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400
Operation Manual
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Table of contents
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trotec laser 400 Operation Manual

8023 | V5.0_EN (11/2015) Technical changes reserved
Trotec Laser GmbH
This documentation with all illustrations is intellectual property of Trotec GmbH. The entire documentation is given to the user for personal use only. This documentation must not be reproduced or made available to others without our written permission. Any breach of law will be prosecuted.
Operation Manual
Speedy 400
8023 | V5.0_EN (11/2015) Technical changes reserved
Trotec Laser GmbH
Trotec Laser GmbH
Linzer Straße 156 A – 4600 Wels AUSTRIA
Tel.: ++43/7242/239-7000 E-Mail: techsupport@troteclaser.com
Trotec cannot be held responsible for any direct or indirect damages, which result from using or working with the products electric circuits or software described herein. The apparatus must be used only by trained and skilled personnel. Before use the manual should be read and followed carefully.
Furthermore Trotec reserves the right to change or alter any product described herein without prior notice.
In case of failure, please check the device first according to section 5.4 Tips for Troubleshooting. If unsuccessful, please note all data of the device (year of manufacture, software version, etc.) and call us from a telephone next to the switched on device.
For queries or technical problems please contact your dealer or Trotec directly at the above address..
8023 | V5.0_EN (11/2015) Technical changes reserved
Trotec Laser GmbH
TABLE OF CONTENTS
1 GENERAL ............................................................................................................ 5
1.1 Operation Manual Use - General Information .........................................................................5
1.2 Designated Use ..........................................................................................................................6
1.3 Disposal remarks .......................................................................................................................6
1.4 Technical Data / Device Specification .....................................................................................7
1.5 Manufacturer's Label ................................................................................................................9
1.6 EU - Declaration of conformity ...............................................................................................10
2 SAFETY ............................................................................................................. 11
2.1 General Safety Information.....................................................................................................11
2.2 Laser Safety Information ........................................................................................................12
2.3 Safety Precautions when Operating the Device ...................................................................13
2.4 Warning and Information Labels ...........................................................................................13
3 BEFORE OPERATION ...................................................................................... 16
3.1 Forklift transport......................................................................................................................16
3.2 Contents of Delivery................................................................................................................17
3.3 Location ....................................................................................................................................18
3.4 Electrical - Requirements .......................................................................................................19
3.5 Exhaust System - Requirements............................................................................................20
3.6 Computer - Requirements ......................................................................................................20
3.7 Connections .............................................................................................................................21
3.7.1 Connecting the Mains ...........................................................................................................21
3.7.2 Connecting the Computer .....................................................................................................22
3.7.3 Connecting the Exhaust System ...........................................................................................23
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4 OPERATION ...................................................................................................... 24
4.1 Machine view and connections front ....................................................................................24
4.2 Machine view and connections back ....................................................................................25
4.3 ON/OFF Switch ........................................................................................................................30
4.4 Keypad ......................................................................................................................................31
4.5 Tables .......................................................................................................................................34
4.5.1 Engraving Table (Standard table) .........................................................................................34
4.5.2 Vacuum Table .......................................................................................................................34
4.5.3 Cutting Table .........................................................................................................................34
4.6 First Steps before Marking .....................................................................................................35
4.7 First marking Tests .................................................................................................................38
4.8 Rotary Engraving Attachment ................................................................................................40
4.9 Tips and Tricks for Laser Engraving .....................................................................................44
4.10 Tips and Tricks for Laser Cutting ..........................................................................................46
4.11 Tips and Tricks for the Production of Rubber Dies .............................................................47
5 MAINTENANCE ................................................................................................. 48
5.1 Cleaning the System ...............................................................................................................48
5.2 Cleaning the Optical Parts ......................................................................................................49
5.2.1 CLEANING THE LENS .........................................................................................................49
5.2.2 CLEANING THE MIRRORS #2, #3 AND #4 .........................................................................51
5.3 Maintenance Plan ....................................................................................................................54
5.4 Material Table ..........................................................................................................................55
5.5 Tips for Troubleshooting ........................................................................................................56
5.6 Acceptance report ...................................................................................................................57
5.7 TRAINING SCHEDULE ............................................................................................................58
5.8 Response Form .......................................................................................................................59
5.9 How to create a Service File ...................................................................................................60
8023 | V5.0_EN (11/2015) Technical changes reserved
Trotec Laser GmbH

1 GENERAL

1.1 Operation Manual Use - General Information

Caution: Please read and follow this Operation Manual carefully, before installation and operation. Damage to persons and/or material can result from not following individual points of the Operation Manual!
Operation of the system is only permitted with equipment and spare parts supplied or listed in the spare parts and consumables lists.
Auxiliary equipment must be adjusted to the base machine (any queries to dealer or manufacturer).
The following symbols are used for easier understanding of the Operation Manual:
If the Operation Manual is not observed, this area represents a particular danger for the operating personnel or the personnel responsible for maintenance.
Caution: This component is under voltage. In these areas strictly observe the safety instructions regarding electricity. Care is to be taken in particular during maintenance and repair work
Caution: In this area pay attention to the possible dangers of the laser beam.
Note or information on individual components of the device, that simplify the use or make it more understandable.
1.2
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1.2 Designated Use

The Trotec laser engraver, Speedy 400, is used for engraving and cutting of signs, stamps and suchlike. A wide variety of materials such as rubber, acrylic, coated metal, tin, special steel, anodized aluminum, cork, cardboard, glass, leather, marble, several plastics and wood can be processed on the laser.
The working process must only be performed with a perfectly adjusted machine (see also Section 4 OPERATION).
For cutting applications with 40 W and more the use of the cutting table is absolutely necessary.
Use of the system in other areas is against the designated use. The manufacturer does not admit liability for damage to personal and/or equipment resulting from such use.
The system must only be operated, maintained and repaired, by personnel that are familiar with the designated field of use and the dangers of the machine!
Non-observance of the instructions for operation, maintenance and repair described in this Operation Manual excludes any liability of the manufacturer if a defect occurs.
Caution when processing conductive materials (carbon fibers,)! Conductive dust or particles in the ambient air might damage electrical components and lead to short circuits. Bear in mind that those defects are NOT warranted.

1.3 Disposal remarks

Do not dispose the machine with domestic waste! Electronic devices have to be disposed according to the regional directives on electronic and electric waste disposal. In case of further questions, please ask your supplier. He might take care of proper disposal.
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Trotec Laser GmbH

1.4 Technical Data / Device Specification

Mechanics
Working area
1000 x 610 mm (39 x 24 in)
Loading area
Up to 1090 x 690 mm x 305 mm (42.9 x 27.1 x 12 in) - depending on working table Up to 1045 x ? x 185 mm (41 x ? x 7.2 in) - depending on working table, with pass-trough
Max. height of work piece
Up to 305 mm (12 in) depending on table configuration and lens
Work piece table
Flexible table design: engraving, vacuum and cutting table; aluminum grid; computer controlled and programmable servo z-axis
Speed of motion system
355 cm/sec. (139 in/sec)
Acceleration
4 g
Motor
Brushless DC servomotor
Encoder
Increment measuring system
Lenses
1.5", 2.0" (standard); 2.5", 4.0" (optional)
Addressable accuracy
5µm
Repeatability
< 0,015 mm (0.0006 in)
Accuracy to size of parts
According to material an process
Maximum material load
20 kgs (55 lbs) area load over the whole working area
Exhaust
Table exhaust via rear of engraving cabinet
Standard Features
Ergonomic access to working area, electro-optic autofocus, laserpointer (655nm, <0,99mWcw), coaxial air assist (without pump), 2.0" lens (can be exchanged free of charge with 1.5", 2.5" or 4.0" lens), trolley base, one working table of choice (vacuum or cutting table, black aluminum grid or engraving table), USB connection, JobControl X Expert software
Options
Harsh environment protection kit, Pass-through opening (back), rotary attachment, air assist including compressor, temperature sensor, laser power upgrade, vacuum table, engraving table, black aluminum grid, cutting table (lamellas), honeycomb table, white plastic cutting grid
Options
Pass-through opening (back)
Height/width: 185 x 1045 mm (7.2 x 41 in) maximum material height 185 mm (7.2 in)
Rotary attachment
Cones, roller or combined version; tiltable
JobControl® Vision camera
Registration marks and compensation system "JobControl® Vision"; max. working area: 1000 x 610 mm (39.3 x 24 in) Engraving via JobControl with camera attached: 975 x 600 mm (38.3 x 23.6 in)
Vacuum table
Vacuum effect for thin or corrugated materials
Honeycomb table
In combination with vacuum table
Black aluminum grid
For reflection-free cutting of small objects
Cutting table
Removable aluminum lamellas
Control System
Software
JobControl X Expert
Laser power
Adjustable 0 - 100%
Interface hardware
USB, RS-232 (RS-232 mandatory for TroCAM and JobControl® Vision)
Interface software
ASCII, HPGL, JobContro
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Trotec Laser GmbH
Laser Equipment
Laser tube
Sealed off CO2 Laser, maintenance-free, Laser Power 40 - 120 W, air-cooled
Wavelength
10,6m
Dimensions
Width/depth/height
1400 x 950 x 1070 mm / 55 x 37.4 x 42.1 inch Weight
Approx. 350 kgs / 770 lbs (depending on laser power)
Ambient conditions
Mandatory ambient temperature +15 to +25 C or 59 to 77 F Humidity 40% to max. 70%, not condensing Dust free environment (2nd degree according to IEC 60947-1)
Laser Safety
Laser class
CDRH laser safety; CE tested Laser class 2 (Laser class 4 when operated with pass-through opening)
Interlock
Duplicate interlock safety system
Loading lid
Front side loading lid
Exhaust
Required
Atmos Duo Plus or equivalent
Electrical Equipment
Power consumption
1,4 kW (60 W laser tube)
Subject to change without notice. Errors and omissions excepted. March 2012
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1.5 Manufacturer's Label

The Manufacturer's Label is located on the backside of the machine (see picture below).
It is recommended to enter data such as serial number and year of manufacture data sheet above so that you always have this data handy if you have problems with your device or require spare parts.
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1.6 EU - Declaration of conformity

(Machine directive 2006/42/EG, appendix II A)
Manufacturer:
Trotec Laser GmbH. Linzer Strae 156, A-4600 Wels
Authorized person for the compilation of technical documentation:
Gerhard KREMPL, Trotec Laser GmbH., Linzer Strae 156, A-4600 Wels
We hereby certify that
Speedy400
Model N 8023 Speedy400
in its conception, construction and form put by us into circulation is in accordance with all the relevant essential health and safety requirements of the EC machinery directive 2006/42/EEC.
Further valid guidelines/regulations for the product:
2006/95/EG Low Voltage Directive 2004/108/EG EMC Guideline
Applied harmonized standards:
- EN ISO12100 Machine Safety
- EN 60335-1/2007 Safety of Household and similar Appliances
- EN 55011 + A1/2010 Electromagnetic Compatibility
- EN 60204-1 Machine Safety - electr. Equipment
- EN 60825-1/2007, EN 60825-4/2006 and EN 60825-14/2006 Safety of Laser Equipment
- EN 61000-6-2/2005, EN 61000-3-3/2008 and EN 61000-3-2 +A1 +A2/2009 Electromagnetic Compatibility
Place, Date:
Wels, 02.07.2012
Personal data of the signer:
Stephan FAZENY, Head of Research and Development
Signature:
_______________________________________________
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2 SAFETY

Please read this chapter before operating or servicing a Trotec Speedy 400 laser system!

2.1 General Safety Information

All personnel involved in installation, set-up, operation maintenance and repair of the machine, must have read and understood the Operation Manual and in particular the "Safety" section. The user is recommended to generate company-internal instructions considering the professional qualifications of the personnel employed in each case, and the receipt of the instruction/Operation Manual or the participation at introduction/training should be acknowledged in writing in each case.
Safety-conscious Working
The machine must only be operated by trained and authorized personnel. The scopes of competence for the different activities in the scope of operating the machine must be clearly defined and observed, so that under the aspect of safety no unclear questions of competence occur. This applies in particular to activities on the electric equipment, which must only be performed by special experts. For all activities concerning installation, set-up, start-up, operation, modifications of conditions and methods of operation, maintenance, inspection and repair, the switch-off procedures that may be provided in the Operation Manual must be observed.
Safety Information for the User and/or Operating Personnel
No working methods are permitted that affect the safety of the machine. The operator must also ensure that no unauthorized persons work with the machine
(e.g. by activating equipment without authorization).
It is the duty of the operator, to check the machine before start of work for externally
visible damage and defects, and to immediately report changes that appear (including behavior during operation) that affect the safety.
The user must provide that the machine is only operated in perfect condition. The user must guarantee the cleanness and accessibility at and around the machine
by corresponding instructions and controls.
Principally, no safety components may be removed or disabled (already here we
emphasize the imminent dangers, for example severe burns, loss of eye-sight). If the removal of safety components is required during repair and service, the replacement of the safety components must be performed immediately after completion of the service and repair activities.
Preparation, retooling, change of work piece, maintenance and repair activities must
only performed with equipment switched off, by trained personnel.
It is forbidden to perform unauthorized modifications and changes to the machine. It
is emphasized, that any unauthorized modifications to the machine are not permitted for safety reasons.
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2.2 Laser Safety Information

To assess the potential dangers laser systems pose, they are classified into 5 safety classes: 1, 2, 3a, 3b and 4. Trotec Speedy 400 is a device of class 2 (USA: Class II) and class 4 (USA: Class IV) with pass through option. Please note that improper operation of the device can override the status of safety class 2 and can cause the emission of harmful radiation.
This laser engraving system contains a carbon dioxide (CO2) laser of class 4 that emits intensive and invisible laser radiation. Without safety precautions the direct radiation or even diffuse reflected radiation is dangerous!
Without safety precautions, the following risks exist with exposure to laser radiation: Eyes: Burns to the cornea for CO2 Laser Skin: Burns Clothing: Danger of fire
Never try to modify or disassemble the laser and do not try to start up a system that had been modified or disassembled!
Dangerous radiation exposure can result from the use of operation or adjustment equipment other than that described here, and if different operational methods are performed.
Service technicians using the service plug are required to wear standard laser safety glasses for CO2 lasers (wavelength 10.6 m).
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2.3 Safety Precautions when Operating the Device

In your Speedy 400, a closed safety system is integrated which immediately switches off the power to the laser tube when the protection cover is opened. Consequently an incomplete engraving can occur if the cover is opened during operation. Therefore, first press the "PAUSE" button, if you want to interrupt an engraving process.
Please remember the following safety precautions when working with this device: A fire extinguisher must always be handy as the laser beam can ignite flammable materials.
Do not store any flammable materials in the inside of the device or in the immediate vicinity of the device. Particularly leftovers of produced materials have to be removed to prevent fire hazard.
Unsupervised operation of the system is not permitted.
Because of their low absorption polished and pure metals like un-coated aluminum, copper, silver and gold can show very weak interaction with the laser beam and lead to strong reflections. Such materials must be handled with care, as a directed reflection could harm the protection cover. The protection cover is damaged if the reflected radiation is focussed in the plane of the protection cover. By accident, this effect is almost impossible.
Adjustment of the beam path must be performed only by especially trained personnel. An improper setting can lead to uncontrolled emission of the laser radiation.
Before processing materials the user must verify, whether harmful materials can be generated and whether the filter equipment of the exhaust system is suitable for the harmful materials. We emphasize that it is the responsibility of the user, to consider the national and regional threshold values for dust, fogs and gases when selecting the filters and the exhaust system. (The values for the maximum workplace concentration must not be exceeded.)
Please refer to the manual of the exhaust system on how and in what intervals you need to replace filters.
PVC (polyvinyl chloride) must under no circumstances be processed with the laser.
Should you have further questions before starting work, please contact your dealer or Trotec.

2.4 Warning and Information Labels

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1
2
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5
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P = xxx W
7
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2 3
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10
The warning and information labels are attached in such positions of the machine that could represent a source of danger during set-up and operation. Therefore, follow the information on the labels. If labels are lost or damaged, they must be replaced immediately.
Visible from outside
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2
3
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P = xxx W
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Lifting points
The machine may only be lifted and transported:
Under the guidance of a
2
nd
person, and
At the points identified.

3 BEFORE OPERATION

You receive your Speedy 400 packed in a wooden crate, which contains the laser and additional accessories. A suitable fork-lift is required to unload from the courier vehicle and lift the machine off its pallet. A powered screwdriver with cross-head bit is recommended for dismantling the wooden crate.
If possible keep the packaging in case the machine ever needs to be relocated or shipped for any reason.

3.1 Forklift transport

If possible keep the packaging in case the machine ever needs to be relocated or shipped for any reason. Dispose all waste according to the applicable waste disposal law.
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1 5 8 2 6 9
3 7 4

3.2 Contents of Delivery

Transport and service packaging Laser including optics Accessories box, which contains the following parts:
1. CD Trotec software / printer driver incl. Operation Manual
2. Mains cable
3. Computer connection cable USB
4. Computer connection cable serial (optional)
5. Cleaning kit for optics
6. Additional lenses (optional)
7. Air assist nozzles(s)
8. Focus tool(s)
9. Allen key set 1.5 - 10 mm
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3.3 Location

Before you install the laser system, you should select an appropriate location. Follow the guidelines shown below:
Avoid locations where the system is exposed to high temperatures, dust and high humidity (The humidity must not exceed 70% and the temperature must not be close to the dew point).
Avoid locations, where the system is exposed to mechanical shocks
Fuse protection: Do not connect other devices via the laser fuse, as the laser system requires the full amperage.
Avoid locations with poor air circulation.
Select a location, whose room temperature is between 15 C and 25 C (59 - 77 F). Avoid higher ambient temperatures and strong exposure of the machine to the sun. Use blinds, if required.
Select a location close to ventilation (if available).
Select a location that is not more than 2.50 m away from your computer (max. cable length to avoid disturbing interferences).
Try to place a working table or a place to put things next to it. This shall avoid, that the machine is misused as a table.
3.4
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3.4 Electrical - Requirements

Make sure that your electrical outlet is capable of providing the proper voltage, frequency and amperage that the laser system requires.
We recommend having individual circuits for
Lasermachine and PC Extractor
Recommended fuse 10A (230V), 16A (115V). Please install your computer to the same circuit as the laser marker to prevent
electromagnetic interactions. DAMAGES FROM AN INADEQUATE OR INAPPROPRIATE POWER SOURCE ARE NOT
COVERED UNDER WARRANTY. Noisy or unstable electricity as well as voltage spikes can cause interference and possible
damage to the electronics of the laser system. It is better to connect the laser system to a dedicated electrical line.
It is highly recommended that you use a surge suppression plugs to protect your computer equipment.
If electrical power fluctuations, brown outs or constant power outages are a problem in your area, an electrical line stabilizer, UPS (Uninterruptible Power Supply) or backup generator might be required. If installing any of these devices, make sure that they meet the electrical requirements of the laser system.
It is your responsibility to provide a suitable electrical supply.
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