VIDEOJET 3320, 3120 Operating Instructions Manual

Operating Instructions

Videojet 3120
Videojet 3320

P/N: AL-69452

Revision: AD, March 2007

Copyright 2006, Videojet Technologies Inc. (herein referred to as Videojet). All rights reserved.

This document is the property of Videojet Technologies Inc. and contains confidential and

proprietary information owned by Videojet. Any unauthorized copying, use or disclosure of it without

the prior written permission of Videojet is strictly prohibited.

Videojet Technologies Inc.

1500 Mittel Boulevard Phone: [phone] Offices - USA: Atlanta, Chicago, Los Angeles, Philadelphia
Wood Dale, IL Fax: [phone] INT’L: Canada, France, Germany, Ireland, Japan, Spain,
60191-1073 USA Int’l Fax: [phone] Singapore, The Netherlands,The United Kingdom

www.videojet.com Distributors Worldwide

i

Table of Contents

1 Safety Instructions....................................................... 1

1.1 Symbols Used.................................................................................. 1

1.2 Laser Classes .................................................................................. 2

1.3 Intended Use.................................................................................... 4

1.4 Maintenance and Service................................................................. 5

1.5 Safety Devices and Warning Lights ................................................. 6

1.6 Dangers to Eyes and Skin................................................................ 7

1.7 Adjustment/Modification of the Marking Field .................................. 8

1.8 Safety Information for Zinc Selenide Lenses ................................... 9

1.9 Fire and Explosion Hazard............................................................. 10

1.10 Electrical Safety ........................................................................... 10

1.11 Decomposition Products .............................................................. 11

1.12 Warning and Information Labels .................................................. 12

2 Installation ................................................................. 15

2.1 Installation and Start-up ................................................................. 15

2.2 Transport and Storage ................................................................... 15

2.3 Unpacking ...................................................................................... 16

2.4 Installation Conditions.................................................................... 16

2.5 Cooling........................................................................................... 17

2.6 Exhaust Unit................................................................................... 17

2.7 Interfaces of the Laser System ...................................................... 17

2.8 Hardware and Software Requirements.......................................... 18

2.9 Installation of the Smart Graph Software ....................................... 18

3 Description of the Laser System ............................... 19

3.1 Functioning of a Vector-Scanning Laser System........................... 19

3.2 The Laser Beam Source ................................................................ 20

3.3 The Marking Head.......................................................................... 20

3.4 The Marking of the Product Surface .............................................. 21

3.5 The Laser Parameters ................................................................... 21

3.6 The Structure of the Laser System ................................................ 22

3.7 Data and Signal Processing........................................................... 23

3.8 Technical Data ............................................................................... 24

3.9 Working Distance and Marking Field ............................................. 26

4 Operating the Laser System...................................... 29

4.1 Operation of the Laser System ...................................................... 29

4.2 Marking Elements .......................................................................... 30

ii

Table of Contents

4.3 Elements on the Supply Unit.......................................................... 31

4.4 System States of the Laser System............................................... 32

4.5 Switch-On/Off of the Supply Unit ................................................... 33

4.6 Data Transmission ......................................................................... 34

4.6.1 Connecting Cable .........................................................................................34

4.6.2 Definition of IP Address ................................................................................35

5 Maintenance.............................................................. 37

5.1 General Notes Concerning Maintenance ....................................... 37

5.2 Maintenance Plan .......................................................................... 38

5.3 Cleaning the Laser Scan Lens....................................................... 39

5.3.1 Disassembly of the Laser Scan Lens............................................................40

5.3.2 Cleaning the Laser Scan Lens......................................................................40

5.3.3 Mounting the Laser Scan Lens .....................................................................40

5.4 Update of the Smart Graph Software............................................. 41

5.5 Protocols for Maintenance, Repair and Replacement.................... 42

6 Malfunctions and Error Messages............................. 49

6.1 Notes.............................................................................................. 49

6.2 Malfunction Descriptions ................................................................ 50

6.3 Warning Messages ........................................................................ 51

6.4 Error Messages.............................................................................. 60

7 Appendix ................................................................... 87

7.1 Assignment of the Customer Interface........................................... 87

7.1.1 Interlock ........................................................................................................87

7.1.2 Inputs and Outputs (Galvanically Separated) ...............................................87

7.1.3 Inputs (Not Separated Galvanically) .............................................................92

7.1.4 Wiring Example 1: Control via PLC...............................................................95

7.1.5 Wiring Example 2: Direct Connection (MOTF - mark on the fly)...................96

7.2 Declaration of Conformity............................................................... 97

7.3 Drawings ........................................................................................ 98

7.4 Safety Data Sheets ...................................................................... 102

7.4.1 Zinc-Selenide (ZnSe) + Thorium Fluoride (ThF4) .......................................103

7.4.2 Acetone.......................................................................................................108

7.5 Abbreviations ............................................................................... 116

12/05 - Rev. AA iii

Preface

Preface

This manual...

...contains all information required for the safe operation, remedy of minor malfunctions and
maintenance of the laser system. The operation manual is always enclosed to every laser sys­tem.

This operation manual is intended for the trained operation and service personnel of the la­ser system.

This operation manual is subject to technical modifications for improvement or technical
progress without notice.

Before starting your work carefully read the chapter "Safety Instructions"!

Make sure that you have understood all notes. In case of any questions please contact Videojet
Technologies Inc. directly.

Strictly follow the instructions!

If you need help...

...please contact Videojet Technologies Inc. at 1-800-843-3610 (for all customers within the
United States). Outside the U.S., customers should contact their Videojet Technologies Inc.
distributor or subsidiary for assistance.

Videojet Technologies Inc.

1500 Mittel Boulevard
Wood Dal IL 60191-1073, USA
Phone (USA): 1 800 843 3610
International: [phone]

Fax (USA): 1 800 582 1343
Internationales Fax: [phone]
Website: www.videojet.com

iv 12/05 - Rev. AA

Preface

Caution Laser Radiation!

Caution!

With open delivery system

dangerous laser radiation

class 4 might be released!

This might cause severe burns of the eyes

and the skin as well as damage to objects!

Thoroughly read this operation manual

and strictly follow the safety instructions!

12/05 - Rev. AA v

Preface

Contents

1 Safety Instructions

2 Installation

3 Description of the Laser System

4 Operating the Laser System

5 Maintenance

6 Malfunctions and Error Messages

7 Appendix

Handheld

Smart Graph

Spart Parts List

vi 12/05 - Rev. AA

Preface

03/07 - Rev. AC 1

Chapter 1
Safety Instructions

1 Safety Instructions

1.1 Symbols Used

Note:

Registered trademarks, patterns, designs and patents are not indicated explicitly in this manu­al. This does not mean that they are out of copyrights or that they may be used freely.

Danger refers to an immediately impending danger. If the danger is not avoided, it

could result in death or severe (crippling) injury.

Warning refers to a possibly dangerous situation. If it is not avoided, it could result in

death or severe injury.

Careful refers to a possibly dangerous situation. If it is not avoided, it could result in

slight or minor injury. May also be used to warn of damage to property.

Caution refers to a possibly harmful situation. If it is not avoided, damage could be

caused to the product or to something in its environment.

Important refers to handling tips and other particularly useful information. This does not

signify a dangerous or harmful situation.

Laser

radiation

refers to the emission of laser radiation and therefore to a possibly danger­ous situation. Please comply exactly with the safety instructions! Failure to
comply with the instructions could result in minor or major injuries to the eyes
or to the skin, together with damage to property.

2 03/07 - Rev. AC

Chapter 1

Safety Instructions

1.2 Laser Classes

The Complete Laser System

The complete and closed laser system acts as a class 1 laser system in normal operation1.
Laser radiation emitted by the laser source is led completely within a shielding until it reaches
the product. The shielding prevents emerging of laser radiation or laser beam reflexes.

The Laser Source

The CO2-laser - hereinafter called laser - is operated in pulsed or continuous wave operation
respectively. The laser itself is classified as class 4. It produces invisible, infrared radiation
which is extremely dangerous for the eye and dangerous for the skin.

In pulsed operating mode the pulse frequency adjusts between 50 Hz and 20 kHz. The actual
operating mode and pulse frequency depends on the application.

Maximum values

1. Normal operation does not include service, maintenance nor repairs.

average power density energy density

at the beam outlet

up to 1,5 x 10

6

W/m

2

7 x 102 J/m2 (at 1 kHz and
50 % duty cycly

a

)

a. duty cycle: The ratio betweeen the period of laser emission and the operation terms.

in focus

up to 5 x 10

9

W/m

2

3 x 106 J/m2 (at 1 kHz and
50 % duty cycly

a

)

Laser

radiation

Caution!

As soon as the closed shielding or the housing of the laser are opened any­where the complete laser system is set to class 4!

In that case appropriate measures have to be taken in order to protect people
working in the laser area against too high radiation!

Laser

radiation

Caution with modifications!

EN 60825, part 1, »Radiation safety of laser systems«, section 4.1.1 says:

If a modification by the user to a laser system previously classified in accor­dance with this standard leads to a change of its performance data and/or its
intended use that person or organization performing the modification is re­sponsible for a new classification and labeling of the laser system.

03/07 - Rev. AC 3

Chapter 1
Safety Instructions

Important The pilot laser can be used for simulation or adjustment without the CO

2

laser. Also in this case you must ware laser safety goggles protecting against
laser radiation of CO

2

lasers.

a

a. In this case the CO2 laser is switched off via the software. Due to the laser safety regulations

safety goggles must be worn.

4 03/07 - Rev. AC

Chapter 1

Safety Instructions

1.3 Intended Use

The laser system must only be used for the treatment of material surfaces. The surfaces
are locally heated by intensive class 4 laser radiation and are modified thereby. These systems
are mainly applied for marking of product surfaces (expiry dates, batch printing, serial numbers,
etc.).

The radiation produced by the laser system is of high energy and therefore improper use rep­resents a danger to persons or objects!

Laser

radiation

• Never expose human beings or animals to laser radiation!
This might result in severe burns of eyes or skin.

• Never expose flammable materials to laser radiation!
Always ensure appropriate shielding of the laser beam! Errors during
marking on flammable materials (e.g. paper) might cause fires. Take suit­able safety measures by installing e.g. smoke or fire detectors, or similar!

• Never expose reflecting surfaces to laser radiation!
The reflected laser beam may cause the same dangers - in individual cas­es even greater dangers - as the original laser beam.

• Never expose unknown materials to laser radiation!
Some materials (e.g. polyethylene, polypropylene, glass) are easily pene­trated by the laser beam, although they seem to be opaque for the human
eye.

• Danger of explosion!
Make sure that the laser area is free of explosive materials or vapors!

• For safety reasons arbitrary modifications or changes to the laser

system are forbidden!

If a modification made by the user to a previously classified laser system
leads to a change of its performance data and/or its intended use that per­son or organization performing the modification is responsible for a new
classification and labeling of the laser system. The person or organization
is then regarded as »manufacturer«.

• The laser system must be operated with open laser and/or open beam
delivery system by specially trained personnel only!
Make sure that the laser protection rules are always observed!

03/07 - Rev. AC 5

Chapter 1
Safety Instructions

1.4 Maintenance and Service

The maintenance tasks described hereinafter should only be carried out by especially trained
personnel. The service tasks are exclusively to be carried out by service personnel of VIDEO-

JET or one of their representatives. During these works the laser system has to be operated in
class 4. The Unfallverhütungsvorschrift (Accident Prevention Regulations) 46.0 »Laser Radi-
ation« (BGV B2) says that the responsible trade cooperative association and the authority re­sponsible for occupational safety (Trade Supervisory Office) have to be given notice of class
3B or 4 laser systems before initial operation.

Note:

In order to facilitate safe performance of all necessary maintenance and service tasks without
assistance and to ensure highest safety for the operating and maintenance personnel we offer
special training seminars.

• Training for technicians:
The trainee gains the knowledge required to perform all maintenance and service tasks at
the laser system safely and professionally without assistance.

• Combined training:
In addition to the knowledge gained during the training for technicians the person is trained
as laser safety officer. This training is accepted by the trade cooperative association (see
above).

Ask for free information material!

Important We urgently recommend:

• Give notice of the laser system to the responsible trade cooperative asso­ciation and the Trade Supervisory Office before initial operation.

• Have a person responsible for the safety of the laser system trained as la­ser safety officer and inform the trade cooperative association in writing
about this person.

6 03/07 - Rev. AC

Chapter 1

Safety Instructions

1.5 Safety Devices and Warning Lights

The complete laser system includes various safety devices and warning lights which shall pre­vent damages to people or objects. There must not be any alterations to safety devices nor
warning lamps (see section "Laser Classes")!

Safety Devices

Warning Lights

Key-operated switch prevents operation of the laser system by unauthorized people.

Make sure that the key is withdrawn and available to authorized
personnel only!

Beam shutter is located within the laser head and prevents the emission of laser

radiation.

Interlock switch(es) open(s) the safety circuit. The marking process is stopped imme-

diately. If several interlock switches are connected: Laser radia­tion cannot be emitted if at least one interlock switch is opened.

Interlock switches can safeguard safety doors, protective covers,
etc. Number and position of the interlock switches are system­specific.

For the marking process all interlock switches must be closed. The
message "Error Interlock open" is displayed in the software.

After closing the interlock switch the marking process can be con­tinued after a delay of 5 seconds.

We recommend the interlock monitoring module for proximity safe­ty switches AES 1235 in combination with the magnetic guard door
BNS 33 and the actuating magnet BPS 33 by Schmersal.

Red light on the marking head lights up when the emission of laser radiation

is possible.

Red light

"Laser emission"

on the control panel of the supply unit, lights up when the emission
of laser radiation is possible.

Additional
warning lights

can be connected as external emission displays (system-specific).

03/07 - Rev. AC 7

Chapter 1
Safety Instructions

1.6 Dangers to Eyes and Skin

The ALLPRINT Laser System produces class 4 laser radiation. Infrared laser radiation is not
visible for the human eye. Therefore eyes and skin are endangered through high-energy laser
radiation.

High irradiation causes an extreme local heating and burning of the tissue. The eyes are
subject to special risks. High radiation intensity causes a local heating and burning of the cor­nea and thus a reduction or loss of sight!

Suitable safety goggles provide protection against direct, specularly reflected or diffusely scat­tered laser radiation.

Suitable safety goggles are:

• designed for the narrow wavelength range of the CO

2

laser of 10.6 µm (optional 9.3 µm).

See name plate of the laser system.

Careful with confusions!

Safety goggles for other lasers, e.g. Nd:YAG laser, do not provide adequate protection
against radiation of a CO

2

laser!

• designed for the power range of the CO

2

laser:

• are designed for pulse and continuous wave operation. The pulse frequency of the laser
system adjusts between 50 Hz and 20 kHz, depending on the application.

The skin can withstand higher radiation intensities than the eye. However - depending on the
radiation period and radiation intensity - the tissue is destroyed through burns. Therefore pro-
tect your skin by wearing adequate protective clothing! Avoid any exposure of your skin to
the laser radiation! Avoid the laser beam to get in contact with your clothing!

People within the area of the laser must wear suitable safety
goggles against laser radiation while carrying out maintenance,
adjustment or service work at the open laser housing and/or open
beam delivery system!

Never look directly into the laser beam!

Videojet 3320 30 W

Videojet 3120 10 W

Important The pilot laser can be used for simulation or adjustment without the CO

2

laser. Also in this case you must ware laser safety goggles protecting against
laser radiation of CO

2

lasers.

a

a. In this case the CO2 laser is switched off via the software. Due to the laser safety regulations

safety goggles must be worn.

8 03/07 - Rev. AC

Chapter 1

Safety Instructions

1.7 Adjustment/Modification of the Marking Field

Via the software the marking field of the laser can be modified in such a way that the laser beam
can possibly be directed to the shielding or onto other components or parts. Thus, surfaces ex­posed to irradiation can be damaged or destroyed.

A password is required for changing the marking field (if the password protection has been ac­tivated in the software). The password can be changed subsequently by a user authorized for
the corresponding user level.

We explicitly point out that the person who will fulfil a modification of the marking field,
will assume the full responsibility for any consequential damages and problems!

Laser

radiation

If, as a result of the modification, the laser beam gets accessible the com­plete laser system is set to class 4 (see section “Laser Classes” auf Seite 2).

Caution Fire and explosion hazard if there are flammable materials or explosive

atmospheres within the area of the laser beam.

03/07 - Rev. AC 9

Chapter 1
Safety Instructions

1.8 Safety Information for Zinc Selenide Lenses

Zinc Selenide

This material contains components which are dangerous to health!

Zinc selenide is toxic when inhaled or ingested. Dust may lead to irritation of the eyes and the
respiratory system. Do not eat, drink or smoke while handling zinc selenide. Wash hands thor­oughly afterwards.

For detailed information see safety data sheet in the chapter "Appendix".

Thorium

Thorium is a potential health hazard when inhaled or ingested. The thorium layer is embedded
within other layers within the lens. Thus no radioactive material can escape from the coating
as long as the lens is intact. Avoid any surface scratches of the lens.

There is no danger of radiation during normal handling and cleaning of the optical sys­tem!

In case of a broken lens...

...do not inhale material particles! In case of breaking of the laser scan lens please collect the
fragments wearing gloves (avoid raising dust when sweeping up the pieces), pack the frag­ments into a closed plastic bag and send them back to us for disposal.

Maintenance of the Laser Scan Lens

Information concerning the maintenance of the laser scan lens can be found in chapter "Main­tenance", section "Cleaning the Laser Scan Lens".

Please contact us if more information is required.

Attention The laser scan lens consists of coated zinc selenide and contains an

extremely small amount of the radioactive substance thorium. This applies to
all CO

2

laser marking systems available on the market.

10 03/07 - Rev. AC

Chapter 1

Safety Instructions

1.9 Fire and Explosion Hazard

1.10 Electrical Safety

The laser system was designed in accordance with the general rules of technology including
regulations EN 60950-1, part 1 »Information technology equipment - Safety« and EN 60825,
part 1 »Safety of laser systems«.

Laser

radiation

The high output power of a class 4 laser can inflame various materials.
Therefore, while performing maintenance and service work at the open la­ser housing and/or open beam delivery system, make sure that fire protec­tion measures were taken before starting the works!

Paper (circuit diagrams, leaflets, posters on the walls, etc.), curtains which
are not impregnated fire retardently, wooden boards or similar flammable
materials can easily be inflamed by direct or reflected laser radiation.

Make sure that the working area of the laser system is free from contain-
ers with flammable or explosive solvents or cleaning agents! Unin­tended exposure of a container to intensive invisible laser radiation might
easily cause fires or explosions.

Caution During works at the open laser housing alive components are accessible!

Make sure that rules and regulations for works on alive components are al­ways observed!

All works at the open laser housing, especially at electrical components,
must only be performed by specially trained personnel!

03/07 - Rev. AC 11

Chapter 1
Safety Instructions

1.11 Decomposition Products

An exhaust unit also prevents contamination and gradual destruction of optical elements of the
beam delivery system by dust particles. We offer different exhaust units as accessories.

Caution When treating materials with laser radiation decomposition products are pro-

duced which are dangerous to health!

Through vaporization of materials fine dust and vapors are produced which
might include hazardous decomposition products depending on type and
composition of the respective materials.

Therefore we highly recommend to install an exhaust unit according to the re­spective requirements which is equipped with special dust and activated char­coal filters to ensure that the decomposition products are sucked off where
they are produced.

Protect yourself and your colleagues against hazardous decomposition
products!

12 03/07 - Rev. AC

Chapter 1

Safety Instructions

1.12 Warning and Information Labels

Label/Symbol Position

on the marking unit

on the marking head

on the marking unit

on the marking head and (if available) on the
beam turning unit

on the supply unit

INVISIBLE LASER RADIATION

MAX. POWER: 40 W

WAVELENGHT: λ = 9 - 11 µm

LASER CLASS: 4

(EN 60825-1/10.03)

AVOID EYE OR SKIN EXPOSURE

TO DIRECT OR SCATTERED RADIATION

INVISIBLE

LASER RADIATION

THIS APERTURE

IS EMITTED FROM

Caution

Invisible laser radiation when open .

Avoid eye or skin exposure

to direct or scattered radiation.

Caution

Invisible laser radiation when open .

Avoid eye or skin exposure

to direct or scattered radiation.

Attention!

Alive unless mains line

disconnected or switched

off by central switch

03/07 - Rev. AC 13

Chapter 1
Safety Instructions

on the supply unit

Label/Symbol Position

Laser class 4 complies to EN 60825-1/10.03 and 21 CFR 1040

LASER MARKING SYSTEM

IDENT.

V

AL-68867

MODEL

SN

A Hz

PH

Wood Dale, II 60191-1073

1500 Mittel Boulevard

Videojet Technologies Inc.

WL µm

14 03/07 - Rev. AC

Chapter 1

Safety Instructions

12/05 - Rev. AA 15

Chapter 2
Installation

2 Installation

2.1 Installation and Start-up

Installation and start-up of the laser system require profound knowledge and experience.
Therefore it should be accomplished by personnel of Videojet Technologies Inc. or one of their
representatives only.

In order to facilitate quick and easy start-up please prepare the place of erection such that the
system can be installed:

• Proceed as described in section "Unpacking".

• Please provide all connections - as described in section "Installation Conditions" and in the
documents you received upon order handling - in time.

In case of questions please contact us.

2.2 Transport and Storage

The laser system is a precision-made instrument and includes numerous electronic and optical
components. Please avoid any mechanical stress (shock, vibrations, etc.) on the laser system!

In case of questions concerning transport and storage please contact us.

Transport

After unpacking the laser system should be transported in a horizontal position. Please make
sure that the supply line ("umbilical") connecting marking unit and supply unit is not
bent! Switch off the laser system before transport and disconnect mains connection!

Storage

Store the laser system in a horizontal position and protected against dust and humidity. Never
expose the laser system or one of its components to direct sunlight! The storage temperature
must not exceed +65 °C.

The laser system has to be protected against frost, which means that the storage temper­ature must not fall below 5 °C. The air humidity must be between 10 % to 90 %.

Note The company operating the laser system is responsible for the safe use of

the laser system, especially for meeting the local codes and regulations
regarding the operation of laser systems and their components (beam pro­tection, exhaust system, cooling, etc.).

Videojet Technologies Inc. does not accept responsibility for any damages
due to misuse of equipment, incorrect operation or negligence.

16 12/05 - Rev. AA

Chapter 2

Installation

2.3 Unpacking

1. Open the packaging and remove the filling material.

2. Remove the individually packed components.

3. Check all parts for damage during transport.

In case of damage please inform the forwarding agent and Videojet Technologies Inc. or
their representative immediately in writing. Keep the packaging material and note damages
on the inside and outside.

4. Transport the laser system and the components to the intended place of installation.

5. Protect the laser system and all components from dust and humidity until installation.

2.4 Installation Conditions

Space Required

The standard dimensions of the laser system can be found in the drawings in the chapter "Ap­pendix".

For systems manufactured according to special customer requirements this information can be
found in the erection plan or the dimension and data sheets you received upon order handling.

Connections

The laser system requires a mains connection. Information on the type, number and reference
values of the connections can be found in the terminal diagrams you have received upon order
handling.

The power connection cable of the laser system is 5 m long. Make sure that the adequate pow­er sockets are in range.

Ambient Conditions

Please ensure that the enwrapping cardboard box, the transport pallet and the
packaging material are recycled separately!

Temperature range: 5 - 40 °C

Air humidity: 10 - 90 %, non condensing

12/05 - Rev. AA 17

Chapter 2
Installation

2.5 Cooling

The laser system is cooled by air. The internal cooling system is designed to supply sufficient
cooling.

Make sure that the cooling air can be sucked in and blown out freely and that there is sufficient
air exchange at the installation site to ensure heat dissipation.

2.6 Exhaust Unit

In order to remove marking residues which might be dangerous to health we recommend in­stalling a exhaust unit. The exhaust unit is to be installed such that marking particles are sucked
off directly at the place of the formation.

In addition a exhaust unit prevents that dust particles gradually destroy optical components of
the laser system.

We offer exhaust units as accessories. If an exhaust unit is part of the complete delivery please
find further information in the enclosed operation manual of the exhaust unit.

2.7 Interfaces of the Laser System

Network interface Connection of the handheld. Electrical power for the handheld is

supplied by the switched-on laser system.

Connection of a PC for controlling via Smart Graph software.

Interlock circuit
(Label IL)

The interlock circuit is used to safeguard the laser system. If one
of the interlock switches connected to the interlock circuit opens
the marking stops immediately. The marking cannot be continued
until all interlock switches are closed and the START-button is
pressed.

The closed interlock circuit is supplied with a voltage of +30 V by
the laser system.

Customer interface The general assignment of the customer interface can be found in

chapter "Appendix".

The customer-specific assignment of the customer interface can
be found in the data sheets you received upon order handling.

18 12/05 - Rev. AA

Chapter 2

Installation

2.8 Hardware and Software Requirements

To operate the Smart Graph software properly the following hardware and software require­ments have to be met:

• Pentium PC

• Windows 2000 or XP

• 128 MB RAM

• min. 50 MB hard disk memory

•CD-ROM drive

2.9 Installation of the Smart Graph Software

If a PC is part of the delivery the Smart Graph Software is installed already.

To install the Smart Graph Software please follow the steps as described below:

1. Insert the Smart Graph Software CD-ROM into the CD-ROM drive of your PC.

2. Select »Execute« from the start-menu of your Windows operating system.

3. Enter CD:\setup.exe in the text field and follow the instructions of the InstallShield wizard

(CD is a place holder for the letter of the CD-ROM drive in your PC).

03/07 - Rev. AD 19

Chapter 3
Description of the Laser System

3 Description of the Laser System

3.1 Functioning of a Vector-Scanning Laser System

The CO2-laser (2) working in pulsed or continuous operation produces an infrared invisible la­ser beam with small diameter. The laser beam is expanded by means of a two-lens telescope
(3) and reaches the marking head (4).

Two movable mirrors deflect it such that it passes over the lines of the opened template on the
product. The lines are divided into vectors (X and Y coordinates). The line up of vectors pro­duces a marking on the product, the laser »writes« on the product surface.

The calculation of vectors and the control of the laser is performed by the Advanced Controller
Card (ACC) in the supply unit (1).

The deflected laser beam is focussed onto the product surface (7) by a laser scan lens (5).
Generally the marking is produced at the focus of the lens (6).

Figure 3-1: Functioning of a vector-scanning laser system

20 03/07 - Rev. AD

Chapter 3

Description of the Laser System

3.2 The Laser Beam Source

A sealed-off CO2-laser serves as beam source for the laser system. Inside the laser source
CO

2

-molecules are stimulated by a high-frequency voltage to emit infrared laser radiation.

The generated laser radiation is reflected between two facing mirrors, and by means of stimu­lated emission the laser radiation is amplified.

The end mirror reflects 100 % of the radiation while the other mirror - the output coupler - re­flects only about 80 % of the laser radiation, which means that 20 % are coupled out for the
marking process.

3.3 The Marking Head

After the laser beam is expanded by the telescope it reaches the marking head. Two movable
mirrors are located inside the marking head which deflect the laser beam vertically and hori­zontally.

The X and Y axes of the coordinate system of the marking field are defined by the position of
the marking head. A translation or rotation of the marking head also translates or rotates the
axes of the coordinate system. X and Y axes in relation to the marking head are defined as
displayed in the following figure:

Figure 3-2: The coordinate system

+ X

+ Y

marking field

03/07 - Rev. AD 21

Chapter 3
Description of the Laser System

3.4 The Marking of the Product Surface

The marking of the product surface is performed by the effect of intense laser radiation on the
product material.

The laser beam is focussed onto the product surface and heats up the topmost layer of the ma­terial, which causes a color change or a vaporization of the topmost dye layer.

The symbols and characters which shall be marked on the product are subdivided into vector
strokes (1). Each vector stroke is again subdivided into smaller vectors.

When the laser beam jumps from one stroke to the next (2) the laser is switched off and the
product is not marked.

Figure 3-3: Strokes and jumps

3.5 The Laser Parameters

Parameters are used to adapt the laser system to different materials. These parameters have
to be determined and adjusted for each application in order to achieve the best possible mark­ing quality.

Determining the correct parameters requires profound knowledge and experience, because
the parameters highly depend on the application and the material which shall be marked. In
case of questions please contact us.

The parameters for individual materials are combined in parameter sets. Parameter sets can
be generated and altered either with the handheld or the Smart Graph software. For detailed
information on the parameters please refer to the respective chapters.

22 03/07 - Rev. AD

Chapter 3

Description of the Laser System

3.6 The Structure of the Laser System

The laser system consists of the supply unit (1) and the marking unit comprising the laser head
(2) and the marking head (3). The supply unit is controlled via the handheld or via the Smart
Graph software on a PC.

The marking head is attached to the laser head. Optionally a beam turning unit is attached be­tween marking head and laser head.

Figure 3-4: The laser system Videojet 3320

Figure 3-5: The laser system Videojet 3120

1

3

2

1

3

2

03/07 - Rev. AD 23

Chapter 3
Description of the Laser System

3.7 Data and Signal Processing

The Advanced Controller Card (ACC) is the main circuit board of the laser system. The ACC
contains two processors controlling the complete system.

PowerPC (PPC): The PPC uses the main memory (128 MB) and controls part of the interfaces.
On the PPC the AOS is running under Linux and communicates via different interfaces (ether­net, USB) with the connected external control units. For integrating the laser system into exist­ing installations the AOS provides various functions and can be adapted to the required task
via a programming language (TCL). In the marking process the AOS generates data from the
existing templates to be transferred to the second processor.

Digital Signal Processor (DSP): The DSP processes the data coming from the AOS and gen­erates position data for the marking head in order to control the movement of the laser beam
according to the template settings. The position data are transferred to the FM board and con­verted into mirror movements. At the same time the laser is switched on and off.

Additionally the DSP controls the fast inputs for trigger signals and incremental encoder per­mitting precisely positioned markings on moving products.

The different interfaces and their processing by the ACC board are displayed in the following
figure:

Figure 3-6: Data and signal processing of the laser system

Supply unit Laser head Marking head

Memory

Ethernet 1

USB

Customer
Interface

Ethernet 2

Serial

LVDS

IOEB (optional)

ACC

CAN

PPC

DSP

MMC

FPGA

Laser

FM

24 03/07 - Rev. AD

Chapter 3

Description of the Laser System

3.8 Technical Data

Unit Videojet 3120 Videojet 3320

Laser type sealed-off CO

2

laser

Operating modes • continuous wave (cw)

• pulsed 50 Hz - 20 kHz

Laser class 4

Laser power typ. W = 10 =30

Max. power consumption kW 0.4 0.7

Supply voltage VAC 85 to 240 (autorange); 1-phase

Mains frequency Hz 50 / 60

Fuse A 10 (quick-action)

Ambient temperature °C 5 - 40

(for special requirements please contact us)

Humidity % 10 - 90; non condensing

Excitation RF

Weight (typical)

- supply unit

- laser head

- marking head SHC 60

- marking head SHC 100/120

kg

11.5
13

1.4

2.2

11.5

19.1

1.4

2.2

Sealing IP 54S (optional IP 65)

Wavelength µm 10.6 10.6 (optional 9.3)

Marking speed

a

mm/s 1 - 30,000

Speed of production line m/s 0 - 10

Characters/Second

a

max. 1200

Focal length of focusing lens

•SHC 60

•SHC 100/120

mm

64; 95; 127; 190; 254

63,5; 85; 100; 150; 200; 300; 351; 400

Focus diameter µm 150 - 450

(depending on the installed optics)

Line width depends on the material

and the laser parameters

03/07 - Rev. AD 25

Chapter 3
Description of the Laser System

Due to our policy of continuous improvement, technical data is subject to change without no­tice.

Fonts (character sets) any standard font

(special characters on demand

for additional charge)

Cooling internal air-cooling

Max. distance between sup­ply unit and marking unit

m 5 (standard 2, others on demand)

Control Handheld and/or IBM-compatible PC with

Smart Graph software

under Windows XP

Interfaces Network interfaces, USB

a. Any statements referring to marked characters or actual markings are typical values. These

values highly depend on the material and may only be taken as a guideline. These are no
specifications

Unit Videojet 3120 Videojet 3320

26 03/07 - Rev. AD

Chapter 3

Description of the Laser System

3.9 Working Distance and Marking Field

Marking Head SHC-60

For more information about the marking head installed in the laser system, please refer to the
Smart Graph software under Configuration > Marking head.

In order to receive this information, the laser system has to be in the online mode.

laser scan lens:
focal length f

64 mm 95 mm 127 mm 190 mm 254 mm

working distance 67 mm 96.5 mm 125 mm 182 mm 236 mm

max. width (A) 44.7 mm 66.3 mm 88.7 mm 132.6 mm 177.3 mm

max. height (B) 44.7 mm 66.3 mm 88.7 mm 132.6 mm 177.3 mm

height for max.
rectangle (b)

41.9 mm 62.3 mm 83.2 mm 124.5 mm 166.5 mm

width for max.
rectangle (a)

32.2 mm 47.8 mm 63.9 mm 95.6 mm 127.8 mm

max. rectangle:
marking field

41.9 x 32.2

mm

2

62.3 x 47.8

mm

2

83.2 x 63.9

mm

2

124.5 x 95.6

mm

2

166.5 x 127.8

mm

2

working distance

03/07 - Rev. AD 27

Chapter 3
Description of the Laser System

Marking Head SHC-100

Marking Head SHC-100

laser scan lens:
Focal length f

63.5 mm

85 mm

a

a. The max. marking field size only is available, when the exhaust nozzle is removed from the focussing module!
In the case of using the exhaust nozzle, the marking field size is reduced to a circular area of 46 mm diameter!

100 mm 150 mm

working distance 89.0 mm 89.0 mm 94 mm 142 mm

max. width (A) 30.8 mm 47.1 mm 73.3 mm 110.0 mm

max. height (B) 38.2 mm 62.6 mm 101.2 mm 151.8 mm

height for max.
rectangle (b)

27.0 mm 44.2 mm 81.3 mm 122.0 mm

width for max.
rectangle (a)

21.8 mm 33.3 mm 56.7 mm 85.0 mm

max. rectangle:
marking field

27.0 x 21.8

mm

2

44.2 x 33.3

mm

2

81.3 x 56.7

mm

2

122.0 x 85.0

mm

2

laser scan lens:
Focal length f

200 mm 300 mm 351 mm 400 mm

working distance 191 mm 278 mm 338 mm 385 mm

max. width (A) 146.6 mm 219.9 mm 257.3 mm 294.7 mm

max. height (B) 202.5 mm 303.7 mm 355.3 mm 406.9 mm

height for max.
rectangle (b)

162.7 mm 244.0 mm 285.5 mm 326.9 mm

width for max.
rectangle (a)

113.3 mm 170.0 mm 198.9 mm 227.8 mm

max. rectangle:
marking field

162.7 x 113.3

mm

2

244.0 x 170.0

mm

2

285.5 x 198.9

mm

2

326.9 x 227.8

mm

2

28 03/07 - Rev. AD

Chapter 3

Description of the Laser System

Marking HeadSHC-120

Marking Head SHC-120

laser scan lens:
Focal length f

63.5 mm

85 mm

a

a. The max. marking field size only is available, when the exhaust nozzle is removed from the focussing module!
In the case of using the exhaust nozzle, the marking field size is reduced to a circular area of 46 mm diameter!

100 mm 150 mm

working distance 89.0 mm 89.0 mm 94 mm 142 mm

max. width (A) 29.1 mm 44.2 mm 73.3 mm 110.0 mm

max. height (B) 36.2 mm 58.8 mm 87.3 mm 130.9 mm

height for max.
rectangle (b)

25.6 mm 41.6 mm 77.6 mm 116.4 mm

width for max.
rectangle (a)

20.6 mm 31.3 mm 53.7 mm 80.6 mm

max. rectangle:
marking field

25.6 x 20.6

mm

2

41.6 x 31.3

mm

2

77.6 x 53.7

mm

2

116.4 x 80.6

mm

2

laser scan lens:
Focal length f

200 mm 300 mm 351 mm 400 mm

working distance 191 mm 278 mm 338 mm 385 mm

max. width (A) 146.6 mm 219.9 mm 257.3 mm 294.7 mm

max. height (B) 174.5 mm 261.8 mm 306.3 mm 350.8 mm

height for max.
rectangle (b)

155.2 mm 232.7 mm 272.3 mm 311.9 mm

width for max.
rectangle (a)

107.5 mm 161.2 mm 188.6 mm 216.0 mm

max. rectangle:
marking field

155.2 x 107.5

mm

2

232.7 x 161.2

mm

2

272.3 x 188.6

mm

2

311.9 x 216.0

mm

2

03/07 - Rev. AD 29

Chapter 4
Operating the Laser System

4 Operating the Laser System

4.1 Operation of the Laser System

The laser system is built up modularly. Depending on the laser system installed in your pre­mises there are several ways to generate a marking template and starting the marking process.
The laser system can be operated:

• via the handheld or

• using a PC with the Smart Graph software.

handheld The handheld gives you easy access to the controls of the

laser system. It is connected to the supply unit via the network
interface. One handheld can be used for different supply units.
It permits you to:

• generate or alter a marking job.

• generate and alter templates (limited).

• adjust the laser parameters.

• configure the laser system.

Smart Graph software The Smart Graph software runs on your personal computer

under Windows 2000 or XP. With the Smart Graph software
you can access the full range of fonts, logos and tools to cre­ate even complex layouts and preview the marking on your
monitor. In addition you can access all laser parameters and
system settings.

Using the Smart Graph software you can transfer the created
templates directly to the supply unit.

30 03/07 - Rev. AD

Chapter 4

Operating the Laser System

4.2 Marking Elements

The following elements must be defined in order to mark a product:

The combination of the four elements marking content, parameter set, product registration and
positioning within a template offers the possibility to adapt the marking to different marking
tasks in a very short period of time.

Examples:

• You want to mark a certain text on synthetic material instead of paper. Hence you change
your parameter set from »paper« to »synthetic material«.

• You want to change the position of the marking on you product. For that you just change the
positioning data directly in your template or in the user interface »Laser Operation« under
»Marking settings«.

Marking Contents The marking content defines the layout of the marking, e.g. text

elements, logos, serial numbers, fonts, etc.

Parameter Set Parameter sets adjust the laser system to the respective material

of the product. A parameter set contains e.g. information on the
laser power or the marking speed.

Product Registation The product registration contains all data necessary to detect the

product and to trigger the marking process.

Positioning Data The positioning data defines the positioning and the size of the

marking on the product.

03/07 - Rev. AD 31

Chapter 4
Operating the Laser System

4.3 Elements on the Supply Unit

No. Type Function

S1 Main switch

(at the back of the
supply unit)

applies the mains power for the supply unit.

S2 Key switch applies the power supply for the laser beam source. The

marking process can be started.

Note:

Remove the key if switched off to protect the system from
unauthorized operation!

S3 Start and stop switch With »START« the currently selected template can be

marked and with »STOP« a marking process can be
stopped.

L1 LED

-white-

• flashes during initialization of the laser system.

• is on when the laser system is ready for operation.

• is on during the marking process.

L2 LED

-yellow-

flashes in case of malfunction.

L3 LED

-red-

is on when the key switch is in position »1«.

Simultaneously the red LED on the marking head lights up.

I1 Socket connection of the handheld.

S1

S2

S3

L1

L3

L2

I1

32 03/07 - Rev. AD

Chapter 4

Operating the Laser System

4.4 System States of the Laser System

On the handheld and in the Smart Graph software the current laser system state is displayed.

There are the following system states:

System State Description

Initialize The control components of the laser system are started.

Key-switch open The initialisation is complete. The system can now be started by

closing the key-switch.

Laser start-up After closing the key-switch the laser and the cooling system are

activated.

Laser ready The laser system is ready for marking.

Prepare for marking After pressing »START« the laser requires a preparation time,

the length depends on the template contents and the configura­tion.

Marking The current marking content is marked onto the product.

Laser radiation is emitted!
Make sure that the safety instructions are observed.

Standby If no marking is carried out for some time the laser switches to

standby in order to relieve the system components.

Interlock open The safety circuit is interrupted (e.g. protective door open). A

marking process is stopped immediately. Marking is only possi­ble with closed safety circuit.

Error An error occurred. To continue operation the error must be con-

firmed. Information on the error can be found on page »Mes­sages«.

Fatal error A fatal error occurred and has deactivated the system. This error

cannot be confirmed and the operation cannot be continued.
The laser system has to be turned off. Information on the error
can be found on page »Messages«.

Service mode This system state enables service and maintenance work and

must only be used by especially trained personnel.

03/07 - Rev. AD 33

Chapter 4
Operating the Laser System

4.5 Switch-On/Off of the Supply Unit

Switch-On

1. Make sure that the safety instructions are observed.

2. If installed: Switch on the exhaust unit.

3. Make sure that the key switch is in position »0«. Put main switch (S1) to position »I«.

The white LED flashes, indicating the initialization of the laser system. This process can take
1 to 2 minutes. After that the system is ready for operation and the white LED is on.

4. Switch on the key switch.

The red LED on the supply unit and the red LED on the marking head are on. The laser is
ready.

Switch-Off

1. Stop the marking process.

2. Turn the key switch to position »0«.

The red LED on the supply unit and the red LED on the marking head are turned off.

3. Turn the main switch to position »0«.

The white LED is turned off.

4. If installed: Switch off the exhaust unit.

34 03/07 - Rev. AD

Chapter 4

Operating the Laser System

4.6 Data Transmission

4.6.1 Connecting Cable

For connecting the components of the laser system the following cables are used:

Handheld

↔ Supply Unit: Special cable

PC (Smart Graph software)

↔ Supply Unit: Crossover Ethernet cable

PC (Smart Graph software)

↔ Switch ↔ Supply Unit: Patch cable

Optional:
Second network interface for connecting a PC and a handheld simultaneously (for
this the board IOEBB is required).

special cable

handheld connection

X8 supply

X12 network

X12 network

crossover ethernet cable

X12 network

patch cable

patch cable

internal network

UPLINK

03/07 - Rev. AD 35

Chapter 4
Operating the Laser System

4.6.2 Definition of IP Address

On the ACC board there is a DIP switch.

Using the DIP switch you can set the IP address as follows:

The DIP switch 1 is set to ON when the laser system is delivered.

DIP switch 1 ON: The IP address 192.168.1.1 with subnet mask 255.255.0.0 is saved

in the system database. Via this address the PC or the handheld
can communicate with the laser system.

DIP switch 1 OFF: The IP address can be set in the Smart Graph software. Thus a net-

work can be installed.

DIP switch

36 03/07 - Rev. AD

Chapter 4

Operating the Laser System

03/07 - Rev. AB 37

Chapter 5
Maintenance

5 Maintenance

5.1 General Notes Concerning Maintenance

The time for maintenance of the laser system is very short. Please carry out maintenance
works in the stated intervals.

The laser system is designed such that maintenance can be performed safely.

Caution • Maintenance has to be performed by instructed operating and mainte-

nance personnel only!

• For reasons of safety make sure that the main key-operated switch is
turned to '0', the key is withdrawn and the mains is disconnected!

Before the beginning of the cleaning works of the laser system and
its environment, the laser system must be disconnected from the
power supply.

• Document the regular maintenance in the maintenance protocols in this
chapter! Non-conformance with the maintenance plan might result in limi­tations of warranty.

38 03/07 - Rev. AB

Chapter 5

Maintenance

5.2 Maintenance Plan

The maintenance intervals are laid out for a use of the laser system of approximately 10 hours
daily and regular dirty work area.

If the time of daily use should exceed 10 hours continuously or in case of very dirty ambient
conditions please shorten the maintenance intervals accordingly. In case of questions please
contact Videojet Technologies Inc. or one of their representatives.

All maintenance works are described in the following sections.

Note:

We offer special training seminars for maintenance and service personnel. In case of questions
please contact Videojet Technologies Inc. or one of their representatives.

Maintenance Interval Measures

Monthly Check the laser scan lens for dust and dirt. Clean the

laser scan lens in case of dust or stains.

Monthly or when control lamp
lights up

If installed: Exchange the filter bag inside the exhaust
unit (refer to manual of the exhaust unit).

Every three months

(more frequently when operated
in dirty ambient conditions)

Carry out a visual inspection of the laser system.

Every six months If installed: Exchange the charcoal filter inside the

exhaust unit (refer to manual of the exhaust unit).

03/07 - Rev. AB 39

Chapter 5
Maintenance

5.3 Cleaning the Laser Scan Lens

The laser scan lens is located at the marking unit. It may be contaminated by dust or floating
particles. Contamination of the laser scan lens can lead to damages of the laser scan lens and
gradually reduce the quality of the marking. Therefore the lens has to be cleaned regularly.

Generally just the outwardly facing side of the laser scan lens has to be cleaned, but check both
sides for contamination and clean them, if necessary.

To clean the laser scan lens you need:

• Optics cleaning paper

•Acetone

• Protective gloves

Warning The laser scan lens consists of coated zinc selenide. This material contains

components which are dangerous to health!

Cleaning must only performed wearing latex protective gloves! In case of con­tact of the laser scan lens with the skin, wash the respective part of skin with
water and soap immediately! Avoid any surface scratches of the laser scan
lens! Do not inhale material particles! In case of breaking of the laser scan
lens please pack the fragments into a closed plastic bag and send them back
to us.

Important As with all optical components the laser scan lens is an object of highest and

sophisticated design.

Slightest damages of the surface might (in the long term) result in unusability
of the component or reduction of marking quality. Any contaminants must only
be removed by means of a cotton tip and acetone (part of the accessory box)!

Make sure that no contaminants enter the marking head while cleaning the la­ser scan lens!

Important Wear protective gloves during the complete procedure!

40 03/07 - Rev. AB

Chapter 5

Maintenance

5.3.1 Disassembly of the Laser Scan Lens

The laser scan lens is in a bayonet socket which is unlocked by a quarter turn.

4. Turn the laser scan lens carefully by a quarter turn in counterclockwise direction.
Do not touch the lens surface with your gloves!

5. Remove the laser scan lens from the marking head.

5.3.2 Cleaning the Laser Scan Lens

1. Place the laser scan lens onto a clean surface. Fold a sheet of optics cleaning paper (at
least 5 times) creating a flat cushion.

2. Hold the optics cleaning paper between thumb and index finger and put some drops of ac­etone onto the optics cleaning paper.

3. Carefully and slowly pull the optics cleaning paper across the surface to be cleaned.
Make sure that you do not touch the surface with the gloves.

Apply only very light pressure onto the paper!

4. If necessary repeat the procedure with a new sheet of optics cleaning paper.

5. Check the surface of the lens side located in the marking head for contamination. If necessary,
clean it as described above.

If the lens cannot be cleaned or the surface of the protective glass is severely scratched: Fit a
new protective glass.

5.3.3 Mounting the Laser Scan Lens

1. Insert the laser scan lens into the marking head.

2. Carefully turn the laser scan lens by a quarter turn in clockwise direction.
Do not use any tools!

Danger Before starting any work the laser system must be dead!

1. Turn the key switch to position »0«.
Remove the key to ensure that the laser system cannot be switched on.

2. Switch off the main switch.

3. Disconnect the mains connector.

Important • Never use polishing agents! Polishing agents destroy the laser scan

lens!

• Never use contaminated optics cleaning paper.

• Make sure that the optics cleaning paper is stored in a clean place.

03/07 - Rev. AB 41

Chapter 5
Maintenance

5.4 Update of the Smart Graph Software

To update the Smart Graph Software follow these steps:

1. Start your PC.

2. Exit the Smart Graph Software (if the Smart Graph Software is not loaded automatically skip
step 2).

3. Put the CD-ROM into the CD-ROM drive of your PC.

4. Click on »Start« in the menu bar of you Windows operating system.

5. Click on »Execute«.

6. Enter CD:\setup.exe in the text field and follow the instructions of the InstallShield wizard
(CD is a place holder for the letter of the CD-ROM drive in your PC).

42 03/07 - Rev. AB

Chapter 5

Maintenance

5.5 Protocols for Maintenance, Repair and Replacement

It is strongly recommended that accurate records are kept of maintenance, repair and replace­ment procedures.

On the following pages you will find forms to record all maintenance tasks specified. Copies
can be made and used to keep an ongoing record of the procedures recommended throughout
the life of the laser system.

You will also find forms to record the repairs and replacements. The records will provide a use­ful tool in anticipating future maintenance requirements and in determining cost of ownership
of the laser system.

03/07 - Rev. AB 43

Chapter 5
Maintenance

Inspection and Cleaning of the Laser Scan Lens

Maintenance interval: Monthly

Carried out on:

Date

Carried out by:

Name

44 03/07 - Rev. AB

Chapter 5

Maintenance

Exchange of Filter of the Exhaust Unit

(if installed)

Maintenance interval: Monthly or when control lamp lights up

Carried out on:

Date

Carried out by:

Name

03/07 - Rev. AB 45

Chapter 5
Maintenance

Exchange of the Charcoal Filter of the Exhaust Unit

(if installed)

Maintenance interval: Every six months

Carried out on:

Date

Carried out by:

Name

46 03/07 - Rev. AB

Chapter 5

Maintenance

Visual Inspection

Maintenance interval: Every three months

Carried out on:

Date

Carried out by:

Name

03/07 - Rev. AB 47

Chapter 5
Maintenance

Update of the Smart Graph Software

Carried out on:

Date

Carried out by:

Name

48 03/07 - Rev. AB

Chapter 5

Maintenance

Repair and Replacement Protocol

Laser model: Serial number:

Date:

Carried out by:

Repair or Replacement Comments

(faults, etc.)

Date:

Carried out by:

Repair or Replacement Comments

(faults, etc.)

Date:

Carried out by:

Repair or Replacement Comments

(faults, etc.)

Date:

Carried out by:

Repair or Replacement Comments

(faults, etc.)

02/06 - Rev. AB 49

Chapter 6
Malfunctions and Error Messages

6 Malfunctions and Error Messages

6.1 Notes

In this chapter you will find a description of possible malfunctions, their possible causes and
suitable measures for troubleshooting. In addition this chapter contains a description of all mes­sages of the laser system and suitable measures for troubleshooting. The measures stated
must be performed by instructed operation and maintenance personnel only.

Important Tasks for troubleshooting going beyond the ones mentioned here must be

performed by specially trained personnel only! Strictly follow the safety
instructions!

50 02/06 - Rev. AB

Chapter 6

Malfunctions and Error Messages

6.2 Malfunction Descriptions

1. The laser system stops operating. The yellow status LED is flashing.

Possible cause(s): Measures:

An error occurred. Connect the handheld or the PC to the sys-

tem and read the error messages. Follow the
remedy instructions given for the error mes­sage on the following pages.

2. START has been pressed on the handheld or the PC but no marking is visible.

Possible cause(s): Measures:

The chosen parameter set is not adapted
to the material.

Select a suitable parameter set.

The laser control is defective. Please contact Videojet Technologies Inc.

The lens is contaminated. Clean the lens.

The distance between product and mark­ing head is not correct.

Check the working distance.

The pilot laser is active. Select the option »Pilot laser OFF« in the

Smart Graph software under »Laser Opera­tion«, page »Marking«.

3. The line width has changed (too wide/not wide enough).

Possible cause(s): Measures:

The working distance between laser scan
lens and product has changed.

Adjust the working distance to the value
stated in the data sheets.

Wrong parameter set or wrong setting of
parameters.

Use the right parameter set or correct the
parameters.

The product surface or the product mate­rial has changed.

Adjust the parameters to the product. In case
of questions please contact us.

02/06 - Rev. AB 51

Chapter 6
Malfunctions and Error Messages

6.3 Warning Messages

W00001: Parts of the marking are beyond the marking field.

Possible cause(s):

Parts of the marking are beyond the user-defined marking field.

Possible effect(s):

Incomplete marking.

Remedy:

• Reduce size of marking.

• Expand marking field to maximum size.

• Select objective with higher focal length and thus increase the max. possible marking field.

W00002: Incomplete marking, product movement too fast.

Possible cause(s):

Parts of the marking contents cannot be marked since the product was not in the marking field.

Usually the reason is that the marking is not executed fast enough. It is also possible that the
start delay has been set too short causing the marking to be started too late. The start delay
must be set so that in the moment of triggering no part of the marking is yet within the marking
field.

Possible effect(s):

Incomplete marking. This applies to all individual markings for which this message is displayed.

Remedy:

• Increase start delay. Usually this requires the sensors to be adjusted.

• Optimize parameters so that the marking can be executed faster.

• Reduce size of marking so that it can be executed faster.

• Select speed-optimized font.

• If possible, increase marking field by selecting a different objective.

W00003: AOS does not send data after trigger (>10ms).

Possible cause(s):

After the trigger it took more than 10 ms before the AOS sent marking data.

Possible effect(s):

Faulty marking.

Remedy:

In case this error occurs in released versions it must be reported to the ALLTEC development
department.

52 02/06 - Rev. AB

Chapter 6

Malfunctions and Error Messages

W00004: Delayed data from the AOS.

Possible cause(s):

During the marking process it took more than 500 µs before the AOS sent new data.

If the AOS does not sent the data as fast as they are marked artificial pauses are added to the
marking. This causes the laser to be switched off even within an vector stroke and switched on
again as soon as data are available. For this process Laser-On-Delay and Laser-Off-Delay are
used.

Possible effect(s):

There might be small burns within vector strokes of the marking.

Remedy:

Increase the values of the start delay or trigger delay. Thus more data can be processed before
the marking execution is started.

W00005: Trigger lost.

Possible cause(s):

Trigger queue overflow, a new trigger had to be rejected.

That means that the trigger signals are coming in faster than they can be processed. The trig­ger queue is a buffer for trigger signals. If it is full and more signals are coming in this warning
is displayed.

Possible effect(s):

The product that has released the trigger is not marked. This applies to each product for which
the message is displayed.

Remedy:

• Since the trigger signals are coming faster than they can be processed the marking time has

to be reduced.

• If the marking time cannot be reduced any more the throughput has to be reduced.

• If you can preclude that there are too many regular trigger signals there might be mistrig-

gers. If e.g. the marking takes 50 ms and there is definitely each 100 ms a new product and
thus a new trigger then the trigger signal is interfered. In this case the blocking should be
checked which usually should be 90 % of the minimum time between two trigger signals. In
the example this would be 90 ms.

W00006: Incorrect index step selected.

Possible cause(s):

Internal error: A not initialized index step has been selected. The system uses the previously
selected index step.

Possible effect(s):

Parameters are not used for marking as previously set.

Remedy:

In case this error occurs in released versions it must be reported to the development depart-

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ment.

W09008: Parts of the marking are not within the marking field of the marking
head.

Possible cause(s):

Parts of the marking are outside the ellipse representing the maximum marking field of the
marking head.

Possible effect(s):

Possibly incorrect marking.

Remedy:

• Reduce size of marking.

• Select objective with higher focal length.

W09016: Communication error ACC -> FM: inadmissible command

Possible cause(s):

ACC sent a command to the marking head which is not admitted in the current mode.

Possible effect(s):

Marking possibly incorrect.

Remedy:

Check optical fibre between ACC and marking head.

W09017: Communication error ACC -> FM: unknown command

Possible cause(s):

ACC sent a for the marking head unknown command to the marking head.

Possible effect(s):

Marking possibly incorrect.

Remedy:

Check optical fibre between ACC and marking head.

W09018: Communication error ACC -> FM: Protocol error

Possible cause(s):

ACC did not keep to protocol.

Possible effect(s):

Marking possibly incorrect.

Remedy:

Check optical fibre between ACC and marking head.

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W10410: The parameter set of the active template has been asjusted to the sys­tem.

Possible cause(s):

The parameter set of the active template contains inadmissible settings for the laser. The ap­plication database possibly belongs to a different laser system.

Possible effect(s):

The automatic adjustment affects the marking and will be taken over when saving the data­base.

Remedy:

When the database has been saved this message will no longer appear.

Possibly the settings of the concerned parameter set have to be modified manually.

W10503: The database format has changed. Please save system.

Possible cause(s):

An older database has been loaded by a new AOS.

Possible effect(s):

None.

Remedy:

Saving the database it is automatically converted to the new format. Then the warning mes­sage will no longer be displayed.

After conversion the database cannot be read by an older AOS.

W10504: Not all previously used templates have been saved.

Possible cause(s):

New templates have been added to the database and selected for marking. Then the system
has been booted without saving the changed database.

Possible effect(s):

If the template marked last does not exist in the database the first template of the database is
selected automatically for marking.

Remedy:

Save the database after creating or importing new templates.

W10505: The template used last was not saved.

Possible cause(s):

A new template has been added to the database and selected for marking. Then the system
has been booted without saving the changed database.

Possible effect(s):

The template marked last does not exist in the database. The first template of the database is
selected automatically for marking.

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Remedy:

Save the database after creating or importing new templates.

W10506: Invalid value of absolute operating hours in SRAM.

Possible cause(s):

The battery buffering the SRAM is running down.

Possible effect(s):

The value of the absolute operating hours corresponds to the value of the last system start.

Remedy:

Check battery and replace if necessary.

W10517: According to the system database there is no marking head connected

Possible cause(s):

The system database contains the entry 'MARKING_HEAD_ATTACHED=0'. Thus the marking
head is not addressed.

Possible effect(s):

Marking is not possible.

Remedy:

If you want to mark a marking head must be connected and the entry in the system database
has to be changed to 'MARKING_HEAD_ATTACHED=1'.

W10552: AllprintBasic - MsgBox:\n\r <name>

Possible cause(s):

This is a regular message, no error.

The AllprintBasic command string triggered the output of this message.

Possible effect(s):

None.

Remedy:

None.

W10555: The AllprintBasic command "Warning" has been executed.

Possible cause(s):

Depending on the AllprintBasic program.

Possible effect(s):

Depending on the AllprintBasic program.

Remedy:

Depending on the AllprintBasic program.

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W10812: Invalid SmartSP telegram 0x%X

Possible cause(s):

Internal communication error.

Possible effect(s):

Marking is not possible.

Remedy:

In case this error occurs in released versions it must be reported to the development depart­ment.

W10904: The customer interface (CI) is not supplied with 24 V by the customer.

Possible cause(s):

The power supply of the customer interface is not available or switched off.

Possible effect(s):

• The output signals of the customer interface are invalid.

• Input signals at the customer interface are ignored.

Remedy:

Connect bus terminal KL9110 pin 2 or pin 6 to external 24 V and pin3 or pin7 to external GND.

W10905: The CAN bus detected a not implemented event (<name>).

Possible cause(s):

Depending on the event a function to be implemented in the future has been used (e.g. CI ter­minal: reserved).

Possible effect(s):

None.

Remedy:

Do not generate the event again.

W10908: External STOP from the CI.

Possible cause(s):

The STOP input is supplied constantly with 0 V so that the START input is not evaluated.

Possible effect(s):

Marking is not possible.

Remedy:

Connect STOP input to 24 V.

W55000: Defective customer interface (CI): The arrangement of the bus terminals
has been changed.

Possible cause(s):

The hardware configuration of the CI has been changed. (Beckhoff error)

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Possible effect(s):

The inputs and outputs of the customer interface do not work properly.

Remedy:

Check the bus terminals of the customer interface.

W55001: Defective customer interface (CI): Incompatible bus terminal.

Possible cause(s):

The bus terminal used is not supported. (Beckhoff error)

Possible effect(s):

The inputs and outputs of the customer interface do not work properly.

Remedy:

Check the bus terminals of the customer interface.

W55002: Defective customer interface (CI): EEPROM error

Possible cause(s):

An error occurred while saving the configuration to the EEPROM. (Beckhoff error)

Possible effect(s):

The inputs and outputs of the customer interface do not work properly.

Remedy:

Check the bus terminals of the customer interface.

W55003: Defective customer interface (CI): Connection error between bus termi­nals.

Possible cause(s):

There has been a communication error between the Beckhoff terminals. (Terminal ERROR)
(Beckhoff error)

Possible effect(s):

The inputs and outputs of the customer interface do not work properly.

Remedy:

Check the bus terminals of the customer interface.

W55004: Customer interface (CI): Unknown error (XX, XX)

Possible cause(s):

The bus coupler of the customer interface (CI) has sent an undocumented error.

Possible effect(s):

The inputs and outputs of the customer interface do not work properly.

Remedy:

Check the bus terminals of the customer interface.

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W58100: Customer interface (CI): CAN bus warning limit exceeded

Possible cause(s):

The bus coupler of the customer interface received too many error frames successively.

Possible effect(s):

The inputs and outputs of the customer interface do not work properly.

Remedy:

• Check bus terminals of the customer interface.

• Check wiring of CAN bus.

W58101: Customer interface (CI): CAN bus OFF

Possible cause(s):

The CAN bus has not been connected correctly to the bus coupler of the customer interface.

Possible effect(s):

The inputs and outputs of the customer interface do not work properly.

Remedy:

Check wiring of the CAN bus.

W58102: Customer interface (CI): CAN bus transmission buffer overflow

Possible cause(s):

The CAN bus has not been connected correctly to the bus coupler of the customer interface.

Possible effect(s):

The inputs and outputs of the customer interface do not work properly.

Remedy:

Check wiring of the CAN bus.

W58103: Customer interface (CI): CAN bus receiving buffer overflow

Possible cause(s):

Internal error of bus coupler.

Possible effect(s):

The inputs and outputs of the customer interface do not work properly.

Remedy:

Exchange bus coupler.

W58104: Customer interface (CI): CAN bus incorrect PDO length

Possible cause(s):

Internal communication error.

Possible effect(s):

The inputs and outputs of the customer interface do not work properly.

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Remedy:

In case this error occurs in released versions it must be reported to the development depart­ment.

W58105: Customer interface (CI): Sync of CAN bus delayed or failed.

Possible cause(s):

The CAN bus has not been connected correctly to the bus coupler of the customer interface.

Possible effect(s):

The inputs and outputs of the customer interface do not work properly.

Remedy:

Check wiring of the CAN bus.

W58106: Customer interface (CI): Guarding of CAN bus delayed or failed.

Possible cause(s):

The CAN bus has not been connected correctly to the bus coupler of the customer interface.

Possible effect(s):

The inputs and outputs of the customer interface do not work properly.

Remedy:

Check wiring of CAN bus.

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6.4 Error Messages

E00100: Critical error SP.

Possible cause(s):

Fatal internal error: A not initialized interrupt has been called or similar.

Possible effect(s):

The system is stopped and must be switched off.

Remedy:

In case this error occurs in released versions it must be reported to the development depart­ment.

E00101: Stack error SP.

Possible cause(s):

Fatal internal error: Stack overflow.

Possible effect(s):

The system is stopped and must be switched off.

Remedy:

In case this error occurs in released versions it must be reported to the development depart­ment.

E00102: SP received unknown command from AOS.

Possible cause(s):

Internal communication error on the ACC. In most cases this error indicates a version conflict.

Possible effect(s):

Possibly incorrect markings.

Remedy:

Check versions, use new MMC if necessary.

E00103: Timing error SP.

Possible cause(s):

Fatal internal error: Internal timing was not met.

Possible effect(s):

Possibly incorrect marking.

Remedy:

In case this error occurs in released versions it must be reported to the development depart­ment.

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E00104: AOS sends repeatedly data with delay

Possible cause(s):

During one marking the AOS needed more than 20 times more than 500 µs to send new data.
The marking is aborted.

See also “W00004: Delayed data from the AOS.” on page 52.

Possible effect(s):

Marking not possible.

Remedy:

Change the parameters so that the marking is carried out slower.

E00105: Marking aborted, product movement too fast.

Possible cause(s):

The marking has been aborted because more than 50 vectors cannot be marked since the
product has already left the marking fied.

Usually this is caused by too slow marking.

It is also possible that the start distance is too small and the marking is started too late. The
start distance should always be long enough so that no part of the marking is in the marking
field at the trigger moment.

See also “W00002: Incomplete marking, product movement too fast.” on page 51.

Possible effect(s):

The marking is not complete. The system is stopped.

Remedy:

• Enlarge the start distance correspondingly, usually by moving the sensors.

• Optimize the parameters so that the marking can be carried out faster.

• Reduce marking so that it can be marked faster.

• Select a font which has been speed optimized.

• Enlarge the marking field by using a different objective if possible.

E00200: Laser not ready.

Possible cause(s):

• Faulty cable to voltage supply of the laser.

• Relay for voltage supply of the laser did not switch.

• Faulty connecting cable between laser and ACC.

Possible effect(s):

Marking is not possible.

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Remedy:

Check LED "Laser Ready". If it is off after switching the laser on there is no voltage supply of
the laser. The cause can be a broken cable or a defective relay. If the LED is on the cable be­tween laser and ACC might be defective.

E00201: Laser supply: voltage too high or too low

Possible cause(s):

Faulty power supply module or incorrect voltage setting.

Possible effect(s):

Marking is not possible.

Remedy:

Check voltage, adjust setting if necessary (30 V) or exchange power supply module.

E00202: Laser overtemperature

Possible cause(s):

Insufficient cooling.

Possible effect(s):

Marking is not possible.

Remedy:

Check cooling system.

E09000: Marking head: Temperature of FM assembly group too high.

Possible cause(s):

The temperature of the FM board in the marking head has exceeded the maximum value.

Possible effect(s):

Possibly incorrect marking.

Remedy:

• Improve cooling of the marking head, clean cooling fins if necessary.

• Increase distance between markings if possible.

E09001: Marking head: Supply voltage too low.

Possible cause(s):

The supply voltage of the marking head is too low (<16V).

Possible effect(s):

Possibly incorrect marking.

Remedy:

Check voltage supply at the marking head, at the power supply module in the control unit and
at the marking head connector.

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E09002: Marking head: Overpositioning of X mirror.

Possible cause(s):

Due to an error the X mirror was brought to a position beyond the admitted maximum area.

Possible effect(s):

Possibly incorrect marking.

Remedy:

• Check X mirror.

• Check wiring in the marking head.

E09003: Marking head: Overpositioning of Y mirror.

Possible cause(s):

Due to an error the Y mirror was brought to a position beyond the admitted maximum area.

Possible effect(s):

Possibly incorrect marking.

Remedy:

• Check Y mirror.

• Check wiring in the marking head.

E09004: Marking head: Overcurrent X mirror.

Possible cause(s):

The FM detected that the current consumption of the X mirror is too high.

Possible effect(s):

Possibly incorrect marking.

Remedy:

• Check X mirror.

• Check wiring in the marking head.

E09005: Marking head: Overcurrent Y mirror.

Possible cause(s):

The FM detected that the current consumption of the Y mirror is too high.

Possible effect(s):

Possibly incorrect marking.

Remedy:

• Check Y mirror.

• Check wiring in the marking head.

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E09006: Marking head: No X mirror connected.

Possible cause(s):

The X mirror is not connected correctly to the FM board. A cable might be loose or broken.

Possible effect(s):

Possibly incorrect marking.

Remedy:

Check connection between X mirror and FM board.

E09007: Marking head: No Y mirror connected.

Possible cause(s):

The Y mirror is not connected correctly to the FM board. A cable might be loose or broken.

Possible effect(s):

Possibly incorrect marking.

Remedy:

Check connection between Y mirror and FM board.

E09012: Communication error ACC -> FM: Gaps in the data flow

Possible cause(s):

The control mode has been canceled since there have been no data from the ACC.

Possible effect(s):

Possibly incorrect marking.

Remedy:

Check optical fibre between ACC and marking head.

E09021: Internal error: Cannot set control mode of the FM.

Possible cause(s):

The FM cannot change to control mode. This indicates an error in the optical fibre communica­tion.

Possible effect(s):

Possibly incorrect marking.

Remedy:

Check optical fibre between ACC and marking head.

E09022: Internal error: Cannot set configuration mode of the FM.

Possible cause(s):

The FM cannot change to configuration mode. This indicates an error in the optical fibre com­munication.

Possible effect(s):

Possibly incorrect marking.

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Remedy:

Check optical fibre between ACC and marking head.

E09023: Internal error: Cannot set download mode of the FM.

Possible cause(s):

The FM cannot change to download mode. This indicates an error in the optical fibre commu­nication.

Possible effect(s):

Marking is not possible.

Remedy:

Check optical fibre between ACC and marking head.

E09100: No communication with marking head.

Possible cause(s):

• No marking head connected.

• Faulty power supply of marking head.

• Faulty optical fibre: not connected or broken.

• Faulty FM.

Possible effect(s):

Marking not possible.

Remedy:

• Check power supply of marking head.

• Check optical fibre between ACC and marking head.

E09101: Internal error: Error status of the FM cannot be reset.

Possible cause(s):

The error flags on the FM cannot be reset. This indicates an error in the optical fibre commu­nication.

Possible effect(s):

Marking is not possible.

Remedy:

Check optical fibre between ACC and marking head.

E09102: Interrupted communication with marking head.

Possible cause(s):

There have been errors on the ACC while receiving data from the FM.

Possible causes:

• Faulty optical fiber, e.g. bent.

• Faulty FM.

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Possible effect(s):

Marking is not possible.

Remedy:

Check optical fiber connection between ACC and marking head.

E09103: Internal error: FM not in configuration mode, cannot executed com­mand.

Possible cause(s):

It has been tried to execute a command in the control mode that is only admitted in the config­uration mode.

Possible effect(s):

The marking is possibly incorrect.

Remedy:

Check optical fibre connection between ACC and marking head.

E09104: No data received from the marking head.

Possible cause(s):

The ACC receives permanently or temporarily not data from the FM because

• the optical fibre connection to the marking head has been separated.

• the power supply of the marking head failed.

Possible effect(s):

Marking is not possible.

Remedy:

• Check optical fibre between ACC and marking head.

• Check power supply of marking head.

E10001: No data can be read from the system database.

Possible cause(s):

Faulty connection to the EEPROM of the system database.

Possible effect(s):

The system is not operable.

Remedy:

• Check connection between ACC and Panel-IO.

• Check whether EEPROM of Panel-IO has been inserted correctly.

E10002: Backup of system database was loaded!

Possible cause(s):

Several entries are missing in the system database. Therefore the backup of the system data­base has been loaded.

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Possible effect(s):

The backup is generated with every saving process. Maybe the last saving process has been
interrupted and the backup file is not up-to-date.

Remedy:

Check entries of system database and correct if necessary.

E10003: Cannot write (all) to the backup of the system database.

Possible cause(s):

Not enough space left on the MultiMediaCard.

Possible effect(s):

In case of an error in the system database the backup file cannot be used. In that case the sys­tem is no longer operable.

Remedy:

Check space on MultiMediaCard and reduce application database if necessary. 1024 Bytes are
required.

E10004: Cannot write to system database.

Possible cause(s):

Faulty connection to the EEPROM of the system database.

Possible effect(s):

The new values cannot be applied. A restart of the system might fail. In that case the system
is no longer operable (see error 0001).

Remedy:

Check the state of the system database and save all data.

E10005: Cannot read backup of the system database.

Possible cause(s):

The backup has not been generated at the previous start of the system or it has been deleted.

Possible effect(s):

The system cannot be started.

Remedy:

Check contents of the system database and contents and memory space of the MultiMedi­aCard.

E10101: Version conflict (command not executed)

Possible cause(s):

An unknown command has been sent to the ACC via the ethernet interface.

Possible effect(s):

The ethernet communication might be disturbed severely, the message appears repeatedly.

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Remedy:

Do not send the unknown command.

If the ethernet communication has been disturbed severely: separate the connection and then
connect again.

E10102: Unknown command: <name>

Possible cause(s):

An unknown command has been sent to the ACC via the ethernet interface, the unknown com­mand is displayed.

Possible effect(s):

None.

Remedy:

Check the program sending the commands.

E10103: Key not found in system database

Possible cause(s):

The database entry requested via ethernet does not exist.

Possible effect(s):

None.

Remedy:

Check the program sending the commands.

E10104: Database write error.

Possible cause(s):

Transmission error while transmitting a database object via ethernet or version conflict be­tween database object and AOS.

Possible effect(s):

A database object transmitted via ethernet cannot be inserted into the database.

Remedy:

Repeat transfer; check version.

E10105: Database read error.

Possible cause(s):

Database entry required for executing a command received via ethernet is missing.

Possible effect(s):

Command is not executed.

Remedy:

Check the database entry.

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E10106: Template contains no data.

Possible cause(s):

Template information has been requested via ethernet. The corresponding template contains
no data.

Possible effect(s):

Informationen werden nicht gesendet.

Remedy:

Check template and save it.

E10107: Template does not exist.

Possible cause(s):

Template information has been requested via ethernet. The corresponding template does not
exist in the application database.

Possible effect(s):

Informationen werden nicht gesendet.

Remedy:

Check template and save it.

E10108: No variables in template.

Possible cause(s):

The variables requested via ethernet do not exist in the template.

Possible effect(s):

Daten werden nicht gesendet.

Remedy:

Vorlage überprüfen.

E10109: Format is invalid.

Possible cause(s):

Via ethernet a command with missing or incorrectly formatted parameters has been sent.

Possible effect(s):

The ethernet communication might be disturbed severely, the message appears repeatedly.

Remedy:

Correct the command format.

E10111: Errors while saving

Possible cause(s):

The MultiMediaCard is full, not inserted correctly or defective.

Possible effect(s):

Data cannot be saved.

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Remedy:

Check MultiMediaCard.

E10113: This database entry cannot be deleted since XX other entries depend on
it.

Possible cause(s):

Othere database entries depend on this entry.

Possible effect(s):

The entry is not deleted.

Remedy:

Delete the depending entries first.

E10114: The transmitted object cannot be saved to the database. Please check
whether your system supports the object.

Possible cause(s):

Version conflict.

Possible effect(s):

The object is not saved to the database.

Remedy:

Check versions and make an update if necessary.

E10115: Too many variables are used in the templates. Please delete all tem­plates you do not need.

Possible cause(s):

Number of variables or number of templates too high.

Possible effect(s):

The templated cannot be marked.

Remedy:

Reduce number of variables or templates.

E10116: Error while reading directory <name>.

Possible cause(s):

The MultiMediaCard on the ACC cannot be read.

Possible effect(s):

Marking is not possible.

Remedy:

Check MultiMediaCard.

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E10300: Data for initialization cannot be read completely from the database.

Possible cause(s):

• Defective system database or customer database.

• The MultiMediaCard is full or damaged.

Possible effect(s):

The system cannot be started.

Remedy:

• Check connection between ACC and Panel-IO.

• Check MultiMediaCard.

E10301: The parameter set <name> contains inadmissible settings which are au­tomatically adjusted before marking.

Possible cause(s):

The application database belongs to a different laser system.

Possible effect(s):

The parameter set is adjusted automatically to the system before marking. This can affect the
marking quality.

Remedy:

To avoid the automatic adjustment of the settings you can modify the parameter set manually.
If you save the corrected parameter set to the database the error message will no longer ap­pear.

E10302: The beam shutter does not stay open.

Possible cause(s):

Defective beam shutter.

Possible effect(s):

Marking is not possible.

Remedy:

Exchange beam shutter.

E10303: The beam shutter does not stay closed.

Possible cause(s):

Defective beam shutter.

Possible effect(s):

The system has to be restarted.

Remedy:

Exchange beam shutter.

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E10401: Template invalid: <name>

Possible cause(s):

The template selected for marking is defective or does not exist.

Possible effect(s):

Marking is not possible.

Remedy:

Check template and used parameters, product registration and (if existing) logos.

Select template again.

E10404: Prompt Once: Value cannot be marked.

Possible cause(s):

The property "Prompt Once" has been set in the template. It has been tried to mark a prompt
with the same value twice.

Possible effect(s):

The marking is not carried out.

Remedy:

Change the contents of the prompt or remove the property "Prompt Once".

E10406: The selected trigger input does not exist.

Possible cause(s):

Trigger 2 or trigger 3 has been selected in the product registration. For trigger 2 a CI-FAST-IN
is required which does not exist in the system. Trigger 3 does not exist in this system.

Possible effect(s):

Marking is not possible.

Remedy:

Select a different trigger input or install a CI-FAST-IN.

E10407: The beam shutter does not open.

Possible cause(s):

The beam shutter got jammed or is not identified.

Possible effect(s):

Marking is not possible.

Remedy:

Check the beam shutter.

E10408: The beam shutter does not close.

Possible cause(s):

The beam shutter got jammed or is not identified.

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Possible effect(s):

After a marking the next marking cannot be started without confirmation of the error message.

Remedy:

Check the beam shutter.

E10409: System error during preparation of marking.

Possible cause(s):

Internal error during preparation of marking.

Possible effect(s):

Marking is not possible.

Remedy:

Start the marking again after confirmation of the error message.

E10500: Cannot load database.

Possible cause(s):

The application database and its backup cannot be loaded.

Possible effect(s):

Marking is not possible.

Remedy:

A new database file has to be written to the MMC.

E10501: Backup database has been loaded.

Possible cause(s):

The application database is defective.

Possible effect(s):

Modifications are lost.

Remedy:

Please save the database.

E10502: System Message: XX

Possible cause(s):

Error during determination of the current template or its variables.

Probably the database does not contain any templates.

Remedy:

If the database contains no template: create and add a new templated and save the database.

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E10507: Error while reading the objective file.

Possible cause(s):

• The objective file does not exist in the comp directory of the MultiMediaCard.

• The MultiMediaCard is not inserted correctly.

Possible effect(s):

The system is not operable.

Remedy:

Check MultiMediaCard, if necessary rebuild MMC.

E10508: Error while reading the laser file.

Possible cause(s):

• The laser file does not exist in the comp directory of the MultiMediaCard.

• The MultiMediaCard is not inserted correctly.

Possible effect(s):

The system is not operable.

Remedy:

Check MultiMediaCard, if necessary rebuild MMC.

E10509: Error while reading the head file.

Possible cause(s):

• The head file does not exist in the comp directory of the MultiMediaCard.

• The MultiMediaCard is not inserted correctly.

Possible effect(s):

The system is not operable.

Remedy:

Check MultiMediaCard, if necessary rebuild MMC.

E10510: No FPGA image file available!

Possible cause(s):

The file fpgaimgX.h is missing on the MultiMediaCard.

Possible effect(s):

The system cannot work properly without FPGA image file.

Remedy:

Check the contents of the MultiMediaCard.

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Chapter 6
Malfunctions and Error Messages

E10511: No SP program available!

Possible cause(s):

The file smartspX.sp is missing on the MultiMediaCard.

Possible effect(s):

The system cannot work properly without SP program.

Remedy:

Check the contents of the MultiMediaCard.

E10512: AllprintBasic: Protocol configuration error

Possible cause(s):

The AllprintBasic command string in the AOS database ("Config","Input") contains a configura­tion error for the serial protocol.

Possible effect(s):

The control via AllprintBasic (serial port) does not work.

Remedy:

Modify the protocol settings on the PC with AllprintBasic and import again via SmartGraph into
the AOS database. Then reboot the ACC.

E10513: AllprintBasic: Configuration error of the serial interface

Possible cause(s):

The AllprintBasic command string in the AOS database ("Config","Input") contains a configura­tion error for the serial interface.

Possible effect(s):

The control via AllprintBasic (serial port) does not work.

Remedy:

Modify the interface parameters on the PC with AllprintBasic and import again via SmartGraph
into the AOS database. Then reboot the ACC.

E10514: FM download error (<name>).

Possible cause(s):

A program has to be transmitted from the MMC to the FM. During this download an error oc­curred.

Possible effect(s):

Fatal: Marking is no longer possible since the FM hardware no longer has a program for mirror
positioning.

Remedy:

Check the optical fiber. Check FM. Check ACC. Reboot.

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Malfunctions and Error Messages

E10515: FM download: File <name> is missing.

Possible cause(s):

The file is required on the MultiMediaCard. The file name is generated from the EEPROM data
of the FM. If the file name is absurd the EEPROM has been programmed incorrectly or not at
all. It is possible that the file name cannot be transmitted to the AOS due to problems with the
optical fibers.

Possible effect(s):

System cannot be set up.

Remedy:

• Copy the missing file to the MultiMediaCard. Check FM-EEPROM.

• Check optical fiber.

E10516: The marking head is not connected.

Possible cause(s):

The connection of the optical fiber to the marking head is faulty.

Possible effect(s):

Fatal error: Marking is not possible. Therefore the FM did not load any marking software.

Remedy:

Check connector of the optical fiber from the ACC to the FM.

E10518: The parameter set <name> does not correspond to the laser type. Please
replace this entry in the database.

Possible cause(s):

A database has been copied to the MMC which does not correspond to the laser type.

Possible effect(s):

Marking is not possible.

Remedy:

Copy a suitable database to the MMC

or

create a new suitable database using the Smart Graph offline. Add a parameter set having the
same name and transfer it to the laser.

In this way all parameter sets of the laser database need to be replaced.

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Chapter 6
Malfunctions and Error Messages

E10550: AllprintBasic: Syntax error (line: XX, column: XX)

Possible cause(s):

The AllprintBasic command string in the AOS database ("Config","Input") contains a syntax er­ror.

Possible effect(s):

The control via AllprintBasic (serial port) does not work.

Remedy:

Test the command string on the PC with AllprintBasic, correct it and import again via Smart­Graph into the AOS database. Then reboot the ACC.

E10551: The template does not contain the requested variable.

Possible cause(s):

The variable to be modified in the AllprintBasic command string does not exist in the template.

Possible effect(s):

The control via AllprintBasic (serial port) does not work.

Remedy:

Check the corresponding template or the AllprintBasic command string and modify if neces­sary. If the command string has been changed the ACC must be rebooted.

E10553: Illegal command in AllprintBasic command string.

Possible cause(s):

Older functions of the AllprintBasic program can no longer be realized due to concept modifi­cation of the new AOS (YAG laser), e.g. SetExtent.

Possible effect(s):

The control via AllprintBasic (serial port) does not work.

Remedy:

Check command string and change if necessary. If the string has been changed you have to
reboot the ACC.

E10554: The AllprintBasic command "Error" has been executed.

Possible cause(s):

Depending on the AllprintBasic program.

Possible effect(s):

Depending on the AllprintBasic program.

Remedy:

Depending on the AllprintBasic program.

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Chapter 6

Malfunctions and Error Messages

E10601: Template list does not exist.

Possible cause(s):

The external template selection has failed because there is no template list.

Possible effect(s):

Marking is not possible.

Remedy:

Create a template list using the Smart Graph or select a template in the Smart Graph.

E10602: The chosen template number XX cannot be assigned to any template.

Possible cause(s):

The external template selection has failed because the selected template number cannot be
assigned to any template in the template list.

Possible effect(s):

Marking is not possible.

Remedy:

Check template list.

E10701: Out of memory. Cannot create database object.

Possible cause(s):

Internal error or database is too large.

Possible effect(s):

Marking is not possible.

Remedy:

If the message is no longer displayed after rebooting, there might be an internal error. Inform
the development department.

If the message is still displayed after rebooting all elements not needed should be deleted from
the database.

E10702: Format error while creating a database object.

Possible cause(s):

Version conflict between database object and AOS.

Possible effect(s):

Marking is not possible.

Remedy:

Check versions of Smart Graph and QMark and carry out an update if necessary.

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Chapter 6
Malfunctions and Error Messages

E10800: DSP does not send telegrams.

Possible cause(s):

The DSP has not been initialized correctly or the connection to the DSP is faulty.

Possible effect(s):

The system does not work.

Remedy:

Restart the system.

E10811: DSP buffer overflow

Possible cause(s):

Internal communication error.

Possible effect(s):

Marking is not possible.

Remedy:

In case this error occurs in released versions it must be reported to the development depart­ment.

E10900: General CAN bus error (XX)

Possible cause(s):

General CAN bus error:

e.g. BusOff, ErrorPassiv, etc.

Possible effect(s):

The system cannot be set up.

Remedy:

Check wiring of CAN bus.

E10901: A CAN node (<name>) has carried out an inadmissible reset.

Possible cause(s):

• The entered CAN bus node is defective.

• Defective wiring.

Possible effect(s):

Marking is not possible.

Remedy:

• Check the CAN bus node.

• Check wiring of CAN bus.

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Chapter 6

Malfunctions and Error Messages

E10902: Lost connection to a CAN node (<name>).

Possible cause(s):

• The entered CAN bus node is defective.

• Defective wiring.

Possible effect(s):

Marking is not possible.

Remedy:

• Check the CAN bus node.

• Check wiring of CAN bus.

E10903: A CAN node (<name>) cannot be initialized.

Possible cause(s):

• The entered CAN bus node is defective.

• Defective wiring.

Possible effect(s):

The system cannot be started.

Remedy:

• Check the CAN bus node.

• Check wiring of CAN bus.

E10906: The customer interface (CI) indicates an error of the external exhaust.

Possible cause(s):

External exhaust defective or incorrect wiring of CI terminal.

Possible effect(s):

External exhaust does not work.

Remedy:

Repair external exhaust or connect the corresponding CI terminal to 24 V.

E10907: The customer interface (CI) indicates an external error.

Possible cause(s):

Detection of external error or incorrect wiring of the CI terminal.

Possible effect(s):

Depending on customer or CI terminal EXT_ERROR.

Remedy:

Remove external error or connect the corresponding CI terminal to 24 V.

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Chapter 6
Malfunctions and Error Messages

E10909: A CAN node (<name>) has carried out an inadmissible state change.

Possible cause(s):

The corresponding node has probably carried out a reset.

Possible effect(s):

All functions of this node are no longer available.

Remedy:

Reboot the system.

E10913: File <name> is missing.

Possible cause(s):

The file is supposed to be on the MultiMediaCard.

Possible effect(s):

The system cannot be started.

Remedy:

Copy desired file to the MultiMediaCard.

E10914: Faulty transmission of a domain to a node (<name>).

Possible cause(s):

Erroneous wiring of CAN bus.

Possible effect(s):

Marking is not possible.

Remedy:

Check wiring of CAN bus.

E10915: A CAN node (<name>) does not react after download or software reset.

Possible cause(s):

• Defective connections.

• Defective CAN node.

Possible effect(s):

The system cannot be started.

Remedy:

• Check wiring of CAN bus.

• Check corresponding CAN node.

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Chapter 6

Malfunctions and Error Messages

E10916: Faulty download to node <name>.

Possible cause(s):

• Defective wiring of CAN bus.

• The corresponding node is faulty.

• Required program not available on MultiMediaCard.

Possible effect(s):

The system cannot be started.

Remedy:

• Check wiring of CAN bus.

• Check corresponding CAN bus node, if necessary update of MDB of the CAN bus node.

• Transmit missing program to MultiMediaCard.

E10917: A CAN node (<name>) signals unsuitable software.

Possible cause(s):

• Defective wiring of CAN bus.

• The corresponding node is faulty.

• Required program not available on MultiMediaCard.

Possible effect(s):

The system cannot be started.

Remedy:

• Check wiring of CAN bus.

• Check corresponding CAN bus node, if necessary update of MDB of the CAN bus node.

• Transmit missing program to MultiMediaCard.

E10919: A driver error prevents triggers being transmitted from the CAN bus.

Possible cause(s):

Internal error

Possible effect(s):

The system cannot be started.

Remedy:

In case this error occurs in released versions it must be reported to the development depart­ment.

E10920: A driver error prevents control of the emission LED.

Possible cause(s):

Internal error.

Possible effect(s):

The system cannot be started.

02/06 - Rev. AB 83

Chapter 6
Malfunctions and Error Messages

Remedy:

In case this error occurs in released versions it must be reported to the development depart­ment.

E10921: Less than two CI input bus terminals connected.

Possible cause(s):

Not enough input bus terminals existing.

Possible effect(s):

The system cannot be started.

Remedy:

Equip system with two input bus terminals.

E10922: Less than two CI output bus terminals connected.

Possible cause(s):

Not enough output bus terminals existing.

Possible effect(s):

The system cannot be started.

Remedy:

Equip system with two output bus terminals.

E10923: Ext. template selection requires at least 4 CI input bus terminals.

Possible cause(s):

To use the external template selection at least 4 input bus terminals must be available at the
customer interface.

Possible effect(s):

The external template selection cannot be used.

Remedy:

Add two input bus terminals.

E10926: Entry (<name>) is missing in the database.

Possible cause(s):

Defective database.

Possible effect(s):

Marking is not possible.

Remedy:

Complete or exchange database.

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Chapter 6

Malfunctions and Error Messages

E10929: CAN bus error (<name>).

Possible cause(s):

Faulty line of CAN bus.

Possible effect(s):

Components are possibly not configured completely.

Remedy:

Check CAN bus cable and connections.

E19201: Template (<name>) does not exist.

Possible cause(s):

The template does not exist in the database.

Possible effect(s):

Marking is not possible.

Remedy:

Create or transmit the corresponding template.

E19202: Template error: <name>

Possible cause(s):

The template selected for marking is defective or does not exist.

Possible effect(s):

Marking is not possible.

Remedy:

• Check template and used parameters, product registration and (if existing) logos.

• Select template again.

E19203: Parameter set (<name>) does not exist.

Possible cause(s):

The parameter set required by a template is missing.

Possible effect(s):

The template concerned cannot be marked.

Remedy:

Assign an existing parameter set to the template or add the required parameter set to the da­tabase.

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Chapter 6
Malfunctions and Error Messages

E19204: Product registration (<name>) does not exist.

Possible cause(s):

The product registration required by a template is missing.

Possible effect(s):

The template concerend cannot be marked.

Remedy:

Assign an existing product registration to the template or add the required product registration
to the database.

E19205: At least one index level does not exist in the parameter set.

Possible cause(s):

The template uses an index level which does not exist in the parameter set.

Possible effect(s):

The template cannot be marked.

Remedy:

Add the missing index level to the parameter set or assign an existing index level to all elements
of the concerned template.

E19210: The direct marking cannot be carried out.

Possible cause(s):

Faulty connection between PC and ACC.

Possible effect(s):

The direct marking cannot (or only incompletely) be carried out.

Remedy:

Check the ethernet connection between PC and ACC.

E19307: The circuit for external laser enable has been opened.

Possible cause(s):

The circuit for the external laser enable is open. This can be caused by an open emergency
switch.

Possible effect(s):

The system remains in state "Key switch open" even if the key switch has been closed.

Remedy:

Close the circuit for external laser enable.

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Chapter 6

Malfunctions and Error Messages

E19308: Cannot select beam source.

Possible cause(s):

Error in the CAN communication.

Possible effect(s):

Marking is not possible.

Remedy:

Check CAN bus.

E19309: The clock had to be restarted. Please set the time!

Possible cause(s):

The clock did stop and has already been restarted. The battery voltage might be too low.

Possible effect(s):

The marked time is not correct.

Remedy:

Set the time. If this happens every time after switch-on exchange the battery.

03/07 - Rev. AD 87

Chapter 7
Appendix

7 Appendix

7.1 Assignment of the Customer Interface

7.1.1 Interlock

7.1.2 Inputs and Outputs (Galvanically Separated)

The galvanically separated inputs and outputs are provided as a standard. They are used for
sending digital status signals and receiving digital command signals.

Feed Terminal

All following terminals are supplied via this terminal and they are separated galvanically from
the internal power supply. The customer has to supply the voltage via X16.1 and X16.5. As de­fault the internal voltage supply is used by bridging X16.1 - X16.2 and X16.5 - X16.6.

Terminal Signal Description

X2.1 INTERLOCK Input for interlock circuit

X2.2 INTERLOCK Input for interlock circuit

Terminal Signal Description

X16.1 U_INTERFACE 24 V customer

X16.2 12 V/24 V 12 V/24 V system

X16.5 GND_INTERFACE GND customer

X16.6 GND GND system

X14

1

2

3

4

5

X2

X16

X6

X20

X7

1

2

3

4

5

1

2

3

4

5

1

23

4

5

6

61

2

3

4

56 7

8

1

2

3

4

5

678

88 03/07 - Rev. AD

Chapter 7

Appendix

Digital Outputs

Terminal Signal Description

X20.1 SYSTEM_READY SYSTEM_READY is set as soon as the

system has completed its initialization
and is ready to operated. Switched off in
service mode. Entries via the digital
inputs are accepted only if this signal is
set.

X20.2 READY_TO_MARK This signal is set as soon as all neces-

sary data and a start signal have been
received. The system is ready to mark
and waits for a trigger signal. The red
LEDs on the supply unit and on the mark­ing head are on.

X20.3 MARKING This signal is set during the marking pro-

cess.

X20.4 SHUTTER_CLOSED This signal is set if the beam shutter is

closed.

X20.5 ERROR This output is LOW active. The system is

stopped immediately if an error occurs
during the marking process (e.g. laser
overtemperature). The output is reset
with the next start (but may be set again
immediately if the error was not cleared).

X20.6 BAD This output is LOW active and indicates

that the last marking was not completed
due to a warning or error. The output is
reset with the next trigger signal.

X20.7 GOOD This output is LOW active and indicates

that the last marking has been completed
without a warning or error. The output is
reset with the next trigger signal.

03/07 - Rev. AD 89

Chapter 7
Appendix

Digital Inputs

Output Specification:

Input Specification:

Terminal Signal Description

X16.3 START Starts the marking process, waits for trig-

ger signal, reacts to rising edge. START
has no function if STOP is set to LOW.

X16.4 STOP Stops the marking process, reacts to

LOW.

The signal has to be set to HIGH if not
used.

X20.8 EXTERNAL_ERROR This LOW active signal is used to evalu-

ate external error messages.

If not used, the signal has to be set to
HIGH.

Rated voltage 24 V DC (-15 %/+20 %)

Load type ohmic, inductive, lamp

Max. output current (per channel) 200 mA (short-circuit proof)

Rated voltage 24 V DC (-15 %/+20 %)

"0" signal voltage 0 V to 5 V

"1" signal voltage 8.5 V to 30 V, nominal 24 V

Current input typ. 10 mA

Min. signal length 300 µs

90 03/07 - Rev. AD

Chapter 7

Appendix

Timing Diagrams

Normal Operation

Error in Marking

System state

User action

Key switch

open

Laser

start-up

Laser
ready

Prepare for

marking

Wait for
trigger

Wait for

trigger delay

Marking

Wait for

trigger

Wait for

trigger delay

Marking

Wait for

trigger

Laser
ready

Key-switch

open

close key switch start trigger trigger stop open key switch

System state

User action

Key switch

open

Laser

start-up

Laser
ready

Prepare for

marking

Wait for

trigger

Wait for

trigger delay

Marking

Error message 2

Wait for

trigger delay

Wait for

trigger

Laser
ready

close key switch start trigger confirmation

start

trigger

Prepare for

marking

03/07 - Rev. AD 91

Chapter 7
Appendix

Warning in Marking

System state

User action

Key switch

open

Laser

start-up

Laser
ready

Prepare for

marking

Wait for

trigger

Wait for

trigger delay

Marking

Wait for

trigger

Wait for

trigger delay

Marking

Wait for

trigger

Laser
ready

Key-switch

open

close key switch

start

trigger trigger stop open key switch

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Chapter 7

Appendix

7.1.3 Inputs (Not Separated Galvanically)

The signals are not separated galvanically. Connected sensors are automatically considered
as part of the marking system.

Trigger Inputs

Incremental Encoder Inputs

Terminal Signal Description

X6.1 TRIGGER Trigger input

X6.2 IN_TRIGGER_ENABLE Enabling of trigger inputs, bridged with ter-

minal X6.5 when delivered. See figure next
page.

X6.3 IN_TRIGGER_MONITOR Input, monitoring trigger

X6.4 GND System ground

X6.5 12 V/24 V Voltage supply

X6.6 GND System ground

Terminal Signal Description

X7.1 ENC_T1 Input for track 1 of encoder

X7.2 ENC_T2 Input for track 2 of encoder

X7.3 ENC_IDX Input for index track of encoder

X7.4 GND System ground

X7.5 GND System ground

X7.6 GND System ground

X7.7 12 V/24 V Voltage supply

X7.8 GND System ground