Universal Laser Systems PLS3.60, PLS4.60, PLS6.60, PLS6.120D Safety, Installation, Operation, And Basic Maintenance Manual

Download

Page 1

Laser Engraving and Cutting System

2007 Professional

Systems

Models PLS3.60, PLS4.60,

PLS6.60, & PLS6.120D

Safety, Installation, Operation,

and Basic Maintenance Manual

System Serial Number: _____________

(Located on the back of the machine and inside the front door)

Laser Tube Serial Number(s):

______________ ______________

Universal Laser Systems, Inc.

16008 North 81st Street

Scottsdale, AZ 85260 USA

Technical Support Department

Phone: 480-609-0297

Fax: 480-609-1203

Web Based Email Support: www.ulsinc.com

March 2008

Page 2

Notice

This publication and its contents are proprietary to Universal Laser Systems, Inc. (ULS), and are intended solely for the contractual use of ULS, Inc. customers.

While reasonable efforts have been made to assure the accuracy of this manual, ULS shall not be liable for errors contained herein or for incidental or consequential damage in connection with the furnishing, performance, or use of this material. ULS reserves the right to revise this manual and make changes from time to time without obligation by ULS to notify any person of such revision or changes.

ULS does not assume any liability arising out of the application or use of any products, circuits, or software described herein. Neither does it convey a license under its patent rights nor the patent rights of others.

This publication and its contents may not be reproduced, copied, transmitted, or distributed in any form, or by any means, radio, electronic, mechanical, photocopying, scanning, facsimile, or otherwise, or for any other purpose, without the prior written permission of ULS.

ULS provides no warranties whatsoever on any software used in connection with a ULS Laser Engraving System, express or implied. Neither does it guarantee software compatibility with any off-the-shelf software package or any software program that has not been written by ULS.

Intended use of this system must be followed within the guidelines of this manual. In no event will ULS be liable for any damages caused, in whole or in part, by customer, or for any economic loss, physical injury, lost revenue, lost profits, lost savings or other indirect, incidental, special or consequential damages incurred by any person, even if ULS has been advised of the possibility of such damages or claims.

WARNING: UNIVERSAL LASER SYSTEMS PRODUCTS ARE NOT DESIGNED, TESTED, INTENDED OR AUTHORIZED FOR USE IN ANY MEDICAL APPLICATIONS, SURGICAL APPLICATIONS, MEDICAL DEVICE MANUFACTURING, OR ANY SIMILAR PROCEDURE OR PROCESS REQUIRING APPROVAL, TESTING, OR CERTIFICATION BY THE UNITED STATES FOOD AND DRUG ADMINISTRATION OR OTHER SIMILAR GOVERNMENTAL ENTITIES. SHOULD THE BUYER USE UNIVERSAL LASER SYSTEMS PRODUCTS FOR ANY

SUCH UNINTENDED OR UNAUTHORIZED APPLICATION, ALL WARRANTIES REGARDING THE UNIVERSAL LASER SYSTEMS PRODUCTS SHALL BE NULL AND VOID. FURTHER, THE BUYER SHALL HAVE NO REMEDY AGAINST UNIVERSAL LASER SYSTEMS AND ITS OFFICERS, EMPLOYEES, SUBSIDIARIES, AFFILIATES AND DISTRIBUTORS FOR, AND THE BUYER SHALL INDEMNIFY AND HOLD THOSE PARTIES HARMLESS AGAINST, ANY AND ALL CLAIMS, COSTS, DAMAGES, EXPENSES AND REASONABLE ATTORNEY FEES ARISING OUT OF, DIRECTLY OR INDIRECTLY, ANY CLAIM ASSOCIATED WITH SUCH UNINTENDED OR UNAUTHORIZED USE, INCLUDING BUT NOT LIMITED TO ANY CLAIM BASED ON WARRANTY (EXPRESS OR IMPLIED), CONTRACT, TORT (INCLUDING ACTIVE, PASSIVE, OR IMPUTED NEGLIGENCE), STRICT LIABILITY, PATENT OR COPYRIGHT INFRINGEMENT OR MISAPPROPRIATION OF INTELLECTUAL PROPERTY.

HP is a registered trademark of Hewlett-Packard Corporation. Windows is a registered trademark of Microsoft Corporation. Macintosh is a registered trademark of Apple Computer Corporation. PostScript, Photoshop, and Streamline are registered trademarks of Adobe Systems Inc. CorelDRAW is a registered trademark of Corel Corporation. AutoCAD is a registered trademark of AutoDesk Inc.

ULS Platforms are protected under one or more of U.S. patents 5,661,746; 5,754,575; 5,867,517; 5,881,087; 5,894,493; 5,901,167; 5,982,803; 6,181,719; 6,313,433; 6,342,687; 6,423,925; 6,424,670; 6,983,001, D517,474; 7,060,934. Other U.S. and International patents pending.

Page 3

Introduction

We would like to thank you for your laser system purchase. Universal Laser Systems, Inc. (ULS) is the pioneer, and highest volume manufacturer, of large field, computer controlled laser engraving, marking, and cutting systems. ULS has devoted years of research and development to further the quality of our products that has resulted in a number of remarkable innovations within the laser industry. Since 1988, the staff at ULS has been dedicated to total customer satisfaction. When you buy Universal you get more than a laser - you get a team of talented, experienced, enthusiastic people who are focused on your satisfaction. Our commitment is to help you now and in the future.

To begin with, we highly recommend that this entire manual be read before attempting to use your laser system. The manual includes important information about safety, assembly, use, and basic maintenance.

How To Get Help

Before contacting our Technical Support Department, make sure that you have read this entire manual as well as any other accompanying manuals included with your laser system.

Step 1:

Try to recreate the problem and write down the circumstances in which the problem occurred. Try to recall if the problem began all of a sudden, worsened over time, or began after you performed any recent maintenance. Also be prepared to describe all pertinent information about the computer being used such as software, ULS printer driver version, computer operating system and computer type.

Step 2:

Make sure that you have the serial number of the laser system available. The serial number tags are located on the back of the machine, next to the exhaust port, and inside the front door, visible when you open it. The Technical Support Department may not be able to assist you without this number.

Step 3:

Contact your local ULS Representative. They may have more details about your particular installation and applications. If possible, call from a phone that is close to the laser system so that it can be operated while talking to our representative.

Step 4:

If your local Sales Representative cannot assist you and you would like to use our FREE, email based support system, log on to our website: www.ulsinc.com. Click on the “Technical Support“ link, then click on the “Technical Support Request Form” and follow the instructions.

Step 5:

If you are unable to obtain Internet access, you may contact our Technical Support Department at:

Universal Laser Systems, Inc.

Technical Support Department

16008 North 81st Street

Scottsdale, AZ 85260

Phone: 480-609-0297

Fax: 480-609-1203

M-F 8am – 5pm Arizona Time

support@ulsinc.com

Page 4

Specifications

System Operating Environment Requirements (user provided)

PLS3.60 PLS4.60 PLS6.60 PLS6.120D

Models

Operating

Environment

Operating

Temperature

Storage Temperature

Operating Humidity

Electrical Power

Particulate/Odor

Outside Ventilated

Exhaust System

Computer

Requirement

Software Requirement

Well-ventilated office (recommended) or clean, light-duty manufacturing

50ºF (10ºC) to 95ºF (35º C) capable

73ºF (22ºC) to 77ºF (25º C) for best performance

50ºF (10ºC) to 95ºF (35º C)

Non-condensing

Single Phase 110/230V AC, 10/5 Amp, 50/60 Hz

Grounded (earthed) and stable (surge and spike protected)

High-pressure vacuum blower capable of:

250 CFM (cubic feet per minute) @ 6

inches static pressure

(425m3/hr at 1.5kPa)

Windows XP or Windows Vista (32-bit version only)

Graphics or CAD based

(See manual for recommendations)

500 CFM (cubic feet per minute)

@ 6 inches static pressure

(850m3/hr at 1.5kPa)

Page 5

Model System Specifications

PLS3.60 PLS4.60 PLS6.60 PLS6.120D

Laser Safety

Work Area

Table

Max Part

Resolutions

Interface

Control

Interconnection

Cabinet Style

Laser Options

CO2 Laser, Interlocked Safety Enclosure = Class I

Red Diode Pointer = Class IIIa

24 x 12 Inch

(609.6 x 304.8 mm)

29 x 17 Inch

(736.6 x 431.8 mm)

29 x 17 x 9 Inch (736.6 x 431.8 x

228.6 mm)

Keypad/small LCD display shows current file name, laser power, engraving

Requires a dedicated PC to operate. Requires Windows XP or Windows Vista

10, 25, 30, 35, 40, 45, 50, 55 and 60 watts

24 x 18 Inch

(609.6 x 457.2 mm)

29 x 23 Inch

(736.6 x 584.2 mm)

29 x 23 x 9 Inch (736.6 x 584.2 x

228.6 mm)

1000, 500, 333, 250, 200, 166 dpi/lpi

speed, PPI and run time

(32-bit version only).

USB 2.0 High Speed port

Floor Standing

(939.8 x 584.2 x 228.6 mm)

32 x 18 Inch

(812.8 x 457.2 mm)

37 x 23 Inch

(939.8 x 584.2 mm)

37 x 23 x 9 Inch

10, 25, 30, 35,

40, 45, 50, 55

and 60 watts

(equipped for

two lasers)

Power Requirements

Size (inch)

Weight

Exhaust Hookup

Laser Cartridge Weight

Available Options

110V/10A

230V/5A

36W x 38T x 30D

(91.4cm W x 96.5cm T

x 76.2cm D)

235 lb (107 kg) 270 lb (122 kg) 325 lb (147 kg) 345 lb (156 kg)

One 4” (10.16 cm)

Rotary Fixture, Air Assist (standard or computer controlled), Air Compressor

(desiccant or refrigerated dryer options), Honeycomb Cutting Table, Dual Head,

36W x 39T x 36.5D

(91.4cm W x 99.1cm T

x 92.7cm D)

44W x 39T x 37.5D

(111.8cm W x 99.1cm T x 95.3cm D)

port Two 4” (10.16 cm) ports

25/30 Watt = 20 lbs (9 kg)

35/40 Watt = 23 lbs (10 kg)

45/50/55/60 Watt = 26 lbs (12 kg)

Assorted Focal Length Lens Kits

230V/15A

Specifications subject to change without notice

Page 6

Table of Contents

Section 1 – Safety

Description of Appropriate Use.....................................................................................................1-1

General Safety..............................................................................................................................1-1

Laser Safety..................................................................................................................................1-2

Safety Labels ................................................................................................................................1-2

EU Compliance (CE)...................................................................................................................1-10

FCC Compliance.........................................................................................................................1-11

Recycling.....................................................................................................................................1-11

Part 1 - Initial Setup

Section 2 – Installation

Establishing a Proper Operating Environment..............................................................................2-3

Providing a Suitable Electrical Power Source...............................................................................2-3

Extracting Fumes and Particulates...............................................................................................2-4

Software Installation and Operating System Requirements.........................................................2-6

Computer Requirements ........................................................................................................2-6

Software Installation CD-ROM ...............................................................................................2-8

Recommended Software Programs .......................................................................................2-8

Section 3 – Graphic Software Setup

General Software Setup................................................................................................................3-1

Specific Software Setup................................................................................................................3-5

CorelDRAW 11.......................................................................................................................3-6

CorelDRAW 12.......................................................................................................................3-8

CorelDRAW X3.....................................................................................................................3-10

AutoCAD 2000i/2002/2004...................................................................................................3-12

Adobe Illustrator CS .............................................................................................................3-13

Section 4 – Assembling the PLS

System Assembly - PLS3.60 and PLS4.60...................................................................................4-1

System Assembly - PLS6.60 and PLS6.120D..............................................................................4-4

Finalizing the Connections............................................................................................................4-8

Checking Beam Alignment - All PLS laser systems ...................................................................4-10

Section 5 – Making a Sample

Step 1 - Loading and Positioning the Material..............................................................................5-1

Step 2 - Creating the Graphic.......................................................................................................5-1

Step 3 - Printing to the Laser System...........................................................................................5-1

Step 4 - Starting the Engraving Process.......................................................................................5-2

Step 5 - Material Removal and Reloading....................................................................................5-2

Part 2 - Laser System Essentials

Section 6 – Basic System Features

The Universal Control Panel (UCP)..............................................................................................6-3

The PLS Keypad...........................................................................................................................6-5

Printer Driver Controls...................................................................................................................6-7

Materials Database Tab .........................................................................................................6-7

Section 7 – Basic Maintenance

Motion System Components Diagram..........................................................................................7-1

Cleaning and Maintenance Supplies ............................................................................................7-2

System Cleaning and Maintenance..............................................................................................7-2

Maintenance Schedule..................................................................................................................7-5

Page 7

Part 3 - Accessories

Section 8 – Accessories

Air Assist .......................................................................................................................................8-3

Air Assist Compressor...................................................................................................................8-8

Dual Head.....................................................................................................................................8-9

Honeycomb Cutting Table ..........................................................................................................8-12

Focus Lens Kits...........................................................................................................................8-14

Rotary Fixture..............................................................................................................................8-15

Part 4 - Advanced User

Section 9 – Advanced System Operation

Printer Driver Controls...................................................................................................................9-3

Manual Control Tab................................................................................................................9-4

Focusing Methods.......................................................................................................................9-17

Making a Sample - Manual Control Tab .....................................................................................9-19

Page 8

Page 9

Section 1

Safety

Description of Appropriate Use

This device is designed for laser cutting and engraving, in a laboratory, workshop, or light duty manufacturing environment. Materials to be processed must fit completely inside the system for proper operation.

Notice: This device is not designed, tested, intended or authorized for use in any medical applications, surgical applications, medical device manufacturing, or any similar procedure or process requiring approval, testing, or certification by the United States Food and Drug Administration or other similar governmental entities. Please see the Notice herein for further information regarding such uses.

General Safety

Use of the equipment in a manner other than what is described in this manual can result in injury to yourself, others, or may cause severe damage to the equipment and your facility. Failure to follow the operational requirements and safety guidelines, listed in this manual, may increase this risk.

• EXPOSURE TO THE LASER BEAM MAY CAUSE PHYSICAL BURNS AND CAN CAUSE SEVERE EYE DAMAGE. Proper

use and care of this system are essential to safe operation.

• NEVER OPERATE THE LASER SYSTEM WITHOUT

CONSTANT SUPERVISION OF THE CUTTING AND ETCHING PROCESS. Exposure to the laser beam may

cause ignition of combustible materials and start a fire. A properly maintained fire extinguisher should be kept on hand at all times.

• NEVER LEAVE MATERIALS IN THE LASER SYSTEM AFTER LASER PROCESSING HAS FINISHED. Materials may ignite

after laser processing has finished. Thoroughly inspect the interior of the laser system and remove any particulate materials before leaving the workstation. A properly maintained fire extinguisher should be kept on hand at all times.

• A PROPERLY CONFIGURED, INSTALLED, MAINTAINED, AND OPERATING PARTICULATE/FUME EXHAUST SYSTEM IS MANDATORY WHEN OPERATING THE LASER SYSTEM. Fumes and smoke from the engraving process must be

extracted from the laser system and exhausted outside.

Page 10

SAFETY

• SOME MATERIALS, WHEN ENGRAVED OR CUT WITH A

LASER, CAN PRODUCE TOXIC AND CAUSTIC FUMES.

We suggest that you obtain the Material Safety Data Sheet (MSDS) from the materials manufacturer. The MSDS discloses all of the hazards when handling or processing that

material. DISCONTINUE processing any material that shows signs of chemical deterioration of the laser system such as rust, metal etching or pitting, peeling paint, etc. Damage to the laser system from caustic materials is NOT covered under warranty.

• CARE SHOULD BE TAKEN WHEN MOVING OR LIFTING THIS DEVICE. Obtain assistance from 3 or 4 additional people when

lifting or carrying (secure motion system and doors). Severe bodily injury may occur if improper lifting techniques are applied or the system is dropped.

• DANGEROUS VOLTAGES ARE PRESENT WITHIN THE

ELECTRONICS AND LASER ENCLOSURES OF THIS SYSTEM. Although access to these areas is not necessary

during normal use, if it becomes necessary to open one of these enclosures for service reasons, please remember to disconnect the power cord from your electrical supply.

• THE POWER SUPPLY CORD IS THE MAINS DISCONNECT DEVICE; THE EQUIPMENT SHOULD BE LOCATED CLOSE TO AN EASILY ACCESSIBLE WALL SOCKET OUTLET. To

disconnect the equipment from the supply mains, the power cord shall be unplugged from the wall outlet or main power inlet (appliance coupler) of the unit.

• THIS DEVICE IS SPECIFICALLY DESIGNED TO COMPLY WITH CDRH PERFORMANCE REQUIREMENTS UNDER 21 CFR 1040.10 AND 1040.11.

CDRH is the Center for the Devices of Radiological Health division of the Food and Drug Administration (FDA) in the USA. It also complies with CE (European Community) safety regulations. No guarantees of suitability or safety are provided for any use other than those specified by Universal Laser Systems, Inc.

Laser Safety

The device contains a sealed carbon dioxide (CO2) laser in a Class I enclosure that produces intense invisible and visible laser radiation at a wavelength of 10.6 microns in the infrared spectrum. For your protection, this enclosure is designed to completely contain the CO2 laser beam. Improper use of controls and adjustments, or performance of procedures other than those specified, may invalidate the safety of this system.

• The intense light that appears during the engraving or cutting process is the product of material combustion or vaporization. DO NOT STARE AT THE BRIGHT LIGHT

OR VIEW DIRECTLY WITH OPTICAL INSTRUMENTS.

• This device may contain a visible Red Dot Pointer (Class IIIa). DO NOT STARE AT THE RED LIGHT OR VIEW DIRECTLY WITH OPTICAL INSTRUMENTS.

Section 1-2

Page 11

SAFETY

• The user door(s) are safety interlocked and will disable the CO2 laser beam from firing when the user door(s) are opened. The Red Dot Pointer is NOT safety interlocked and can be automatically activated with the door(s) either open or closed.

• DO NOT OPERATE THE LASER SYSTEM IF ITS SAFTEY FEATURES HAVE BEEN MODIFIED, DISABLED OR REMOVED. This may lead to accidental

exposure to invisible and visible CO2 laser radiation which may cause permanent blindness and/or severe burns to your skin.

Safety Labels

CDRH and CE regulations require that all laser manufacturers affix warning labels in specific locations throughout the equipment. The following warning labels are placed on the laser system for your safety. DO NOT remove them for any reason. If the labels become damaged or have been removed for any reason, DO NOT OPERATE the laser system and immediately contact Universal Laser Systems, Inc. for a free replacement. Labels are NOT to scale.

LaserProcessing System Manufactured By:

LASER SYSTEMS INC.

Scottsdale, Arizona

Model No: Manufactured: Serial No: Made in USA

221-0002-0 221-0007-0

XXX XXXX

XXXXX

SERIAL #: XXXXX DATE: XXXXX

NEVER OPERATE THE LASER SYSTEM

WITHOUT CONSTANTSUPERVISION

EXPOSURE TO THELASER BEAMMAY

CAUSE IGNITION OF COMBUSTIBLE

MATERIALSWHICH CAN CAUSE SEVERE

DAMAGE TO THEEQUIPMENT

221-0012-0 221-0013-0

WARNING

THIS LASER SYSTEM CONTAINS A

CO LASE R IN A CLASS I EN CL O S URE.

THE LA SE R SY STEM HAS BEEN

CLASSIFIED AS CLAS S 3 R DUE

WARNING

TO THE PRESENCE OF A

VISIBLE LA SER DIODE.

THIS EQ U I PME NT CON FO R MS

TO PROVISIONS OF

US 21 CFR 1040.10

AND 1040.11

221-0015-0 221-0016-0

Section 1-3

CAUTION

CLASS4INVISIBLELASER RADIATION

WHENOPEN

DEFEATED

DIRECTORSCATTEREDRADIATION

ANDINTERLOCKFAILEDOR

AVOIDEYEORSKIN EXPOSURE

Page 12

SAFETY

CAUTION

CLASS 4 INVISIBLE LASER

RADIATIONWHEN OPEN

AVOIDEYE OR SKIN EXPOSURE TO

DIRECT OR SCATTERED RADIATION

221-0017-0 221-0018-0

WARNING

TURN THE LASER SYSTEM OFF BEFORE

CONNECTING OR DISCONNECTING

THE ROTARY FIXTURE

221-0019-0 221-0020-0

AVOID EXPOSURE

INVISIBLE LASER RADIATION IS

EMITTED FROM THIS APERTURE

WARNING

TOAVOIDRISK OF ELECTRIC SHOCK

ALWAYSDISCONNECT POWER CORD

BEFORE REMOVING THISCOVER

INPUT POWER:

110 VAC; 50/60 Hz; 10 A

221-0021-0 221-0022-0

INPUT POWER:

230 VAC;50/60 Hz; 15A

ULS LASER SYSTEM. THIS LASER

DOES NOT COMPLYWITH U.S. CODE 21 CFR SUBCHAPTER J

5,881,087; 5,894,493; 5,901,167; 5,982,803; 6,181,719; 6,983,001

THIS LASER MANUFACTURED BY

UNIVERSAL LASER SYSTEMS

16008 N. 81ST ST

SCOTTSDALE, AZ 85260USA

IS DESIGNED FOR USE ONLYAS A COMPONENT IN A

IS A CLASS 4 DEVICE AND

OR EUROPEAN STANDARDEN 60825-1:1994.

THIS LASER PRODUCT IS MANUFACTUREDUNDER ONE

OR MORE OF U.S. PATENTS 5,661,746; 5,754,575; 5,867,517;

OTHER U.S. ANDINTERNATIONALPA TENTSPENDING.

221-0024-0 221-0031-0

Section 1-4

Page 13

SAFETY

DANGER

CAUTION LASER RADIATION

DO NOT STARE INTO BEAM OR VIEW

DIRECTLY WITH OPTICAL INSTRUMENTS

CLASS 3R LASER PRODUCT

LASER DIODE

WAVE LENG TH: 630-680 nm

MAX. OUTPUT: 5 mW

LASER RADIATION- AVOID

DIRECT EYE EXPOSURE

LASER DIODE

WAVELENGTH: 630-680 nm

MAX. OUTPUT:5 mW

CLASS 3R LASERPRODUCT

221-0033-0 221-0034-0

INPUT POWER:

230 VAC;50/60 Hz; 5A

THIS SYSTEM IS DESIGNED FOR

NON-OXIDIZING GASES ONLY

(i.e. DRY CLEANAIR, CARBON DIOXIDE, HELIUM, NITROGEN). CONNECTING FLAMMABLE OR

SYSTEM CREATESASERIOUS

SAFETYAND/OR FIRE HAZARD.

SOURCES EXCEEDING 75 PSI

UNIVERSALLASER SYSTEMS

ASSUMES NO RESPONSIBILITY ARISING FROM THEIMPROPER

WARNING

USE WITH INERTAND

OXIDIZING GASES TOTHIS

DO NOT CONNECTANY GAS

(5ATM)PRESSURE.

USE OF THISSYSTEM.

221-0036-0 221-0037-0

THIS PRODUCTIS MANUFACTUREDUNDER ONE

OR MOREOF U.S. PATENTS 5,051,558; 5,661,746; 5,754,575;

5,867,517; 5,881,087;5,894,493; 5,901,167; 5,982,803; 6,181,719;

6,313,433; 6,342,687;6,423,925; 6,424,670; 6,983,001;

D517,474; 7,060,934

OTHER U.S.AND INTERNATIONALPA TENTSPENDING.

Do use in medical or surgical

NOT

applications or to manufacture medical devices. See the Safety, Installation, Operation, and Basic

Maintenance Manual, or the OEM

Laser Integration Manual for

WARNING

further information.

221-0065-0 221-0081-0

Section 1-5

Page 14

SAFETY

PLS3.60, PLS4.60, PLS6.60 Label Placement

221-0086-0 221-0087-0 221-0088-0 221-0089-0

221-0007-0

221-0031-0

221-0017-0

221-0018-0

Laser Tube

221-0033-0

221-0016-0

221-0018-0

221-0012-0

221-0034-0

221-0013-0

221-0022-0 221-0036-0

Section 1-6

Page 15

SAFETY

221-0021-0

221-0020-0

221-0016-0

221-0037-0

221-0016-0

221-0020-0

221-0002-0

221-0081-0

221-0015-0

Back View of laser system

221-0065-0

Section 1-7

Page 16

PLS6.120D Label Placement

SAFETY

221-0086-0 221-0087-0 221-0088-0 221-0089-0

221-0007-0

221-0031-0

221-0017-0

221-0018-0

Laser Tube

221-0033-0 221-0034-0

221-0016-0

221-0018-0

221-0012-0

221-0013-0

Section 1-8

221-0007-0

Page 17

SAFETY

221-0021-0

221-0016-0

Back View of laser system - Rear cover open

221-0020-0

221-0024-0

221-0016-0

221-0002-0

221-0015-0

221-0065-0

221-0037-0

221-0081-0

Back View of laser system - Rear cov er closed

Section 1-9

Page 18

SAFETY

EU Declaration of Conformity

Product Identification: PLS3.60, PLS4.60, PLS6.60, and PLS6.120D

Laser Engraving and Cutting Systems Manufacturer: European Office:

Universal Laser Systems, Inc. Universal Laser Systems GmbH 16008 N. 81 Scottsdale, AZ 85260 A-1160 Vienna/Austria USA

The manufacturer hereby declares that the equipment specified below is in conformity with the following directives:

based on the standards listed. Standards Used:

Note: This is not a declaration of conformity. The importer of this equipment supplies the declaration of conformity.

Warning

This is a Class A product. In a domestic environment this product may cause radio interference in which case the user may be required to take adequate measures.

St. Lerchenfelder Guertel 43

89/336/EEC (EMC Directive) 73/23/EEC (Low Voltage Directive) 98/37/EEC (Machinery Directive) 2002/95/EEC (ROHS Directive) 2002/96/ECC (WEEE Directive)

Safety:

EN 60950: 2002 EN 60825-1: 2002 (Class 3R)

EMC:

EN 55024 1998 (Class A) EN 55022: 2003 (Class A) EN 61000-3-2: 2001 (class A) EN 61000-3-3: 2002 EN 61000-4-2: 2001 (4kV CD, 8kV AD) EN 61000-4-3: 2003 (3 or 10 V/m) EN 61000-4-4: 2002 (1 or 2 kV power line) EN 61000-4-5: 2001 (class 3) EN 61000-4-6: (3 or 10Vrms) EN 61000-4-8 EN 61000-4-11

Section 1-10

Page 19

SAFETY

FCC Compliance

This ULS laser system has been tested and found to comply with Federal Communication Commission (FCC) directives regarding Electromagnetic Compatibility (EMC). In accordance with these directives ULS is required to provide the following information to its customers.

FCC Compliance Statement and Warnings

This device complied with FCC Rules Part 15. Operation is subject to the following two conditions:

1. This devi ce may not cause harmful interference, and

2. This device must accept any interference received, including interference that may cause undesired operation.

This equipment has been tested and found to comply with the limits for a Class A digital device as set forth in Part 15 of the FCC Rules. These limits are designed to provide reasonable protection against harmful interference when the equipment is operated in a commercial environment. This equipment generates, uses and can radiate radio frequency energy and, if not installed and used in accordance with manufacturer’s instructions, may cause harmful interference to radio communications. Operation of this equipment in a residential area is likely to cause harmful interference in which case the user will be required to correct the interference at his or her own expense.

Users should be aware that changes or modifications to this equipment not expressly approved by the manufacturer could void the user’s authority to operate the equipment.

This equipment has been type tested and found to comply with the limits for a Computing Device per FCC part 15, using shielded cables. Shielded cables must be used in order to insure compliance with FCC regulations.

Recycling

By placing the above symbol on our products and accessories Universal Laser Systems is indicating that we are committed to helping reduce the amount of waste electronics ending up in municipal landfills. Therefore Universal Laser Systems urges consumers to recycle this product and its accessories. Universal Laser Systems is equipped to recycle any of its electronic products and accessories and will assist our customers with their recycling options. To arrange for recycling of your ULS product or accessory, please contact Universal Laser Systems for more information.

Section 1-11

Page 20

SAFETY

Section 1-12

Page 21

Part 1 - Initial Setup

Page 22

Page 23

Section 2

Installation

The following operational guidelines are vital to a safe and productive environment. It is your responsibility to provide a proper operating environment. This section will also give you step-by-step instructions for site preparation, and computer and software setup. Please follow the instructions in the order shown:

1. Establishing a Proper Operating Environment

2. Providing a S uitable Electrical Power Source

3. Extracting Fu mes and Particulates

4. Software Installation and Operating System Requirements (Sections 2 & 3)

5. Assembling the PLS (Section 4)

Damage to the laser system due to an inadequate or improper operating environment is considered abuse and

warranty. In no event will ULS be liable for any damages caused, in whole or in part, by customer, or for any economic loss, physical injury, lost revenue, lost profits, lost savings or other indirect, incidental, special or consequential damages incurred by any person, even if ULS has been advised of the possibility of such damages or claims.

WILL NOT be covered under

1. Establishing a Proper Operating Environment

Environment (user supplied)

• The laser system MUST be installed in an office-type or light duty manufacturing environment. Dusty or dirty air environments can damage the laser system. Keep the laser system isolated from any type of sandblasting, sanding, oily, or any other machinery that produces airborne particles.

• Avoid small, enclosed, non-ventilated areas. Some materials, after laser engraving or cutting, continue emitting fumes for several minutes after processing. Having these materials present in a confined, unventilated room can contaminate the room.

• For best results, since the lasers are air-cooled, we recommend operating the laser system between the ambient temperatures of 73ºF (22ºC) to 77ºF (25º C).

• Avoid storing the laser system outside the temperatures of 50ºF (10ºC) to 95ºF (35º C) as excessively cold or hot temperatures can damage the laser cartridge or reduce its lifetime.

• Ambient humidity levels must be non-condensing.

• A suitable working surface for all material processing.

2. Providing a Suitable Electrical Power Source

Electrical (user supplied)

• For your system’s electrical requirements, please refer to the “INPUT POWER” label near the ON/OFF switch and/or power inlet.

• NEVER REMOVE THE GROUND LEAD TO THE ELECTRICAL CORD AND PLUG THE SYSTEM INTO A NON-GROUNDED OUTLET. This is very

dangerous and can lead to a severe, if not fatal, electrical shock. Always plug the system into a properly grounded (earthed) outlet. Also, without proper grounding, the laser system may exhibit sporadic or unpredictable behavior.

• Noisy or unstable electricity as well as voltage spikes may cause interference and possible damage to the electronics of the laser system. If electrical power fluctuations, brown outs, or

Section 2-3

Page 24

INSTALLATION

constant power outages are a problem in your area, an electrical line stabilizer, UPS (Uninterruptible Power Supply), or backup generator might be required. You may also need to connect the laser system to a dedicated electrical line to resolve the problem.

• The laser system is designed as a Class I, Group A, pluggable device. It is also designed for connection to IT power systems which provides the most flexibility to the user.

3. Extracting Fumes and Particulates

Exhaust System (user supplied)

• The exhaust system MUST be capable of supplying a minimum of 250 CFM (cubic feet per minute) of airflow while under a load of 6 inches of static pressure (425m3/hr at 1.5kPa). DO NOT install forward incline, backward incline, in-line, or ventilator fans because these types of air handlers are inadequate and inappropriate for this type of installation. A high-pressure blower MUST be used to meet minimum airflow requirements.

• For personal safety and noise control reasons, we recommend that the blower be mounted OUTSIDE the building.

• Rigid tubing should be used for 90% of the distance traveled between the blower and the laser system. The tubing should be smooth walled and have as few 90 degree bends as po ssible.

• Install a gate to control airflow and to close off the exhaust from the outside environment when the laser is not in use. Place this gate within 5 – 10 feet from the laser system.

• Use a short piece of industrial grade, wire reinforced rubber tubing to connect the end of the gate to the laser system. This will provide mobility and will dampen blower vibrations.

• Have the blower electrically wired to a wall switch in the same room for easy ON/OFF control.

Note: The following diagram shows a typical exhaust system layout. Use this as a guideline to proper exhaust system installation. Although this diagram just serves as an example, we recommend installation of the exhaust system by a licensed contractor to meet safety and local code requirements as well as being able to calculate the correct size blower required for your particular installation. Length of exhaust pipe, exhaust pipe diameter, number of 90-degree angles, and other restrictions must be calculated when determining the correct exhaust blower unit. Installing an undersized or oversized blower is not only unsafe, but it can also lead to premature and excessive wear and tear to the laser system.

Section 2-4

Page 25

PLS3.60 and PLS4.60

INSTALLATION

(1) Exhaust blower mounted outside. (2) Weatherproof shield (3) Rigid ducting matching the diameter of the blower inlet (4) Shut-off or air-flow gate (5) Reducer to 4 inches (6) Flexible, wire-reinforced, industrial grade rubber hose (7) On/Off switch (8) Computer (user supplied)

PLS6.60 and PLS6.120D

5 6

(1) Exhaust blower mounted outside. (2) Weatherproof shield (3) Rigid ducting matching the diameter of the blower inlet (4) Reducer to 4 inches (5) Y-pipe (6) Shut-off or air-flow gate(s) (7) Flexible, wire-reinforced, industrial grade rubber hose (8) Connection to laser (9) On/Off switch (10) Computer (user supplied)

Section 2-5

Page 26

INSTALLATION

4. Software Installation and Operating System Requirements

Your computer is critical component in the operation of the PLS. In fact, you cannot operate the PLS if your computer is not connected, powered on, running Windows, and running the Universal Control Panel software (UCP).

Only ONE PLS per computer is allowed. You will need to purchase a separate computer for each PLS you own. Also, the PLS is NOT designed to be a network printer. YOU MUST operate the PLS using the computer that is directly attached to it via the PROVIDED, 6 foot, USB cable. USB cables longer than 6

feet may cause the PLS to malfunction.

A. Computer Requirements

Minimum PC Configuration (user supplied)

2.0 GHz processor Mouse and keyboard Windows XP Home, Professional Edition, or Windows Vista**. Macintosh computers not compatible with VersaLASER. 1 GB of RAM Computer speakers 40 GB hard drive (15 GB free space) 600 DPI scanner (optical) VGA monitor (minimum 1024 x 768 resolution) CD-ROM Drive/Burner

**The PLS machine is compatible with a 32 bit Windows Vista version. See www.microsoft.com for the minimum computer requirements to run Windows Vista.

NOTE: Some computer motherboard manufacturers USB ports DO NOT comply with USB 2.0 High Speed standards. This may cause erratic behavior from the PLS such as freezing and lock-ups.

Other USB peripheral devices that demand a large amount of computer processing power may slow down the operation and productivity of the PLS. We recommended not using these devices while operating the PLS.

NOTE: Laptop computers are known for having low powered USB ports. If using a laptop most likely you will need to use an external USB port hub, that has its own AC power adapter, and install it between the computer’s USB port and the PLS’s USB port.

Optimizing Windows XP Performance

Windows XP, by default, displays many “visual effects” that slow down the computer by utilizing RAM and processor time. We recommend that you turn OFF these effects by right-clicking on the My Computer icon on your desktop, then click Properties and then click the Advanced tab. In the Performance section, click Settings, then click Adjust For Best Performance, and then click Apply.

Computer Power Management

Power management is a configuration setting in Windows XP that reduces the energy consumption of computers and monitor by shutting them down after a period of inactivity. However, since your computer is a critical component in the operation of the PLS, you MUST NEVER allow your computer to go into the Standby or Hibernate mode.

Available USB 2.0 High Speed compliant port

Internet connection and email address (optional)

Section 2-6

Page 27

INSTALLATION

1. To properly configure Power Management in your Windows XP computer, right-click on your desktop.

2. From the list of options, select “Properties”. The “Display Properties” box will open.

3. In Displ ay Properties, select the Screen Saver tab. Set the Screen saver to “(None)”.

4. Then in the b ox “Monitor power”, Click the button “Power…”

5. Select the tab “Power Schemes”.

6. For the Power Scheme in use, select “Never” for all the setting options: Turn off monitor, Turn off hard disks, System standby, and System hibernates.

7. Click “Apply”, then “OK” on both open windows.

If you have further questions on how to configure or upgrade Windows XP, please contact

NOTE: Your chosen graphical software AND PLS software MUST be

installed and operational before operating the machine.

Microsoft Corporation.

Section 2-7

Page 28

INSTALLATION

B. Software Installation CD-ROM

At this point you need to install the Windows XP printer driver. In order to install the software you NEED to have administrative privileges on the user account that is currently logged on. The Software Installation CD-ROM can be found in a pocket on the inside of the back cover of this manual.

1. Insert the Software Installation CD-ROM into your PC’s CD drive. It should automatically open the “ULS Engraver Software Setup” window. Read the instructions and then click the “Install” button. a. If the window does not automatically

open, you can open it from Windows Explorer through your CD drive. Double-click on the file Setup.exe. The software will automatically begin to load.

2. The installation process will begin indicated by a progress bar. Be patient. Loading the files can take a few minutes depending on your processor speed.

3. You will be prompted to select your model. Select the laser engraver you are installing on the computer then click on “Ok”. The software will continue loading as indicated by a progress bar. a. If the incorrect model is selected you

will receive an error message later in the engraving process. Uninstall the printer driver and reinstall it by choosing the correct model.

4. When the installation process is finished the “Completing the ULS Engraver Software Setup Wizard” window will appear. Read the instructions and make your proper selection. If you Reboot Now save all your work prior to rebooting. Click on the “Finish” button to complete installation. The window will automatically close. Remove the Software Installation CD-ROM. All the files required to operate your machine have been loaded onto your computer.

Section 2-8

Page 29

INSTALLATION

C. Recommended Software Programs

ULS does not guarantee software compatibility with any off-the-shelf software program that has not been written by ULS. However, the following suggested programs are widely used by ULS customers and are considered to be the most functional and compatible programs to use with the laser system.

Vector Graphics Programs (user supplied)

• CorelDRAW 12 or X3**, Adobe Illustrator CS

•

Bitmap / Scanning Software (user supplied)

Corel PHOTO-PAINT or Adobe Photoshop

•

Raster to Vector Conversion Software (user supplied)

CorelTRACE

•

CAD Software (user supplied)

AutoCAD for Windows

•

FONTS (user supplied)

Use True Type fonts ONLY. Do not use PostScript or bitmapped fonts.

**Most users purchase the CorelDRAW 12 or CorelDRAW X3 Graphics Suite package which contains all the software necessary to operate the PLS to its fullest capability. Earlier versions of CorelDRAW have experienced problems with the XP operating system, which in turn, causes problems with the operation of the PLS. As a result ULS recommends CorelDRAW 12 over earlier versions. Whether you decide to use CorelDRAW12 or a different graphics software package, it is critical that you fully understand how to use the software in order to successfully operate the PLS. While ULS has made reasonable efforts to make the PLS as compatible as possible with graphics and CAD software written for the Windows XP operating systems, ULS cannot guarantee complete compatibility with any software not manufactured by ULS.

Once you have installed your preferred software according to the manufactures instructions you will need to configure your graphics software according to our instructions.

Proceed to section 3 to continue with the

software configuration.

Section 2-9

Page 30

INSTALLATION

Section 2-10

Page 31

Section 3

Graphics Software Setup

Choosing the right graphics software program to run the laser system is essential for maximum usage and control of the laser system. Not all software can be used to run the laser system because many have limitations. Because you may be using word processing software to output to your laser printer does not mean you should use it to output to your laser engraving system. Setting up your software correctly is essential to running the laser system properly.

The following examples assume that you are configuring the software for a PLS Series machine. If you have a different Platform machine, substitute the correct maximum page size. For example:

PLS3.60 = 24 x 12 inches (609.6 x 304.8 mm)

PLS6.60, PLS6.120D = 32 x 18 inches (812.8 x 457.2mm)

NOTE: We have provided specific instructions for setting up CorelDRAW 11/12/X3, AutoCAD 2000i/2002/2004, and Adobe Illustrator CS in order for these programs to work well with the laser system. You will find them at the end of this section.

General Software Setup

There are many software programs that you can purchase off-the-shelf that will work with the laser system. Some of them can access more features of the laser system than others may. Whichever program you choose, it must be set up to work with the laser system otherwise unexpected results may occur. Use the following GENERAL guidelines when configuring your software program.

Page Setup

To properly generate and position artwork, most graphics software will permit the customization of the page size and orientation. Set the page orientation, in the graphics software to Landscape, and the page size to match your maximum engraving area of your Platform. The driver’s orientation and page size MUST then be set to match these specifications EXACTLY; otherwise the artwork may not print correctly. When setting page orientation and driver orientation to Landscape mode, the laser system will operate in the horizontal direction, left to right. If page orientation and driver orientation is set to Portrait mode, the laser system will operate in the vertical direction, front to back. The laser system is designed to operate best in the Landscape mode and this orientation is highly recommended. The page size may also be reduced to match the size of the engraving material, but remember to adjust the page size in the driver’s to correspond to the graphics software’s page size. Note that in production situations it is often more efficient to leave the page size at its maximum page size and engrave or cut more than one object at a time. This is accomplished by duplicating the image on screen as many times as necessary to fill up the entire page.

Ruler Setup

Usually the graphics software will provide on-screen rulers, which can be configured to match the rulers in the laser system. Using rulers in the software and matching them with the ones provided in the laser system gives the ability to correctly align the graphic on the screen with the material in the laser system. For now, consider that the laser system’s origin is fixed in the upper left corner of the engraving area and cannot be altered. Later on you will learn how to relocate the origin. But for right now, change the ruler position on screen to match the laser system with the origin (0,0) in the upper left corner. It is also possible to use a page size smaller than the maximum engraving area. For example, if you desire an 8inch (203.2 mm) x 10-inch (254 mm) page size, set this page size in the graphics software as well as in the printer driver. The laser system will automatically move the engraving area to the origin so place the object all the way up into the left-hand corner against the rulers in the laser system.

Page 32

GRAPHICS SOFTWARE SETUP

Power Control through Color Selection

The laser system allows the use of 8 different colors to access 8 different power settings when cutting and engraving. The printer driver controls this feature. When using this power change feature with driver, the colors that are used MUST exactly match the colors listed in the driver. The colors are black, red, green, yellow, blue, magenta, cyan, and orange. Some programs will provide these basic colors predefined and other programs may require the creation of each of the colors by defining them in RGB. If you are using CorelDRAW we have made our own custom palette and placed the file on the Software Installation CD-ROM. Please refer to the software setup instructions for your specific version of CorelDRAW. If you are using other graphics software and need to mix your own colors, use the chart below to create them.

RED (R) GREEN (G) BLUE (B)

BLACK 0 0 0

RED 255 0 0

GREEN 0 255 0

YELLOW 255 255 0

BLUE 0 0 255

COLORS

MAGENTA 255 0 255

CYAN 0 255 255

ORANGE 255 102 0

If using a color other than the exact colors listed above, the driver will attempt to match it to a color in the driver that it most closely resembles. The driver will then use that color’s power setting and apply a halftone pattern to represent the original color’s shade. For example, if using a color like pink to fill a rectangle, the driver takes a reading of the percentage of different colors used to create that color and will use the power setting assigned to one of the eight colors of the driver that it most closely resembles. It might be expected that the driver will use the power setting assigned to the color red but instead the driver may choose the magenta setting and halftone the rectangle as a representation of the pink color’s lighter shade. To prevent the incorrect assignment of laser power, be sure to use the correct colors. If using graphics with colors other than the eight listed above or to simplify the assignment of power settings, try using the Clipart Mode feature in the driver. This feature will cause the system to only use the power setting assigned to the color black and halftone all of the other colors.

Outlines and Fills

The driver distinguishes between raster mode (engraving) and vector mode (cutting) by the type of graphic artwork being used. Basically, all graphics other than outlines of very thin line widths will be interpreted as engraved images and the raster mode will be used for output. If laser cutting is desired, set the line thickness of the lines that are drawn in the graphics software to .001 inches (.025 mm) or the smallest possible line thickness that is available. The printer driver will interpret these objects as vectors and will cut them out providing that your software has the capability of vector output. Basically, all software programs have the ability to provide raster output. However, not all programs have the ability to provide vector output even if you set the line width to the smallest thickness possible. Check with Section 2-9 of this manual for software that can vector output. The use of color fills or bitmaps will cause the laser system to engrave. The combination of engraving and cutting is available in most graphics software. We suggest that when combining engraving and cutting objects, use different colors for the fills and outlines since engraving requires different power settings than cutting objects. One thing to keep in mind when creating cutting objects is that if the outline thickness is set too thick, the driver might interpret the outline as a filled object and will engrave the outline instead of cutting. This might be desirable if engraving thick outlines is necessary. The outline thickness at which the driver will interpret cut lines as filled objects is dependent on the software used. Usually, any line thickness .008 inches (.2 mm) or greater will engrave. The only way to determine the cross over point for line thickness is to experiment with different line widths. Software programs that do not have outline capabilities definitely will not have the ability to cut.

Image Processing Order

When cutting or engraving a graphic image, the laser system will perform all engraving first, and then proceed to vector cutting. Raster engraving will proceed in the exact order of the colors listed in the driver. For example, all black filled objects will engrave first, then all red filled objects, then all green filled objects and so on. When all engraved objects have been completed, the laser system will proceed to

Section 3-2

Page 33

GRAPHICS SOFTWARE SETUP

vector cut any outlines present in the artwork. Vector output order is dependent on your operating system, printer driver version, and your software. Refer to the printer driver controls for more details.

Overlapping Fills

If the artwork created has overlapping filled areas, the driver will automatically filter these fills to prevent the overlapped area from being engraved twice. This is similar to color separation in the printing industry. The entire filled area of the object on top will be engraved and only the visible part of the underlying filled area will be engraved. The final result is a what-you-see-is-what-you-get output. In this way the color white can be used as an effective drawing tool. Since the laser system will not engrave the color white (this is the background color), it can be used to block out the undesired engraving areas of filled regions and/or bitmaps. However, you cannot use a white fill to cover an outline, the outline will vector cut even though you cannot see it on screen.

Overlapping Outlines

The driver does not filter outlines that overlap each other. If placing one outline one on top of another, both outlines will be cut by the laser system. This is a useful feature that will allow deeper cutting by passing the laser over a single outline path twice or more. To take advantage of this feature, duplicate the outline on top of itself.

Hidden Vector Lines in Artwork

The driver does not automatically filter out outlines that are overlapped by engraved objects such as fills. If there are filled objects with some hidden outlines underneath, the laser system will then engrave out the fill and cut the hidden outline on top of the fill. This is a common occurrence when using pre-drawn clipart designed for laser printers. To prevent this from happening, turn on the Clipart Mode feature in the driver. This feature disables the cutting mode and converts all visible outlines to engraved objects and ignores all hidden outlines.

Speed Optimizing

It is advantageous to engrave an object in its longest direction because total engraving time will be reduced when the motion system has to make fewer stops and starts. If the engraving object is longer than it is tall, rotating the graphic 90 degrees and placing the material in the laser system sideways can achieve a greater engraving speed. Be aware that some graphics programs do not allow the rotation of bitmaps. In this case, it may be necessary to use a bitmap image processing software to first rotate the bitmap before importing the bitmap into the graphics program. If the artwork contains engraved objects of the same color with a great deal of space between them in the engraving direction, processing time can be longer since the laser must make long strokes to engrave both objects at the same time. To reduce engraving time in cases like these, use different colors for each of the objects but assign the same power setting to both colors. This will cause the laser to engrave one object at a time, skipping over all blank space, which in many cases will reduce engraving time. On the other hand, if the objects are relatively close together in the engraving direction, then leave them the same color because it will be quicker to engrave them both at the same time. Experiment with these techniques to optimize the speed of engraving.

Bitmapped / Scanned Images

There are primarily three types of bitmaps available. They are monochrome (black and white), grayscale, and color. Bitmaps are patterns of dots (pixels) blended to form pictures. Scanning artwork into a computer through a scanner creates most bitmaps. Drawing them in a bitmap image-processing program creates others.

The laser system can print all three types of bitmaps providing that either the driver or the bitmap imageprocessing program converts the grayscale and/or color bitmaps into a monochrome bitmap. Essentially, the laser system is a monochromatic printer, either it fires the beam to burn a dot or it does not fire the beam to leave an empty dot on the material.

There are several different bitmap storage formats available: TIF, JPG, BMP, PCX, and others. The format makes no difference to the laser system. The difference in formats involves how they are stored on your computer’s hard disk. Bitmaps cannot be edited in most graphics software. Some basic functions such as cropping, scaling, or mirroring might be possible but it is usually necessary to use a bitmap image processing software to perform a dot by dot editing, rotation, or scaling of the bitmap.

Section 3-3

Page 34

GRAPHICS SOFTWARE SETUP

Monochrome Bitmaps

If you scan the image in monochrome (black and white) mode, set your scanner to at least 600 DPI. The higher the DPI, the smoother the image will be. Scanning monochrome images at 300 DPI is the minimum recommended resolution but scanning them at 600 DPI will provide a significant improvement in the image quality. Clean it up in your bitmap image-processing program and save it to your hard disk. You can now either print the image directly from your bitmap image processing program, or import the bitmap into a graphics program and print it from there. Monochrome bitmaps are engraved in the same manner as black filled text. The black area will turn the laser on and the white area turns the laser off.

Grayscale Bitmaps

When scanning an image in grayscale mode, you should scan the image at no more than 300 DPI. Scanning at a higher DPI does not improve image quality but it consumes more memory and will take longer to print. Grayscale images cannot be printed directly to the laser system. Since the laser system actually works like a black and white printer, grayscale images must be converted into black and white images. To do this, either the driver will do it automatically or you can convert the grayscale image to a black and white image in your bitmap image-processing program.

The two, primary grayscale image conversion techniques are Halftone or Error Diffusion. The printer driver can print either one and it is selected in the driver under the Raster sub-tab. Please refer to the section on the printer driver for more details on how to set these parameters. Since the driver has a fixed method of conversion, you may want to experiment by using your bitmap image-processing program to make the conversion. These software programs usually have more options for controlling the size, angle, shape, and the amount of black and white dots (pixels) created when converting the image. Experiment with all of the controls to see which looks the best. Big dots look good on some materials and small dots look better on others. Once the image is converted by your program, save and print it directly from that program or import it into your graphics program and print it from there. Essentially, a Halftone image and an Error Diffusion image are actually both monochrome images and can be treated as such. If you decide not convert the grayscale image to a monochrome image in your bitmap image editing program, then the driver will do it automatically and will use settings based on the Resolution settings in the driver.

Color Bitmaps

The printer driver handles color bitmaps the same as grayscale bitmaps. Since color bitmaps use more memory, they are unnecessary and are therefore NOT recommended, however, you can still use them.

Encapsulated Postscript (EPS) Images

Bitmap images cannot be cut by the laser system only engraved. The only way to have the laser system cut out or vector a bitmap is to first convert it to a vector file format such as an EPS. Raster to vector conversion programs are available that trace the bitmap (this only works well with monochrome bitmaps) and creates a separate EPS vector file. These EPS files can then be imported into the graphics program and printed out from there. Since tracing programs have many adjustments, some practice with them is necessary to produce desirable results.

The laser system does not support Encapsulated PostScript (EPS) printing directly. EPS files can only be edited and printed if they are first imported into a graphics program. However, since EPS files support engraving and cutting objects, they are therefore useful for transferring artwork from one graphics program to another. Once an EPS file has been imported into a graphics program, the objects can be outlined, stretched, rotated, mirrored, filled with different colors, or anything else desired just as long as your graphics software can edit EPS images. Be careful when using EPS files in layout software as opposed to true graphics software. Layout software may allow the placement of EPS files in the artwork but may not actually import and convert the EPS file to a useful format for the printer driver and therefore may not print correctly. Please refer to your graphics software’s documentation on whether or not it can edit and print EPS images to a non-Postscript printer.

Section 3-4

Page 35

GRAPHICS SOFTWARE SETUP

Postscript (PS) Images

The laser system is NOT a postscript device. This means that postscript fills, postscript textures, and especially POSTSCRIPT FONTS WILL NOT be able to print to the laser system. Sometimes using Adobe Type Manager (ATM) will allow some postscript fonts to print correctly but most of the time it does not work properly.

Helpful Tip

If you are having any problems printing a font and you cannot figure out what is going on, select the font and “convert to curves” or “convert to paths” in your graphics software. This will convert the font into a bitmapped image and will print correctly to the laser system. Refer to your graphics software on how to convert fonts. However, postscript textures and postscript fills cannot be converted and will not print to the laser system.

Specific Software Setup

Some graphics software programs require a special setup procedure in order for the software to function correctly with the ULS printer driver. In the following pages you will find setup instructions for the most popular software programs that our customers use. If you are having trouble with other software programs not included in this document, you may want to switch to one of them. As a reminder, ULS provides no warranties whatsoever on any software used in connection with a ULS Laser Engraving System, express or implied. Neither does it guarantee software compatibility with any off-the-shelf software package or any software program that has not been written by ULS.

Section 3-5

Page 36

GRAPHICS SOFTWARE SETUP

CorelDRAW 11

Windows XP

Note: CorelDRAW 11 is not compatible with Windows Vista. Therefore, we have only included setup instructions for Windows XP.

1. Make sure that you have installed all Service Releases and software patches from Microsoft. For Windows XP, install Service Pack 2. If you are reading this document from the Software Installation CD-ROM, as a service to you, you can find the file on this CD. For the latest releases, check Microsoft’s website, www.microsoft.com. Please contact Microsoft if you have any questions regarding these upgrades. ULS is not responsible for any problems as a result from the usage of these patches.

2. If you have not already done so, install CorelDraw on your computer, but do not open it yet.

3. It is important that your version of CorelDraw is updated with the latest patches and service releases. For the latest patches and updates go to CorelDraw’s website, www.corel.com. Be sure to check for any updates from time to time to keep your version up to speed. Please contact CorelDraw if you have any questions regarding these upgrades. ULS is not responsible for any problems as a result from the usage of these patches.

4. The ULS Windows Printer Driver must be loaded before continuing. Please refer to Section 2-8 on the manual on how to install the driver. If you have already installed the printer driver, you will need to re-insert the Software Installation CD-ROM back into your CD drive at this time.

5. Using Windows Explorer, locate the file named “ULS.CPL” and “ULS.PAL” on the Software Installation CD-ROM, and copy this file over to the C:\Program Files\Corel\Corel Graphics 11\Custom Data\Palettes folder. Note: ULS.CPL may not show up with a .CPL file extension. It may be listed as ULS with “Control panel extension” shown as a detail.

6. While still in Explorer, locate a file named “corelapp.ini” located in the C:\Program Files\Corel\Graphics11\Config folder. Double-click on the file it will open up in Notepad. Scroll down past the semi-colons to the [Config] header. Then scroll down about 30 lines to the line that reads “Fontrasterizer=1”. Change the 1 to a 0 (this is a zero, not an o). Save this file and then close Notepad.

7. Open CorelDraw and start a new graphic.

8. In the main menu at the top of the screen, click on “Window”, then “Color Palettes”, and then click on “None”. Once again click on “Window”, then “Color Palettes”, and then click on “Open Palette”. After the palette pop-up box appears, from the “Files of type” dropdown list, choose either “Custom Palette (*.cpl)” or “Process Palette (*.pal), then double-click on the ULS palette. The color palette will now appear on the right side of the screen. Directly above the Black-colored square there is a box, click on this box and then click "Set as Default".

9. On the property bar, click on the landscape orientation (the sideways rectangle). If you would like the drawing units in metric, choose millimeters from the drop down list. Now type in the page width and height that matches your laser platform.

10. We now need to adjust the vertical ruler, on the left side of the screen, to match the rulers in the laser system. To do this, we need to adjust the ruler's vertical origin. Double-click directly on the vertical (side) ruler. The “Options” dialog box will appear. In the vertical origin box, type in the same height value as you did when you set up the page height in the previous step. For example, 12 inches for a PLS3.60 machine. If you would like the scale to be displayed in tenths, choose “10 per Tick” in the “Tick Division” drop-down list box.

11. While still in the “Options” dialog box, double-click on “Global” to expand the list. Then double-click on “Printing” to expand the list. Make sure that the laser system's name is displayed in the printer dropdown list. In the settings specific for this driver dialog box, make sure that ALL the check boxes are UNCHECKED. Now click on “OK” to close the “Options” dialog box.

12. The next step is to set the default value for the line width and color when drawing graphic objects. To do this, click on the outline tool, then the outline pen dialog in the flyout. With “Graphic” being the only one selected, click “OK”. Click the down arrow in the Color dropdown box to expand the list and click on the color red. Click the down arrow in the “Width” dropdown box to expand the list and click “Hairline”. The units can be “Inches”, “millimeters” or anything else you prefer. Click “OK to close the Outline Pen dialog box.

13. In the top menu, click “Tools, then click “Color Management”. Click on the down arrow to expand the “Style” dropdown list. Click “Color Management Off”, and then click “OK”.

Section 3-6

Page 37

GRAPHICS SOFTWARE SETUP

14. Finally, at the top of the screen, click on “Tools”, then “Options”, then “Document”, and then select “Save Options as Defaults for New Documents”. Make sure ALL the options listed are CHECKED then click “OK”.

15. The setup defaults for CorelDRAW 11 are now complete. Whenever you start a new document, all of the default settings that we had setup will automatically apply to the new document.

Next proceed to section 4 for laser system

assembly.

Section 3-7

Page 38

GRAPHICS SOFTWARE SETUP

CorelDRAW 12

Windows XP

Note: CorelDRAW 12 was optimized for Windows XP and is not compatible with Windows Vista. We also suggest not running it under Windows 95/98. Therefore, we have only included setup instructions for Windows XP.

2. If you have not already done so, install CorelDraw on your computer, but do not open it yet.

5. Using Windows Explorer, locate the file named “ULS.CPL” and “ULS.PAL” on the Software Installation CD-ROM, and copy this file over to the 12\Languages\EN\Custom Data\Palettes folder. Note: ULS.CPL may not show up with a .CPL file extension. It may be listed as ULS with “Control panel extension” shown as a detail.

6. While still in Explorer, locate a file named “corelapp.ini” located in the C:\Program Files\Corel\Graphics12\Config folder. Double-click on the file it will open up in Notepad. Scroll down past the semicolons to the [Config] header. Then scroll down about 31 lines to the line that reads “Fontrasterizer=1”. Change the 1 to a 0 (this is a zero, not an o), save the file, and exit Notepad.

7. Open CorelDRAW 12 and start a new graphic.

8. In the menu bar, click on “Window”, then “Color Palettes”, and then click “None”. Once again click “Window”, then “Color Palettes”, and then “Open Palette”. In the pop-up box, double-click on "ULS.CPL" which allows it to appear on the right side of the screen.

9. On the property bar, click on the landscape orientation (the sideways rectangle) (1). Now type in the page width and height that matches your laser platform (3). If you wish you can change the units from inches to millimeters (2).

Section 3-8

C:\Program Files\Corel\Corel Graphics

Page 39

GRAPHICS SOFTWARE SETUP

10. The rulers on screen need to match the rulers in the PLS. Adjust the ruler's vertical origin by double-clicking directly on the vertical (side) ruler. The “Options” dialog box will appear. In the vertical origin box, type in the length of the vertical ruler of your PLS. In this example the vertical ruler is 12 inches. Click OK.

11. Set the default value for line width and color of the graphic objects, by clicking the outline tool (1) and then the outline pen dialog in the flyout (2). With “Graphic” being the only selection checked, click “OK”. Click the down arrow in the Color dropdown box to expand the list and click on the color RED. Click the down arrow in the “Width” dropdown box and click “Hairline”. The units can be “inches”, “millimeters” or anything else you prefer. Click OK to close the Outline Pen dialog box.

12. In the top menu, click “Tools”, and then click “Color Management”. Click on the down arrow to expand the “Style” dropdown list. Click “Color Management Off”, and then click “OK”.

13. Finally, at the top of the screen, click on “Tools”, then “Options”, then “Document”, and then select “Save Options as Defaults for New Documents”. Make sure ALL the options listed are CHECKED then click “OK”.

14. The setup defaults for CorelDRAW 12 are now complete. Whenever you start a new document, all of the default settings that we had setup will automatically apply to the new document.

Remove the Software Installation CD-ROM from your CD-ROM drive and store it either back into the pocket of the rear cover of the manual or in a safe place.

Next proceed to section 4 for laser system

assembly.

Section 3-9

Page 40

GRAPHICS SOFTWARE SETUP

CorelDRAW X3

Windows XP and Windows Vista

Note: CorelDRAW X3 was optimized for Windows XP and is compatible with Windows Vista. We also suggest not running it under Windows 95/98. Therefore, we have only included setup instructions for Windows XP and Windows Vista.

2. If you have not already done so, install CorelDraw on your computer, but do not open it yet.

5. Using Windows Explorer, locate the file named “ULS.CPL” and “ULS.PAL” on the Software Installation CD-ROM, and copy these files over to the C:\Program Files\Corel\Corel Graphics SUITE X3 (13)\Languages\EN\Custom Data\Palettes folder. Note: ULS.CPL may not show up with a

.CPL file extension. It may be listed as ULS with “Control panel extension” shown as a detail.

6. Open CorelDraw and start a new graphic.

7. In the main menu at the top of the screen, click on “Window”, then “Color Palettes”, and then click on “None”. Once again click on “Window”, then “Color Palettes”, and then click on “Open Palette”. After the “Open Palette” pop-up box appears, double-click on "ULS.CPL". The color palette will now appear on the right side of the screen.

8. On the property bar, click on the landscape orientation (the sideways rectangle) (1). If you would like the drawing units in metric, choose millimeters from the drop down list (2). Now type in the page width and height that matches your laser platform (3).

9. We now need to adjust the vertical ruler, on the left side of the screen, to match the rulers in the laser system. To do this, we need to adjust the ruler's vertical origin. Double-click directly on the vertical (side) ruler. The “Options” dialog box will appear. In the vertical origin box, type in the same height value as you did when you set up the page height in the previous step. For example, 12 inches for a PLS3.60. If you would like the scale to be displayed in tenths, choose “10 per Tick” in the “Tick Division” drop-down list box.

Section 3-10

Page 41

GRAPHICS SOFTWARE SETUP

10. While still in the “Options” dialog box, double-click on “Global” to expand the list. Double-click on “Printing” to expand the list. Now click on “Driver Compatibility”. Make sure that the laser system's name is displayed in the printer drop-down list. In the settings specific for this driver dialog box, make sure that ALL the check boxes are UNCHECKED. Now click on “OK” to close the “Options” dialog box.

11. The next step is to set the default value for the line width and color when drawing graphic objects. To do this, click on the outline tool (1), then the outline pen dialog in the flyout (2). With “Graphic” being the only one selected, click “OK”. Click the down arrow in the Color dropdown box to expand the list and click on the color red. Click the down arrow in the “Width” dropdown box to expand the list and click “Hairline”. The units can be “Inches”, “millimeters” or anything else you prefer. Click OK to close the Outline Pen dialog box.

12. In the top menu, click “Tools”, and then click “Color Management”. Click on the down arrow to expand the “Settings” dropdown list. Click “Color Management Off”, and then click “OK”.

13. Finally, at the top of the screen, click on “Tools”, then “Save settings as Defaults”.

14. The setup defaults for CorelDRAW X3 are now complete. Whenever you start a new document, all of the default settings that we had setup will automatically apply to the new document.

Remove the Software Installation CD-ROM from your CD-ROM drive and store it either back into the pocket of the rear cover of the manual or in a safe place.

Next proceed to section 4 for laser system

assembly.

Section 3-11

Page 42

GRAPHICS SOFTWARE SETUP

AutoCAD 2000i, 2002 and 2004 for Windows XP

NOTE: AutoCAD version 2000 is not compatible with ULS laser systems. You must upgrade to version 2000i or higher. Also, we recommend installing ULS printer driver version 2.17.29 or higher.

Make sure the ULS Printer driver is installed prior to setting up AutoCAD.

2. If AutoCAD is already installed and you are just upgrading ULS printer drivers:

• Close all open programs.

• In Windows, Click Start>Printers & Faxes.

• Delete ALL ULS drivers from the Printers (Printers and Faxes) folder.

• With the Printers and Faxes folder still open, click File>Server Properties>Drivers and remove

ALL ULS printer drivers from the list. Close Printers & Faxes.

• Using Windows Explorer, search for all files and folders with a .pc3 extension then delete all ULS

Printer pc3 files (i.e. PLS360.pc3).

• Next, search for files with a .pmp extension and delete all ULS Printer .pmp files (i.e.

PLS360.pmp).

• Reboot the PC.

3. Start AutoCAD and open a new drawing.

4. Click File>Plotter Manager, and double-click Add a Plotter Wizard. If the Autodesk Hardcopy System

window appears, select the version of AutoCAD you are using, and then click Continue.

5. Click Next. Select System Printer, and then click Next.

6. Select the appropriate ULS Printer Driver, and then click Next.

7. DO NOT click the Import file button, simply click Next.

8. You may edit the plotter name, if desired, and then click Next.

9. Click on Modify Standard Paper Sizes (Printable Area) in the Device and Document Settings Tab

window, and then click the Modify button. Change ALL margins to 0.00, and then click Next.

10. Edit the PMP file name if you desire then click Next. DO NOT click the Print a Test Page button, click

Finish. Click OK to exit the Plotter Configuration Editor window and then click Finish.

11. Click File>Page Setup, and then select the Plotter Configuration name, pc3 name (not the driver)

from the dropdown list.

12. If you would like to change the drivers settings, click the Properties button, then click the Custom

Properties button. Make your changes and then click OK and then OK again.

13. Click New to create a new Plot Style table to set your pen widths. As a default, the ULS print driver

produces vector output when pen widths are set to 0.001 inches (0.025 mm). If the pen widths are set between 0.002 – 0.008 inches (0.050 – 0.20 mm), then the ULS print driver may or may not convert the lines to raster images – this will depend on the image being plotted. Therefore it is recommended that for colors requiring vector output, set the pen widths to 0.001 inches (0.025 mm), and for colors requiring raster output, set pen widths greater than 0.008 inches (0.20 mm). So now, select Start from scratch, and then click Next. Enter a name and then click Next. Click the Plot Style Table Editor button. Click Color 1, hold the shift key on your keyboard and click colors 2 through 7. You can only use colors 1 through 7 with the ULS printer driver. With all 7 colors highlighted, click the Edit Lineweights button and then select the units desired. Add a lineweight of 0.001 inches (0.025 mm) to the Value column by clicking on Edit Lineweight and entering 0.001 (or 0.025 for metric settings). Click OK, click Save & Close, and then click Finish.

14. Click the Layout Settings tab and set the Plot Scale to 1:1.

15. AutoCAD is now set up properly to work with the ULS printer driver.

Next proceed to section 4 for laser system

assembly.

Section 3-12

Page 43

GRAPHICS SOFTWARE SETUP

Adobe Illustrator CS for Windows XP

Adobe Illustrator CS, in combination with the new ULS printer driver version 2.17.29 or later, is now capable of both raster and vector output as well as full-field engraving capability. The following procedure assumes that you are familiar with the use and operation of Windows XP, and Adobe Illustrator CS.

Procedure

1. Close all Windows programs.

2. Upgrade to Adobe Illustrator CS but do not launch it yet.

3. Upgrade to ULS printer driver version 2.8.4 or later.

4. Set your Windows default printer to the ULS printer driver.

5. Launch Adobe Illustrator CS and start a new graphic.

6. You will now need to set the Page Setup, in Adobe, to the largest square page that is equal to the

width of your laser systems field. For example, if your laser system has a 24 x 12 inch field, then set the page setup in Adobe to 24 x 24 inch Portrait mode (not Landscape). If you laser system has a 32 x 18 inch field, set the page setup in Adobe to 32 x 32 Portrait.

7. Now, place your graphics ONLY within the top portion of your page in Adobe. Don’t use the

bottom portion that extends below the physical size of the engraving area of your machine. Since your laser system truly doesn’t have a usable area as big as the page size you created, the only way to make Adobe work is to trick it into thinking it is outputting to a larger, square-fielded, device.

8. If you would like vector output, in Adobe, set your stroke weight to either .001 inches or .1 points.

You will have to type in this setting because it is not available from the dropdown list.

Next proceed to section 4 for laser system

assembly.

Section 3-13

Page 44

GRAPHICS SOFTWARE SETUP

Section 3-14

Page 45

Section 4

Assembling the PLS

Depending on what model PLS you have purchased assembly of your laser system maybe required. Once the system has been assembled it is necessary to install the laser tube on the back of the machine and perform a beam alignment check. DO NOT power up your laser system until the final step, “Checking Beam Alignment”.

CARE SHOULD BE TAKEN WHEN MOVING OR LIFTING THIS DEVICE. Obtain assistance from 3 or 4 additional people when

lifting or carrying (secure motion system and doors). Severe bodily injury may occur if improper lifting techniques are applied or the system is dropped.

System Assembly - PLS3.60 and PLS4.60

Cart

(1) Back panel (2) Legs (both are identical) (3) Side Panels (2) (4) Shelf Panel (5) 1/4-20 x ½, socket head screws with lock and flat washers (6) Nuts (4) (7) Non-locking casters (8) Locking casters (9) 10-32 x 3/8 socket head screws with lock and flat washers (10) Connect to main enclosure

Page 46

ASSEMBLING THE PLS

1. Unpack the laser system from its packaging.

2. Remove the unassembled cart from the top of the laser system.

3. Assemble the cart as it appears in the diagram on the previous page but leave all of the screws slightly loose except for the casters, which should be tightened as far as it can go into the cart leg.

4. With the assistance of three or four other people, place the system on top of cart and secure with the screws provided.

5. Open front door all the way to ensure that it does not come in contact with the cart legs. If it does, gently spread the legs apart. Securely tighten all the screws and re-check.

6. Attach your exhaust system’s flexible rubber hose to the exhaust port at the rear of the laser system and secure with a hose clamp.

7. Locate the laser system in its final resting location.

8. Place a bubble level across the rear legs (1). Adjust the caster height using the adjustment screw (2) until both the rear part and the front part of the legs are level with respect to each other. Once the system is level, secure all casters by tightening the nut (3) up against the cart leg.

9. Open the top door and remove the rubber band that is holding the arm in place.

10. Remove any remaining packing materials, accessories or any other items that may be located inside the cabinet or on top of the engraving table.

POWER

PPIPPI COLOR

COLOR

SPEED

Section 4-2

Page 47

Laser Cartridge Installation

ASSEMBLING THE PLS

1. Make sure that your power cord IS NOT plugged in at this time. Press on the backside of the two hinges to release the latch. Gently fold back the rear cover.

3. Observe the “V” groove along the upper (3) and lower (2) part of the laser cartridge and the alignment plate (1) at the end.

2. Visually locate the two mounting blocks (1), the laser latch (2), alignment fork (3), and power connector (7). Notice that the alignment fork has two plates, one small (4) and one large (5). Locate the gap between the two plates (6).

4. Pick up the laser cartridge by the sides and tilt it downward on a 30-degree angle. Mount the cartridge onto the mounting blocks by placing the upper “V” groove on top of the mounting blocks. Slide the cartridge to the right until the OUTER EDGE of the alignment plate contacts the INSIDE EDGE of the large plate of the alignment fork.

Section 4-3

Page 48

ASSEMBLING THE PLS

5. Slowly rotate the laser cartridge making sure that the alignment plate is centered in the gap of the alignment fork between the small and large plates. As you slowly release the weight of the laser, you should feel it lock (clunk sound) itself smoothly into place, parallel to the mounting surface. NEVER FORCE THE LASER INTO POSITION. If the laser does not install smoothly, check for obstructions such as pinched wires or hoses or a binding laser latch. Once installed, verify that the alignment plate is centered within the alignment fork.

6. Plug in the power connector (1). Slowly close the rear cover and making sure that

wires or hoses do not become pinched when the cover is closed . Push down on

the latches until they “click”.

Proceed to Section 4-8 once the laser tube has been installed.

System Assembly - PLS6.60 and PLS6.120D

Unpack the laser system from its packaging. If the doorway is not wide enough to allow to you roll the laser system through it, the system MUST be

detached from the cart stand, rotated sideways, passed through the doorway, then re-attached to the cart stand (Section 4-5).

If your doorway is wide enough, you can skip the following procedure and proceed to “Leveling the System” (Section 4-6). It would help if you had a PADDED floor dolly to transport the machine through the doorway. If one is not available, it will need to be carried through the doorway.

The laser system without the cart stand weighs approximately 200 lbs. Obtain assistance from as many people as possible (3 or 4 people). Always use a back-support device when lifting. Do not attempt lifting the machine if you are physically handicapped or are injured in any way. Seek the advice of a physician if you are unsure.

Section 4-4

Page 49

ASSEMBLING THE PLS

Detaching laser system from cart

1. Make sure unit is unplugged from an

electrical outlet.

2. At the back of the system, locate the four screws; remove them and the cover plate.

4. Open the rear cover by pressing down on the button part of the latches until the latches pop up.

5. Fold the rear cover down to a resting position.

3. Locate the three white connectors and the two black connectors. Unplug all five connectors. They are held in place by latches so you will squeeze on the sides in order to release the latches to pull the connectors off.

6. Locate the cavity (1) where the cables reside. Gently pull the cables upwards and rest them on top as the diagram indicates.

7. Close and re-latch the rear cover.

8. Remove any packing materials or

accessories from inside the laser syste m .

9. Using strong shipping tape or rope, tape the front door closed so that it does not open up when you tilt it.

Section 4-5

Page 50

ASSEMBLING THE PLS

10. Remove the eight (8) screws, flat washers, and lock washers that attach the cart stand to the laser system from the bottom.

11. Lift the laser system straight up, clearing the cart stand.

12. Place the laser system face down on the dolly and roll it through the doorway. If you do not have a dolly, you will need to carry it through.

13. After you get the laser system and the cart stand through the door, carefully line up the laser system and place it back on top of the cart stand. Be careful not to pinch your

fingers.

14. Attach your screws, flat washers, and lock

washers. Gently push the cables back into the cavity, re-connect the five connectors, reattach the cover plate, close the rear cover, and push down on the latches until they “click”.

Leveling the System

Move the laser system to the desired operating location. If the floor underneath the laser system, at this location, is uneven, the casters must be adjusted.

Uneven flooring can cause mechanical problems with the operation of the motion system, which can seriously affect engraving or cutting quality.

1. Place a bubble level across the back (1) legs. Adjust the caster height using the adjustment screw (2) until the rear parts are level with respect to each other. Once the system is level, secure all casters by tightening the nut (3) up against the cart leg.

2. Open the top door and remove the rubber band that is holding the arm in place.

3. If you haven’t already done so, remove any remaining packing materials, accessories or any other items that may be located inside the cabinet or on top of the engraving table.

4. Gain access to the rear of the laser system to install the laser cartridge(s).

Section 4-6

Page 51

ASSEMBLING THE PLS

Laser Cartridge Installation

Note: The following images illustrate a PLS6.120D laser system. If you have purchased a PLS6.60 laser system ignore the mention of the two laser system setup and install the single laser tube.

Before connecting and powering on your system, you must install the laser cartridges.

1. Make sure that your power cord IS NOT plugged in at this time. Press on the backside of the two hinges to release the latch. Gently fold back the rear cover.

2. Locate the laser mounting blocks (1), the laser latches (2), and alignment forks (3). Notice that the alignment forks have two plates, one small and one large. Locate the gap between the two plates. Observe the “V” groove (4) along the upper and lower part of the laser cartridge and the alignment plate (5) at the end.

3. If you have purchased two lasers, mount the first cartridge onto the LOWER mounting blocks first. Single laser users should mount the laser in the top position. Tilt the laser cartridge downward on a 30-degree angle. Place the upper “V” groove (4) of the cartridge on top of the mounting blocks (1). Slide the cartridge to the right until the alignment plate (5) of the laser cartridge makes contact with the inside of the large plate of the alignment fork (3). Slowly rotate the laser cartridge making sure that the alignment plate (5) is centered in the fork. As you slowly release the weight of the laser, you should feel it lock (clunk sound) itself smoothly into place, parallel to the mounting surface. NEVER FORCE THE LASER INTO POSITION. If the laser does not install smoothly, check for obstructions such as pinched wires or hoses or a binding laser latch. Mount the second laser on the top mounts in the same manner as the bottom. Once installed, re-verify that the alignment plates (5) are centered within the alignment forks (3).

Section 4-7

Page 52

ASSEMBLING THE PLS

The power connectors are labeled “Top” (6) and “Bottom” (7). It is very important that you plug in the correct connector into the appropriate laser; otherwise the laser system will not function properly. The power connectors are keyed so it will only insert one way. Single laser users should just leave the bottom connector unplugged and out of the way. Close the rear cover slowly, making sure that you do not pinch any wires, and push down on the latches until they “click”.

You are now done installing the laser tube(s) and need to Finalize the Connections.

Finalizing the Connections

Make the following connections in the exact order described otherwise static electricity can damage the computer and/or the laser systems electronics.

1. Connect your 4-inch flexible rubber exhaust system hose to the 4-inch outlet found at the rear of the laser system. Use a hose clamp so that it doesn’t fall off.

2. Connect the laser systems power cord and your computers power cord to a grounded electrical source. International users may need to connect an adapter to the power cord to be able to plug it into their power source. MAKE SURE THAT YOU ATTACH THE ADAPTER CORRECTLY TO THE

POWER CORD AND THAT YOUR POWER SOURCE IS PROPERLY GROUNDED (EARTHED) OTHERWISE SERIOUS DAMAGE CAN OCCUR TO THE LASER SYSTEM. DO NOT POWER ON EITHER DEVICE AT THIS TIME.

Having a 9 volt battery installed into the PLS is necessary to operate the laser system. The laser system will not function without a battery or if the battery is low in power. Keep a spare 9 volt battery at hand at all t

imes.

Install the Thermal Sensor battery into the PLS system.

a. Remove the Thermal Sensor battery ho

from the side of the PLS by inserting a small screwdriv

er in the hole and GENTLY

push upward.

c. Insert the 9 volt battery provided into the black battery holder according to the diagram inside

the encasing.

d. Reinsert the battery holder into the cavity until it makes a “click” sound.

lder

b. Once you push upward pull the screwdriver

Section 4-8

towards you to withdraw the battery holder.

Page 53

ASSEMBLING THE PLS

USB 2.0 High Speed (only)

The laser system comes equipped with a high quality 6-foot USB cable. Please use this cable and do not substitute it with any other. Connect the printer cable directly from your computers USB port to the port in the rear of the laser system. DO NOT USE ANY ADAPTERS, EXTENSION CABLES,

SWITCH BOXES, ZIP DRIVE, OR ANY DEVICE BETWEEN THE COMPUTERS USB PORT AND THE PORT ON THE LASER SYSTEM OTHERWISE DAMAGE TO THE COMP

ASER SYSTEM CAN OCCUR AS WELL AS FILE TRANSMISSION PROBLEMS.

a. Connect the USB cable provided between the USB port of the computer and

the side of the PLS. Do not use a USB cable longer than 6 feet (2 meters).

b. After connecting the USB cord, the Found

New Hardware Wizard will open. You will be asked if Windows should connect to the Windows Update to search for software. Select “No, not at “Next” to continue.

c. Select “Install the software automatically”.

Then Click “Next” to continue. You DO NOT need to ROM.

d. A message will appear, “The ULS PLS

Engraver Firmware Loader has not passed Windows Logo testing”. Select “Continue Anyway”. Do not be concerned. Installing the ULS Firmware WILL NOT harm your computer in a begin to load.

insert the Software Installation CD-

this time”. Then click

ny way! The firmware will

UTER OR THE

the USB port on

Section 4-9

Page 54

ASSEMBLING THE PLS

e. The New Hardware Wizard will indicate

when the installation is c “Finish” to close the Wizard.

f. You may notice a small pop up appear on the bottom right

saying “Found New Hardware PLS USB Printing Support.”

g. Another set of New Hardware Wizard windows will appear after the initial USB connection.

Follow the same instructions as the hardware is installed and ready to use.

omplete. Click

hand corner of your display screen

ones mentioned above. Once completed your new

Checking Beam Alignment - All PLS laser systems

Note: You will not engrave anything at this time.

1. Open the top door.

2. Place a small piece of masking tape across the 3/4” hole in the focus carriage (1). Gently rub the tape around the edge of the hole so that you can see the then close the top door.

3. Power ON the laser system (switch on the back right-hand side).

4. Powe

5. After a few seconds have passed a red dot will appear on the

. Laser beam alignment is now complete. Power OFF the laser system and remove the masking tape.

r on your computer and verify that the blue shaped icon

is present on the taskbar. If not, activate it by double-

clicking on the ULSEngraver icon on your desktop. masking tape (3). The red dot should appear centered, or close to

the center of the hole, within 1/8 inch. If not, remove and re-install the laser cartridge(s) and try again. If the red dot still does not appear within 1/8” of the cente Technical Support Department.

outline of the hole through the tape (2) and

r of the hole, please contact our

Finally, proceed to section 5 to learn how to

make a sample with your newly installed laser

system.

Section 4-10

Page 55

Section 5

Making a Sample

We will now illustrate how to use the laser system to create a product from start to finish. As an example, we will raster engrave and vector cut a key chain from a 2 by 4 inch, 1/8 inch thick piece of hardwood. It is preferable to use a hardwood such as Cherry or Walnut as opposed to grainy wood such as Oak or a manufactured product such as plywood or melamine.

NOTE: In order to make a proper sample verify you have followed all Installation instructions up to this point.

Step 1 – Loading and Positioning the Material

Open the top door and position the piece of wood (1) into the upper left corner of the table, against the rulers, as the diagram indicates. If the piece of wood is bigger than the example then use the rulers to measure the size of the piece.

Step 2 – Creating the Graphic

Verify that the page size, in your graphic software, matches the ULS printer driver’s maximum page size. We recommend that you always leave the page size set to the maximum for your system and position your graphic accordingly. Create some text with a BLACK colored fill and NO outline. For example, type in the word “KEYCHAIN”. Draw an outline box around the text, color the outline RED, give the outline a thickness of .00005 inches (or the smallest possible line width), remove the fill color (if any), and round the edges if desired. Now add a circle with the same RED outline .00005 inches (or the smallest possible line width) an d NO fill, for the key ring.

Position the graphic, on your computer screen, relative to size of the wood and how the piece of wood is positioned in the engraving area.

If you are not familiar with your graphics program run a few tutorials and become familiar with the graphics program. If tutorials were not provided you may have to learn the software on your own by experimenting with the software.

0 2 3 4

Page 56

MAKING A SAMPLE

Step 3 – Printing to the Laser System (Materials Database Tab)

The following steps assume that CorelDraw X3 is being used as your graphics software and using the Materials Database Tab in the printer driver. Other graphic software programs may differ.

When you are ready to print the file to the laser system, click FILE and then click PRINT. Make sure that the laser system appears in the DESTINATION NAME dropdown list, and then click PROPERTIES (Figure 4) to display the PLS printer driver settings (Figure 5).

Choose your material by selecting the appropriate category from the material categories on the left (in this case wood) and then select the correct material type from the material types on the right (in this case hardwood) (Figure 5). Since we are placing the material directly on the work surface, leave the Fixture Type set to NONE. If you were using an optional accessory or custom fixture you would choose it from the fixture list. Using a calipers or similar measuring device, enter the thickness of the material (in this case .125 inch). For this sample there is no need to make changes to the INTENSITY ADJUSTMENT or AIR ASSIST boxes. If you have purchased two laser tubes and would like to make your sample using both laser tubes select BOTH in the “Which Laser?” box (PLS6.120D only). When you have made all the appropriate selections and entered the material thickness, click OK. The printer driver closes and reverts back to the Print Dialog box and now click on PRINT (Figure 4). As the print job is being created, a small printer icon will appear in your taskbar in the lower right corner of your computer screen. Once the icon disappears the print job is completed

and is now stored on your hard drive. Click on the PLS icon in the taskbar print job will appear in the Viewer Tab of the Universal Control Panel (Figure 6). Now click on the System Tab and verify that the Auto Z box is checked. Return to the Viewer Tab and proceed to the next step.

Figure 4

and the current

Figure 5

Step 4 – Starting the Engraving Process

• Turn ON the exhaust system and PLS machine. Laser tube fans will stop spinning once the laser system has been turned on. This is normal and the fans will start spinning once engraving has started.

• Make sure the material is positioned correctly within the engraving area.

• Make sure the top door is closed.

• Click the green START button on the UCP to begin laser processing (Figure 6).

WARNING: Observe that the laser system is functioning as desired. If any abnormalities are present, including but not limited to, flaming, sparking, melting, or excessive smoking of the material you are engraving, STOP THE ENGRAVING PROCESS IMMEDIATELY BY EITHER PRESSING THE PAUSE BUTTON OR OPENING THE TOP DOOR! Recheck the settings in the printer driver as well as the laser system. If everything seems to

Figure 6

Section 5-2

Page 57

MAKING A SAMPLE

be correct, the material is not suitable for laser engraving or cutting and you MUST DISCONTINUE processing this material or any material that may cause damage to the laser system. NEVER LEAVE

THE LASER SYSTEM UNATTENDED DURING THE ENGRAVING OR CUTTING PROCESS.

While the laser system is processing the material, you may stop the process by clicking the PAUSE button and waiting for the system to finish what it was doing and move to the home position (upper right corner). As long as you do not move the material inside the laser system, you can resume processing by clicking the RESUME button. As a safety feature, if at any time you open either the top or front

door, the laser beam will shut off first, and then the focus carriage will pause and move to the home position. However, this method of stopping the process may ruin your application material because you will be unable to resume operation exactly where it paused.

Step 5 – Material Removal and Reloading

Once the laser system has completed processing the material, the laser beam will turn off, the focus carriage will move to the home position in the upper right hand corner, and the red light on the keypad will turn OFF.

Before opening the top door, wait a few seconds to let any remaining fumes that are leftover from the laser engraving or cutting process, to evacuate through the exhaust system. Open the top door and remove the material. Some materials will continue to emit fumes, from several minutes to sometimes hours, after the engraving or cutting process is completed. We recommend that you relocate these materials to a well-ventilated and unoccupied area.

WARNING: Some materials, when engraved or cut with a laser, can produce toxic and caustic fumes. We suggest that you obtain the Material Safety Data Sheet (MSDS) from the materials manufacturer. The MSDS discloses all of the hazards when handling or processing that material.

NOTE: If you start a file with the top or front door open you may notice that a red dot pointer appears on the Z-axis table simulating where the CO2 laser beam will fire. However, please note that the red dot pointer is NOT triggered like the laser beam itself and while the system is simulating raster engraving or vector cutting, the area in which the Red Dot moves actually represents the complete motion of the mechanical assembly, and is not an exact indication of where the CO2 laser beam will burn. The laser beam will be activated somewhere within that motion depending on the graphic itself.

Congratulations! You have just completed your first engraving and cutting project with your new PLS machine.

Section 6 explains the PLS Keypad, Universal Control Panel (UCP), and Printer Driver in further detail. If you have accessories or have questions about system maintenance, sections 7-8 answer these questions. If you are an advanced user refer to the last section of this manual.

Section 5-3

Page 58

MAKING A SAMPLE

Section 5-4

Page 59

Part 2- Laser System Essentials

Page 60

Page 61

Section 6

Basic System Features

From the Universal Control Panel menus and buttons to the PLS Keypad and basic printer driver features, this section describes many of the features of the laser system. If you have done so already, power ON your computer and let it boot up completely BEFORE powering ON the laser system otherwise your laser system can “lock up” when attempting to run the first file and the only way to clear this error is to power the system OFF and then ON again. You do not need to turn on your exhaust system at this time.

The Universal Control Panel (UCP)

The Universal Control Panel on the computer provides access to all of the controls necessary for cutting and engraving operations. When the laser system has finished initializing and homing, and if all the doors are closed the red light on the Keypad will be illuminated and ready to accept files.

Once you have installed the UCP using the installation disk, a blue square-shaped icon (Figure 1) will appear in the lower right corner of your Windows taskbar. This icon indicates that the UCP is active. It will automatically activate itself every time you power on your computer. If for any reason the UCP is deactivated you can reactivate it by double-clicking on the shortcut (Figure 2) found on your computers desktop screen. You can access the UCP at anytime by left-clicking once on the icon in the taskbar. The following describes the features of each tab of the UCP:

Viewer Tab

Selecting this tab will allow you to preview your file and control features of the laser system.

System Controls

The upper right side contains the software version of the Keypad buttons found on the PLS laser system. These buttons operate identically to the physical buttons on the PLS.

o The green START button begins the engraving process. o The PAUSE button stops the engraving process and clicking the PAUSE button again

resumes the engraving process where it was last stopped.

Figure 1

Figure 2

o The four Navigation buttons

o The red Z-Axis buttons o The Home XY button re-home’s/moves the focus carriage to the upper right hand corner. o The Home Z button re-home’s/moves the Z-Axis table towards the bottom of the laser

system.

Basic View (drop down list)

• Shows a preview window of the currently selected job.

• The cursor becomes a magnifying glass (Zoom Tool) if you pass it over the preview window. Left-clicking your mouse zooms in and right-clicking zooms out.

• Clicking the Settings button you back to the printer driver. If mistakes where made or would like to make additional changes clicking this button allows for those changes. Further information about the printer driver can be found in Section 6-8 of this manual.

move the focus carriage back and forth or left and right.

moves the engraving table up or down.

takes

Section 6-3

Page 62

BASIC SYSTEM FEATURES

Focus View (drop down list)

• The focus button gives you the opportunity to move the focus carriage to a desired position on the laser systems table. To have a full range of motion of the X-Axis arm verify that you are zoomed out in the preview window by right-clicking on the mouse before entering the manual focus window. o Moving the cursor over the preview

window once the focus button has been clicked, changes your cursor to a blue target with dashe

d vertical and horizontal lines. Clicking once on the preview window moves the focus carriage to that position. Selecting another feature from the drop down list

terminates focus feature and re-home’s the

focus carriage.

o To move the focus carriage to a specific location, click the GO

button near the bottom right hand corner. The Focus window will appear. Type in the X and Y coordinates. Once you have finished typing in the coordinate’s press the GO button within the focus window

and the focus carriage will move to the

specified location.

Estimate View (drop down list) The “estimate” feature approximately calculates the amount of time it will take the PLS to finish the engraving or vector cutting job. The more complex the

ngraving job is the longer it will take to finish and visa versa. e

Relocate View (drop down list) If after sending the print job from your graphics program to the UCP you decide you want to engrave it in another location within the engraving field this feature gives you the opportunity to move the graphic within the b

asic view screen.

When this feature is activated the image is surrounded with 9 small white squares (anchor points) and allows you to move it around the b

asic view screen. The current anchor point selected, in blue, is the axis of movement.

We recommend you write dow

raphic in its original location.

n the original coordinates in case you would like to reposition the

Relocation Types

1. You ca

n click on any anchor point available to move the graphic within the basic view

area.

Section 6-4

Page 63

BASIC SYSTEM FEATURES

2. If you would like to move the graphic to the upper left hand corner select the top left

hand anchor point and type in your desired X Y coordinates into the boxes that appear

on the right hand side. This process can be done with any available anchor

point.

3. Enter the XY menu on your PLS keypad. Using your motion control keys move the

focus carriage to your desired location where you would like the image to be placed. Use the red LED as a reference point. Go back to the UCP and click on the TO CARRIAGE button. According to the anchor point you sele in reference to the location of the focus carriage’s red LED.

File

Management

Displays the name of current job, the number of files stored, your hard drive, and the run time nea the top of the window.

o The print job navigation buttons

allow you to preview the print jobs stored on your hard drive. If you navigate through the files using the UCP the file name on the Keyboard display changes accordingly and visa versa.

cted the image will move

the date and time it was stored on

o The “open folder” button

displays and allows you to select your print jobs in a file management style. It also allows you to delete print jobs stored from your hard drive, and save print jobs as .efm files.  The PURGE button deletes ALL

cached

print jobs stored on your hard

drive.

 If the Permanent box is marked this

indicates that the selected file will not be deleted from your hard drive even after clicking the PURGE button.

System Tab

Selecting this tab will allow the configuration of certain features of the laser system.

• The PRINT CACHE number is adjustable. It indicates the maximum number print jobs that you would like to be stored on your hard drive. If you exceed the number shown, automatically begin deleting the oldest jobs as newest ones enter the cache.

• LANGUAGE allows you to switch between multiple languages according to your preference.

• If the laser machine was improperly shut down the engr feature turned off, check the Disable box under AUTO also be helpful when troubleshooting Z-Axis problems.

• UNITS allow you to choose between Metric or Inches.

• AUTO Z should be enabled if you would like the device to focus the laser beam by automatically

adjusting the height of the Z-axis table. This operating pr that you specify in the PLS Printer Driver (Section 6-9). If it is disabled, you will need to set focus manually by using the included Focus Tool (Section 9-17).

• When running the Dual Head accessory, please enable the DUAL HEAD feature in the System Tab. If this feature is not enabled the laser system will not properly process the job.

• The TUNING (UNIVERSAL) number is a value set by the PLS manufacturing factory for your particular machine. In the future value to sharpen the resulting image. Do not change this number unless instructed to do so by our Technical Support Department.

• The LENS SIZE selected from the list should be the same as the number printed on the lens assembly on the front of your PLS Focus Carriage. If you change lenses (available accessory) other than the standard 2.0, then you MUST select the value that matches your installed lens and calibrate

the software will

aving table will home at start up. To have this

MATIC Z-HOMING. Disabling this feature can

inciple is based on the material thickness

, as your system gets broken in, it may be necessary to change this

Section 6-5

Page 64

BASIC SYSTEM FEATURES

the focus lens to the top surface of a table by clicking the red CALIBRATE button, otherwise the PLS will not focus the laser beam pr question about lens calibration.

• The ALIGNMENT Launch button opens the Alignment Mode window.

• CUTTING TABLE allows you to calibrate a new Z-height to the top surface of Honeycomb Cutting

Table. Y button.

• ROTARY is activated once the rotary accessory is installed. Rotary calibration should be done once when the rotary is installed for prop Accessories section on this manual.

• If the SOUNDS box is checked the computer will play the sound shown indicated once the fil finished engraving. Be sure that your computer speakers are on and at an appropriate volume.

• MANUAL FOCUS POSITION automatically moves the focus carriage to the coordinates entered by the user once the Z-Axis menu is entered or if the Auto-Focus button is pressed on the PLS keypad.

ou need to have the Honeycomb Cutting Table installed in the PLS to activate the FOCUS

operly. Contact the Technical Support Department if you have any

er engraving. For more information about the rotary read the

e has

Diagnostics Tab

The Diagnostics Tab displays important inform about your laser system and personal computer.

• ENGRAVER shows the current Firmware and FPGA version being used. It also displays the Serial Number of your laser system. The Serial Number is needed when c Support Department at ULS.

• AIR ASSIST displays the current device being used, shown by a green check mark, to supply compressed air to the laser system. According to the Air Assist device being used it may show if a Low or H version.

• LASERS displays if the Top or Bottom laser tube (if applicable) is being used and the watts being produced by the laser. It also displays the current version being used. If a red ‘x’ appears this indicates that the laser tube is not functioning properly or a door is opened on the laser system.

• OTHER DEVICES displays the current firmware version of th It also displays the current firmware version of the Homing Sensor on the laser sy

• SYSTEM displays information about your personal computer.

• INTERLOCKS show you if the Top, Front, or Rear Doors are Opened or Closed.

• ALARMS alert you if the inside the laser system i

Thermal Sensor battery is low in power. If the Thermal Sensor inside the laser system is trig alarm will sound and shut down your laser system.

FIXTURES indicate if a cutting table or rotary is installed and properly working.

•

igh setting is being used and the firmware

alling the Technical

ation

e Keypad/Display on the laser system.

stem.

s above the recommended temperature or if the

gered an

The PLS Keypad

The Keypad on the laser system provides limited access to controls necessary for cutting and engraving operations. When the laser system has finished initializing and homing, and if all the doors are closed, the red light on the keypad will be illuminated and ready to run a file.

he Red LED (Light Emitting Diode) will act differently depending on the current state of the laser system.

lease refer to the chart below.

Section 6-6

Page 65

BASIC SYSTEM FEATURES

ed LED

CONDITION REASON

FLASHING The top, front, or laser cover door is open.

The system has initialized. The top, front, and laser cover doors are closed and the system is ready to receive a file.

le. The system is running a fi The system is turned off. OFF The system is initializing.

START: Begins laser processing of the current file displayed on the keypad screen. If any of

the doors are opened when you press this button, the motion system will start to move as if it is processing the file, however, the CO2 laser beam is disabled and the red diode pointer will be enabled to simulate the laser process.

PAUSE: If a file is running, the PAUSE button halts the engraving or cutting process and

the focus carriage will move to its home position in the upper right corner of the engraving

area. If the PAUSE button is pressed again after the initial pause it will resume cutting or engraving again at the location where the motion system was paused. Please wait for the motion system to stop and m from the po d at.

ove to the home position before opening any door otherwise the laser beam will not resume

sition it stoppe

SELECT:

ESCAPE: This button exits you

you have made to that menu item.

This button enters the menu item the cursor is currently on.

back to the previous menu or it cancels any changes that

MOTION CONTROL: Pressing and holding down one or two adjacent, arrow buttons will

cause the Focus Carriage to move in the respective direction while in the XY menu. The

focus carri

the button(s).

age will start to move slowly and will accelerate to a faster speed until you release

UP and DOWN: Moves the cursor up or down on the display. These buttons also

move the X-Axis arm back and forth when on the XY me Z-Axis menu these buttons move the table up and down.

nu of the display. When in the

LEFT and RIGHT: While in the XY menu, the LEFT and RIGHT buttons move the

focus carriage left and right. While on the FILE menu the buttons scroll through the files in memory, changes Colors, increases or decreases Power, Speed and PPI settings on the fly. While on the Z-Axis menu the LEFT a

between the tenths and hundreds decimal place.

nd RIGHT buttons moves the cursor

AUTO-FOCUS: This button has two purposes: Manual Focus and Auto-Focus. While on

the main menu of the display, pressing the AUTO-FOCUS button once will move the focus carriage to the predetermined position as entered in the Manual Focus Position box under the System Tab. While on the main menu of the display, holding the AUTO-FOCUS button for one second will move the table up and down automatically in order to find the top surface of the material being engraved fo

cusing is complete once the table stops moving. To exit Auto-Focus press the ESCAPE button.

. Auto

Section 6-7

Page 66

BASIC SYSTEM FEATURES

enu System Keypad M

MAIN MENU

After the system is powered ON, the laser systems model name will appear, along with the model version, copyright date, company name, and if the Universal Control Panel is not running, DISCONNECTED will be displayed. After the Universal Control Panel is launched and after a few seconds pass it will home to the upper right corner. The display on the keypad will automatically change to the main menu which will display the last printed file, FILE, XY, and Z. If a file is sent to the laser system for cu

ettings of the file.

FILE

This menu appears automatically after the first file has been sent to the laser system. Utilizing the LEFT or RIGHT buttons while on the File Name (A) displays the appropriate downloaded file and pressing the START button will begin laser processing. Utilizing the UP and DOWN buttons allow you to scroll through the File Name and timer (A), Color (B), Power (C), Speed (D), and PPI (E). The Power, Speed, and PPI of the file being engraved can be changed, on the fly, by pressing the LEFT and RIGHT buttons as the file is being processed. The t

e PAUSE button is pressed and starts up again when PAUSE is pressed.

This menu displays the current position of the focus carriage according to the ru

lers and allows you to move the focus carriage back and forth and left to right.

This menu displays the current position of the engraving tab laser system and allows you to move the table up and down.

tting or engraving the display will change with the Color, Power, Speed, and PPI

imer will pause when

engraving table

le relative to the inside base of the

Printer Driver Controls

This part of the section describes the use of the Materials Database Tab of the printer driver.

Materials Database Tab

This tab of the printer driver is for the beginning user

nd requires little knowledge about the laser system.

Category List

This section allows you

f material categories.

Material List

Once you choose a category a variety of materi ty

pes will appear to the right of the category section.

Intensity Adjustments

Intensity Adjustments give you the opportunity to change the intensity of your Raster Engraving, Vector Marking, and Vector Cutting. The default settings are set to 0% but they can be changed from -50% to +50%. Increasing the settings increases the intensity of the engraving process giving you deeper results. Decreasing the intensity decreases the engraving process and gives you shallower results. Always start at 0% on a scrap piece of material and make any appropriate changes m

ake changes to these controls only if undesired results are produced.

to choose from 8 original types

accordingly. There is not need to

Section 6-8

Page 67

BASIC SYSTEM FEATURES

Air Assist

If you have the Air Assist accessory on the laser system you can activate it through this option. You are able to turn on Air Assist for Raster Engraving, Vector Marking, and Vector Cutting. If you activate this feature adjust the air flow according

ith Air Assist turn OFF the feature.

to your desired results. If the laser system does not come equipped

Material

The NEW button allows you to add a custom Category and Material to the printer driver. Th g

ives you the opportunity to modify the selected Material by creating a copy of the original.

NOTE: This part of the Materials Database requires you to have knowledge of the

atures. You can learn about the Manual Control Tab in Section 9 of this manual.

e EDIT button

Manual Control

Material Editing

This feature gives you further control over the Materials Database and has similar features as the Manual Control Tab in the printer driver (Section 9). Custom categories and materials can be added and deleted. They can also be modified to your specific requirements. Once you have added the new material the printer driver will add the new material to the list. This new material will

e available for you to use for future jobs.

b To access this window you will need to select a

current category or material and click the NEW or EDIT button. The Materials Editing window and the Manual Control Tab have similar f can refer to Section 9-4, Manual Control Tab, for further explanation on these features.

eatures. You

Material Code

The Material Code box will automatically me made when makin Y

ou can add a custom Material Code from 9000-9999 if desired.

g a new material and category.

Taper

This drop down menu is activated when Print Mode is set s

imilar to the one in the Raster sub-tab for Rubber Stamping.

to Rubber Stamp. This feature is

3D Power

This button can be activated by setti s

imilarly to the Raster sub-tab for 3D.

ng the Print Mode to 3D. This feature can be modified

Vector Marking - Blue Pen

hese settings are similar to the ones on the Raster Sub-Tab under the Manual Control Tab.

Vector Cutting - Red Pen

This section of the Material Editor window allows the user to input preliminary numbers for the Material Editor to properly calculate future power and speed settings. To properly configure the Vector Cutting - Red Pen section you will need to vector cut 2 materials in the laser system so M

aterial Editor can calculate the appropriate percentage amounts for different thicknesses.

If the material being added to the Material Editor can be vector cu “M

aterial Can Be Vector Cut” and input the percentages it asks for.

The Shallow Cut Settings and Deep Cut Settings sections are similar to one another. First measure two identical material types but of different thicknesses for example a 1/8” piece of acrylic and a ½” of acrylic. Input the thinnest material measurement in the Cut Depth box of the Shallow Cut Settings. Next, type in the thickest material measurement in the Cut Depth box o th

e Deep Cut Settings section. The Power and Speed in both settings refer to the least amount

Section 6-9

t check the empty box called

the

Page 68

BASIC SYSTEM FEATURES

of percentage power required to cut through the material without causing undesired results

ay have to experiment with this section several times to get the exact results you desire.

. You

Max Depth

The number inputt s

ystem not to cut.

ed in this box refers to the maximum thickness you would like the laser

PPI

vailable settings are 1 to 1000. For further explanation about this setting read Section 9-4.

Shallow Cut Settings

hese parameters set the starting point for the Printer Driver’s Material Editor.

Deep Cut Settings

These parameters set the starting point for the Printer Driver’s Material Editor.

How to create a new Category and Material

In order to create a new Category and Material you need to have your Materials Database Tab active. Select one of the existing Categories on the left and click on the NEW button. The Material Editing window appears. From the Category drop down menu list on the left select **New Category. The Material Category window appears allowing you to type a name of the new category in the blank space. A Category ID (900-999) will automatically be assigned once a new category is made. Click on the OK button. Once a category is made you can add a material name to the new category by typing in a name in the Material Name blank area. Once that is done you can make your necessary modifications to each area in the Material Editing window. To save your new category and material you must click the APPLY button then click the CLOSE

. If you click the CLOSE button your changes will not be saved in the Materials Database

button

ab.

T To verify that your new category and material have been made you will be able to see your new

category on the left hand side of the Materials Database Tab. Click once on your new category and your new material will appear to the right of the Category list. Select your new material, make your necessary adjustments on the Materials Database Tab and click th on your laser system and start the Universal Control Panel and print your job.

e OK button. Turn

Which Laser? (PLS6.120D only)

If you would like to only use the top or bottom laser tube to engrave or vector cute select from TOP or BOTTOM. If you only purchased one laser tube, select the appropriate laser tube according to th o

f your laser system. If you would like to use both laser tubes for your project select both boxes.

e set up

Material Thickness

In order for the laser system to properly vector cut and/or engrave on the material it needs to know the thickness of the material before it starts engraving. Using a caliper or simila th

e thickness of your material and enter it into the Material Thickness box.

r measuring device, measure

Units

his section allows you to switch between Metric and Inches.

Fixture Type

None

If you are not using any type of fixture set the drop down menu to NONE.

Rotary

If you have purchased this accesso A

SSECCORIES section of this manual.

ry read how to install and operate this fixture in the

Section 6-10

Page 69

BASIC SYSTEM FEATURES

Custom

If you prop up the material you are going to engrave on a surface othe will need to add the height of the prop in the Custom Height field.

NOTE: The Materials Database is meant for the novice and beginning user. As a user operates the laser system and understands how it works he or she may edit the existing Materials Database for further control. Editing the Materials Databa m

aterials to the existing database if desired.

se is not necessary but you can add many different

r then the table provided, you

If you would like to use the Manual Control Tab refer to Part 4 -

Advanced User for further information.

Section 6-11

Page 70

BASIC SYSTEM FEATURES

Section 6-12

Page 71

Section 7

Basic Maintenance

Keeping the laser system clean will ensure the highest quality engraving. The frequency of cleaning will depend entirely on the type of material being engraved, the performance of your exhaust system, the operating environment, and the amount of laser system usage over a given period of time. Dirt or debris that is allowed to build up on the motion system components will cause uneven or rough engraving, or loss of engraving position as well as premature component failure. Smoke or dirt buildup on the optics can cause damage to them, loss of laser power, or premature failure of these components. Use good judgment and keep in mind that a clean machine is the best performing machine. Always turn the laser engraving system OFF and unplug it before performing any cleaning procedures.

Motion System Components Diagram

NOTE: #2 Mirror Cover and

X-axis Motor Cover Plates have been removed for visibility.

1) Focus carriage

2) X-axis bearing (3)

3) #3 mirror (inside cover plate)

4) Focus lens (inside cover plate)

5) X-axis rail (arm)

6) X-axis bearing track (2)

7) X-axis belt

8) X-axis home sensor flag

9) X-axis idler pulley

17) Y-axis drive gear (2) (one on right side, one on left side)

18) Y-axis shaft (2) (one on right side, one on left side)

19) Y-axis shaft flex coupler (one on right side, one on left side)

20) Y-axis motor

21) Y-axis idler pulley (2) (one on right side, one on left side)

22) Y-axis home sensor flag

23) Flex cable

10) #2 mirror and holder

11) X-axis motor and drive gear

12) X-Y home sensor board (upper flex board)

13) Y-axis belt (2)

14) Y-axis bearing (4) (2 on right side Y-axis rail, 2 on left side Y-axis rail)

15) Y-axis rail (2)(one right side and one left side)

16) Y-axis rail bearing track (2) (one on right side, one on left side)

Page 72

BASIC MAINTENANCE

Cleaning and Maintenance Supplies

• Soap solution mixture of 1 tablespoon (2 cl) liquid soap and 1 quart (liter) of water in a spray bottle

• Window cleaner

• Paper towels

• Cotton cloth

• Denatured alcohol (NOT to be used on any painted surface, plastic, or the Top Window)

• Acetone (can be used on the engraving table but nowhere else)

CAUTION

When using acetone or denatured alcohol, please follow the instructions on the printed label of

these materials for safe handling procedures.

• Cotton swabs (supplied)

• Lens cleaner (supplied)

• Vacuum cleaner

• Set of Allen wrenches sized from .050 to 3/16 inch

System Cleaning and Maintenance

Motion System

• Turn off and unplug the laser system.

• Open the top door and thoroughly remove all loose dirt and debris from inside the machine with a

vacuum cleaner.

• Clean the engraving table surface with either a soap solution, or alcohol or acetone, and paper

towels. NEVER pour or spray any solution directly into the laser system. Always dampen your paper towel or cloth outside of the machine with the cleaning solution and then wipe down the parts you are cleaning with the dampened cloth.

• Clean X-rail and the Y-rails by using either the cotton swabs or paper towels, and soap solution. Pay

close attention to the bearing tracks since any debris left to build up in these bearing tracks will cause the bearings to wear and the engraving quality to become rough.

• After the rails and tracks are cleaned, use a clean swab or paper towel, and soap solution to clean all

of the bearings by holding the swab against each bearing and moving the motion system by hand to roll the bearings against the swab. There are seven bearings in the system, three (3) on the focus carriage, two (2) on the left side of the X-rail, and two (2) on the right side of the X-rail.

The Main Enclosure

• Clean the top window with a cotton cloth or paper towel and window cleaner. The top window is

made out of glass; therefore, DO NOT use abrasive cleaning clothes because they will scratch the glass. Also, DO NOT use abrasive chemicals as these chemicals will damage the glass. Only use cleaners compatible with glass.

• Use a soft cloth or paper towels and the soap solution to clean the enclosure. DO NOT use alcohol,

acetone, or any other harsh chemical, as this will damage the paint.

Optics

A visual inspection of the #2 and #3 mirrors, beam window, and focus lens should be performed at least once a day.

DO NOT clean an optic that is visually clean. Excessive cleaning can damage the optic. To prevent contamination, wash your hands thoroughly before cleaning any optic. NEVER touch any optic with your fingers. The acids from your skin can destroy the optical coatings. NEVER clean any optic right after engraving or cutting because the optic may be hot and the cool lens cleaning solution may thermally shock the optic and crack it.

Section 7-2

Page 73

BASIC MAINTENANCE

#2 Mirror

To gain access to the #2 mirror, the mirror cover must be removed. Remove the thumbscrew and slide the cover to the right and then lift the cover straight up.

Inspect the #2 mirror and clean it only if there is debris present. To clean the #2 mirror with a cotton swab, moisten the cotton swab with the lens cleaning solution supplied with the laser system. DO NOT use other types of cleaners or solutions. Gently roll the cotton swab across the mirror once. DO NOT drag the swab or roll it back and forth as this can scratch the mirror. If the mirror did not come clean, use a fresh cotton swab and repeat the procedure. Do not be concerned about small pieces of lint that come off of the cotton swab. They will be vaporized as soon as the laser hits it. You can cause more damage to the mirror by trying to remove the lint than by leaving it alone.

#3 Mirror and Focus Lens

To gain access to the #3 mirror (3) and the focus lens (4), hold the front cover (2) with one hand, and remove the three thumbscrews with the other hand. Pull the front cover straight out. The #3 mirror and the focus lens are both mounted to the front cover.

Tilt the front cover enough to enable you to apply the lens cleaning solution directly to the #3 mirror and to the focus lens. Flood the reflective surface of the #3 mirror with the solution. If heavy debris is present, let the solution soak in for a minute. Roll a fresh cotton swab across the mirror in one direction. Use a fresh swab for each pass. Be gentle when cleaning the optic to avoid scratching the surface. Repeat this procedure for the focus lens but make sure you clean both sides of the lens.

Beam Window

The beam window is where the laser beam enters into the engraving area. It is located in the upper left hand corner of the engraving area against the back wall and is yellow in color. It is only necessary to clean the front side of the beam window. Do not remove the optic to clean it; simply clean it in the same manner as the #2 mirror.

Section 7-3

Page 74

BASIC MAINTENANCE

If your system is equipped with Air Assist, using your fingers, rotate the beam window cover counter-clockwise (B) and then off at a 45degree angle (C). If the beam window cover is stuck use a 1/16 Allen wrench to loosen or remove the screw (A) and try again. Set the cover off to the side and clean the optic, if necessary. Reinstall the beam window cover opposite of removal being careful not to scratch the optic.

Exhaust Plenum Cleaning (PLS3.60 and PLS

4.60)

• Power the laser system and UCP on.

• Using the Z-axis controls, raise the Z-axis table as high as

possible. Power the system OFF.

• Locate and remove the two button head screws (1) found

on the back of the laser system.

• Open the front door. Using both hands, reach in and grab

exhaust plenum. Lift the plenum straight up until the tabs (2) of the plenum clear the two flat head screws (3) they are resting on. Tilt the bottom of the plenum towards you and remove it from the system. Using your soap and water solution, clean the inside of plenum as well as the inside rear wall of the Laser System.

• Installation is opposite of removal. Make sure that the

plenum tabs rest on the two flat head screws.

NOTE: The PLS6.60’s and PLS6.120D’s exhaust plenums are removed in the same fashion but these two laser systems come with two exhaust plenums.

Back View

Inside Front View

Cooling Fan Filters (PLS3.60 and PLS 4.60)

This air-cooled laser system will require periodic cleaning of the cooling fan filters. Since ambient air is used to cool the laser cartridge, the air must be filtered before it enters the inside of the laser system. Dirt or dust contamination may reduce the cooling fan’s ability to keep the laser cartridge, as well as the CPU and power supply, from overheating. An overheated laser cartridge will lose laser power during engraving and will eventually shut down completely.

The cooling fan filters are located on the back of the laser system. To service the filters, first turn OFF and unplug the laser system. There are two large filters (1) and two small filters (2). To remove the filter(s), simply snap off the black cover and remove the foam element. Wash the element in a soap and water solution, dry, and re-install.

NOTE: The PLS6.60 AND PLS6.120D has a total of 6 filters. Four large and one small filter(s) located on the back, and one large filter located on the side near the power switch.

Back View

NEVER OPERATE THE LASER SYSTEM WITH THE COOLING FAN FILTERS REMOVED. This can permanently damage the laser system.

Damage to the laser system, from this kind of abuse IS NOT covered under warranty.

Section 7-4

Page 75

BASIC MAINTENANCE

Adjustments and Lubrication

There are no periodic adjustments normally required. The bearings in the motion system will self adjust to take up any clearances as they begin to wear. The belts are fiber reinforced and will not stretch under normal use so that periodic tension adjustment is not necessary. Optical alignment is not necessary because the laser and the #2 mirror are fixed.

All bearings in the system are sealed and do not require lubrication. DO NOT lubricate the tracks that the bearings ride in. The only lubrication that may be required is the screw threads for the table lifting mechanism. After some time, contaminants can adhere to the lubricant, which can cause the engraving table to bind up or sound squeaky. If this is the case, wipe off the contaminated grease with a soft cloth dampened with alcohol and apply fresh white lithium grease to the screw threads. NEVER SPRAY ANY DEGREASING SOLUTIONS DIRECTLY ONTO THE THREADS. Run the table up and down to work in the fresh grease. Repeat if necessary.

Maintenance Schedule

Since the maintenance requirements of the laser system is dependent on the type of material being run, the quantity of material being removed, the hours of operation, and the quality of the exhaust blower, it must be user defined.

As a starting point, we recommend the following schedule:

• As necessary

Engraving table Main enclosure Top door window

• Every 8 hours of engraving

Clean X-axis and Y-axis bearings Clean X-axis and Y-axis rails and bearing tracks Clean X-axis belt. Check beam window, #2 mirror, #3 mirror, and focus lens for debris. Clean ONLY if dirty.

• Every month

Clean cooling fan filters Clean and re-lubricate Z-axis lead screws Check for X-axis and Y-axis belt wear – replace as necessary Check and/or clean X-axis and Y-axis drive gears Check for X-axis and Y-axis bearing wear – replace as necessary Inspect system for loose screws and mechanical parts – tighten if necessary

• Every 6 months

Exhaust plenum

If you are noticing a considerable buildup of debris on the optics and the motion system, clean the system at more frequent intervals. If your system has remained relatively clean, you can extend your cleaning intervals. Keep in mind that a clean machine is a better performing machine and can extend the life of the parts as well as reduce the possibility of down time. If you have any questions about maintaining the laser system, please contact our Technical Support Department.

Section 7-5

Page 76

BASIC MAINTENANCE

Section 7-6

Page 77

Part 3 - Accessories

Page 78

Page 79

Section 8

Accessories

There are optional accessories, not included with the basic laser system, that are available at additional cost. Instructions on how to use these accessories are included in this section. The user can purchase and install all accessories, except Air Assist, which is a factory installed option ONLY.

Before attempting to use any accessory, make sure that you have read the entire manual up to this point. It is vital that you have a complete understanding of how the laser system works before attempting to use an accessory. Incorrect or inappropriate usage of an accessory may be a safety hazard and may cause severe damage to the system.

Air Assist

The Air Assist System consists of a nozzle that attaches to the focus carriage, Optics protection adapters, tubing, mounting brackets, needle valve, and pressure gauge. The purpose of this system is to force air or other types of gases directly onto the surface of your material to reduce the burning effects of the laser beam and helps disperse the smoke and gases created when cutting or engraving materials. The optics protection parts assist in helping keep the optics cleaner from flying debris created from the pressurized nozzle. Use of this system requires a minimum compressed air source capable of 60 PSI @ 2.5 cfm. This supply MUST be free from oil, water, and particulate matter. Another accessory called the “Air Assist Compressor”, can supply this source.

Air Assist IS NOT intended to decrease maintenance of the laser system. The use of this Air Assist has been known to increase the frequency of cleaning maintenance due to debris being blown around, inside the engraving area, during laser processing.

Standard and Computer Controlled styles

There are two styles of Air Assist, standard and computer controlled. The computer controlled option uses three solenoids to control low-pressure air, high-pressure air, and an external gas supply and is selectable in the printer driver. Because these solenoids work with the running of the laser system, the air and/or gas supply is only used when needed and shut down automatically when laser processing stops. The standard system does not have solenoids, is not computer controlled, and can only deliver only one air pressure per file. It is also not gas compatible. The standard Air Assist accessory is acceptable in most applications, however, for the ultimate control, the computer controlled Air Assist is highly recommended.

Requirements (both styles)

The Air Assist option requires compressed air supplied from the Air Assist Compressor Unit (optional) or from a user supplied compressed air source. If you choose to provide your own source, it must be capable of supplying 60 PSI (pounds per square inch) at a constant rate of 2.5 CFM (cubic feet per minute). The air supply MUST be oil-free, moisture-free, and particulate filtered.

A contaminated air supply will cause severe damage to the laser system. Air or gas supply pressures higher than 60 PSI can rupture the internal hoses

of the control box and can possibly damage the valves. Damage to the laser system from contaminated or improper air or gas supply

is considered abuse and IS NOT covered under warranty.

Section 8-3

Page 80

ACCESSORIES

Making the Connections

Standard Air Assist style

In the left rear part of the system you will find the pressure gauge (1), flow adjustment valve (2), quick release coupling (3), and release lever (4).

Push in the release lever and pull down on the quick release coupling to remove it from the machine. Attach your compressed air supply hose to this fitting (1/4 NPT threads) and use Teflon tape on the threads to prevent leaks. Re-insert the fitting until it “clicks” into place.

Attach the other end of the supply line (5) to a particulate filter (6), desiccant/dryer (7), and then to an oilfree compressed air source (8).

Computer Controlled Air Assist style

In the left rear part of the system you will find the Air Assist control box. Attached to the box (not shown in picture) there should be two special quick release couplings secured with plastic tie wraps (1). Using a pair of scissors or wire cutters, cut off the plastic tie wraps and discard.

The AIR IN (2) fitting is where you attach the compressed air supply. The GAS IN (3) fitting is where you would attach an inert gas supply (optional). If you purchased the optional Air Compressor, you would connect the control wire to the COMPRESSOR (4) connector (refer to the Air Compressor instructions for more details).

Section 8-4

Page 81

ACCESSORIES

Locate the locking lever (1) attached to both fittings. Push in the lever until it clicks. Attach the larger quick release coupling (3) (1/4 NPT threads) to your compressed air supply line (4). Use Teflon tape on the threads to prevent leaks. Push the quick release coupling (3) into the fitting (2) until it clicks into place. Attach the other end of the supply line (4) to a particulate filter (5), desiccant/dryer (6), and then to an oil-free compressed air source (7). If you have purchased the optional Air Compressor, connect the control wire (8) from the compressor (7) to the COMPRESSOR connector (9). If using an inert gas, attach the smaller quick release coupling (11) (1/4 NPT threads) to the supply line (12) using thread sealant or Teflon tape. Push the quick release coupling (11) into the fitting (10) until it clicks into place. Attach the other end of the supply line (12) to an external

pressure regulator (13) and then on to the gas tank (14).

Cone Installation and Removal (both styles)

The cone must be attached to direct the air or gas supply to the laser beam's focus point. To install the cone, insert the cone (1) into the cone base completely until it bottoms out. Using a .050 inch Allen wrench, tighten the setscrew on the side of the cone base (2) until it is snug. Re-check to make sure that the cone is all the way into the base and is not tilted. To remove the cone, simply loosen the setscrew (2) and pull the cone straight down. DO NOT remove or loosen the cone base mounting screws (3) & (4) to mount or dismount the cone. These screws keep the cone base aligned with the laser beam.

DO NOT install the cone unless you plan on using Air Assist. Leaving the cone attached to the cone base and running the laser system without either air or gas flowing through the cone will destroy the focus lens within a few minutes. If you are not using Air Assist, REMOVE THE CONE. Damage of this nature is due to neglect and WILL NOT be covered under warranty.

How it Works

Standard Air Assist

The Quick Release Fitting (1) is the entry point into the rear enclosure of the laser system. From there, the air lines branch off into two paths, the optics protection path and the cone path. The optics protection path is a direct path from the quick release fitting (1) to the #2 mirror (4) and the #3 mirror (5). Since this is a direct path, the amount of air pressure and flow that is coming from your compressed air source will be applied to

the optics to help keep them clean from flying debris. The cone/backsweep path goes through the flow adjustment valve (2), and then to the cone (3). The amount of air, flowing through the cone, is adjusted using the flow adjustment valve (2). The cone path protects the focus lens and provides a downward flow directly into the beam path at the focus point.

Section 8-5

Page 82

ACCESSORIES

NOTE: Air will always be flowing through the system as long as the compressed air source is turned ON. We recommend installing a shut off valve in between your compressed air supply and the laser system.

Before you run your material, we suggest that you adjust your air and/or gas flow. To do this, you must first turn on your compressed air source so that there is flow through the system. Now, either turn the laser system ON or leave it OFF.

With the top door of the laser system open, pass a piece of paper underneath the cone and use it to note the amount of air flowing through the cone and against the paper or place your finger underneath the cone to try to feel the pressure.

As a safety precaution, you should place your finger underneath the cone ONLY when power to the system has been turned OFF. If the power is ON, you should use the paper method.

Turn the adjustment valve knob clockwise or counterclockwise until either the desired airflow or PSI reading on the gauge is achieved. Clockwise adjustments reduce flow while counterclockwise adjustments increase flow.

Computer Controlled Air Assist

The control box (1) (represented by the dotted lines) directs the compressed air source to the optics protection path and also to the cone. The optics protection path is a direct path from the entry point of the compressed air source (2) to the #2 mirror (3), and #3 mirror (4). The air supply for the cone or backsweep comes from either the AIR valve(5) or the

GAS valve (6), then travels through a flow control device (7) which adjusts it’s flow in increments of 25%, 50%, 75%, or 100% and finally to the cone or

backsweep. Flow control device (7) can be adjusted through the printer drivers’ settings (Section 9-5). The cone path protects the focus lens (8) and provides a downward flow directly into the beam path at the focus point. You choose which source (Gas or Air) (5 or 6) to open through the printer drivers’ settings (Section 9-

5). If you choose to use an inert gas to supply the cone, the supply must go through the GAS coupling (9).

As the diagram indicates, the optics protection path is neither regulated nor solenoid valve controlled. If you are using your own compressor, the optics protection air will always be flowing regardless of whether the laser system is running or not. You must install either a manual shut off valve (not supplied) or an external electronic solenoid valve system (not supplied). If you purchased the Air Compressor option the optics protection air will turn ON and OFF as the compressor turns ON and OFF respectively.

When you press the “Start” button on the laser system, the Air Assist control box will send out a +5 VDC signal through the COMPRESSOR control wire, which can be used to turn ON the Air Compressor (optional) and will keep the Air Compressor ON until the file completes. This type of control saves electricity, reduces the running time of the compressor, and reduces ambient noise when the laser system is not running.

The control box also has built in pressure sensors that will detect insufficient supply pressure and will shut down the laser system. An error message, “The air pressure is low or unstable” will appear on the computer monitor, indicating that there is a problem with your supply of either air or gas.

Section 8-6

Page 83

ACCESSORIES

Programming the PC Printer Driver

The Air Assist option provides printer driver controlled activation and deactivation of solenoid valves that direct the flow through one of three paths with its final destination being the cone. It also has been designed to work in conjunction with the optional Air Compressor to turn it ON and OFF when the job starts and finishes, respectively. You can choose between “OFF, “AIR”, or “GAS” valve activation setting for each one of the eight colors in the printer driver.

Power up your PC and open up or create a graphic to print to the laser system. When ready to print, go to the laser system printer driver and set all of your parameters. After selecting a color, choose which pathway you desire by selecting from “OFF, “AIR”, or “GAS” from the dropdown list for the “Flow” option which is on the right hand side of the printer driver.

Choose the rest of your parameters and send the file to the laser system. Make sure the cone is installed. Insert your material into the laser system and set the

Windows XP printer driver

focus by using one of the focus methods in Section 9-

17. Make sure that your air and gas supplies (if using) are ON. Turn on your exhaust blower and press the START button.

Air Flow Setting Guidelines (both styles)

Use as much or as little air flow necessary to produce the desired results. There are no particular setting s that we can offer to you. As a rule of thumb, start with low flow and adjust upward until flaming is suppressed. Setting the flow too high can result in excessive particulate matter being blown around causing faster system contamination, which would require an increase in maintenance. It can also push the hot engraving or cutting smoke back onto the material or into the cut line and cause contamination of the surface or side edges of the material. On some scrap material play around with different flow settings to obtain the best results, then write down your settings for various materials. Remember, the intent of the Air Assist option is to suppress flaming and/or melting of the material during laser processing.

Maintenance (both styles)

• Keep your air supply and/or gas supply moisture free. Check your desiccant (water dryer) frequently.

Replace desiccant when saturated or use the manufacturer’s recommendation to remove water moisture from the desiccant crystals. Water moisture may contaminate the air assist system and can cause malfunctions as well as damages to the unit.

• Clean your laser system more frequently when using Air Assist. You will need to check, and possibly

clean, your optics frequently. Do not let the optics protection part of the Air Assist system lead you to a false sense of security. Since more debris gets kicked up by the downward air or gas flow through the Cone, the laser systems rails, bearings, and other motion system components will get dirtier faster than by not using the Air Assist option.

• Periodically check the cone alignment with the laser beam especially if you have replaced or adjusted

the laser systems optics. You will know if your cone is not aligned if you suffer a substantial loss in laser power when laser cutting or engraving with the cone installed as opposed to the cone removed. A misaligned cone will cause the beam to make contact with the inside of the cone, possibly splitting the beam and/or reducing the power at the focus point.

Section 8-7

Page 84

ACCESSORIES

Cone Alignment Check and Adjust (both styles)

1. Power the laser system ON and start the UCP.

2. Open the top door.

3. Position the focus carriage in the middle of the field.

4. Place a piece of paper (1) underneath the cone and observe

the position of the red beam (2) in relation to the center of the bottom of the Cone (3) and be sure to check it from the front and side.

5. If the red beam is not centered, remove and reinstall the cone

to see if it was due to an improperly installed cone.

6. If the red beam is still not centered, check all your optics for

looseness or mechanical misalignment.

7. If still not centered, loosen the two base mounting screws (4)

slightly (1/4 turn) and slide the base (5) around until the red diode laser comes out of the centered of the cone. Remember to check this from the front and side of the focus carriage.

8. Tighten the base mounting screws (4) gently and re-check the cone’s alignment.

2.0

Air Assist Compressor

The Air Assist Compressor option is a 60 PSI @ 2.5 cfm source for oil-free, water-free, and particulate matter-free compressed air. It contains a sound insulated air compressor, water dryer (desiccant), and coalescent particulate filter. This compact and custom designed unit is a great compliment to the Air Assist System option.

Installation

• Make sure the laser system is turned off.

• Plug one end of the blue coiled hose into the compressor fitting (push in the fitting lever until it clicks

before inserting) and the other end into the air inlet fitting in the laser system.

• In the computer controlled version, plug one end of the control wire to the Air Compressor and the

other end into the compressor connection on the machine.

• Plug in the compressor into a wall outlet. Please check the rating on your air compressor for the

proper power requirements.

• The compressor has a three way switch: ON, OFF, and AUTO. Push the switch to the left and it will

turn the compressor on all of the time. This mode is useful for non-computer controlled models. OFF is obviously off. The AUTO position allows the compressor to turn on and off only when it receives a signal from the laser system that has the computer controlled option. If you have selected the AIR or GAS setting in the printer driver, the Air Compressor will automatically turn ON when the file runs and OFF when the file is complete.

Maintenance

The filter and desiccant should be inspected every 8 hours of use. It may be necessary to clean out the filter and change the desiccant that is inside the dryer assembly.

To inspect the filter, you must remove it. To inspect the desiccant you can observe the color of the crystals through the slots in the metal enclosure without having to remove it. If you start to see water droplets or moisture coming through the air lines, you will definitely need to change the desiccant inside of the dryer assembly but it should never get to that point. Indication that the desiccant needs changing is the lack of blue color pigments in the desiccant. The desiccant can be regenerated. Bake it in an oven at 350 degrees F until some of the crystals turn blue again.

Section 8-8

Page 85

ACCESSORIES

Removal, Cleaning, and Replacement of the Filter

• Turn the Air Compressor OFF and unplug it.

• Unscrew the cover by turning it 1/8 turn counterclockwise

like you were unscrewing a jar, and pull down. The clear plastic container might still remain attached to the top. Gently pull this part straight down.

• You will see a red colored foam filter. Unscrew the filter,

and wash it out with water. Make sure that it is completely dry, then reinstall.

• Empty and clean out any residue or dust that may have

accumulated on the bottom of the clear plastic container.

• Install the clear plastic container into the cover and line up

the tabs so that they fit one inside of the other.

• Insert the combination of the cover and the clear plastic

container into the top of the assembly. Gently twist the cover 1/8 turn clockwise to lock it into place.

Removal, Cleaning, and Replacement of the D

• Turn the Air Compressor OFF and unplug it.

• Pull down on black lever and rotate metal cover 1/8

turn counterclockwise. pulling it straight down.

• With a gentle and slight twisting motion, pull the clear

container d desiccant.

• Refill clear container with fresh desiccant from a

sealed bag. Fill to about ¼ inch from top of contain

• Clean off rubber o-ring on the top

• Insert container up into the top.

Install metal cover and turn 1/8 turn until lever clicks into place.

•

ownward slowly. Pour out and discard old

Remove the metal cover by

of the container.

esiccant

er.

Dual Head

The Dual Head option was created to enhance productivity when engraving large quantities of the same item providing that two or more of the same item fit within the horizontal engraving area (X-axis) of your laser system. The Dual Head option can significantly reduce your overall engraving time if you divide the total processing time by the quantity of items engraved, however, there are limitations involved when

sing this option.

• It is not “twice

from 25-75%

• In som

head.

• There is an overall laser power loss due to additional optics ranging from 1% - 5%.

• The beam is not split EXACTLY 50/50 although it is close enough for most applications.

• Because of optical angles and the effect of passing the beam through splitting optics, the engraving

field most likely WILL NOT be split EXACTLY in half. There may be a small tolerance in absolute beam positioning by as much as +/- 1/16 the difference by adjusting the spacing between your objects in the engraving area.

e applications, using the Dual Head option may reduce efficiency than engraving with a single

as fast” than engraving with a single head. Typical productivity increases may vary

of an inch. In this case, you would need t

o compensate for

Section 8-9

Page 86

ACCESSORIES

How it Works

With the Dual Head installed, the special “Beam Splitter” optic inside of the Dual Head splits the laser beam in half. It reflects one half of the laser beam’s energy down through the focus lens inside the Dual Head and passes the other half of the laser beams power through the beam splitter. The laser beam goes through the beam tube and then onward through to the single heads #3 mirror where the laser beam is reflected downward through the single head’s focus lens.

Laser Beam

Beam Splitter

Beam Tube

#3 Mirror

Focus Lens Focus Len

Dual Head

Single Head

By splitting the laser beam’s power in half, you effectively get approximately 50% of the power at the Dual Head and 50% at the single head. However, since the beam splitter absorbs some energy, and there are other losses involved, getting an exact 50/50 split is not possible, but the difference in most applications, is negligible.

Installation

NOTE: The example below assumes that you have also purchased the Air Assist option. If you do not have the Air Assists option, please ignore any references to the “cone(s)” or “air hose” as these two items are the only differences between the regular Dual Head and the Dual Head with Air Assist option.

• If your laser system is not off right now, turn it OFF.

• The Dual Head will be installed to

the left side of the single head. Pick up the Dual Head assembly and note that the lower X-axis bearing pivot arm should be in about the 2 o’clock position (A) (from the backside view, and 10 o’clock from the front side.) Starting with the Dual Head rotated about 30-45 degrees counter-clockwise and tilted back towards you, slightly position the lower X-axis bearing in the lower bearing track of the X-axis rail. Gently pull up on the Dual Head while turning it clockwise back to the 0 degree position and “hooking” the top two X-axis bearings into the upper bearing track of the X-axis rail.

• Verify that all three bearings are in their respective track. Gently push the carriage to the left and

then back to the right. It should roll smoothly, if not, verify and/or re-install the Dual Head.

NOTE: B in the above image shows the Air Assist version.

Section 8-10

Page 87

ACCESSORIES

• If there is a button head screw located on the top of the Dual Head and or the single head, remove it.

• Pick up the Dual Head tube and note the “L” (Left) and “R” (Right) markings. Install the tube using

the supplied thumbscrews and tighten securely.

• If you have the Air Assist option, locate the 1 (one) black

thumbscrew on the side of the Single Head. This thumbscrew serves two purposes, it blocks air from coming out when in Single Head operation and secures the Dual Head Air Hose when in Dual Head operation. Regardless of whether or not you will be using the Air Assist option, you should always attach the Air Hose to get it out of the way. REMINDER: If you have the Air Assist option

and will not be using it, you MUST remove the air assist cone(s) before operating the system otherwise damage to the Focus Lens will occur. Refer to your Air Assist documentation on how to remove the cone(s) properly.

Brass Tube with bracket

• Remove the thumbscrew from the previous step and attach the end of the air hose to the single head

by inserting the brass tube with bracket into the hole where the thumbscrew was removed. Attach the thumbscrew into the other threaded hole (right next to the original hole), and tighten securely.

• Installation is now complete. Turn the laser system ON.

• Open the top door to illuminate the Red Diode Pointer. You will notice that the Single Heads red dot

will be brighter than the Dual Head’s red dot. This is because the Beam Splitter, inside the Dual Head does not reflect/pass visible light at a 50/50 ratio. Using the Motion Control buttons, position the Dual Head all the way as far as it will go into the upper left corner of the engraving area (0,0). It should be relatively close to (0,0) with +/- 1/16

of an inch. Now observe the position of the Single Head red dot. This is the (0,0) position of the second object and your reference point for placing your material.

Section 8-11

Page 88

ACCESSORIES

Operation

NOTE: In the following example, we will assume that your laser engraving system is a PLS4.60 that has a

maximum engraving area of 24” x 18” Landscape mode.

1. Turn ON your computer (if it is not ON already). Start your graphics program, create a new graphic or open an existing graphic.

2. Select “Print”, choose your printer (if the laser system is not set as your default), and select “Properties” to bring up the Printer Driver settings.

3. Click on the Engraving Field sub-tab within the Manual Control Tab and then click the “Dual Head” option box. A pop-up message will appear asking you to verify your page size in your graphics software because the driver’s “Width” will now be half of what it was. Make the Height less than the Width. For example, Page Orientation = Landscape, Page Width = 12 inches, Page Height = 11 inches. NOTE: Some graphics programs do not allow your “Width” to be smaller than your

“Height” when in the Landscape mode and will force you page size in your graphics program to “Portrait” mode. If this is the case and you cannot get the laser to engrave in the proper location, you might need to reduce your “Height” to something slightly smaller than your “Width” in both the Printer Driver and the graphics software program. In this example, we set the “Height” to 11 inches just to be safe.

4. Adjust the page size and orientation in your graphics program to match the page size and orientation

in the driver.

5. Adjust your rulers in your graphics program so that the upper left corner of the page, on screen is the (0,0) position.

6. Position your graphic, load your material(s) into the laser system and begin engraving.

Removal

When finished using the Dual Head, you must remove the option opposite of its installation. In the printer driver, uncheck the “Dual Head” option. If you have the Air Assist option, remember to put the black thumbscrew back into its original hole. This will prevent the loss of air pressure in the cone of the single head.

Honeycomb Cutting Table

The purpose of the Honeycomb Cutting Table is to support the material that you are cutting off of the engraving table’s surface to minimize surface contact area. It also redirects exhaust airflow below and above the material for better smoke removal. The cutting table is installed directly on top of the engraving table. It is composed of a sheet metal box, alignment rulers, and a replaceable honeycomb style bed. The honeycomb material is reflective only in the area that contacts your material to minimize laser beam reflection. It can also be used as a vacuum table, providing you have a very strong exhaust blower, to hold down slightly warped materials or materials that tend to warp during cutting or engraving.

Installation

1. Turn on your PLS machine.

2. Lower the table down all the way down.

3. Remove the strip(s) from the exhaust plenum(s) with an Allen wrench. There is one (1) exhaust plenum on the PLS3.60, PLS4.60, and PLS6.60 models and two (2) on the PLS6.120D model (as the diagram indicates).

4. Before installing the cutting table into the

laser system, loosen the screws, without removing them, on the side of the cutting table, just enough to allow the adjustable manifold to slide in and out. Extend the adjustable manifold out as far as it can go.

STRIPS

Section 8-12

Page 89

ACCESSORIES

5. Open the front door of the laser system and carefully slide the cutting table into the laser system so that its body is squarely pushed up against the engraving table rulers on the top and the side of the table. The rulers of the cutting table should now overlap the rulers on the engraving table.

6. Slide the adjustable manifold squarely up against the exhaust plenum and tighten the four (4) screws on the side of the cutting table. Be careful not to move the cutting table while tightening the screws. The objective is to have the cutting table fit snugly up against the rulers of the engraving table and the adjustable manifold fit tightly against the exhaust plenum.

7. We now need to adjust the rulers of the cutting table so that they match the engraving field of the laser system. Using the focus tool method (Section 9-17), adjust the Z Axis and focus directly onto the surface of the honeycomb.

8. Loosen slightly, but do not remove, the five (5) screws that hold down the rulers.

2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24

2 3 4 5 6 7 8 9 10 11121314151617181920 21222324

ADJUSTABLE MANIFOLD

CUTTING TABLE

ENGRAVING TABLE

EXHAUST PLENUM

ADJUSTABLE MANIFOLD

23456789101112131415161718192021222324

SCREWSSCREWS

SCREWS

1) POSITION DIODE HERE 2) THEN HERE X-AXIS RULER

23456789101112131415161718192021222324

SCREWS

Y-AXIS RULER

2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23

3) AND FINALLY HERE

9. Activate the red diode pointer by opening the top door. Position the focus carriage at (0,0). With the red diode pointer still ON, slide the X-axis ruler so that its zero (0) point lines up with the red diode pointer and tighten down the left side screw.

10. Now position the red diode pointer at the (32,0) position for the PLS6.60 and PLS6.120D series machines or (24,0) position for the PLS3.60 and PLS4.60 series machine. Adjust the right side of the X-axis ruler until it is lined up with the diode. Tighten down the right side screw of the X-axis ruler. Now tighten down the middle screw.

11. Line up the right edge of the Y-axis ruler with the zero (0) line of the X-axis ruler and tighten down the top screw of the Y-axis ruler.

12. Finally, position the red diode pointer at the (0,18) position for the PLS6.60 and PLS6.120D series machine or the (0,12) position for the PLS3.60 and PLS4.60 series machine. Align the bottom of the Y-axis ruler with the red diode pointer and tighten down the bottom screw of the Y-axis ruler. The cutting table is now installed but lens calibration is needed.

Section 8-13

Page 90

ACCESSORIES

Focus Lens Calibration

To properly use the Honeycomb Cutting Table you NEED to calibrate your focus lens to the top of the Honeycomb Cutting Table surface. If you do not calibrate the focus lens the focus carriage may cause damage to your Honeycomb Cutting Table and focus carriage.

13. After you have installed the Honeycomb Cutting Table into the

PLS, manually focus to the Honeycomb Cutting Table surface by following the Focus Tool Method instructions in Section 9-17.

14. Once that is complete, go directly to your System Tab of the UCP and you will notice that the red CALIBRATE button for the Cutting Table box will be activated. Click on the CALIBRATE button. A window will appear. To accept the new Z-height click on SAVE. You are now done calibrating the new Z-height for engraving or cutting on the Honeycomb Cutting Table.

When removing the cutting table, lower the engraving table and slide the table out of the front door. Re-install the exhaust plenum strip(s). As long as you followed the installation instructions exactly, it is designed so that you will NOT need to adjust the adjustable manifold or the X or Y-axis rulers when re-installing the cutting table.

EFFECT ENGRAVING

AREA

Focus Lens Kits

There are three optional Focus Lens Kits available other than the standard 2.0”, they are the 1.5”, 2.5”, and the 4.0” kits. Included in these kits are the focus lens (A), #3 mirror (B), front plate (C), thumbscrews (D), and a focus tool (E).

Different lenses produce different spot sizes and have different focal ranges. For example, the 1.5” lens produces a spot size of .003” and has an effective focal range of +/- .075”. This lens can engrave very fine detail but can only be used on very flat materials. On the opposite end, the 4.0” lens has a spot size of .013” but has an effective focal range of +/- .2”. Although this lens cannot engrave very fine detail, its focal range allows you to engrave on slightly rounded or curved objects without the need for rotation. Using a baseball as an example, focus the beam halfway between the highest point and the lowest point of engraving. Since a 4.0” lens has a greater focal range than a shorter lens, you can engrave a considerable distance around the ball without having to rotate it. Attempting to engrave further around the ball will result in a loss of engraving power and a distorted image.

Refer to the following chart for spot sizes and focal ranges of the lense s availa ble.

HIGH POINT

FOCUS HERE

LOW POINT

Section 8-14

Page 91

ACCESSORIES

FOCAL LENGTH SPOT SIZE FOCAL RANGE

1.5 “ .003 “ + / - .075 “

2.0 “ .005 “ + / - .100 “

2.5 “ .007 “ + / - .125 “

4.0 “ .013 “ + / - .200 “

Rotary Fixture

The Rotary Fixture has been designed to engrave cylindrical objects. Two attachments come with the fixture, a cone shaped disk attached to the motorized end of the fixture and an inverted cone shaped disk attached to the adjustable end of the fixture. These attachments are used to hold wineglasses, mugs, cups, etc. To make it easier to understand, we will illustrate a step-bystep procedure to engrave an image on a glass.

NOTE: These instructions apply to many different models even if your system has a smaller or larger field size. If the rotary is installed and mounted on the table in any other manner then the one mentioned below please contact the Technical Support Department for further instructions on calibrating the rotary.

Installation

1. Turn the UCP and laser system ON.

2. Make sure AUTOFOCUS is NOT activated because the Rotary Fixture was not designed to work with

AUTOFOCUS.

3. Remove any materials that may be underneath the engraving table and lower the table ALL THE WAY down to the bottom or at least far enough down so that the focus carriage will clear the top of

the Rotary Fixture when it is installed on the table.

4. Now, turn the laser system OFF.

5. Open the top door. Place the bracket on the table (1). Insert the thumbscrews and washers (2) into

the screw holes but do not tighten down completely. Leave the thumbscrews loose enough so that the bracket can slide.

2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24

10 11

6. Place the Rotary Fixture on a flat surface. Using an Allen wrench, attach the two socket head shoulder screws (3) to the side of the base plate.

7. Place the Rotary Fixture on top of the bracket so that its pivot bolts set into the forks in the bracket. Gently push the fixture (4) flat up against the top ruler. NOW, tighten down the thumbscrews (5).

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24

Section 8-15

Page 92

ACCESSORIES

8. With the power to the system still OFF, connect the 7-pin Rotary Fixture control cable to the receptacle on the laser engraving system (6).

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24

TURN THE LASER SYSTEM OFF BEFORE

WARNING

CONNECTING OR DISCONNECTING

THE ROTARY FIXTURE

9. Before loading the glass into the fixture, measure the diameter (7) of the glass in the area where the engraving is to be located by using a caliper or similar

measuring device. Either remember this number or write it down.

10. Place the open end of the glass (10) on the right side of the Rotary Fixture. Lift the lever

(8) on the adjustable end of the fixture and slide it up against the base of the glass so the glass rests firmly centered inside of the inverted cone. Push the adjustab le end of the

fixture (9) to the right, firmly against the bottom of the glass. Do not to apply too much pressure, especially with glass. You only need enough pressure to prevent the object from slipping on the cone while it rotates. Lower the lever on the end of the fixture to lock it in place.

NOTE: If engraving a tapered object (1), the Rotary Fixture can be rotated to maintain proper focus. To do this, lift

up the left end of the fixture and place some sort of spacer underneath the fixture (2) to prop it up. Slide the spacer left and right until the su rface of

the object is parallel (3) to the Focus Carriage. Be careful not to raise the

Rotary Fixture too high (5), otherwise parts of it might interfere with the Focus Carriage (4). If you operate the fixture in this manner, you might need to taper your graphic in your software so that it matches the taper angle of your object. Otherwise, your graphic might appear to be tapered when it is engraved.

11. Power ON the laser system. The rotary will run through a self test and will slightly rotate. This movement is normal. If rotary calibration is needed proceed to the next page. If rotary calibration is not needed proceed to the next page, “Determining Graphic Placement”.

Section 8-16

Page 93

Calibration

ACCESSORIES

1. Select the System Tab and click on the CALIBRATE button in the Rotary box. After the button has been clicked a Rotary Calibration window will appear with Y Position and Z Position boxes. Now, in the Y Position box use the Y Axis buttons (2) to move the focus carriage back and forth. Place the focus carriage exactly at 2.625”. Next, use the X Axis buttons (1) to move the focus carriage left and right and place the red LED over the flat part of the concave metal fixture normally located on the left hand side on the rotary. Now, use the Z Axis buttons (3) or the Z Axis Menu on your keypad (recommended) to move the table up and down and use the Focus Tool method (Section 9-17) to focus on top of the flat part of the concave metal fixture with the focus tool. DO NOT focus on top of the black metal cover that is located on the left hand side of the rotary. Ignore any mention to the MANUAL FOCUS POSITION feature and carefully focus on the top of the concave metal fixture.

2. After focusing is complete click both SAVE buttons on the Rotary Calibration window. If asked to overwrite an existing position accept the new value by clicking on YES. Once complete click the CLOSE button and the focus carriage will re-home once you exit the window. Calibration is now complete.

The rotary option on the printer driver has to be set and the rotary has to be installed properly and calibrated in order for this accessory to function correctly.

Determining Graphic Placement

We now need to determine where we want the engraving to appear on the glass. You can use the top ruler as a visual aid in referencing the engraving area of the glass or you can use the Red Diode Laser and the X-Y coordinate system to precisely place the graphic in your graphics program. To be more precise, we will use the Red Diode Laser Pointer.

To activate the Red Diode Laser Pointer, open the top door, if it’s not already open. Using the MOTION CONTROL buttons on the PLS keypad, position the Focus Carriage above the glass and observe the Red Diode Lasers position by entering the XY menu. Stop movement where you would like the top of the graphic (the right dotted line in the engraving area) to begin. Look at the XY menu and read the “X” position. Remember this number or write it down. Ignore the “Y” position. Now, position the red dot at the lowest point (the left dotted line in the engraving area) on the glass where you would like the engraving to end. Remember this “X” coordinate or write it down.

In this example our upper limit is about 20.500” and the lower limit is 19.000”. We have now set up the glass to be engraved. Close all doors of the laser system, go to your computer, and open your graphics software.

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24

Section 8-17

Page 94

ACCESSORIES

Printer Driver Settings

With your graphics software open, proceed immediately to “Printer Setup” and open the printer driver. In the printer driver, click on the Engraving Field sub-tab within the Manual Control Tab, and set to the maximum field size of the laser system in the Engraving Field section by typing in the size or clicking on the “Max Size” button. In this example, we will set it to 24 x 12 inches. Then, click on the “Enable” selection box in the Rotary section and type in the diameter of the glass that was measured. Do not change the “Rotation Factor” number unless it needs to be changed or calculated the number according to Section 9-16. Set your appropriate power and speed settings in your printer driver before engraving the object.

Notice that while typing in the diameter, the size of the height dimension changes automatically. Remember or write down this new page size. In this example, the diameter of the glass is 3.075 inches. After typing in this number, observe that the new page height is now 9.66 inches. Click on “OK” and go back to the graphics software’s page setup and change it to EXACTLY match the new page size that the Printer Driver established when the diameter of the object was typed in.

This new vertical page size is now the actual circumference of the object that is going to be engraved. From the top of the page (on screen) to the bottom represents one complete revolution of the Rotary Fixture. For example, if engraving a glass that has a diameter of 3.075 inches (78.1 mm), the driver calculates that the circumference of the glass (and

2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24

vertical page size) is 9.66 inches (245.4 mm).

Position the graphic, on screen, so that it will fit vertically within the new vertical page height (circumference) and horizontally within the upper and lower engraving limits that we earlier determined with the Red Diode Laser Pointer. If the graphic does not fit within the vertical page size limits, the portion that is outside the page limit will not engrave. Remember, the new page size that the driver calculates from the diameter of the glass is its actual circumference. From the top of the page down to the bottom is one complete revolution of the glass. Since the Rotary Fixture will not turn more than 360 degrees, make sure that the graphic lies between the page limits.

You are now ready to print to the laser system. Make sure that your system is ready to engrave and then begin the process.

Rotary Fixture Removal

Turn the UCP and laser system OFF. Unplug the fixture’s power cable. Remove fixture from laser system by lifting it off the bracket. If you plan on using your fixture daily, you might want to leave the bracket attached to the table so that you can easily load and unload the fixture. If you seldom use the fixture, you might want to remove the bracket from the engraving table because the bracket may interfere with using “Autofocus”. If you use “Autofocus” and leave the bracket attached to the table, the thinnest piece of material that you can “Autofocus” on would be the thickness of the bracket because the “Autofocus” sensor can only detect materials taller than the bracket unless the bracket is removed. If you do not use “Autofocus”, then you can leave the bracket attached to the table, it is your choice.

Section 8-18

Page 95

Part 4- Advanced User

Page 96

Page 97

Section 9

Advanced System Operation

From the Universal Control Panel menus and buttons to focusing, loading and unloading materials, this section covers the actual laser engraving and cutting process for the advanced user.

Printer Driver Controls Definitions and Terminology

Vector Graphic: An image generated from mathematical descriptions that determine the position,

length, and direction in which lines are drawn. Vector graphics are composed of fills and/or outlines.

Fill: A color, bitmap, fountain, or pattern applied to the interior area of a vector graphic. Outline: The line that defines the shape of a vector graphic. Bitmap: An image composed of grids of pixels or dots. Motion System: The mechanical/electrical system that delivers the laser beam by moving the

focusing lens directly above the application material.

Laser Beam Delivery Method (Mode): Three distinct ways the laser system can deliver the laser

beam to the application material called raster engraving, vector marking, and vector cutting.

Raster: The process where the laser beam makes a series of bi-directional, horizontal scan lines to produce an image. Fills and Bitmaps are automatically raster engraved by the laser system.

Vector: The process where the laser beam follows the path of the outline (if present) of the graphic.

Marking: Setting the laser power low enough to only penetrate the surface of the material. Cutting: Setting the laser power high enough to cut all the way through the material (if the material can be cut).

Section 9-3

Page 98

ADVANCED SYSTEM OPERATION

NOTE: When adjusting the printer driver settings in the Manual Control Tab, it is highly recommended that you practice engraving or cutting on a scrap portion of that material in case the settings need to be re-adjusted to obtain the desired results.

Manual Control Tab

The Manual Control Tab in the printer driver gives you full control of the engraving and vector settings. This tab of the printer driver is meant for the advanced user.

Color, Power, Speed, and PPI

To change the % Power, % Speed, and/or PPI of a color, position the mouse arrow o n the color na me and click once. This will highlight the color’s parameters and will allow the changing of the settings by using the scroll bars, plus (+) or minus (-) buttons, or by typing in each setting in the appropriate control box. It is possible to click on more than one color to set them to the same setting at the same time.

% Power

Available settings are from 0 to 100%. This setting is directly related to how deep the engraving will be. The higher the setting, the deeper it engraves, marks, or cuts, and vice-versa.

% Speed

Available settings are from 0 to 100%. This setting determines the maximum rate of travel of the motion system. Actual engraving time (throughput) is not only dependent on the % Speed setting, but is also dependent on the size and the placement of the graphic in the engraving field. The motion system will accelerate/decelerate as fast as it can up to the chosen speed. If the motion system cannot achieve the chosen speed based on the size of the graphic or graphical placement in the field it will automatically adjust its speed internally to the maximum speed it can achieve. This is evident when you see the motion system automatically slow down while cutting curves or circles as opposed to straight lines. Automatic proportional pulsing (see PPI) of the laser beam will ensure that there is no difference in the depth of cut from straight lines to curves. Remember that depending on the graphic and your chosen settings, increasing or decreasing the speed setting will not necessarily process the file faster or slower, respectively. We will discuss how to optimize the throughput of the system later in this manual.

% Power and % Speed work together in determining how deep the engraving or cutting will be. Higher power and slower speeds produce deeper results. Lower power and higher speeds produce shallower results.

NOTE: arm, movements in the Y-direction, and also depending on which model you have, vector speeds will range from one-third to one-half the maximum raster speed.

PPI

Available settings are 1 to 1000. The laser beam is always pulsing and never “on” continuously even though it may appear that way. The PPI setting indicates how many laser pulses, per linear inch, the laser cartridge will emit. The pulsing of the laser beam is electronically linked to the motion system. These pulses will always fire, equally spaced, from one to the next, regardless of changes in speed.

In raster mode, the laser pulses are applied in bi-directional, horizontal scan lines just like a dot matrix printer. If you set the PPI to 500 and use the standard focusing lens (2.0”) which has a laser spot size of five thousandths of an inch (.005”), pulses will fire every .002 inches (500 PPI), which will produce pulse overlap. Raising the PPI higher, such as 1000, the pulses will overlap more whereas lowering the PPI to something like 150 will spread the pulses out far enough where they may not overlap at all. When raster engraving filled objects, it is advisable to use a PPI setting of 500 or higher.

100% raster speed is different than 100% vector speed. Due to the inertia of the X-axis

Section 9-4

Page 99

ADVANCED SYSTEM OPERATION

If using less, the image resolution of the engraving is reduced. In some rare cases, using less than 500 PPI may produce better results.

In vector mode, laser pulsing follows the path of the outline of the object. Imagine the laser system working like a sewing machine where the stitching always remains consistent whether you sew fast, slow, or around curves. The setting you use will be application material dependent. Using less than 150 PPI may result in the pulses being spread so far apart that they may or may not touch one another. Perforated paper has this characteristic. Higher PPI settings may cause more of a melting or burning effect on the edges whereas lower PPI settings may reduce the burning, melting, or charring, but may result in a serrated or perforated-looking edge. Increasing or decreasing the PPI setting does not affect engraving speed, only the frequency of the pulses.

Mode (drop down menu)

The driver uses the word “MODE” because the laser system works similar to the operation of a pen plotter output device. A pen plotter physically selects a colored pen that matches the same colored objects in your graphic, called “color mapping”, and draws the graphic, on paper, in that color. The laser system, however, applies a Mode, % Power, % Speed, PPI, and Flow (computer controlled air assist models only) setting to the individually colored objects in your graphic. Up to eight (8) sets of user-adjustable parameters, which control laser beam delivery to your application material, can be “mapped” to the respectively colored filled or outlined objects in your graphic.

NOTE: Black and white, grayscale, and color bitmaps are all mapped to the black color’s settings.

Selecting the appropriate color and clicking the drop down menu button toggles through the following laser beam delivery modes for the each of the eight respective pen colors.

• RAST/VECT (default) rasters fills and vector marks or cuts proper outlines.

• RAST rasters all fills AND outlines regardless of outline thickness.

• VECT only vector marks or cuts proper outlines. It will skip all fills and will skip all outlines with

line weights thicker than a hairline.

• SKIP ignores all fills and outlines.

Laser (drop down menu) (PLS 6.120D only)

If your system comes equipped with more then one laser tube you are given the choice of using either both laser tubes or a single laser tube (Top or Bottom). If your laser system has one laser tube, select the appropriate laser tube according to your laser system setup.

Z-Axis (drop down menu)

This control on the Printer Driver lets you offset the Z-axis table from the current focal point. When the feature is turned on and a height is set the table lowers the height entered and starts engraving. This feature can be used as a Material Thickness focusing method as mentioned on Section 9-18 of the manual.

Flow (drop down menu)

If your system DOES NOT have the Air Assist option, you MUST leave the setting to OFF otherwise your system will hesitate up to 10 seconds after you press the start button on the machine. If you purchased the Air Assist option please refer to Section 8-7 for more detailed instructions on how to use the printer driver controls properly.

Flow Rate (drop down menu)

To control the Flow Rate of the Air Assist accessory the Flow on the drop down menu needs to be activated. The Flow Rate ranges from 0% - 100% in increments of 25%.

Set Button

After making % Power, % Speed, PPI, and any other adjustments for the Pen parameters you must click the SET button to register the changes. The changes will not be saved until the OK or APPLY buttons are clicked. If the CANCEL button is clicked after the SET button the changes will not be saved and reverted back to the previous settings.

Section 9-5

Page 100

ADVANCED SYSTEM OPERATION

Save Button

By clicking Save, the “Save Engraving Setup” dialog box will appear and will allow you to enter in a file name. All settings will be stored in this file that has a “.LAS” extension. DO NOT rename the extension; the driver will not recognize the file as a laser settings file if it does not have the “.LAS” extension name. These files can be stored in any directory on your hard drive and you can have as many setting files as your disk can hold. Verify that you have clicked the SET button before you save any .LAS files to ensure you have properly saved your settings.

Load Button

To recall printer driver settings that have been previously saved, click on the “Load” button and choose the desired .LAS settings file. The settings that are currently on screen will be replaced by the settings from the .LAS file. You may abort this change by clicking Cancel; clicking OK will approve the change.

Default Button

This button will reset the driver settings to the original manufacturer values.

Cancel Button

This button closes the printer driver window and takes you back to the previous window. If the SET, OK, or APPLY buttons were not clicked the changes will not be saved by the Printer Driver.

Apply Button

The APPLY button saves all changes made to the Manual Control Tab. These changes include any modifications made to the Raster, Vector, or Engraving Field sub-tabs.

Raster Sub-Tab

Print Special Effects

In this dropdown list, you can choose from 4 different printing modes, Normal (default), Clipart, 3D, and Rubber Stamp.

Clip Art

This control simulates laser printer output and is very useful if using a drawing with many colors, shades of gray, or many outlines. It is recommended to turn this control ON when using DRAWN clipart because there may be some underlying cutting lines hiding behind filled areas. Having this control ON gives a whatyou-see-is-what-you-get output very similar to laser printer output. The entire drawing will be raster engraved, including all outlines, and only the Black color setting is used. The driver automatically turns OFF its color-mapping feature and all colors are engraved as different shades of gray, represented by a halftone pattern. The type of halftone pattern is based upon the “Quality” setting of the driver the same way grayscale bitmaps are interpreted. Since clipart images use a wide variety of colors, shades, and outlines, the only effective way of engraving these images is to have this control turned ON. Clipart mode also provides greater compatibility with Windows software that does not work well with vector devices such as the laser system. Do not activate this control when printing photographs or bitmapped images; use it ONLY with DRAWN clipart.

There are two ways to use this feature. The first method is used produce an engraving that has a contoured depth, giving it a three dimensional feel. It is used in combination with grayscale bitmaps by automatically assigning laser power levels to the shades of gray of the bitmap WITHOUT converting the image to a halftone. These power settings are based off the setting you entered for the color black, in the printer driver. The darkest shades of gray (black) will be assigned the value of the setting for the black color. The lightest shade of gray (white) will automatically be assigned a 0% power. All other shades of gray that fall between black and white will automatically be assigned an appropriate power level that matches the darkness of the color. The engraving will appear “3D” because the depth of the engraving

Section 9-6