Trotec Speedy C12, Speedy C25, Speedy C100, Speedy C50 Service Manual
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I N D I V I D U A L M A R
K I N G S Y S T E M S
SERVICE MANUAL
8003 Trotec Speedy C12
8003 Trotec Speedy C25
8003 Trotec Speedy C50
8003 Trotec Speedy C100
Trotec Produktions- u, Vertriebs GmbH
Linzer Straße 156
A-4600 Wels
Tel: ++43/7242/239-0
Fax: ++43/7242/239-7380
E-Mail: TROTEC@trodat.net
Version 1.1
January 1999
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This publication and it´s contents are proprietary to Trotec Wels and are intended
solely for the contractual use of Trotec customers.
This publication and it´s contents may not be reproduced or distributed for any other
purpose without the written permission of Trotec Wels.
Notice
Trotec Wels does not assume any liability arising out of the application or use of any
products, curcuits or software described herein. Neither does it convey a license
under it´s patent rights nor the patent rights of others. Trotec Wels further reserves
the right to make any changes in any products described herein without notice. This
document is subject to change without notice.
CAUTION
Use of controls or adjustments or performance of procedures other than
those specified herein may result in hazardous laser radiation exposure.
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Table of contents
1. Main components of the Speedy laser engraver...................................................................5
2. Safety information.................................................................................................................7
General...............................................................................................................................................7
Laser Safety .......................................................................................................................................9
US laser classes.............................................................................................................................................. 9
Safety Interlock System............................................................................................................................... 11
Dangers of Electricity......................................................................................................................12
Emission indication and safety labeling........................................................................................13
Light Emitting Diodes.................................................................................................................................. 13
Audible Warning ......................................................................................................................................... 13
Safety Labels ............................................................................................................................................... 14
3. Laser beam alignment on Speedy.......................................................................................15
4. Laser pointer adjustment ....................................................................................................20
5. Replacing the laser tube...................................................................................................... 22
Measuring the laser power:............................................................................................................23
Laser tube replacement (12W and 25W) ......................................................................................25
Laser tube replacement (50W and 100W) ....................................................................................26
6. Adjusting the Software........................................................................................................28
Adjusting the tickle power..............................................................................................................28
Adjusting the Power Correction factor CL:.................................................................................30
Adjusting the Offset parameters: ..................................................................................................31
Overtook adjustment:.....................................................................................................................33
Tab „correction“ in the service setup............................................................................................34
Tab „acceleration“ in the service setup.........................................................................................35
7. Adjusting the Hardware......................................................................................................36
Ruler adjustment and rectangularity adjustment of the motion system ...................................36
How to check the ruler position................................................................................................................... 37
Ruler adjustment.......................................................................................................................................... 38
Rectangularity adjustment of the motion system.......................................................................................... 38
Table adjustment.............................................................................................................................40
8. Servicing the X axis.............................................................................................................44
9. Special instructions for X-belt tensioning..........................................................................50
10. Instructions for changing the X-gearing assembly.......................................................... 53
11. Servicing the Y axis left part.............................................................................................56
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12. Servicing the Y axis right part ..........................................................................................60
13. The electric system of the Speedy......................................................................................63
Block wiring diagram .................................................................................................................................. 64
Connector Assignment................................................................................................................................. 65
Checking the different components: ............................................................................................................ 66
14. Firmware Update...............................................................................................................67
Steps for updating the firmware................................................................................................................... 67
15. Network installation of Trotec laser engravers................................................................ 69
16. Software tips&tricks..........................................................................................................72
Rastering images in Corel Draw................................................................................................................. 72
How to produce a Seal Press........................................................................................................................ 73
17. Marking metals using metal mark paint.......................................................................... 74
18. Speedy error codes.............................................................................................................75
Software feedback...........................................................................................................................75
Hardware feedback.........................................................................................................................78
19. FAQ´s.................................................................................................................................80
20. Recommended service intervals........................................................................................ 83
Warranty Regulations.....................................................................................................................83
Recommended replacement intervals for wear-and-tear parts..................................................85
21. Recommended tools...........................................................................................................86
22. Recommended spare parts Speedy - Starter Kit ............................................................. 87
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1. Main components of the Speedy laser engraver
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1 service socket 15 Power supply
2 autofocus sensor 10 X-axis
3 focussing head 11 keypad
4 engraving table 12 front lid
5 Y-axis connector 13 power socket
6 Polycarbonate door 14 service access panel
7 Laser tube cover 16 right interlock front lid
8 Exhaust connector 18 maintenance panel
9 Product ID label
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2. Safety information
Please read this chapter before operating or servicing a Speedy laser system!
General
The Speedy is an industrial apparatus with a high level of security. To guarantee a
safe operation it is necessary to know potential dangers and avoid risks. The
dangers can be classified in three categories:
ì Dangers caused by the laser beam
ì Dangers caused by electricity
ì mechanical dangers
General Safety Instructions
When working with the laser engraver please take note of the following safety
instructions:
1. Operation and service of the Speedy may only be performed by trained
personnel.
2. Direct exposure of skin or eyes to laser radiation may cause severe injuries.
The correct operation and service according to the manual can prevent
hazards. Operators may perform procedures required inside the housing
only through the interlocked door. They must never attempt to defeat the
door interlocks nor remove non interlocked portions of the housing.
3. The laser beam can ignite flammable materials. Therefore a fire
extinguisher should always be nearby. Do not store flammable materials
near or inside the laser engraver.
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Working with the laser or setting the system to service mode without
supervision is not permitted.
4. Many materials, especially non-anodized aluminium, copper, silver and
gold, cannot be engraved with the laser engraver due to the very low
absorption of laser radiation. This means that most of the energy of the
laser beam is reflected. Therefore those materials must not be present in
the laser beam path as otherwise a reflected laser beam could destroy the
cover of the laser unit.
5. Beam adjustment may only be done by trained personnel. Otherwise there
could be uncontrolled emission of laser radiation. There are only limited
possibilities to adjust the mirrors due to a mechanic restriction. These
restrictions may only be altered by authorized personnel.
6. Before starting to work check whether the engraving of the material can
cause harmful fumes and whether the filters of your exhaust system are
suitable for these fumes. It is emphasized that it is the user’s responsibility
to obey the national and regional threshold values for dusts, fumes and
gases. (The maximum concentration of harmful substances must not be
exceeded). Never use the laser engraver without an exhaust unit with
appropriate filters for the treated material, as cutting or engraving certain
materials can produce vapours. Materials causing toxic or carcinogenic
smokes or fumes must not be treated without an exhaust unit with
appropriate filters. Furthermore it is the user’s responsibility to ensure the
safe removal and disposal of the smokes and particles from the laser
machine according to the national and regional threshold values.
In the US reference should be made to Section 7.3 in the ANSI Z136.11993 Standard for the safe use of lasers, to the exposure criteria in CFR
1910 Subpart Z from the US government, and to the Threshold Limit
Values (TLVs) published by the American Conference of Governmental
Industrial Hygienists (ACGIH).
7. Please refer to the manual of your exhaust system regarding the change
intervals of the filters. We recommend to make a note of the last change of
filters on an adhesive label.
8. PVC (Polyvinylchloride) must not be processed with the laser engraver.
If you have any questions please contact your supplier or Trotec.
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Laser Safety
The safety of a laser apparatus is defined by one of five safety classes: I (1),II (2),
IIIa (3a), IIIb (3b) and IV (4). The Speedy without laser pointer is in the EU safety
class 1 (with an installed laser pointer laser class 2) and therefore presents no
hazard to personnel when properly used during normal operation or routine
maintanance. In the US all machines are classified as classII laser products. This
status is guaranteed by the safety housing and safety devices that are built into the
product.
Please be aware that improper operation of the laser apparatus nullifies this safety
class and allows under certain circumstances the emission of radiation which can be
potentially dangerous.
This laser engraving system contains a carbon dioxide (CO2)-laser class IV (4)
product, which emits an intensive and invisible radiation. Without safety devices
the direct radiation and also diffuse reflected radiation is dangerous.
Please be aware:
The Laser Radiation of a CO2 Laser is Invisible!
US laser classes
As posted by the Center for Devices and Radiological Health (CDRH) regulation 21 CFR 1040.10
and 21 CFR 1040.11, the standard classification for lasers are as follows:
Class I laser product
No known biological hazard. The light is shielded from any possible viewing by a person and the
laser system is interlocked to prevent the laser from being on when exposed. (large laser printers
such as the DEC LPS-40 has a 10mW HeNe driving it which is a Class IIIb laser, but the printer is
interlocked so as to prevent any contact with the exposed laser beam, hence the device produces
no known biological hazard, even though the actual laser is Class IIIb. This would also apply to CD
players and small laser printers, as they are Class I devices).
Class II laser products
Power up to 1 milliwatt. These lasers are not considered a optically dangerous device as the eye
reflex will prevent any occular damage. (I.E. when the eye is hit with a bright light, the eye lid will
automatically blink or the person will turn thier head so as to remove the bright light. This is called
the reflex action or time. Class II lasers won't cause eye damage in this time period. Still, one
wouldn't want to look at it for an extended period of time.) Caution labels (yellow) should be placed
on the laser equipment. No known skin exposure hazard exist and no fire hazard exist.
Class IIIa laser products
Power output between 1 milliwatt and 5 milliwatt. These lasers can produce spot blindness under
the right conditions and other possible eye injuries. Products that have a Class IIIa laser should
have a laser emission indicator to tell when the laser is in operation. They should also have a
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Danger label and output aperature label attatched to the laser and/or equipment. A key operated
power switch SHOULD be used to prevent unauthorized use. No known skin hazard of fire hazard
exist.
Class IIIb laser products
Power output from 5 milliwatts to 500 milliwatts. These lasers are considered a definate eye
hazard, particularly at the higher power levels, which WILL cause eye damage. These lasers
MUST have a key switch to prevent unathorized use, a laser emission indicator, a 3 to 5 second
time delay after power is applied to allow the operator to move away from the beam path and a
mechanical shutter to turn the beam off during use. Skin may be burned at the higher levels of
power output as well as the flash point of some materials which could catch fire. (I have seen
250mW argons set a piece of red paper on fire in less than 2 seconds exposure time !) A red
DANGER label and aperature label MUST be affixed to the laser.
Class IV laser products
Power output >500 milliwatts. These CAN and WILL cause eye damage. The Class IV range CAN
and WILL cause materials to burn on contact as well as skin and clothing to burn. These laser
systems MUST have:
A key lockout switch to prevent unauthorized use Inter-locks to prevent the system from being
used with the protective covers off Emission indicators to show that the laser is in use Mechanical
shutters to block the beam Red DANGER labels and aperature labels affixed to the laser
The reflected beam should be considered as dangerous as the primary beam. (again, I have seen
a 1,000 watt CO2 laser blast a hole through a piece of steel, so imagine what it would do to your
eye !)
Registration of laser systems
Any laser system that has a power output of greater than 5 milliwatts MUST be registered with the
FDA and Center for Devices and Radiological Health if it has an exposed beam, such as for
entertainment (I.E. Laser light shows) or for medical use (such as surgery) where someone other
than the operator may come in contact with it. (this is called a 'varience' and I have filled them out
and submitted them and they ARE a royal pain in the backside !)
Risks of Laser Radiation:
If the built in safety measures are defeated or the laser is operated with the housing
open, there is a risk of setting clothing or other flammable materials on fire. Laser
energy at a power of up to 150W (Model C100) at a wavelength of 10,6 µm could be
present inside the housing.
Therefore operators can perform procedures required inside the housing only when
the interlocked door has been opened. (A normal user must never defeat the door
interlocks or remove portions of the protective housing, except the machine is not
powered).
Therefore you must under no circumstances neither alter the laser tube unit nor
dismantle it nor set a system to work which has been altered or dismantled!
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Safety Interlock System
Your Speedy is equipped with an integrated safety interlock system which cuts off
the power of the laser tube immediately as soon as one of the doors is opened.
CAUTION
Do not attempt to alter the interlock system as that could result in
hazardous radiation exposure.
CAUTION
Technicians who are performing service procedures must be trained in
laser safety, and if they are defeating interlocks, they must wear laser
protective eyewear designed for the 10,6µm CO2 laser energy.
The top door, front door and the maintenance access panel are interlocked. If the
interlocks are defeated access to laser class IV radiation is possible through any of
these doors.
All other covers are not interlocked.
CAUTION
When a non interlocked cover is opened (and the machine is powered)
access to class IV laser radiation is possible.
These covers are labeled with „DANGER: INVISIBLE LASER RADIATION
WHEN OPEN. AVOID EYE OR SKIN EXPOSURE TO DIRECT OR
SCATTERED RADIATION“
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Dangers of Electricity
When you open the covers of the engraving system there is the danger to get in
contact with parts under high voltage. Therefore it is absolutely necessary that
service and repair work is only done while the power supply is unplugged. In any
case all safety laws and standards in connection with electricity must be obeyed.
IMPORTANT REMARK:
Usually you do not need to get in touch with the electrical and electronic
components. In case you do that when servicing or repairing the laser engraver,
please be sure that you first plug off the power supply.
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Emission indication and safety labeling
Light Emitting Diodes
On the keypad of the laser engraver there is on the left side a red LED (light emitting
diode) which is illuminated when laser radiation is emitted.
If the service plug is used to defeat the door interlocks, the red LED close to the
service button is flashing (which indicates that the machine now is in service mode).
In this case the machine represents a laser class IV (4) product and special safety
provisions are necessary.
emission indicator
Audible Warning
When starting up the laser engraver without closing the cover there is an intermittent
beep. This indicates that the interlock system has not been checked yet. (You can
run the machine only if all interlock switches are closed). Close the cover of the laser
engraver to cause the machine to initialize.
On emitting a laser beam (which is called test pulse) by pressing the „TEST"- and
"SERVICE" button simultaneously there is a beep (as long as you keep the buttons
pressed) to remind you of the possible risks.
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Safety Labels
The laser safety standards require that any removable panels that could permit
access to laser energy include laser safety labels. These labels are visible before
and after opening a cover.
Labels with the name of the manufacturer, date of production, description of the
product, model number, serial number and safety labels are placed on the outer side
of the apparatus. All these labels are mounted when producing the laser engraver.
These labels must not be removed.
If the labels are lost or damaged please contact Trotec. Replacements will be sent to
you free of charge. All labels and their exact place is mentioned in the user manual:
The labeling meets the standards
F 21 CFR 1040 – Laser safety
and
F EN 60825-1(1994)
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3. Laser beam alignment on Speedy
What you need:
laser protection glasses (for CO2 lasers)
the toolbox enclosed to your engraver
masking tape
CAUTION To make sure that there is no laser emission out of a
controlled area establish a limited access area by using non flamable
beam blocking curtains, temporary walls or other enclosures.
CAUTION The laser beam alignment may only be performed by service
technichians that have been trained by Trotec and are familiar with the
hazards from lasers
CAUTION
Never expose any part of your body to the beam as this could result in
serious injuries.
CAUTION
To do the alignment it is absolutely necessary to wear laser protection
glasses.
What you have to know:
The number of the mirrors is counted from the outlet of the laser tube to the
engraving head from one to three.
The whole alignment is done while your machine is running. To make sure the
system works at a suitable power level switch your machine off and on again.
The laser beam is invisible. To make it visible, you use adhesive tape. It is burned at
the spot, where it is hit by the laser beam and shows so a mark.
The tolerable displacement (distance from burned dot to the centre) is one sixth of
the diameter of the mirror or hole where you check the position.
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Beam path of the Speedy:
CO2 Laser Tube
Mirror No 2
Mirror No 3
Mirror No 1
Beam coupler
Aiming Laser diode
Beam path of the Speedy model
X-Axis
Left Y-Axis
Right Y-Axis
Maintenance
panel
Service access
panel
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What you have to do:
1. Disassemble the cover on the right side of the machine (10mm allen key).
2. Take your laser protection glasses and remove the grey cover of the first mirror at
the rear of your laser (right side) wearing the sign „DANGER. INVISIBLE LASER
RADIATION WHEN OPEN. AVOID EYE OR SKIN EXPOSURE TO DIRECT OR
SCATTERED RADIATION.“
3. Remove mirrors #2 and #3.
Removal of mirror #2
Removal of mirror #3
mirror unit 3
cover of mirror 1
mirror unit 2
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4. Put a piece of masking tape on the hole (black anodized aluminium part) in front
of mirror #2.
alignment of mirror no.1
5. Move the x-axis to the top position.
6. Press the test button, keep it pressed and then press the service button until you
see a little mark on the adhesive tape. (This is only possible if all doors are closed
or a service plug is put into the socket). The mark should be in the centre of the
hole. (If you don´t see a mark adjust the two brass screws at mirror #1 until you
can see a mark.
adjustments at mirror #1
7. Move the x-axis to the bottom position.
height adjustment
screw
left-right
adjustment screw
slider fixing screws
slider
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8. Repeat step 6, but this time try to hit the spot that you´ve created first.
9. Repeat steps 5 to 8 until the two spots are exactly at the same place.
10. If the spot is not centered bring it to the center by moving the slider of mirror#1.
11. Replace mirror #2.
12. Put a piece of masking tape on the hole in front of mirror #3.
checking the beam position at mirror #3
13. Move the engraving head to the top right corner.
14. Again press the test button, keep it pressed and then press the service button
until you see a little mark on the adhesive tape.
15. Move the engraving head to the top left corner and adjust the two brass screws at
mirror #2 until you hit the spot created in step 14.
16. Repeat steps 13 to 15 to check the position. If necessary readjust mirror #2.
17. Move the x-axis to the bottom position and check the alignment on the bottom left
position. If necessary do small corrections at mirror #1.
18. At the end check alignment on all four corners.
19. Assemble all parts again.
20. Now your engraver is aligned properly.
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4. Laser pointer adjustment
Attention: To do the laser pointer adjustment it is absolutely necessary to wear laser
protection glasses!
What you need:
laser protection glasses
the toolbox enclosed to your engraver
a philips screwdriver
adhesive tape
What you have to know:
The alignment is done while your machine is running. To make sure the system
works at a suitable power level switch your machine of and on again.
The laser beam is invisible. To make it visible, you use adhesive tape. It is burned at
the spot, where it is hit by the laser beam and shows so a mark.
The tolerable displacement (distance from burned dot to the centre) is one sixth of
the diameter of the mirror or hole where you do the adjustment.
1.) After you´ve installed the laser pointer glue some paper tape on the beam
entrance hole of the engraving head (first remove the last mirror and the lens).
3
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2.) Move the engraving head to the upper left corner of the engraving table.
3.) Fire the test pulse by pressing the test button, keeping it pressed and pressing at
the same time the service button, until you can see a small spot on the paper
tape.
4.) Adjust the three small screws (see attached picture) close to the laser pointer
until the red dot hits exactly the burned spot on the paper tape.
5.) Check the beam position on all four corners of the engraving table. You can get
the highest sensitivity to changes of the pointer position in the lower left corner of
the engraving table.
Adjustment screw
Laserpointer
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5. Replacing the laser tube
The laser tube is one of the main components of any laser engraver. The Speedy
uses for the 12, 25, 30 and 50W version Synrad tubes, and for the 100 W version a
Coherent tube. The 50 and 100W tubes are liquid cooled, all other tubes are air
cooled.
To make the tube fire it must be
- Connected to the power supply (48V for the 100W unit, for all other
machines 30V)
[On Synrad tubes this will be indicated with a green LED]
- Provided with a control signal (BNC connector, two for the 50W)
The control signal is a 5V TTL signal that comes from the main board.
[if there is a signal Synrad tubes will indicate this with an illuminated red
LED]
Additionally on the 100W machines the coolant velocity must be above 5.7 l/min.
All tubes have an integrated overtemperature protection. If the tube exceeds a
certain limit it is switched off to prevent a damage of the gas/electronics.
The following reasons might cause you to replace the tube:
• A too low laser power
• Fluctuations of laser power (typically jumps from 100% to 50% engraving
depth on a 25W unit, or from 100% to 75% on a 50W machine)
The frequency of these power fluctuations is low (e.g. every 5 minutes)
• Uncontrollable timing behaviour (high frequency effect).
This effect shows shifted start/end points of the pulses so that the image looks
frayed although the mechanics (of the motion system) and software
adjustment are OK.
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Measuring the laser power:
To measure the laser power you need:
1. Laser protective goggles
2. Laser power meter
3. Interlock defeat tool
tools for measuring the laser power
CAUTION To make sure that there is no laser emission out of a
controlled area establish a limited access area by using non flamable
beam blocking curtains, temporary walls or other enclosures.
CAUTION The laser power measurement may only be performed by
service technichians that have been trained by Trotec and are familiar with
the hazards from lasers
CAUTION
Never expose any part of your body to the beam as this could result in
serious injuries.
CAUTION
To do the laser power measurement it is absolutely necessary to wear
laser protection glasses.
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• Open the Trotec manager and connect to the engraver
• Enter the Advanced Options menu (Settings>Advanced options, Tab
Testpulse) and switch Power Testpulse to 100%. Press update.
increasing the test pulse to full power
• Defeat the interlock by plugging the interlock defeat tool into the socket on
the left side of the engraving area.
• Remove the lens
• Put the power meter with the black absorbing area in one of the corners of the
engraving table
• Move the table to a height level so that the distance between engraving head
and target area is approximately four centimetres.
setup for measuring the laser power
• Press the reset button on the power meter and fire the testpulse (press test,
keep it pressed and then press service)
• After some seconds you will hear a beep sound, which indicates that the
measurement has been finished.
• Repeat the procedure in the other corners
interlock
defeat tool
target area of
the power
meter
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The wattage difference between the four corners should be smaller than 10% of the
average laser power. Otherwise something is wrong with the beam alignment.
In this case measure the power directly at the beam aperture.
Laser tube replacement (12W and 25W)
1. Switch off the Speedy and open the service acces panel using a 10 mm allen
key. Remove also the cover of the electronic compartment.
2. Unplug the power connector (black-red) for the lasertube on the main board.
connectors on the power board
3. Remove the protective cover of the cooling fans.
power
connector
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4. Take out the metal grid and disconnect the cooling fans.
Pull out the black-red power cable.
5. Remove the fan enclosure
6. Pull out the power cable (black-red) and unplug the signal cable on the lasertube.
7. CAUTION: Before you perform that step please ask a second person to assist
you. The risk here is to drop the tube. Loosen the two 4mm screws on the right
side of the tube and remove the four philips screws on the left side (before you
can do that remove the cover of mirror unit 1).
8. Remove the tube
9. Assemble the new tube in the reverse way.
10. After the replacement you´ve to do the beam alignment.
Laser tube replacement (50W and 100W)
1. Switch off the Speedy and open the service acces panel using a 10 mm allen
key. Remove also the cover of the electronic compartment.
2. Unplug the power connector (black-red) for the lasertube on the main board.
3. Remove the tube enclosure.
4. Disconnect the six push fit fittings that are connected to the tube and
disassemble the two that fix the plastic water distributor.
5. Remove also all fittings on the left side of the tube.
6. Pull out the power cable (black-red) and unplug the two signal cables on the
lasertube.
7. CAUTION: Before you perform that step please ask a second person to assist
you. The risk here is to drop the tube. Loosen the two 4mm screws on the right
cooling fan
connector
BNC
connector
metal
grid
fixing
screws of
cooling fan
protective
cover
power
cable
fan
enclosure
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side of the tube and remove the six philips screws on the left side (before you can
do that remove the cover of mirror unit 1).
8. Remove the tube
9. Assemble the new tube in the reverse way.
10. After the replacement you´ve to do the beam alignment.
11. Pack the tube and ship it back to Trotec.
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