Engraving Head are already connected together and
separately packaged from the Rack and Optical fibre. The necessary wires, interface DSP2
board to be installed in the PC, Smartist4 engraving software and related manual are also in
the packaging.

The System installation procedure involves the following phases:

• Preparation of the Personal Computer (P.C.) and installation of the DSP2 board,

• Mechanical attachment of the laser head. See Appendix A. Technical specifications for

the points for attaching the laser head.

• Electrical system connections

• Optical fibre connection.

DSP board installation

The complete engraving laser system includes the following components:

• DSP board, to be connected to a standard or industrial PC PCI type slot.

• DSP board driver (available for Windows 95 / 98 / 98Me / NT4 / 2000 / XP).

• DSP Control program for tuning engraving parameters

• Graphic editor for creating engraving models.

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The hierarchy of the components is illustrated in the following figure:

Smartist4

Control)

Control program (DSP

Graphic Editor

Driver

DSP Board

Picture 9: Software management diagram

For the complete installation procedure of the DSP board and Smartist4 software see the
related dedicated manuals (Smartist4 instruction and installation manual)

Connectors

The system is equipped with the wires and connectors described below:

• DL: plug-plug wire (length 3m) connecting the AIMING BEAM connector of the rear

• TS: SUB D 9 Female socket-socket wire (length 3m) connecting the GALVO SUPPLY

• STS: SUB D 25 pin Male plug-plug wire (length 3m) connecting the 25 pole Female

• PC: SUB D 9 Male plug-plug wire (length 3m) connecting the PC connector of the rear

• Mains socket/plug wire.

Management Panel of the power supply box and the SMB socket located on the laser
resonator body.

connector of the rear Management Panel of the power supply box and the SUB D 9 pin
Male connector located on the scanner head.

SUB-D connector of the DSP board and the SUB D 25 pin Female connector located on
the scanner head.

Management Panel of the power supply box and the DB 9 pin Female connector of the
DSP board.

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PC

TS

DL

STS

OPTICAL
FIBER

Picture 10: Layout of connection wires

Electrical connections

The sequence of the electrical connections involves the following phases:

• Make sure the main switch MS is in the OFF position.(

• Connect the DL wire between the AIMING BEAM connector (6) of the rear Management

Panel of the power supply box and the SM B socket located on the laser head body.

• Connect the TS cable between the GALVO SUPPLY connector (4) of the rear
Management Panel of the power supply box and the SUB D 9 pin M connector on the
scanner head.

• Connect the STS wire between the SUB-D 25 pole F connector of the DSP board and
SUB-D 25 pin F connector located on the Scanner Head;

• Connect the PC wire between the PC connector (8) of the rear Management Panel of the
power supply box and the DB 9 pin F connector on the DSP board.

• Connect the power supply wire (1) of the rear Management Panel.

• Connect the monitor, mouse and keyboard to the related connectors on the PC.

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the connectors (11) RF and (9) SLAVE OUT are not used in the Megalight™ engraving

N.B.:

system.

It is possible to connect all the devices aimed at making the laser source safe in series

N.B.:

with EXTERNAL INTERLOCK connector (5).
For detailed wiring and connection diagrams, see Appendix B. Wiring and connection diagrams.

Optical fiber connection.

The optical fibre is connected between the laser opening of the power supply box (connector
10: OPTICAL FIBER) and the optical fibre connector socket on the rear wall of the Resonator.

Picture 11: Optical Fibre Connection

The procedure to connect the optical fibre to the rack is as follows:

1. Make sure the main switch MS is in the OFF position (O ).

WARNING:

Laser radiation may leak from the OPTICAL FIBER connector (10) of the power
supply box. Never work with the device power on. Working with the device
power on may cause serious optical risk.

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2. Slide the optical fibre into the spring mounted grommet in the supplied back cover.

3. On the Rear Management Panel of the power supply box, remove the protective sticker
and seal on the OPTICAL FIBER connector (10).

4. Referring to Fig. 12: optical fibre connector, remove the protective cap (1) from the
optical fibre connector, by unscrewing nut (4).

5. Insert the optical fibre connector in the OPTICAL FIBER connector (10) of the power
supply box:

- gently place the optical fibre connector on the fibre socket

- carefully insert the optical fibre connector, making absolutely certain that the
optical surface of the fibre connector (2) does not come into contact with any
other surface.

WARNING:

The operation for inserting the fibre needs to be carried out very carefully.
Absolutely avoid letting the optical surface of the fibre connector come into
contact with any other surface.
Contact of the fibre optical surface with any other surface may damage it.

6. Make sure the mechanical supports (3) on the male/female connectors are in the
correct position.

7. Screw down nut (4) in the OPTICAL FIBER connector of the power supply box.

8. Screw down the rear cover on the power supply box.

Picture 12: Optical fiber connector

The procedure to connect the optical fibre to the Resonator is as follows:

1. Make sure the main switch MS is in the OFF position (O ).

WARNING:

Laser radiation may leak from the free end of the optical fibre. Never work on
the device with the power on.
Operating with the rack power on may cause serious optical risk.

2. Remove the rear cove of the resonator, by unscrewing the three screws (see Appendix
A. Technical specifications).

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3. Slide the optical fibre into the spring mounted grommet in the back cover.

4. Remove the protection cap from the fibre socket located on the rear wall of the
Resonator.

5. Referring to Fig. 12: Optical fibre connector, remove the protective cap (1) of the
optical fibre connector, by unscrewing nut (4).

6. Insert the optical fibre connector in the fibre socket present on the rear wall of the
Resonator:

- gently place the optical fibre connector on the fibre socket

- carefully insert the optical fibre connector, making absolutely certain that the
optical surface of the fibre connector (2) does not come into contact with any
other surface.

WARNING:

The operation for inserting the fibre needs to be carried out very carefully.
Absolutely avoid letting the optical surface of the fibre connector come into
contact with any other surface.
Contact of the fibre optical surface with any other surface may damage it.

7. Make sure the mechanical supports (3) on the male/female connectors are in the
correct position.

8. Screw down nut (4) on the Resonator fibre socket connector.

9. Screw down the rear cover on the Resonator again.

N.B.:

Keep the protection caps for the optical fibre and fibre socket. Returns of optical
fibres or resonators without these caps will not be accepted.

WARNING:

The optical fibre must never be subject to curve radii under 15 cm. to prevent
damaging it or breaking it.

WARNING:

The optical fibre is an integral part of the laser engraving system.
Do not work with the optical fibre disconnected or damaged.
Using an optical fibre which is greatly bent, damaged or poorly connected may lead
to a serious optical risk.

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Preliminary Commissioning (Safety instructions)

WARNING:

When commissioning and before the laser radiation protection barriers have been
positioned, always wear goggles with an optical density OD of 5 or higher, which
are certified as in conformity with both wavelengths of 808nm and 1064nm.
Always avoid direct viewing of the laser beam. No goggles are able to withstand

direct laser radiation for long.

WARNING:

The installation, use or maintenance of the system in a manner other than that
described in this manual may cause dangerous exposure to laser radiation or
electrical risk.

Commissioning

Before starting the start-up procedure make sure the following preliminary operations have
been carried out:

• Make sure the operating area is free from clutter.

• Make sure there is enough free space in front of and behind the power supply box, to

ensure cooling air flow.

• Make sure that the plug is correctly inserted.

• Make sure all the electrical connection have been correctly effected.

• Make sure the optical fibre is connected to the power supply box and Resonator.

• Make sure the protective cover of the scanner head lens has been removed.

• Make sure the optical path of the laser beam terminates at the end of its useful path.

Start-up procedure (Hardware)

1. P ut the main switch MS in the closed position (I) and make sure the following events
occur at the same time:

• the display goes on

• the fans start

2. Give the START command, using an impulse command to close the contact between pin
04 and 12 of the COMMAND BOX connector (7) located on the rear Management Panel
of the power supply box (see Appendix B. Wiring and connection diagrams). Make sure
that the following event occurs:

• GREEN led on POWER ON condition

3. After around 1 second, if the laser diode temperature is correct, the device is ready to
operate and goes to the Stand-by condition. Make sure that the following events occur:

• ORANGE led on: STANDBY condition

• The aiming red diode appears at the output of the laser beam

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4. Enable the ELECTRONIC SHUTTER, closing the contact between pin 07 and 08 of the
COMMAND BOX connector (7) located on the rear Management Panel of the power
supply box (see Appendix B. Wiring and connection diagrams).
Make sure that the following events occur:

• RED led on: READY condition

• The aiming red diode disappears from the beam

5. Disable the ELECTRONIC SHUTTER, reopening the contact between pin 07 and 08 of the
COMMAND BOX connector (7) located on the rear Management Panel of the power
supply box (see Appendix B. Wiring and connection diagrams).
Make sure that the following events occur:

• ORANGE led on: return to STANDBY condition

• The aiming red diode reappears at the beam

once this hardware start-up phase is finished, the laser source is in the condition to

N.B.:

accept the ENABLE command and pass from STANDBY to READY and ready to operate.

Start-up procedure (Software)

1. Start the Personal Computer where the DSP2 board has been installed on the P.C.I. Bus
following the instructions in the Smartist4 Manual.

2. Install the Smartist4 engraving software.

3. Follow the instructions for starting the software and engraving contained in the
Smartist4 Manual.

4. Carry out the start-up procedure to bring the device to READY condition.

WARNING:

From this point on the source is ready to emit laser radiation for the Resonat or or
engraving head, if connected.

5. Select an engraving file and then give the START ENGRAVING command.

6. Effect a few engravings to make sure the device is operating correctly.

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Shutting Down

1. Disable the EL ECTRONIC SHUTTER, opening the contact between pin 07 and 08 of the
COMMAND BOX connector (7) located on the rear Management Panel of the power
supply box (see Appendix B. Wiring and connection diagrams).

2. Give the STOP command, opening the contact between pin 04 and 12 of the COMMAND
BOX connector (7) located on the rear Management Panel of the power supply box (see
Appendix B. Wiring and connection diagrams).

3. Exit the Smartist4 engraving program.

4. P ut the main switch MS in the open position (

O ) .

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CHAPTER 3:

USE and MAINTENANCE

In order to use the device on a daily basis, the Installer must take care of installing all the
Safety devices consists of casings or protection barriers suitable for preventing access to the

laser device and/or the work area and preventing leakage of dangerous laser radiation. The
use of suitable protection devices is able to reduce the acceptable emission limit (AEL) of the
dangerous Class IV laser source, to the level of a Class I source, considered not dangerous.
The casings or protection barriers must be sufficient for intercepting the emitted laser radiation
from the source and resistant to perforation.
For the Megalight™ engraving system and for medium-low power laser, a metallic protection of
a 1 mm thickness is able to completely and indefinitely shield non-focalized laser radiation .
If it is necessary to access the device inside the casing by removing part of the casing, it is
necessary to use safety blocks, which reduce the laser radiation to non-dangerous levels when
they are activated. This can be created by electric interlocks, which must be in conformance
and tested as a safety device.
Any inspection or observation windows must have built-i n Optical Density filters able to lower
the AEL to Class I. The filters must be in conformance and tested as a safety device.

General use instructions for Class IV lasers

The use of remote controls is also envisaged for Class IV lasers as well as starting with a key
command, existence of an emission warning, availabi lity of an attenuation/shutter command,
positioning of controls outside the radiation access area and clearly visible appropriate warning
labels.
The manufacturer of Megalight™, makes the possibility of complying with these regulations
available to the Installer. Nevertheless, it is the Installer’s responsibility to integrate all the
necessary safety devices in the laser system.

The external safety devices include:

• Connecting an interlocking contact to the remote locking connector (External
Interlock) which blocks laser emission and prevents it from restarting if it is open.

• Connecting an emergency laser contact to the connector (Command Box) which blocks
laser emission and only allows restarting after an intentional manoeuvre if it is open.

• Equipping the system with a key start command connected to the connector
(Command Box) which can be removed in the OFF position to prevent unaut hori zed
personnel from using the laser system.

• Connecting an external device for enabling/disabling the shutter to the connector
(Command Box), aimed at temporarily blocking laser emission.

• If the three color led on the rear panel of the rack is not directly visible, connect an
external device which signals laser radiation emission in progress, for example a
flashing red light, to the connector (Command Box).

• Position the Operator commands in an ergonomic position outside of the optical risk
area.

• Repeat the warning labels on all removable panels, which when removed, allow access
to the optical risk area.

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Individual Protection Devices (I.P.D.)

Before using the laser system, the Operator must be instructed on the risks involved with
using the laser system and the necessity of wearing protective goggles during all operations
which require accessing the radiation.
The Nominal Ocular Hazard Distance (NOHD) for the Megalight™ is equal to approximately
15m in the case of direct or reflected radiation and 0.5m in the case of scattered radiation.

Warning:

the goggles are not sufficient for protecting the eye from direct laser radiation.

Before using the laser system, the Operator must be instructed on the risks associated with
using the device primarily resulting from the possibility of igniting flammable material, when
hit by laser radiation, such as volatile substances, resins or plastics.
The interaction of the laser beam with organic or inorganic compounds causes the formation of
fumes and vapours, which may be harmful or toxic.

Make sure the personnel assigned to using the System have read this manual and the

N.B.:

Laser Safety Manual before using the engraving system.

Daily use by an Operator

The Operator is required to carry out the following preliminary tests before each use of the
laser device:

• Make sure the operating area is free from clutter.

• Make sure there is enough free space in front of and behind the power supply box, to

ensure cooling air flow.

• Make sure that the plug is correctly inserted.

• Make sure all the electrical connection have been correctly positioned.

• Make sure the optical fibre is correctly connected to the power supply box and

Resonator.

• Make sure the protective cover of the lens, located on the engraving head, has been
removed.

Turning on

The Operator must carry out the procedure described below to turn on the system:

1. Put the main switch MS on the CLOSED position (

2. Start the P.C.

3. Start the Smartist4 engraving software (see the specific manual).

4. If necessary, wear the specific individual protection devices

5. Start the device by giving the START command and making sure the following events
occur:

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• ORANGE led on: STAND-BY condition

• The aiming red diode appears on the beam

6. Enable the ELECTRONIC SHUTTER using the STAND-BY / READY button and make sure
the following events occur:

• RED led on: READY condition

• The aiming red diode disappears from the beam

7. If this occurs, temporarily remove the protections to access the work area.

8. Adjust the focus of the laser and engraving parameters, following the instructions in the
Smartist4 Manual.

9. Restore the protections, if they were removed earlier.

10. Start engraving.

WARNING:

From this time on the source is enabled for emitting laser radiation from the
engraving head. Be careful not to expose yourself to optical risk.

Turning off

1. Disable the EL ECTRONIC SHUTTER using the STAND-BY / READY button and make su re
the following events occur:

• ORANGE led on: STAND-BY condition

• The aiming red diode appears on the beam

2. Give the STOP command and make sure the following events occur:

• GREEN led on POWER ON condition

• The aiming red diode disappears from the beam

3. Exit the Smartist4 engraving program.

4. P ut the main switch MS in the open position (

O ) .

5. Replace the protective cover on the lens, located on the engraving head.

6. Disconnect the device from the mains.

Replacing the lens

If it is necessary to replace the lens, proceed as follows:

1. Make sure the main switch MS is in the OFF position (O ).

2. Ca p the lens with the specific lens supplied with the system.

3. Unscrew the lens from the engraving head and cap the upper surface as well.

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4. Screw the new lens into the engraving head, after having removed the upper protection
cap and cleaned the optical surface.

Make sure the new lens is mechanically compatible with the engraving head seat. If the

N.B.:

new lens is not compatible with the engraving head seat, create an adaptation flange.
Once the lens has been replaced, the laser focus needs to be adjusted again.

Ordinary maintenance

Ordinary maintenance performed by the Operator exclusively involves cleaning the protection
glass of the lens and cleaning the area around the fans.
These operations must be carried out on a weekly basis.

Cleaning the lens protection glass

• Turn off the System.

WARNING:
Disconnect the device from the mains before doing any maintenance work.

• Pour a few drops of acetone or ethyl ether on a rag.

• Gently rub the glass with a circular movement, from the centre towards the outside.

(See the following Picture).

WARNING:

Let any flammable solvents or cleaning fluids used to clean the lenses dry before
the laser is put back into operation.

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Picture 13 Cleaning of objective lens

The operator is not required to perform any other operations, except periodically checking the
condition of the optical fibre. If the optical fibre breaks it is advisable to replace it with an
original fibre supplied by the manufacturer to avoid a decrease in the degree of safety.

Extraordinary maintenance

WARNING:

The Operator is forbidden to carry out the extraordinary maintenance described
below. These operations require specific training on the necessary maneuvers and
safety measures to be adopted.

The Manufacturer’s warranty shall be considered null and void following
unauthorized work carried out by unqualified personnel on Manufacturer
supplied parts.

If it is necessary to recalibrate the system or replace or do maintenance work on liv e internal
parts, only use qualified personnel which is authorized by the Manufacturer or its legal
representative.
For all Technical Assistance needs or extraordinary maintenance work it is possible to contact
the Manufacturer’s CALL CENTER at [phone], providing the following preliminary
information:

• device model and serial number

• detailed description of the fault, evident damage or decrease in performance

• outcome of any tests performed

• name and phone number of the contact person

If the Manufacturer authorizes a return, the device or its parts are returned in the original
packing. Following receipt of the returned part, the Manufacturer will determine the status of
the warranty and communicate the estimate for the repair (if necessary) and the scheduled
return date.

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WARNING:

Serious electrical risk may result from accessing the internal parts of the electrical
system. Only qualified and authorized personnel are allowed access t o the internal
parts of the electrical system.
Schilling Marking Systems GmbH shall not be held liable for work don e on the live
parts by unauthorized personnel.

WARNING:

Only qualified and authorized personnel are allowed access to the int ernal parts of
the laser Resonator.
Schilling Marking Systems GmbH shall not be held liable for work don e on the live
parts by unauthorized personnel.

WARNING:

The operations described below involve intentional access to laser radiation.
Schilling Marking Systems GmbH shall not be held liable for work don e on the live
parts by unauthorized personnel.

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TROUBLESHOOTING

The following information is aimed at permitting a first level of intervention in th e event of a
fault.
If the fault is different than those described below, or if the suggested remedy does not solve
the problem, see the Troubleshooting manual. The Troubleshooting manual contains more
detailed information and procedures which require trained and authorized personnel. For this
reason the Troubleshooting manual is only issued to qualified installers authorized by the
Manufacturer.
For more information contact the Manufacturer’s CALL CENTER at [phone].

PROBLEM CAUSE REMEDY
The laser does not go on

-Display off

-Status led off

-Fans off

2) The laser does not go on

-Display in alarm

-Status led off

3) The laser does not go on

-Display in alarm

-Status led off

Power absent

Interlock enabled with the
message “INTERLOCK ENABLED”

Interlock enabled with the
message
“EMERGENCY ENABLED”
Interlock enabled with the
message
“START NON OK”

Voltage protection tripped with
presence of Alarm “DC POWER
FAULT”

Check the power supply wire

Make sure the fuses are intact

Check the external connections
(pin 1-2 of the External Interlock
connector)
Check the external connections
(pin 1-2 of the Command Box connector)

Check the external connections
(pin 4-12 of the Command Box
connector)
Check the opening of the external
contact
(READY command present before START)
Turn the switch to OFF, wait 10s and turn
to ON.
Contact the Call Centre

4.a) The laser is not enabled

-Display in alarm

-Status led off

4.b) The laser is not enabled

-Display in alarm

-Status led green

4.c) The laser is not enabled

-Display in alarm

-Status led green

5) The laser does not go to
emission

-Display signals STAND­BY

-Status led Orange

-Laser in STAND-BY

6.a) No Laser emission

-Display signals READY

-Status led Red

6.b) No Laser emission

-Display signals ENABLE

-Status led Red

Interlock enabled with the
message
“ENABLE NON OK”

Power protection tripped with
presence of Alarm
“MAX POWER ALARM”

Current protection tripped with
presence of Alarm
“MAX CURRENT ALARM”

Wait for shutter open command

Wait for PEN-UP command

LEVEL signal absent Make sure the Personal Computer

Check the external connections
(pin 7-8 of the Command Box connector)
Check the opening of the external
contact
(READY command present before START)
Turn the switch to OFF, wait 10s and turn
to ON.
Contact the Call Centre

Turn the switch to OFF, wait 10s and turn
to ON.
Contact the Call Centre

Check the external connections
(pin 7-8 of the Command Box connector)

Check closing of the external contact
(pin 7-8 of the Command Box connector)

Make sure the Personal Computer
hardware and software is installed
correctly
Check for the presence of the signal (5V)
)pin 3 – 2 of the PC connector
Replace the DSP board in the P.C.

hardware and software is installed
correctly

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7) No aiming red laser

-Display signals READY

-Status led Orange

8.a) The laser stops emitting

-Display in alarm

-Status led Green

8.b) The laser stops emitting

-Display in alarm

-Status led Green

8.c) The laser stops emitting

-Display in alarm

-Status led Green

-Display signals READY

-Status led Red

-Display signals READY

-Status led Red

11) The scanner head does not

work

No power

Temperature protection tripped
with presence of Alarm
“MAX TEMPERATURE ALARM”

Temperature protection tripped
with presence of Alarm
“M/S HIGH DIODE TEMP”

Temperature protection tripped
with presence of Alarm
“M/S INCORRECT DIODE TEMP”

Variation of the output optical
power

Decrease of the output optical
power

No power or no signal

Check for the presence of the signal
(10V)
(pin 3 -1 of the PC connector)
Replace the DSP board in the P.C.

Check the connection wire between the
rack and Resonator

Replace the DL connection wire

Make sure the cooling air circulates
freely

Make sure the fans are running correctly
Check the ambient temperature

( max.35 °C )
Turn the switch to OFF, wait 10s and turn
to ON.
Contact the Call Centre
Make sure the cooling air circulates
freely

Make sure the fans are running correctly
Make sure the radiator is clean
Make sure the cooling air circulates

freely
Make sure the fans are running correctly

Make sure the ambient temperature is
above 5 °C and below 35°C
Check the output optical power 9) Laser emission is irregular

Check the level signal

Check the hours of operation 10) Laser emission is low

Contact the Call Centre

Check the connections of the TS and STS
wires

Replace the DSP board

Technical modifications reserved 40 Edition 2004

Schilling Marking Systems GmbH
In Grubenäcker 1 DE-78532 Tuttlingen

[phone] [phone]

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info@schilling-ma rking.de

MegaLight Installation

APPENDIX A:

Technical specifications:

System Specifications

Identification

Laser device model Megalight™
Product code (O.E.M. set-up) 0EUOEM5000
Product code (MARKER set-up)
Serial number EUMKxyyzz

N.B.:

the device was NOT created and designed to be used in the presence of flammable

mixtures.

the device was NOT created and designed to be used in category Ex environments.

N.B.:
N.B.:

the device was NOT created and designed to be used in applications on humans.
the device was NOT created and designed to be sold as a finished product.

N.B.:

Conformity

The MEGALIGHT™ device was built in compliance with statutory European Directives related to
safety and the constructions provisions for industrial device, specifically it is in conformance
with the following European Community Directives:

98/37/EEC “Machinery Directive” (for the MARKER version with safety box)
89/336/EEC “Electromagnetic Compatibility” (for the O.E.M. version)
73/23 / EEC “Low voltage” (for the O.E.M. version)

The main applied standards are listed below:
EN 60204-1 Safety of machinery

EN 60825-1 Safety of laser products
EN 55011-1 Emission standard
EN 61000-6-2 Immunity standard

The device is supplied with the obligatory certification and mark s of conformity to the essential
safety requirements prescribed by the applied European Directives.

Laser Source Classification

According to Standard CEI EN 60825-1 2001 Safety of laser devices.

Working laser source Class IV pulsed source
Aiming laser source Class 2M continuous source
Nominal ocular hazard distance (NOHD) Scattered radiation: 50 cm

Goggle minimum Optical Density >5 @808nm / 1064nm
Light transmittances >30% 500-700nm

0EUMA05000 - 0EUMA05001 - 0EUMA05002

Direct radiation: 1,500 cm

Technical modifications reserved 41 Edition 2004

Schilling Marking Systems GmbH
In Grubenäcker 1 DE-78532 Tuttlingen

[phone] [phone]

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info@schilling-ma rking.de

MegaLight Installation

Type of goggles prescribed DIR

Equipment electrical specifications

Electricity Single phase 90-240Vac (±10%) 50/60Hz
Rated power
Protection fuses 2 x 6.3A / 250V type T (5 x 20 mm)

500 VA cosφ = 0.8

Environmental and installation specifications

Ambient temperature: During operation: from +15°C to +35°C

Storage: from -5°C to +55°C
Relative ambient humidity Max 80% without condensation
Altitude: Max 1500m
Vibration: Not allowed
Acceleration Max 0.5R
Protection category Rack: IP 20

Resonator: IP 54

Engraving Head: IP 54
Type of cooling Air circulation in filtered environment
Heat charge towards environment Max WC = 80W
Maximum internal temperature Dissipaters 60°C
Operating type Continuous
Acoustic emissions Max sound level < 65dbA

Laser Source Specifications

Working laser

Enabled medium Nd:YAG
Wave length 1064nm ± 5nm
Diameter of the beam output by Beam
Expander
Divergence of the beam output by the
Resonator
Mode/Beam quality TEM00 / M2<1.2 (@ full power)
Polarization Random
Operating type Impulse
Pulse duration 9ns (typical)
Repetition frequency Fixed 25kHz (typical)
Maximum average power 5W ± 5%
Maximum instantaneous power 28kW ± 20%
Maximum impulse energy
Point Stability
Pump Laser Diode
Wave length 808nm ± 4nm
Rated power 25W ± 10%
Average life Max 10000 hours
Radiation transmission system
Connector type D80 LKA
Optical fiber minimum curve radius 150mm
Optical fiber standard length 3m
Beam divergence at optical fiber output 400mrad
Aiming Laser Diode
Wave length 635 nm± 5nm
Maximum power 3mW CW

5mm (@ 1/e2)

< 3mrad (full angle)

230µJ ± 5%

< 50µrad

Optical fibre 600µm NA 0.22

Technical modifications reserved 42 Edition 2004

Schilling Marking Systems GmbH
In Grubenäcker 1 DE-78532 Tuttlingen

[phone] [phone]

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info@schilling-ma rking.de

MegaLight Installation

Mechanical specifications

Dimensions [mm] Rack: 180x500x450

Resonator: 70x260x70

Miniscanner Engraving Head: 110x120x110
Weight (Kg) Rack: 19

Resonator: 3

Miniscanner Engraving Head: 1

O.E.M. device standard equipment

N° Component Code Serial number

1 Rack model DL25 72.5000.1 RK25xyyzz
1 Resonator model MEGALIGHT™ 72.5200.1 RISExyyzz
1

Optical fiber 600µm
2 Fuses 6.3A / 250V (5 x 20 mm) 72.5100
1 Mains power supply wire 50.300

72.5010

Separately supplied parts

N° Component Code Serial number

1 Engraving Head Miniscanner model 72.5400.1 E08Yxyyzz
1 Head power supply wire (TS) 72.5500
1 Head signal wire (STS) 72.5510
1 PC connection wire 72.5515
1 Aiming Beam connection wire (DL) 72.5610
1 F-theta lens 160mm 72.5430.1
1 DSP2 board for PCI bus
1 CD-Rom Smartist4
1 Floppy disk Files .ini
1 Resonator attachment bracket
1 Engraving head attachment plate

MARKER device standard equipment

N° Component Code Serial number

1 Rack model DL25 72.5000.1 RK25xyyzz
1 Resonator model MEGALIGHT™ 72.5200.1 RISExyyzz
1

Optical fiber 600µm
2 Fuses 6.3A / 250V (5 x 20 mm) 72.5100
1 Mains power supply wire 50.300
1 Engraving Head Miniscanner model 72.5400.1 E08Yxyyzz
1 Head power supply wire (TS) 72.5500
1 Head signal wire (STS) 72.5510
1 PC connection wire 72.5515
1 Aiming Beam connection wire (DL) 72.5610
1 F-theta lens 160mm 72.5430.1
1 DSP2 board for PCI bus
1 CD-Rom Smartist4
1 Floppy disk Files .ini
1 Engraving head attachment plate

72.5010

Technical modifications reserved 43 Edition 2004

Schilling Marking Systems GmbH
In Grubenäcker 1 DE-78532 Tuttlingen

[phone] [phone]

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info@schilling-ma rking.de

MegaLight Installation

Possible field of adjustment

Based on the pump power, the laser emission is a “threshold” process, i.e. the laser action
only starts from a certain pump power value and consequently laser diode power supply
current value. When the range of the laser diode power supply current is established
(maximum value set by the manufacturer), the progress of the power emitted at the
Resonator output for the Megalight™ source is shown in the following graph: normally, there is
laser action around 45% and 100% of the maximum power supply current value (threshold).

6

5

4

3

2

Average Power (W)

1

0

0 20 40 60 80 100

% of current to the diode

Similarly, the graph below represents the progress of peak power based in the percentage of
power supply current:

30

25

20

15

10

Peak Power (KW)

5

0

0 20406080100

% of current to the diode

Technical modifications reserved 44 Edition 2004

Schilling Marking Systems GmbH
In Grubenäcker 1 DE-78532 Tuttlingen

[phone] [phone]

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info@schilling-ma rking.de

MegaLight Installation

Warning Labels and their positioning

Rack front panel

LASER RADIATION

AVOID EYE OR SKIN EXPOSURE TO
DIREC T OR SCATT ERED RAD IATION

CLASS IV LASER

LASER

EMISSION

Technical modifications reserved 45 Edition 2004

Schilling Marking Systems GmbH
In Grubenäcker 1 DE-78532 Tuttlingen

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Rack rear panel

MegaLight Installation

AVOID EXPOSURE

LASER RADIATION IS EMITTED

FROM THIS APERTURE

Technical modifications reserved 46 Edition 2004

Schilling Marking Systems GmbH
In Grubenäcker 1 DE-78532 Tuttlingen

[phone] [phone]

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info@schilling-ma rking.de

Marking Systems GmbH

Laser Nd: YAG CLASS IV

Wavelength:
Max CW output power:
Max pul s e energy:
Pulse duration:
Max r epetitio n rat e:

INVI SIBLE LASER RADIATION

This Laser system complies with FDA performance Standards for laser products

except for deviations pursuant to Laser Notice N° 50, dated July 26, 2001

808 nm
20 W CW

MegaLight Installation

Fö hr e ns tr. 47
D-7 853 2 T ut tlingen
Tel.: [phone]

1064 nm
5 W
250 µJ
13 ns
20 kHz

CAUTION

EQUIPMENT SUPPLIED EVEN
WITH THE D OORS OPENED

Technical modifications reserved 47 Edition 2004

DANGER

VISIBLE OR INVISIBLE L ASER

RADIATION WHEN OPEN

AVOID EYE OR SKIN EXPOSURE

TO DI RECT OR SC ATTER ED RADIATION

Schilling Marking Systems GmbH
In Grubenäcker 1 DE-78532 Tuttlingen

[phone] [phone]

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info@schilling-ma rking.de

Coupler

MegaLight Installation

DANGER

VISIBLE OR INVISIBLE L ASER

RADIATION WHEN OPEN

AVOID EYE OR SKIN EXPOSURE

TO DI RECT OR SC ATTER ED RADIATION

Engraving Head

AVOID EXPOSURE

LA SER RADIATION IS EMITTED

FROM THIS APERTURE

AVOID EXPOSURE

LA SER RADIATION IS EMITTED

FROM THIS APERTURE

Technical modifications reserved 48 Edition 2004

Schilling Marking Systems GmbH
In Grubenäcker 1 DE-78532 Tuttlingen

[phone] [phone]

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info@schilling-ma rking.de

MegaLight Installation

Detailed label description

N° Label

Optical Safety Label

Location

1

On the source, panels and covers, in a
dominant position so it is visible from all
sides and even outside of the optical risk
area.

Optical Safety Label

Location

Upper panel of the power supply rack

2

Marking Systems GmbH

Laser Nd: YAG CLASS IV

Wavelength:
Max CW output power:
Max pulse energy:
Pulse dura tion:
Max repet i tion rate:

INVISI BLE LA SER RADIA TION

808 nm
20 W CW

1064 nm
5 W
250 µJ
13 ns
20 kHz

Optical Safety Label

3

LASER RADIATION

AVOID EYE OR SKIN EXPOSURE TO

DIRECT OR SCATTERED RADIATION

CLASS IV LASER

Location

On every OEM laser device, preferably near

label no. 1.

Optical Safety Label

Location

On every Class IV laser device, near the

aperture where laser radiation is emitted.

4

AVOID EXPOSURE

LA SER RADIATION I S EMITTED

FROM THIS APERTURE

Optical Safety Label

Location

On every guard panel, which once removed

allows access to the radiation.

5

DANGER

VISIBL E OR INVISIBLE LASER

RADIATION W HEN OPEN

AV OI D EY E O R SKI N EX P O SU RE

TO DI RECT OR SC ATTERED RADIATION

Type

Technical modifications reserved 49 Edition 2004

Schilling Marking Systems GmbH
In Grubenäcker 1 DE-78532 Tuttlingen

[phone] [phone]

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info@schilling-ma rking.de

6

7

8

MegaLight Installation

AVOID EXPOSURE

LA SER RADIATION I S EMITTED

FROM THIS APERTURE

LASER RADIATION

LASER RADIATION DO NOT STARE

INT O BEAM O R VI EW DIREC TLY

WITH OPTICAL INSTRUMENTS

CLASS 2M LASER PRODUCT

LASER

EMISSION

Optical Safety Label

Location

On every moveable panel equipped with a

safety interlock.

Optical Safety Label

Location

On the mobile part of a casing containing a
visible aiming laser which is not turned off
in the event of opening, if the class of the

aiming beam is <=2M.

Optical Warning Label

Location

Front power supply rack panel: it indicates
laser emission when the led is red.

9

10

Electrical Safety Label

Location

Near the electrical sockets.

CAUTION

EQUIPMENT SUPPLIED EVEN
WITH THE D OORS OPENED

Electrical Safety Label

Location

On every guard panel (irremovable), which

once removed allows access to the radiation.

Technical modifications reserved 50 Edition 2004

Schilling Marking Systems GmbH
In Grubenäcker 1 DE-78532 Tuttlingen

[phone] [phone]

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info@schilling-ma rking.de

11

MegaLight Installation

General Warning Label

Location

On the OPTICAL FIBER connector of the
power supply rack, when the optical fiber is

disconnected.

Component identification plate

12

Location

On every removable Laser component.

Device identification plate

Location

13

Upper panel of the power supply rack

Mechanical drawings

The following drawings show:

• Overall mechanical view of the Resonator and Engraving Head (OEM set-up)

Technical modifications reserved 51 Edition 2004

Schilling Marking Systems GmbH
In Grubenäcker 1 DE-78532 Tuttlingen

[phone] [phone]

www.schilling-markin g.de
info@schilling-ma rking.de

MegaLight Installation

Technical modifications reserved 52 Edition 2004

Schilling Marking Systems GmbH
In Grubenäcker 1 DE-78532 Tuttlingen

[phone] [phone]

www.schilling-markin g.de
[e-mail]

MegaLight Installation

APPENDIX B:

Wiring diagrams

Description of signals on connectors

Command Box (CB) Connector

On this connection all the inputs / outputs indispen sable for control and interface of the device
with the external devices necessary for creating an engraving system.
The figure below shows the contact sequence of the 25 pin female connector located on
the rear panel of the power supply box:

Input

Pin N° Signal Description Status

1 (+)

2 (return)

4 (+)

12 (return)

7 (+)

8 (return)

Output

Pin N° Signal Description Status

18 H/L logic POWER ON

19 0V GND GND reference for pin 18

20 H/L logic

21 0V GND GND reference for pin 20 and 22

22 H/L logic LASER ENABLE

Warning: Pins 3-5-6-9-10-11-13-14-15-16-17-23-24-25 not assigned in the list are
internally connected and used by the Manufacturer. Do not use any connection of those

indicated in the table above!

The time sequence of the commands is described in the Timing Diagram paragraph.

N.B.:

Technical modifications reserved 53 Edition 2004

Potential free
contact
Potential free
contact
Potential free
contact
Potential free
contact
Potential free
contact
Potential free
contact

Picture 13: Command Box Connector (25p / f)

STOP LASER Contact open = STOP

START Contact closed = START

STAND BY /

READY

_____________
LASER READY

Contact open = STAND BY
Contact closed = READY

0 Volt = Laser power off
12 Volt = Laser power on

0 Volt = Laser ready
12 Volt = Laser not ready

0 Volt = Laser Disabled
12 Volt = Laser Enabled

Schilling Marking Systems GmbH
In Grubenäcker 1 DE-78532 Tuttlingen

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MegaLight Installation

External Interlock Connector

It is possible to connect all the emergency devices aimed at making the laser source safe, in
series with this connector.

3

1

2

Picture 14: External Interlock connector (3p / f)

Pin N° Signal Description Status

1 (+) Potential free

contact

2 (return) Potential free

contact

INTERLOCK

Open contact = Emergency
Enabled

3 0 V GND

N.B.: If the emergency is enabled by opening the Interlock contact it cannot be reset.
Resetting is only possible by putting the main switch MS in the Open position (
the closed positions (

I ).

O ) and then

Galvo Supply Connector

1 2 3 4 5

6 7 8 9

Picture 15: Galvo Supply Connector (9 p /m)

Pin N° Signal Description Status

1–6-2 (-) - 15 V NEGATIVE SUPPLY

Negative power supply -15V / 3°
max

7–3–8 (0) 0 V COMMON Common

4–9-5 (+) +15 V POSITIVE SUPPLY

Positive power supply +15V / 3°
max

Slave Out Connector

8 7 6 5 4 3 2 1

15 14 13 12 11 10 9

Picture 16: Slave Out Connector (15p / f)

Technical modifications reserved 54 Edition 2004

Schilling Marking Systems GmbH
In Grubenäcker 1 DE-78532 Tuttlingen

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MegaLight Installation

Pin N° Signal Description Status
1 (+) +12 V -------------- Not used in this version
9 (+) +24 V -------------- Not used in this version
15 (0) 0 V -------------- Not used in this version
2-3-4-5-6­7-8-10-11-

n.c. --------------

Internal connections (do not
use)

12-13-14

P.C Connector

Picture 17: PC Connector (9 p / f)

Pin N° Signal Description Action

1 (+)

Analogy 0­10V

POWER LEVEL Regulates Laser power

6 ----------- ----------------- Not used in this version

2 (+) H/L logic

8 +12 V EXTERNAL SUPPLY

3 0 V COMMON

Aiming Beam Connector

+ 5V

Pin N° Signal Description Status

+5V Logic 3.5 - 5 V POSITIVE Aiming Laser Positive Power Supply
0V 0 V RETURN Aiming Laser Power Supply 0V

5 4 3 2 1

PEN UP

9 8 7 6

Up = Engraving impulse emission

External Positive Power Supply +12V /
50mA min.
0V External power supply / Signal
common

0 V

Technical modifications reserved 55 Edition 2004

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MegaLight Installation

R.F. Connector

Pin N° Signal Description Status

-------- ------------------------- ----------------- Not used in this version

--------- ------------------------- ----------------- Not used in this version

Wiring diagrams

The Manufacturer agrees to supply upon request the circuit diagrams, lists of component parts,
calibration instructions or other information useful f or adequately qualified personnel to repair
the parts of the device which the Manufacturer considers repairable.

The following diagrams are supplied:

• Rack interface wiring diagram.

• Interface signal timing diagram.

• Laser command signal timing diagram.

• Wiring diagram of DSP2 (optional) command signals.

• Interface wiring diagram for the DSP2 (optional) board I/O module.

Technical modifications reserved 56 Edition 2004

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DWG n°

E203AL004

DESCRIPTION

External back-up fuses 16A gG /gL

L1

PE

L2

Remote External Interlock
(potential free N.C.contact)

Remote Emergency STOP
(potential free N.C.contact)

Remote START
(potential free manteined
contact . KEY-SWITCH)

Remote STAND-BY/READY
(potential free make contact)

Laser POWER ON
(12V-50mA; active=Power ON)

Laser NOT READY
(12V-50mA;active=Laser not Ready)

Laser ENABLE
(12V- 50mA;active=shutter opened)

MegaLight Installation

REVISED

REL. 03

G1

TLP523

U23

U24

U25

110-230Vac/50-60 Hz

SB4

SB1

0 I

SB2

SB3

KA1

KA2

VIOLINO EUMARKER EXTERNAL WIRING

A.C.Supply

6.3A - F

External Interlock

1
2

Command Box

1

2

4

18
19

7

20

8

21

22

24

KA3

12

Line Filter (leakage 0.42 mA)

1

2

2.2k

3

1

+12V

2

2.2k

4

12

2.2k

19

7

8

21

24

2.2k

U12A

TLP521

U12B

U12D

U12C

+12-15V

18

20

22

15V

0V

+12V

+12V

+12V

NOT USED

Power level signal
(analog 0-10V)

Pen-Up
(digital signal)

External DC supply
(12V - 50 mA)

Galvo supply
(+/- 15V-3A)

Not used

External P.C.Command

0-10V

L - H

Marking Head

X
Y

­0

+

+12V ext

0V ext

Slave out

P.C.

1

2
3

8

Galvo Supply

1
6
2

7
3
8

4
9
5

R.F.

+12V

max.200mA

+24V

NOTE: do not use others pins
internally connected!
Use only original cable.
Max.wiring distance < 3m.
(15m with twisted and shielded
cable submitted to approval)

0

-

0

0.36k

0.36k

LM324

+

6N137

CNY17-3

0V ext

-15V

0V

+15V

1

6
2
3

8

+12V ext

1
6
2

7
3
8

4
9
5

HCPL7800

5.6k

U8

G2

R.F.Driver

Red Aiming Beam
Laser
(5V -50mA)

Technical modifications reserved 57 Edition 2004

Aiming Beam

U17

Schilling Marking Systems GmbH
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Remote EmergencySTOP
(Connector Command Box
Pin 1-2)

Remote External Interlock
(Connector Ext.Interlock
Pin 1-2)

MegaLight Installation

DWG n°

E202AL009

Remote START
(Connector Command Box
Pin 4-12)

Laser POWER ON
(Connector Command Box
Pin 18-19)

Laser NOT Ready
(Connector Command Box
Pin 20-21)

Remote STAND-BY/READY
(Connector Command Box
Pin 7-8)

Allarm or Warning
(internally generated)

Laser ENABLE(Beam Attenuation off)
(Connector Command Box
Pin 22-24)

KA1

KA2

KA3

LASER OFF

0 I

min.100ms

0 I

min.100ms

1s

0 I

DESCRIPTION

VIOLINO series TIMING DIAGRAM

LASER
ENABLE

LASER
ENABLE

LASER
ENABLE

WAIT OF START

START LASER

NOTE:

Technical modifications reserved 58 Edition 2004

WAIT OF ENABLING

Schilling Marking Systems GmbH
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LASER
INIBHITED

LASER READY

LASER
INIBHITED

LASER READY

LASER OFF

or

INTERLOCKED

REVISED

REL. 03

(

p

Emergency STOP

Stand By / Ready

Laser Emission Pen Up

TTL IN )

Power Level (ANALOG IN )
0 – 10 V

DIODE Current (pumping

ower %)

YAG (output power %)

Typ 100 ms

Typ 1 sec…

Typ 10 ms

Delay 200 µ s

MegaLight Installation

Delay 200 µ s

Delay 800 mSec

Technical modifications reserved 59 Edition 2004

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MegaLight Installation

-X1 DSP Connector
(Mini D -50p/F)

X1-10
X1-35

X1-12

X1-37

X1-14

X1-39

to Scanner Head Digital /Analogic Converter

X1-1

X1-2 X1-3 X1-4 X1-5 X1-6 X1-7 X1-8 X1-26 X1-27 X1-28 X1-29 X1-30 X1-31 X1-32 X1-33 X1-9 X1-11 X1-13 X1-15 X1-16

A0+ B0+ C0+ D0+ E0+ F0+ G0+ H0+

SP5V
SP5V

*

SP12V
SP12V

*

SM12V
SM12V

A0- B0- C0- D0- E0- F0- G0- H0-

DSP2 Board

gnd gnd gnd gnd gnd

X2-8

L - H

PEN-UP
digital signal

X2-2

MODULATION
digital signal

to RACK VIOLINO -P.C.Connector

-X2 DSP Connector
(Sub D -9 pin Female)

X2-6

L - H

X2-1 X2-3

0 -10V

LEVEL
analog signal

+12V 0V

G5

DC/DC 12V
MAX500mA

X1-17

N.C.

X1-42

*

*

** ** * * *

A1- B1- C1- D1- E1- F1- G1 H1-

*** * * * * *

A1+ B1+ C1+ D1+ E1+ F1+ G1+ H1+

gnd gnd gnd gndgnd

* not used

Technical modifications reserved 60 Edition 2004

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In Grubenäcker 1 DE-78532 Tuttlingen

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[e-mail]

MegaLight Installation

DWG n° E203AL004

pull-up resistors

Step - Y
Step - X
Step -Z
Dir - Z
Dir - Y
Dir - X

Zero X limit switch

Zero Y limit switch

Zero Z limit switch

Disable X

Disable Y

Disable Z

MODULE 0 EXTERNAL WIRING

X3 Connector

(DB 25 pin Male)

break-x

break-y

break-z

ext.in.a

ext.in.b

ext.in.c
ext.in.d

ext.out.a

1

2

15

3

16

4

17

5

18

6

19

7

20

8

21

9

22

10

23

11

12

1

A3.4

A3.7

A3.3

A3.6

A3.9

25
13

A3.1

A3.8

A3.5

A3.2

4.7k
E3.7

E3.8
E3.9

E3.10

A3.10

E3.1 E3.2 E3.3 E3.4 E3.5 E3.6

+12V

0V

Laser END
Laser BUSY

Laser READY

Marking Start

Marking Stop
Laser READY

External Supply max 30V dc

+

ext.in.e

ext.in.f

max.50 mA

ext.out.b

ext.out.c

ext.in.g

ext.in.h

X4 Connector

(DB 15 pin Male)

1

6

2

3

4

5

12

7

13

8

14

9

15

10

7

9

1

12

2

3

8

10

15

A4.1

6

A4.2

7

A4.3

A4.5

13

A4.4

14

A4.6

5
4

E4.2

E4.1

E4.3

E4.4

E4.5

+12V

E4.6

0V

Technical modifications reserved 61 Edition 2004

Schilling Marking Systems GmbH
In Grubenäcker 1 DE-78532 Tuttlingen

[phone] [phone]

www.schilling-markin g.de
info@schilling-ma rking.de

MegaLight Installation

APPENDIX C:

Safety notes

Auto diagnosis chart for the installer related to the completeness of safety measures
on a Class I laser device containing Class IV laser sources.

In conformity with the provisions of the following standards:
EN61040

EN60825-1
EN 207
EN 208
EN 12626
CEI 60825-5

REQUESTED
REQUIREMENT

1) The Classification of
the finished laser
system must be class I

2) The laser radiation
must be completely
confined and end at
the end of its optical
path

3) The observation
windows must have an
optical density and
stability to the
radiation able to resist
the maximum forecast
radiation, even in the
event of a first fault, to
which they may be
subject.
The windows must be
of a type and
construction
sufficiently robust to
withstand the
maximum forecast
mechanical stress.

SOLUTION TO ADOPT PROOF YES NO NA

If the class of the
source is greater than
I, the level of
accessible radiation
must be brought to the
limits of class I
Closing of the optical
path up to the point of
application and
confinement of the
reflected and scattered
radiation in a specific
opaque container
applied to the
radiation.
Adopt filters suitable
for the wavelength, use
procedure, scale index,
adapted to the laser
and maximum power
which can be used. The
filters must be
permanently attached
to the protection
casing.

Presence of suitable
protection barriers. N.B.:
goggles are considered as
an additional but not
alternative measure!

No crack or opening must
make the radiation
accessible for viewing. N.B.:
If the optical fibre is greatly
bent it does not comply with
this provision! However it
should not be disconnect
able without using a tool.

Certification from the
manufacturer on the
suitability of the filter.
Calculations on the
necessary O.D. in the worst
condition which can occur.
Attachment with mechanical
systems which require a tool
for removal.

Technical modifications reserved 62 Edition 2004

Schilling Marking Systems GmbH
In Grubenäcker 1 DE-78532 Tuttlingen

[phone] [phone]

www.schilling-markin g.de
info@schilling-ma rking.de

MegaLight Installation

4) The fixed covering
panels must not be
able to be removed
without the use of a
tool, after they have
been removed they
must not be able to
remain in position
without being attached.

5) Movable panels
and/or doors must be
interlocking with the
laser radiation so that
their opening reduces
the accessible radiation
to the levels of class I.
Restoration of the laser
radiation must only
take place after a
subsequent intentional
manoeuvre and not
following simple
reclosing of the door.

6) The laser system
must be started only
with a manual
command via an
intentional manoeuvre
effected by trained
personnel with a key
device.

7) An acoustic or
luminous warning
must signal the
imminent presence and
then presence of laser
radiation.

8) A manual beam
attenuation command
must be available at all
times.

9) A remote lock
connector must be
available and
connected to the
interlock devices.

Screw down the cover
panels with screws
avoiding frames and
bends which can hold
the panels in place
even without screws.

Fit the doors and
removable panels with
limit switches to
connect to the remote
locking connector of
the laser.
If a mechanical hazard
exists as well, the limit
switches must also
interlock any
movements in process.

Fit a key device which
can be removed in the
off position.

Fit a light that goes on
when the laser is
enabled and thus ready
to emit its radiation
upon a command.

Install a button which
acts on the
electromechanical or
electronic shutter

Use a specific
connector to install a
connection to the
remote external lock
limit switches (see
point 5).

Mechanical construction
suitable for ensuring that
they do not move without
the use of specific tools.

Presence and functionality of
the limit switch with forced
opening and positive
manoeuvre.

No possibility of starting
without the key and
activating it. Removable key
in the off position. N.B.: a
resent modification to the
standard permits
considering a software
password or badge as a key.
The light must go on at least
5 seconds before the laser is
emitted and with the light
off (laser in stand-by) any
emission commands must
not activate radiation in any
way.
The action of the shutter
must immediately stop or
attenuate the radiation to
levels under those allowed
for class I. A subsequent
release action may allow the
radiation to be restored
Opening of this circuit must
lead to a reduction of the
accessible radiation to the
levels of class I. Restoration
of the laser radiation must
only occur after a
subsequent intentional
manoeuvre and not by
simply reclosing the circuit.

Technical modifications reserved 63 Edition 2004

Schilling Marking Systems GmbH
In Grubenäcker 1 DE-78532 Tuttlingen

[phone] [phone]

www.schilling-markin g.de
info@schilling-ma rking.de

MegaLight Installation

10) A manual laser
emergency command
must be available,
separate from the line
switch.

11) All the warning
labels required for
Class IV must be
present on the source.

12) All the warning
labels required for
class I must be present
on the system.

13) A warning label
needs to be present on
the interlocking panels,
doors

14) Parts containing
dangerous voltage
must have appropriate
warning plates
regarding electrical

risks.

Install a red mushroom
head button with
appropriate laser
emergency labeling
(CEI symbol) with
priority over all other
commands.

Install warning labels
no. 1-no. 2-no. 3-no. 4
See “Warning labels”.

Install the “Laser class
I” warning labels.

Install warning label
no. 6
See “Warning labels”.

Install warning labels
no. 9-No. 10
See “Warning labels”.

Activation of the mushroom
head button with forced
opening contacts must stop
the radiation immediately
which must not be able to
reactivate unless the restart
procedure is carried out.
N.B.: if the laser device is
installed in a more complex
system, e.g. a robot or
engraving line, which also
have a mushroom head
button, two emergency
circuits with different
functions are not allowed!
Therefore it is necessary to
create a single emergency
circuit which stops both the
machine and laser, the
second mushroom head on
the laser will identify the
secondary circuit which only
acts as a laser emergency.
The labels are positioned
and have the form,
dimensions and description
corresponding to the
Standard provisions.
No other label is necessary if
label no. 1 is usually put on.

The labels are positioned
and have the form,
dimensions and description
corresponding to the
Standard provisions.
The labels are positioned
and have the form,
dimensions and description
corresponding to the
Standard provisions.

15) The electrical
cabinet must have a
plate identifying the
device.

Install warning label
no. 13
See “Warning labels”.

The labels are positioned
and have the form,
dimensions and description
corresponding to the
Standard provisions.

Note 1:

If the provision is not applicable (NA) objective data must support its actual non-

applicability.

Note 2:

The labels must be in the Manufacturer’s langu age, if the product is not intended for
export, otherwise, if intended for export, EVEN TEMPORARILY, it must be in the country of
destination in the European Community.

Technical modifications reserved 64 Edition 2004

Schilling Marking Systems GmbH
In Grubenäcker 1 DE-78532 Tuttlingen

[phone] [phone]

www.schilling-markin g.de
info@schilling-ma rking.de

MegaLight Installation

Note 3:

For export to the United States the following warning needs to be applied:

NOTICE
This laser component complies with FDA Performance Standards for Laser Products except for
deviations pursuant to Laser Notice N°50, dated July 26, 2001.

since there is a difference not yet transposed by Federal regulations 21 CFR 1040 between the
provisions of standard CEI 60825 and the provisions of these Federal regulations.

Technical modifications reserved 65 Edition 2004

Schilling Marking Systems GmbH
In Grubenäcker 1 DE-78532 Tuttlingen

[phone] [phone]

www.schilling-markin g.de
info@schilling-ma rking.de