KERN DHS User manual

KE
DHS
System
Manual

Kern Electronics & Lasers, Inc. d.b.a. Kern Laser Systems
Wadena, Minnesota 56482
KCAM© is a copyright protected software.
Manual Rev 2.11.2015
Kern Electronics & Lasers, Inc., All Rights Reserve

NOTICE
The purchase of the KCAM© software grants the purchaser the license to use the software, not the ownership of the
KCAM© software.
This document may not be copied in whole or in part without the expressed written permission of Kern Electronics &
Lasers, Inc.
Although every effort has been made to assure that the information in this document is accurate and complete, Kern
Electronics & Lasers, Inc. shall not be liable for any direct, indirect, incidental, or consequential damages resulting from
any deficiencies in this document. All information in this document is subject to change without notice.
Kern Electronics & Lasers, Inc. makes no warranty as to the usefulness of its products for any particular application. It is
the Buyer’s responsibility to develop processes within the operating envelope of Kern products.
The user must understand the hazards of motion control systems and lasers before operating the software and hardware.
Kern Electronics & Lasers, Inc. will not assume responsibility for failure to operate the Kern Laser System automated
equipment in a safe manner. If you, the customer, have questions about operating a Kern Laser System, please call the
factory for written assistance.

Contact Information
Kern Laser Systems
1501 Industrial Drive
Wadena, MN 56482 U.S.A.
Phone: [phone]
Fax: [phone]
Email: [email protected]
Website: www.kernlasers.com
Office Hours
Monday – Friday: 8AM – 4:30PM Central Time
Customer Service
Toll Free: 888-660-2755 (US and Canada)
Phone: [phone]
Email: [e-mail]
Sales
Toll Free: 888-660-2755 (US and Canada)
Phone: [phone]
Email: [email protected]

Table of Contents
1 Getting Started
Safety ............................................................................................................................ 1
Sealed Beam Path............................................................................................................ 2
Laser Processed Materials and Applicable Standards............................................................. 2
CDRH Standards.............................................................................................................. 2
Material Capability and Fume Extraction ............................................................................. 3
Mandated Safety Labels.................................................................................................... 4
CDRH Procedures for Compliance....................................................................................... 6
System Requirements ...................................................................................................... 6
2 System Setup
Description ..................................................................................................................... 8
Intended Purpose ............................................................................................................ 9
Lighting.........................................................................................................................10
Uncrating.......................................................................................................................10
Material Handling, Floor Space and Leveling.......................................................................10
Computer ......................................................................................................................11
Control Boxes.................................................................................................................11
Mounting Laser on Gantry................................................................................................13
Chilling Unit ...................................................................................................................14
Electrical Panel...............................................................................................................14
Air/Assist Gas.................................................................................................................14
Vacuum System .............................................................................................................14
Mirrors and Lenses..........................................................................................................15
Height Follower Controller (Optional).................................................................................15
3 Running the System
Daily Startup .................................................................................................................16
EMF Printer Driver...........................................................................................................16
Cutting a .PLT file ...........................................................................................................17
Engraving a .TIF file........................................................................................................18
4 System Calibration
Mirror Alignment.............................................................................................................20
Focusing the Optics.........................................................................................................20
Squaring the Table..........................................................................................................21
Setting Zero-Zero Point...................................................................................................21
Aligning the Engraving Pixels............................................................................................22
5 KCAM
Installation ....................................................................................................................23
Upgrades.......................................................................................................................23
Overview.......................................................................................................................23
Setup Icon.....................................................................................................................25
Table Icon......................................................................................................................34
Cut Icon ........................................................................................................................39
Test Icon (Test/Manual Mode) ..........................................................................................41
6 Metal Cutting
Focusing the Optics.........................................................................................................42
Setting the Focus Height..................................................................................................42
How to Cut Mild or Stainless Steel.....................................................................................42
Metal Cutting Optics Assembly..........................................................................................43
7 K-Vision
Overview.......................................................................................................................44
Basic Settings Tab ..........................................................................................................45
Advanced Settings Tab....................................................................................................46

Calibration Settings Tab...................................................................................................47
Calibration Screen ..........................................................................................................48
Camera View Screen .......................................................................................................49
K-Vision Operation..........................................................................................................49
8 Rotary Stage
Installing the Chuck Rotary Stage.....................................................................................50
CorelDRAW Setup...........................................................................................................50
KCAM Setup...................................................................................................................50
9 CorelDRAW
Initial Setup...................................................................................................................51
Kern EMF Printer Driver...................................................................................................51
Creating a .PLT Cutting File..............................................................................................52
Creating a .TIF Engraving File ..........................................................................................52
Setting the Cut Order......................................................................................................53
10 AutoCAD
Printing to KCAM.............................................................................................................54
Selecting Cut Order.........................................................................................................54
Creating a Polyline..........................................................................................................55
11 PhotoGrav
Installing Photograv........................................................................................................56
Processing a Photo..........................................................................................................56
12 Maintenance
Daily.............................................................................................................................57
Weekly..........................................................................................................................57
Monthly.........................................................................................................................57
Mirror............................................................................................................................58
Lens..............................................................................................................................59
Lead Screw Nut Adjustment .............................................................................................60
13 Troubleshooting
KLMC Box ......................................................................................................................62
DSP Box ........................................................................................................................64
Mechanical.....................................................................................................................64
Computer ......................................................................................................................65
Electrical........................................................................................................................65
Laser.............................................................................................................................66
14 System Diagrams
Mirror Alignment.............................................................................................................67
DHS Optics Assembly......................................................................................................68
DHS Gantry ...................................................................................................................70
DHS Height Follower .......................................................................................................72
Blower Installation..........................................................................................................74
15 Warranty
In Warranty Systems ......................................................................................................76
Out of Warranty Systems.................................................................................................76
Laser Power Meter ..........................................................................................................76

A Message from the President
Thank you for choosing a Kern Laser Cutting and Engraving System. All of our systems are
designed, built, tested, and delivered with quality, productivity and customer satisfaction
in mind. With proper care and minimal maintenance of your system, you should receive
years of productivity from your laser system. If you encounter any problems or have any
questions about your system please call us for assistance.
Thank You.
Gerald Kern
President

Congratulations on the purchase of your KERN LASER SYSTEM!
Everyone at Kern takes great pride in manufacturing a quality laser system and providing the best technical
support for years after the sale. Feel free to give us a call when in need of assistance with your Kern Laser
System.
Please take time to review the instructional videos posted on the kernlasers.com website. This will aid in
connecting all the components of the system and get everything aligned and calibrated before operation can
begin. All connections are labeled at the factory to help simplify the process. Everyone operating the laser
system must read and understand the Kern laser manual before using the system.
Installation of a phone next to the laser system is encouraged and will help in expediting troubleshooting and
answering any technical questions that may arise about our software or operation of the system.
All components need to be inspected during setup and installation of the system to make sure damage did not
occur in the shipping process. Please call Kern immediately at 218-631-2755 with any questions or concerns.
Safety
Please read through these basic safety guidelines before operating the laser system:
•Wear certified laser safety eyewear (wavelength 10.6 µm @ optical density 6) when operating or
viewing the laser system.
•Direct eye contact with the invisible output beam will cause serious injury and may cause blindness.
•Never leave the laser system unattended while cutting or engraving.
•Always wear rubber gloves or finger gloves when handling the optic lens. Lenses are made of zinc
solenoid and can be harmful to your health.
•Cutting acrylic or thicker material at slow speeds and/or low air pressure may cause fires.
•The 1” honeycomb grid and 1” ecolite grid must be cleaned on a regular basis and replaced if needed.
If material residue buildup accumulates in the grid work, materials may catch on fire during the
cutting and/or engraving process. Clean with detergent and water.
•Clean and remove any material buildup from the bottom of the table’s vacuum chamber. If the black
painted surface is worn, remove the grid work and recoat the worn spots inside of the table’s vacuum
chamber with hi-temp flat black spray paint. Wait for the paint to dry and fumes to subside before
operating the system.
•Laser cutting and engraving are extremely high temperature burning processes. Many materials may
emit harmful gasses when cut or engraved with a laser. Refer to the materials MSDS safety sheet to
verify if the material is safe to laser cut or engrave before proceeding.
•Use proper ventilation within the room housing the laser system. The exhaust air from the vacuum
blower may need to be filtered for certain types of materials.
•Do NOT oil or lubricate the Teflon coated lead screws. The black Teflon coating will flake off and jam
up the nut. A clean, dry, soft cloth can be used to wipe down the lead screw.
•The “DANGER” laser safety sign included with each system is required to be posted at each entrance
of the room that the laser is located in. If additional safety signs are needed, please call Kern.
•At least one person must be assigned as the Laser Safety Officer (LSO). Their duty is to fully
understand and train all other personnel on safe operating procedures and aspects of the laser
system. Call Kern with additional information regarding LSO training.
•It is imperative to understand the hazards of operating a motion control system equipped with a laser
without proper training.
•Do not stare at the laser beam when cutting or engraving. Small amounts of ultra-violet light can be
emitted from the vaporized material.
•Operators are not to be under the influence of drugs or alcohol.
•Wear close fitting clothing. Operators are not to be wearing loose clothing. Operators must remove all
jewelry (rings, bracelets, necklaces, or similar items) as they can be hazardous and can be electrical
conductive for burns.
•People with long hair are to tuck hair back possibly into a cap.
•If safety questions arise, please call Kern at 218-631-2755 for assistance.
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Sealed Beam Path
Operators and maintenance personnel are protected from hazards on the machine by a sealed tube that
encloses the optical assembly of the laser.
This interlock is considered a necessary part of this machine. This interlock that controls access to the optical
assembly of the laser source is needed to protect maintenance personnel. This makes it possible to access the
laser source when maintenance personnel need to align the laser. The laser is only permitted to operate under
normal safety conditions. The hinged movable cover needs to be interlocked to ensure operators are not at
risk of exposure to reflected laser light or toxic fumes.
Operating Modes
Kern’s DHS model is normally operated in Automatic mode. In Manual mode it is possible to fire the laser
source, operate X and Y motion systems and check air pressure. Manual mode can only be used if all safety
interlocks are in operation. Manual Mode is normally used to test or calibrate the laser system.
Access to Manual mode is password protected
There is a need to operate the laser source while aligning the laser beam when the lid over the optical assembly
is open. This is made possible by introducing a Maintenance MANUAL mode of operation that can only be
accessed by entering a password. In Maintenance mode it is possible to operate the laser with the hinged lid
over the optical assembly open, but only under necessary enhanced safety conditions.
Laser Processed Materials and Applicable Standards
Laser material processing can generate by-products as air contaminants that can be noxious, toxic and even
fatal. The resulting vapors, fumes, and/or particles should be thoroughly evaluated and the adequacy of your
provisions for fume extraction, filtering and venting should be carefully considered.
Refer to Section 7.3 of the ANSI Z136.1-2007 “American National Standard for Safe Use of Lasers”, to the
exposure criteria in 29 CFR 1910 Subpart Z from the United States Government, and to the Threshold Limit
Values (TLV’S) published by the American Conference of Governmental Industrial Hygienists (ACGIH).
It may also be necessary to consult with state or local government agencies regarding restrictions on the
outdoor venting of vapors.
Before cutting or engraving any material, acquire the MSDS Safety Data Sheet for the material to verify the
product is safe to cut or engrave. Fumes from the cut material may be toxic.
CDRH Standards
This laser system complies with the requirements of the current version of the following:
U.S. Department of Health and Human Services, Title 21 Code of Federal Regulations, Subchapter J, Part
1040.10, Performance Standard for Laser Products.
The above regulation is sometimes referred to as the CDRH regulation, the FDA regulation or 21CFR 1040.
It is recommended to strictly follow the user requirements in the ANSI Z136.1-2007 “American National
Standard for Safe Use of Lasers”. These standards deal with such subjects as the appointment of a laser
safety officer, the operation of the system in a limited access area by trained authorized personnel and the
posting of signs warning of the potential hazard. The ANSI Standard manual is available from the Laser
Institute of America. Call 1-407-380-1553 or visit www.laserinstitute.org to obtain a copy.
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