Full Spectrum Laser Pro Series User manual

User Manual Pro-Series 36x24 & Pro-Series 48x36

Table of Contents
Section I. Safety First ............................................5
General Safety......................................................6
Laser Safety. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Fire Safety .........................................................9
Electrical Safety. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Section II. Uncrating Your Pro-Series . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Parts & Accessories .................................................13
Upgrades & Recommended Accessories ................................14
Uncrating Your Pro-Series. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Section III. Installation & Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Remove Zip Ties ....................................................17
Connect the Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Install Laser Tube ...................................................20
Connect the Water Chiller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Assemble the Air Compressor .........................................28
Connect Electrical Power .............................................30
Connecting Ethernet Cable. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Connect to RetinaEngrave ............................................32
Section IV. Tests & Adjustments ..................................33
Alignment Test......................................................34
Alignment Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Focusing ..........................................................45
Section V. User Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Button Functions ....................................................47
Modes ............................................................48
Jog Buttons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Section VI. Software .............................................50
Validating Control Card. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
RetinaEngrave Software ..............................................52
Topline Menus......................................................53
Tabs..............................................................54
Line Two Menus ....................................................55
Control Panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Section VII. Operations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Raster Engrave Tab..................................................59
Raster Properties. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Vector Cut .........................................................64
Vector Import. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Design Tab ........................................................67
Design View. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Drawing & Shop Properties . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Section VIII. Maintenance & Troubleshooting .....................72
Belt Installation .....................................................72
General Maintenance ................................................73
Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Appendixes......................................................77

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Pro-Series Laser Cutter User Manual
Congratulations on your purchase of a Full Spectrum Laser Pro-Series laser cutter. With proper
usage and upkeep, your Pro-Series machine should provide years of productive output. This
user manual will guide you through the safety guidelines and operation of your machine. It is
recommended that you familiarize yourself with this manual before using your laser cutter.
COMPLIANCE STATEMENT
The Full Spectrum Laser Pro-Series Laser System is a class 3R laser product, as dened in International Standard IEC 60825-1.
The Full Spectrum Laser Prop-Series Laser System complies with 21 CFR 1040.10 and 1040.11, the Federal Performance Standards for Light-Emitting
Products, except for deviations pursuant to Laser Notice No. 50, dated July 16, 2001. The Center for Devices and Radiological Health of the US FDA
issued Laser Notice No. 50 to permit manufacturers to classify and manufacture their products in accordance with the International Standard.
PRO-SERIES
48X36
PRO-SERIES
36X24

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Attention Icon:
Calls attention to an
important point.
Shock Icon:
Warns of potential
electrical hazards.
Fragile Icon:
Warns of fragile parts or
materials, such as glass.
Temperature Icon:
Warns of potential temperature
issues with your machine.
Caution Icon:
Warns of important area
of caution not covered by
other icons.
CO2 Gas Icon:
Warns of potential gas leaks
and associated hazards.
Laceration Icon:
Warns of potential sharp
edges that could cause
cuts or injury.
Safe Disposal Icon:
Calls attention to proper
disposal of waste materials.
Pro Tips:
Watch for this icon to receive
valuable advice in getting the
most from your machine.
Fire Icon:
Warns of potential
re hazards.
Laser Icon:
Warns of potential dangers
associated with laser usage.
Level Icon:
Indicates the need
for a level surface.
Familiarize yourself with these icons. They indicate areas that require special attention.
SECTION I. SAFETY FIRST

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ALWAYS inspect the laser cutter for damage or breakage before each use. Do not
operate machinery that is damaged or defective in any way.
ALWAYS have a clean, level, and open work space to uncrate and place your laser cutter.
ALWAYS be aware that the laser tube is made of glass and is therefore extremely
fragile and can cause severe lacerations if broken.
ALWAYS be aware that the laser tube is lled with CO2 gas. While carbon dioxide is a
class 2.2 gas (nonammable and nontoxic), release of this gas from the laser tube will
render your laser inoperable.
NEVER modify, disassemble, or in any way alter the construction of the laser and never
start up a system that has been modied or disassembled.
NEVER leave the laser system unattended during operation.
KEEP YOUR LASER SYSTEM CLEAN – A build up of cutting and engraving
residue and debris is dangerous and can create a re hazard. Keep your laser system
clean and free of debris. Regularly remove the cutting grid to clean any small pieces
that have gotten stuck or fallen through.
DO NOT disassemble the machine or remove any of its protective covers.
NEVER place hands or ngers into moving parts such as cooling fans.
General Safety
Read and be familiar with all safety protocols and procedures before operating any machinery. It is the
responsibility of the operator to ensure all safety precautions are correctly followed and the machine is
properly assembled and in working order.

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The output of the CO2 engraving laser is fully contained in a Class 1 enclosure during normal
operation. The laser cabinet has a safety interlock switch that deactivates the laser if the door is
opened during operation. No special precautions are necessary to operate the high power
laser safely, however, the output beam of the alignment laser (visible red diode laser) is accessible
to the operator during normal operation, giving the total system an overall rating of Class 3R.
Class 3R lasers have minimal safety concerns when used properly and handled with care.
Follow these safety guidelines at all times:
NEVER operate the machine with any of the panels removed. Be aware that removal of any portion
of the cabinet will expose the laser system and greatly increase the risk of injury and/or re. Personal
injury and re risks are especially pronounced if the machine is operated with any panel removed.
NEVER engrave or cut any material containing PVC or vinyl. These materials (along with other
chlorine/ chloride containing materials) produce a corrosive vapor that is extremely harmful to
humans and will destroy your machine. Your warranty will be void if your machine is damaged
by corrosion from engraving or cutting PVC or vinyl.
NEVER engrave or cut any unknown material. The vaporization/melting of many materials,
including but not limited to PVC and polycarbonates, can give off hazardous fumes. Please refer
to the MSDS sheet from the material manufacturer to determine the response of any work
material to extreme heat (burning/re hazard).
ALWAYS use the air assist, especially while vector cutting. Vector cutting movements are
relatively slow and apply an extremely large amount of heat to the workplace. This buildup of
heat can create a signicant re risk.
NEVER operate the alignment laser without the focus lens in place. The unfocused beam can
be reected out of the chassis.
NEVER operate the machine without a properly operating ventilation system. Most materials
produce an irritating smoke when engraved. Some materials, including but not limited to: paint,
varnish, composition board, and plastics, produce compounds that can be harmful if concentrated.
NEVER look into the beam of the alignment laser (visible red diode laser).
Laser Safety

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The standard reference for laser safety is the American Standard for the Safe Use of Lasers,
Z136.12000, developed by the American National Standards Institute (ANSI). This reference is
the basis for many of the federal regulations for laser and laser system manufacturers, and for the
Occupational Safety and Health Administration (OSHA) laser safety guidelines. It contains detailed
information concerning proper installation and use of laser systems. While the ANSI standard itself
does not have the force of law, its recommendations, including warning signage, training, and the
designation of a laser safety ofcer, may be compulsory under local workplace regulations when
operating laser systems above Class I. It is the operator’s responsibility to ensure that the installation
and operation of the Full Spectrum Laser System is performed in accordance with all applicable laws.
Copies of ANSI Standard Z136.12000 are available from: LASER INSTITUTE OF AMERICA 12424
RESEARCH PARKWAY, SUITE 125 ORLANDO, FL 32826 (407) 3801553.
Laser Safety (cont.)

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Laser cutting and engraving systems can present a signicant re hazard due to the extremely
high temperatures generated by the laser beam. While the objective of most cutting and engraving
operations is to vaporize material without burning, most materials capable of being cut or engraved
are inherently combustible and can ignite. Usually this is a small ame of burning material issuing
from the cut zone which self extinguishes due to the air assist or depowering of the beam. However,
it is possible for the ame to propagate and set re to the machine and its surroundings.
ALWAYS keep a properly maintained and inspected 5lb or larger re extinguisher on hand.
Full Spectrum Laser recommends a Halotron 1 re extinguisher or a multipurpose dry chemical re
extinguisher. Halotron 1 extinguishers are more expensive than a dry chemical, but offer certain
advantages should you ever need to use an extinguisher. The Halotron 1 extinguisher discharges a
clean, easily removable substance that is not harmful to the mechanics or wiring of the laser system.
The dry chemical extinguisher discharges a sticky, corrosive powder that is very difcult to clean up.
BE AWARE that stacking materials (especially organic materials such as paper) can lead to
increased risk of ame propagation or work piece ignition.
NEVER operate your machine unattended. There is a signicant risk of re if the machine is set
improperly; or if the machine should experience a mechanical or electrical failure while operating.
ALWAYS keep the area around the machine clean and free of clutter, combustible materials,
explosives, or volatile solvents such as acetone, alcohol, or gasoline.
ALWAYS use air assist when vector cutting.
BE CAREFUL when vector cutting. Many materials have the potential to burst suddenly into
ames – even materials that may be very familiar to the user. Always monitor the machine when
it is operating.
NEVER CUT PVC (polyvinyl chloride) under any circumstances: fumes are highly toxic
and potentially lethal.
NEVER store any ammable materials in the inside of the device or in the immediate vicinity of
the device. Debris and leftover produced materials within the machine must to be removed to
prevent re hazard.
ALWAYS have on hand a rst-aid kit designed for the initial treatment of burns and smoke
inhalation. Be sure to store this kit in an area that is outside risk areas.
Fire Safety

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Woodshop Dust Fire Safety Considerations*
Before processing materials the user must verify whether harmful materials can be generated
and whether the lter equipment of the exhaust system is suitable for the harmful materials. We
emphasize that it is the responsibility of the user, to consider the national and regional threshold
values for dust, fogs and gases when selecting the lters and the exhaust system.
(The values for the maximum workplace concentration must not be exceeded.)
Be mindful of large quantities of fuel in the form of wood and wood products, sawdust, and
ammable materials such as paints, oil nishes, adhesives, solvents, and liquid propane for
internal combustion engines.
Preventing the buildup of dust is one of the key means for controlling re and explosion hazards.
The principal engineering control technology for control of dust is exhaust ventilation. The primary
work practice control is good housekeeping.
Dust collection is best accomplished at the source-at the point of operation of the equipment, if
feasible. For many pieces of equipment, well-designed ducts and vacuum hoods can collect most
of the dust generated before it even reaches the operator.
Very ne dust that manages to escape point-of-source collection can be captured from above by
general exhaust points located along the ceiling. These control technologies are effective for most
equipment, excepting machines that commonly produce the very nest dust or large quantities of dust.
*These guidelines come from the U.S. Department of Labor
Fire Safety (cont.)

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The power supply is capable of outputting DC 20,000V at up to 30mA—always make sure to give
the supply capacitors adequate time to discharge before accessing the electronics area. This
power is also provided to the discharge terminals on the laser tube itself. Your laser shipped with
silicone terminal covers that prevent access to bare wiring—notify Full Spectrum Laser support and
immediately cease operations if these covers ever slip and expose bare wire.
DO NOT open any of the machine’s access panels while the unit is plugged in. Opening a panel
may expose the operator to the unit’s AC input power. The AC input power is potentially lethal and is
located on the far right within the cabinet.
NEVER make or break any electrical connections to the system while the unit is turned on.
NEVER access the electronics area with hands or tools unless the unit is disconnected from power
for at least one hour.
NEVER replace the installed 10 amp fuse with a fuse of a higher rating. This will void your warranty
and the electronics will not be adequately protected from surges or short circuits.
POWER ON/OFF is controlled by the large red button (e-stop) located on the top of the case in the
far right. This is a normally-open twist to release button. To power the laser down, simply press the
button down until it locks. To power the laser up, twist the button clockwise according to the indicating
arrows on the surface of the button.
IN CASE OF A BLOWN FUSE determine the cause of the overload before replacement to
protect the machine from damage.
Electrical Safety

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Pro-Series Toolbox Parts
Your laser ships with a toolbox containing parts and accessories:
1. Ignition Keys 2. Door Panel Keys 3. Hex Wrench Set
4. Screw Driver 5. Spare Limit Switch 6. Lens & Mirror Removal Tool
7. Focus Ruler 8. Air Flow Connector 9. Thermal Paper
SECTION II. UNCRATING
Figure 2.1
Figure 2.2

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4. 110v Main Machine
Power Cord
7. Air Compressor
2. Ethernet Cable
5. Honeycomb Cutting
Table
1. Water Tubes
(Toolbox)
3. Exhaust Fan
6. 6” Exhaust Tube Band
Clamps (3) (Toolbox)
Pro-Series Parts & Accessories
Your laser shipped with the following included parts and accessories:
Hose Clamp
Ducting
Exhaust Fan
Air Hose
Air Compressor

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1. Water Chiller 2. Large Fume
Extractor
3. Medium Fume
Extractor
6. 2.0” Focus Lens4. Small Fume
Extractor
7. 2.5” Focus Lens
5. 1.5” Focus Lens
8. 5” Focus Lens
Optional Upgrades & Recommended Accessories

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1. Create a Work Space: You will need a large, level oor space to place your laser cutter. A
clean, open and well-ventilated area is best. Be sure the workspace is free of re hazards and always
have a re extinguisher handy in case of emergency.
2. Carefully Open Wooden Crate: Your machine will arrive packed in a large wooden crate
and will require a forklift to move. Set the crate on a at space near where you will place the machine.
Open the crate carefully, starting with the top. If you use tools to open the crate, be careful not to
touch the machine or any packed accessories. Always use all tools with caution and only as specied
by the manufacturer. Next open the sides of the crate and clear away the wood panels.
3. Remove the Machine from the Crate: With the foam packaging intact, carefully lift the
machine and place it in your oor space. The Pro-Series 36x24 and Pro-Series 48x36 will require a
forklift to place the machine in your workspace.
4. Remove Accessories: Some of the accessories are zip-tied to the front beam attenuator, Cut
the zip tie and remove the bags with cords and small accessories. If you ordered a water chiller, it
is shipped within the crate in a separate box. The air compressor is shipped in a separate box with
the exhaust fan inside the crate as well. Also inside the machine is a toolbox with more parts and
accessories. Inspect these parts to insure they are accounted for and intact.
5. Remove “Honeycomb” Cutting Table: Remove honeycomb table from work area and
remove the thin foam sheet. Once we have removed the packaged ducting we will insert it on top of
the knife blade table.
6. Insert the Honeycomb: Place the honeycomb into the laser cutter machine body and lay at.
Be careful not to hit other machine components during this procedure.
7. Inspect the Machine: Examine your Pro-Series machine for defects and breakage. In
particular, check that there are no cracks or breakage on the glass laser tube. If you nd any defects
or breakage, contact your sales representative immediately. Have pictures of the damage ready to
share. Otherwise, your machine is now ready for minor assemble.
Uncrating Your Pro-Series Laser Cutter
When your Pro-Series 48x36 (or 36x24) Laser Cutter arrives, it will require careful
uncrating and examination of parts. Follow these instructions for best results.
ATTENTION! Be sure to keep the box crate and the packing
material used during shipping in case you need to return the
machine for warranty service.

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With your laser cutter uncrated and placed in its permanent work space we can now assemble
the operating systems. This is a simple process that should take less than an hour to complete.
The following stages will be described in detail.
Assembly Stages:
1. Remove the Zip Ties
2. Connect the Exhaust
3. Install Laser Tube
4. Connect the Water Chiller
5. Assemble the Air Compressor
6. Connect Power
7. Connect the Ethernet Cable
8. Connect to RetinaEngrave Software
SECTION III. INSTALLATION & ASSEMBLY
In addition, you will need the following tools and accessories
(not included with your machine purchase):
1. 2 Gallons of Distilled Water
2. Internet Connection (to connect to software)
3. Flathead Screwdriver
4. Clippers

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Assembly Stage 1: Remove Zip Ties
To secure the machine during shipping, zip ties are used to hold secure the drive belts. These must
be removed before operating your laser cutter for the rst time.
1. Locate Zip Ties: The motion system is restrained by three (3) zip ties: one on the X-Axis drive
belt, and one on each Y-Axis drive.
2. Cut and Remove Zip Ties: Using a small pair of clippers (nail cutters work remarkably well),
carefully cut and remove all three (3) zip ties listed above. Be careful NOT to damage any part of the
machine during this process.
= Cut = Do Not Cut
Figure 3.1

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Assembly Stage 2: Connect the Exhaust
It is mandatory that an exhaust blower is connected and operating whenever you run a job on your
laser. A properly installed exhaust blower removes smoke and fumes from the case and exhausts
them to the outside of the building.
1. Position Ducting: On the back of the machine, you will see a 6” exhaust “ange”. Place your
6” ducting to the angled ange that connects to the catch bin and secure with the 6” ducting clamp.
2. Secure with Ducting Clamps: Secure and seal the ducting to the Exhaust Port using the
included 6” ducting clamps.
3. Attach Exhaust Fan: Secure the ducting connected to the machine to the ange side of the
exhaust fan (see gure 3.5). Now repeat the ducting and clamping process on the exhaust port of the
exhaust fan creating a sequence of machine to ducting to exhaust fan to second ducting.
Figure 3.2
Figure 3.4
Figure 3.3
Figure 3.5
From Pro Series
To
Outside Exhaust
Flange
Exhaust Port

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4. Ventilate Outside: Attach the open end to an installed ventilation outlet. Check your system
for leaks—most can be remedied with duct tape. Please be aware that the protective housing is not
designed to be airtight; the front grill is designed to allow an exhaust system to draw fresh air through
the work area.
5. Fume Extractor Upgrade (optional): You can also upgrade to a fume extractor. Fume
extractors are air puriers that clean the air through HEPA Filters. Fume extractors do not require an
exhaust fan or outside ventilation. This is a great option for workshops that do not have the option to
ventilate outside. Both the extractors and the lters are available on the Full Spectrum Laser website
at https://www.fslaser.com/Products/LaserAccessories. For the 36x24 and the 48x36 machines
we recommend the Large Fume Extractor: https://www.fslaser.com/Product/LargePurier.
https://www.fslaser.com/Products/LaserAccessories.
FSL300 Fume Extractor
FSL200Fume Extractor
FSL100 Fume Extractor
Fume Extractor lters require routine cleaning and replacement, dependent on use and materials cut.
Generally, fume extractor suction will diminish and odors will be detected as lters clog.
NEVER use a fume extractor without all lters in place.
Follow these maintenance guidelines:
Pre-Filters
Clean often. Use a shop vacuum to clean as debris builds. Check weekly, especially if cutting a lot of
wood. When accumulated debris remains over 70% after cleaning, replace Pre-Filter.
HEPA Filters
Clean immediately when suction is reduced. Use a shop vacuum to clean accumulated dust. When
cleaning does not return optimal suction power, replace HEPA Filter.
Activated Carbon Filters
Clean when odors are detected or suction is reduced. Gently shake excess dust and debris from
carbon lter and follow with a shop vacuum. When cleaning no longer eliminates detectable odors,
replace Activated Carbon Filters.

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Assembly Stage 3: Install Laser Tube
Please carefully read all instructions before beginning the laser tube installment procedure as there
are several critical steps which must be properly followed. Remember to never operate your laser
without properly installed air and water systems running.
FRAGILE GLASS! Pulling on the tube wires will break
your laser tube at the neck. The water connections are very
fragile, DO NOT pull or force the connection tubes— gently
work the tubes off of the connectors.
1. Prepare the Laser Tube Mount: Using a small 2mm hex wrench, unscrew and remove
the two (2) M4 screws from the mounting. Keep these screws close by as they will
be reinserted after the laser tube is mounted and connected.
Rear View of Laser Tube
Tube Mounts
Figure 3.6
Figure 3.7