Schilling Megalight User manual

K:\Bedienungsanltg\Lasertechnik\BA-Erstellung\General Manual MegaLight_NEW_GB.doc
Marking Systems GmbH
Megalight™
Marking Laser
G
Ge en ne er ra al l M Ma an nu ua al l
Schilling Marking Systems GmbH
In Grubenaecker 1
DE-78532 Tuttlingen Germany
Tel.: [phone]
Fax.: [phone]
www.schilling-marking.com
[email protected]
Edition: 20.03.2004

Schilling Marking Systems GmbH
In Grubenäcker 1 DE-78532 Tuttlingen [phone] [phone] [e-mail]
www.schilling-marking.de
MegaLight Installation
Technical modifications reserved 2 Edition 2004
Edition: Subject areas covered in the new edition No. of pages added or
modified
20/03/2004
Foreword
Megalight™ is a Complex Component not intended to be marketed as a single commercial
unit but rather distributed exclusively as Original Equipment Manufacturer (OEM) to qualified
Suppliers, Users, Installers who have the technical background in relation to the Safety
requirements which an Installed Laser System must possess to become a Laser Machine,
as defined by standard EN 12626 (ISO 11553).
The information contained in this manual is addressed to a qualified installer able to integrate
the device in a system, completing all the protection systems required by international
standards and local laws.
The following manual refers to the model Megalight™, in the two versions Marker and OEM,
i.e. relative to a Laser source which has been designed and developed as a single component
to be integrated in more complex systems to create a Laser engraving system.
The Manual has been written in compliance with the requirements of EC directive 98/37 and
subsequent modifications and integrations, and is intended to supply a qualified installer with
instructions for:
Conformity
Shipping
Use instructions
Use contraindications
Installation
Commissioning
Use
Adjustments
Maintenance
Repair (if necessary)
Training instructions
Technical specifications
Specifications of accessories
Mechanical drawings
Wiring diagrams
The functions required from creating an engraving system must be supplied by an external
Personal Computer, with an appropriate Engraving Software installed on it.
The Marker version is supplied with an Engraving Head and Smartist 4 engraving software
with DAC 2 Hardware (Board for PCI bus and D/A converter) needed for creating the
engraving system. Installation and use instructions for Smartist 4 are provided separately in a
specific manual called: Smartist 4 Manual.
The OEM version does not include the Engraving Head, Hardware and Engraving Software.
It is advisable to carefully read the laser safety instructions contained in this manual and to
refer to the separately provided Laser safety guide.
Make sure the system has not undergone damages from shipping when you receive it and
before installing it. If there are any signs of possible damage, contact the shipping company to
lodge a complaint and notify us at:

Schilling Marking Systems GmbH
In Grubenäcker 1 DE-78532 Tuttlingen [phone] [phone] [e-mail]
www.schilling-marking.de
MegaLight Installation
Technical modifications reserved 3 Edition 2004
Schilling Marking Systems GmbH
In Grubenaecker 1
DE-78532 Tuttlingen - Germany
Tel.: [phone]
Fax: [phone]
eMail: [e-mail]
The information contained in this document is subject to modification and review without prior
notification. All the names of the products referred to are registered trademarks belonging to
the companies that created them. Reference is made to them for editorial reasons only.
Microsoft, MS, MS-DOS, Windows 98, Windows NT, Windows 2000, Windows XP, Visual Basic,
PowerPoint, Microsoft Press, are registered trademarks or trademarks of Microsoft Corporation
in the United States and in other countries. TrueType is a registered trademark of Apple
Computer, Inc.
N.B.:
Schilling Marking Systems GmbH shall not be held liable for any damage or injury
arising from incorrect installation of its product by unqualified personnel and for
damage or injury resulting from on conforming use of the supplied equipment!
N.B.:
This product is intended to be incorporated in an O.E.M. laser system and requires
additional functions to make it in compliance with the specifications set forth in
21CFR 1040 or-60825. Class IV product.

Schilling Marking Systems GmbH
In Grubenäcker 1 DE-78532 Tuttlingen [phone] [phone] [e-mail]
www.schilling-marking.de
MegaLight Installation
Technical modifications reserved 4 Edition 2004
CONTENTS
Symbols related to equipment safety pg. 6
Definitions pg. 7
Main preliminary safety warnings pg. 8
Shipping pg. 9
Disposal pg. 9
CHAPTER 1: DESCRIPTION OF THE EQUIPMENT pg. 10
Intended Use pg. 10
Use contraindications pg. 10
Use warnings pg. 10
Composition pg. 11
Layout of the device pg. 12
Rack pg. 14
Description of the main electrical system components pg. 18
Main switch pg. 18
I/O board pg. 18
Current driver board pg. 18
Laser diode pg. 18
Peltier cell pg. 18
Aiming laser diode pg. 19
Display pg. 19
Laser resonator pg. 19
Engraving scanner head pg. 20
Objective lens pg. 21
CHAPTER 2: INSTALLATION and START-UP pg. 22
Preliminary installation notes pg. 22
Installation procedure pg. 23
Environmental requirements pg. 23
1. Connection to the mains pg. 23
2. Connections pg. 24
DSP board installation pg. 24
Connectors’ pg. 25
Electrical connections pg. 26
Optical Fibre Connection pg. 27
Preliminary commissioning (Safety instructions) pg. 30
Commissioning pg. 30
Start-up procedure (Hardware) pg. 30
Start-up procedure (Software) pg. 31
Shutting Down pg. 32
CHAPTER 3: USE and MAINTENANCE pg. 33
General use instructions for Class IV lasers pg. 33
Individual Protection Devices (IPD) pg. 34
Daily use by an Operator pg. 34
Turning on pg. 34
Turning off pg. 35
Replacing the lens pg. 35
Ordinary maintenance pg. 36

Schilling Marking Systems GmbH
In Grubenäcker 1 DE-78532 Tuttlingen [phone] [phone] [e-mail]
www.schilling-marking.de
MegaLight Installation
Technical modifications reserved 5 Edition 2004
Cleaning the lens protection glass pg. 36
Extraordinary maintenance pg. 37
TROUBLESHOOTING pg. 39
APPENDIX A: TECHNICAL SPECIFICATIONS pg. 41
System Specifications pg. 41
Identification pg. 41
Conformity pg. 41
Laser Source Classification pg. 41
Equipment electrical specifications pg. 42
Environmental and installation specifications pg. 42
Laser Source Specifications pg. 42
Mechanical specifications pg. 43
O.E.M. device standard equipment pg. 43
Separately supplied parts pg. 43
MARKER device standard equipment pg. 43
Possible field of adjustment pg. 44
Warning labels and their positioning pg. 45
Detailed label description pg. 49
Mechanical drawings pg. 51
APPENDIX B: WIRING DIAGRAMS pg. 53
Description of signals on connectors pg. 53
Command Box (CB) Connector pg. 53
External Interlock Connector pg. 54
Galvo Supply Connector pg. 54
Slave Out Connector pg. 54
P.C. Connector pg. 55
Aiming Beam Connector pg. 55
R.F. Connector pg. 56
Wiring diagrams pg. 56
APPENDIX C: Safety notes pg. 62

Schilling Marking Systems GmbH
In Grubenäcker 1 DE-78532 Tuttlingen [phone] [phone] [e-mail]
www.schilling-marking.de
MegaLight Installation
Technical modifications reserved 6 Edition 2004
SYMBOLS RELATED TO DEVICE SAFETY
Symbol Meaning
I
INDICATION: this symbol indicates that in this position the device
power switch is off
O
INDICATION: this symbol indicates that in this position the device
power switch is on
GENERIC WARNING: (caution, warning, danger): this symbol
indicates that the instructions regarding important manoeuvres or
maintenance operations need to be carefully read.
ELECTRICITY WARNING: this symbol indicates the presence of
associated dangerous voltage, or powerful enough to constitute an
electrical risk. This symbol must appear on the finished machine as
well, at the electrical risk area.
LASER WARNING: this symbol indicates the danger of exposure to
visible or invisible laser radiation. This symbol must appear on the
finished machine as well, at the optical risk area.
FIRE WARNING: this symbol indicates the danger of a fire when
processing flammable materials. For this reason it is necessary to
follow the instructions provided by the manufacturer when
commissioning the machine.
CONFORMITY: this symbol indicates that the device has been
produced in conformity with European Community directives.
READ THE WARNING: this symbol indicates that it is obligatory to
read the important remarks in the manual before continuing
TEMPERATURE WARNING: this symbol indicates the presence of
high temperatures which may involve a risk of being burned

Schilling Marking Systems GmbH
In Grubenäcker 1 DE-78532 Tuttlingen [phone] [phone] [e-mail]
www.schilling-marking.de
MegaLight Installation
Technical modifications reserved 7 Edition 2004
Definitions
Term Definition
Fp Symbol of impulse repetition frequency
Q Symbol of energy of one impulse
Pm Symbol of the average power of a series of impulses
Hz Hertz, unit of measurement for frequency (1 Hz – 1 impulse/s)
J Joule, unit of measurement for energy
W Watt, unit of energy for power (1W = 1 joule/second)
mJ millijoule = one thousandth of a joule
µ J microJoule = a millionth of a joule
DO Optical Density, the exponential to the power of 10 of optical
radiation absorption for laser protection glasses
NOHD Nominal ocular hazard distance
λSymbol for wavelength (λin nm)
αSymbol for the divergence of the laser beam (αin mrad)
V ac Rsm value of the alternate voltage in Volts
Note for laser parameters
The energy related to a single laser impulse is measured in microJoules. The average power of
a train of impulses is measured in Joules/second, or Watts. This average power (Watts) is
equal to the energy per impulse (Joules) multiplied by the impulse repetition frequency
(Hertz).

Schilling Marking Systems GmbH
In Grubenäcker 1 DE-78532 Tuttlingen [phone] [phone] [e-mail]
www.schilling-marking.de
MegaLight Installation
Technical modifications reserved 8 Edition 2004
Main Preliminary Safety Warnings
Before continuing with the installation of the device carefully read the following important
preliminary safety warnings.
WARNING:
The main laser radiation of Megalight™ is in Class IV. The free beam produced by a
Class IV laser source may represent a significant risk for the eyes and skin even
from a great distance!
The device is intended for use by instructed and informed personnel strictly within
an industrial plant!
N.B.:
Before continuing with installation of the device make sure you have suitable
goggles for protection against scattered radiation. Even with goggles, it is possible
to damage your vision by viewing direct laser radiation. Avoid viewing direct
radiation!
WARNING:
Before continuing with installation make sure that the environment is suitable
for the intended use. In particular make sure there are no openings (windows or
other) towards the outside which can let dangerous radiation leak out!
WARNING:
Install the laser on a stationary support. Unforeseen risks may be caused if the
device falls!
WARNING:
The intensity of this laser is sufficient to ignite flammable material. Do not aim the
laser beam at flammable material.
WARNING:
The interaction of the laser beam with the material causes the formation of fumes
and vapors, which may be harmful or toxic. It is advisable to eliminate the fumes
with a specific suction device and only release them to the air after they are
filtered.

Schilling Marking Systems GmbH
In Grubenäcker 1 DE-78532 Tuttlingen [phone] [phone] [e-mail]
www.schilling-marking.de
MegaLight Installation
Technical modifications reserved 9 Edition 2004
Shipping
Megalight™ must be shipped in its original packing to prevent it from undergoing bumping and
vibration. The packing has a device which is sensitive to excessive bumping which may
damage the internal parts.
WARNING:
After shipping and before starting unpacking operations make sure the
Antishock Wave label applied to detect any bumping during shipment, is intact,
If not, return to the sender.
WARNING:
Before starting unpacking operations carefully read the instructions on
attached to the packing regarding handling the device.
N.B.:
Keep the packing; it needs to be used if the device is reshipped.
In addition, avoid exposing the device to rain, cold, excessive heat and/or humidity.
During shipping do not expose the device to environmental conditions other than those listed
below for more than 24 hours:
•ambient temperatures from - 5°C to + 55°C;
•relative humidity of 100% without condensation.
Disposal
No part of the device, including electronic, mechanical and optical, requires special precautions
for disposal.

Schilling Marking Systems GmbH
In Grubenäcker 1 DE-78532 Tuttlingen [phone] [phone] [e-mail]
www.schilling-marking.de
MegaLight Installation
Technical modifications reserved 10 Edition 2004
CHAPTER 1:
DESCRIPTION OF THE EQUIPMENT
Megalight™ is a Nd:YAG/passively Q-switched laser with wavelength equal to 1064nm,
maximum power equal to 6W (in continuous operation) and operating frequency equal to
25KHz, pumped by a laser diode at 808 nm and air-cooled. The pumped source is remote
controlled in relation to the laser head (Resonator) and is situated inside the rack. Coupling
between the pump diode and laser head is cone via Optical Fibre.
Intended Use
The device is designed and built for the application of engraving of non-flammable
metal and plastic materials. If the intended use of the source is changed, for example for
applications other than material processing, collateral risks may arise associated with the
interaction of laser radiation with the material.
Use contraindications
Do not subject materials other than those the device was designed for to Laser radiation.
The laser possesses intensity sufficient for igniting flammable material, so do not direct the
laser beam on flammable material. The interaction of the laser beam with the material
causes the formation of fumes and vapours, which may be harmful or toxic. It is advisable to
use appropriate suction devices to eliminate fumes and filter fumes before releasing
them into the air.
Use warnings
Megalight™ is a Laser device able to emit class 2M visible radiation (aiming red beam) and
a Class IV main invisible radiation (laser beam).
Visible lasers which are not able to damage the eye for momentary viewing but may represent
a danger if viewed through a magnifying class belonging the class 2M.
Class IV includes lasers which can produce risks, not only from direct or reflected radiation, but
also from scattered radiation! The main radiation is included in Class IV. The free beam
produced by these laser sources may represent a significant risk for the eyes even at a
substantial distance!
The device is intended for use by trained and informed personnel only within an industrial
plant!
The installer must put into effect all measures aimed at containing the radiation to make sure
that it is terminated at the end of its useful path. In addition, the final User (Operator) must be
informed of the risks from exposure to Laser radiation and must wear specific I.P.D. (individual
protection devices) including goggles that protect against radiation and are certified as such.

Schilling Marking Systems GmbH
In Grubenäcker 1 DE-78532 Tuttlingen [phone] [phone] [e-mail]
www.schilling-marking.de
MegaLight Installation
Technical modifications reserved 11 Edition 2004
Composition
The Megalight™ device in its basic “O.E.M.” version is composed of:
•A power supply Rack containing the pump laser diode
•A compact laser Resonator, designed to take up little room.
•A connection Optical fibre
The components required to create the “Marker” set-up can be supplied separately as an
option:
•Engraving scanner head
•Interfacing electronic boards and engraving software (Windows-based)
•A Personal Computer with Monitor, keyboard and mouse.
All engraving operations can be managed with the Smartist 4 software program.
(the minimum Personal Computer requirements and Software operating instruction are
provided in the Smartist4 Manual).
The pictures below show the composition of an engraving system and the Megalight™ with
Miniscanner model
Picture 1: Megalight™ engraving laser system
MONITO
R
MOUSE AND
KEYBOARD
PERSONAL
COMPUTER
LASER ENGRAVING
HEAD
LASER RACK

Schilling Marking Systems GmbH
In Grubenäcker 1 DE-78532 Tuttlingen [phone] [phone] [e-mail]
www.schilling-marking.de
MegaLight Installation
Technical modifications reserved 12 Edition 2004
Device layout
The essential layout of the device highlights the main system components, composed of a
power supply rack which generates Pump radiation at 808 nm, optical fibre which
transports the pump radiation to the Resonator, Resonator which converts the 808 nm
continuous radiation to pulsed radiation at 1064 nm, engraving head scanner which aims and
deflects the laser beam on the engraving surface.
Picture 2: Laser MegaLight Layout
POWER SUPPLY
RACK LASER RESONATOR
SCANNING HEAD OPTICAL FIBE
R

Schilling Marking Systems GmbH
In Grubenäcker 1 DE-78532 Tuttlingen [phone] [phone] [e-mail]
www.schilling-marking.de
MegaLight Installation
Technical modifications reserved 13 Edition 2004
The following figure shows the system layout diagram.
AC/ D.C
POWER
SUPPLY
DIODE LASER
λ=808 nm / CW
DRIVER
DIODE
LASER
OPTICAL
FIBER
I/O BOARD
λ
=1064 nm/pulsed
Max.5W
LASER
RESONATOR
RED DIODE
PILOT BEAM SCANNING HEAD
External
A.C. Supply
λ=635 nm/CW
Max.3mW
RACK
Picture 3: System layout of MegaLight
™

Schilling Marking Systems GmbH
In Grubenäcker 1 DE-78532 Tuttlingen [phone] [phone] [e-mail]
www.schilling-marking.de
MegaLight Installation
Technical modifications reserved 14 Edition 2004
Rack
The power supply box contains the following components:
•AC/DC Power supplies able to provide all the required service power supply
•Coupler for the pump laser diode with 808 nm wavelength.
•Current driver powering the laser diode.
•Input/Output board.
•Radiators for heat dissipation via forced ventilation completely separated from the
electrical part.
The front indicator panel is aimed at the Operator of the Megalight™ laser device and
includes the following elements:
•Multilingual display for displaying alarm messages and indications
•Three color LEDs indicating the device operating status
- POWER ON (green)
- LASER IN STAND BY (orange)
- LASER READY (red)
•Hour meter for recording the total activation time of the laser diode, making it
possible to monitor the life of the laser diode and plan maintenance work ahead of time.
•Fan for circulating radiator cooling air

Schilling Marking Systems GmbH
In Grubenäcker 1 DE-78532 Tuttlingen [phone] [phone] [e-mail]
www.schilling-marking.de
MegaLight Installation
Technical modifications reserved 15 Edition 2004
IINDICATOR LED
FAN
HOUR METE
R
MULTILINGUAL DISPLAY
Picture 4: system rear panel: external indicators

Schilling Marking Systems GmbH
In Grubenäcker 1 DE-78532 Tuttlingen [phone] [phone] [e-mail]
www.schilling-marking.de
MegaLight Installation
Technical modifications reserved 16 Edition 2004
The rear management panel faces the side opposite the operator and includes the following
elements:
1 Socket for 230/110 Vac – 3/6A – 50/60Hz mains supply
2 Main switch to disconnect from the mains
3 Protection fuses (5x20mm, 6.3A/250V type T)
4 Galvo Supply connector (sub-D, 9 p., male) for Scanner Head power
5Internal Interlock Connector (DIN, 3 p., male) for connection to an external
emergency interlocks circuit.
6 Aiming Beam connector (SMB, female) for connecting the red aiming diode.
7Command Box connector (sub-D, 25 p., female) for connection to an external
command box.
8P.C. connector (sub-D, 9 p., female) for connecting the device to the DSp2 contained
in the external Personal Computer.
9Slave Out connector (sub-D, 15 p., female) (not used in this version).
10 Optical Fibre connector (D-80-LKA) for the optical fibre connection between the
Rack and Resonator.
11 R.F. connector (not used in this version).
12 Cooling fan

Schilling Marking Systems GmbH
In Grubenäcker 1 DE-78532 Tuttlingen [phone] [phone] [e-mail]
www.schilling-marking.de
MegaLight Installation
Technical modifications reserved 17 Edition 2004
Picture 5: Rear management panel: external connectors
2. MAIN SWITCH
3. PROTECTION FUSES
1. SOCKET MAINS SUPPLY
4. GALVO SUPPLY
5. EXTERNAL INTERLOC
K
8. PC
10. OPTICAL FIBE
R
12. FAN 1
6. AIMING BEAM
9. SLAVE OUT
11. R.F.
7. COMMAND BOX
12. FAN 2

Schilling Marking Systems GmbH
In Grubenäcker 1 DE-78532 Tuttlingen [phone] [phone] [e-mail]
www.schilling-marking.de
MegaLight Installation
Technical modifications reserved 18 Edition 2004
Description of the main electrical system components
Main switch
A line bipolar main switch (230/110Vac-10A) is contained in a filter with socket with double
fuse holder. It is located on the rear Management Panel and carries out the following functions
at the same time:
•Power disconnection device
•Protection device against overloading and short circuits (up to 1500 A)
•Category 0 emergency device.
The main switch is normally used in turn on and turn off operations.
Input/Output board
The input/output Board IOB communicates with the various elements of the electrical system,
centralizing and sorting operational and management functions. The board IOB receives
voltage directly from main switch and interfaces with:
•the AC/DC service power supplies,
•the radio frequency driver board (RFD), providing the 15Vdc low voltage and the
command signals for driving the Q-switch (not used in this version)
•the current driver board
•the display
•the three color LED
•the hour meter
•the rear panel
•the fans
•the Peltier cells
In addition the IOB board communicates with the DSP2 laser management board and creates
the interface towards the outside.
Current driver board
The current driver board manages and controls the current which supplies the laser diode in a
closed circuit.
Laser diode
The power laser diode LD is contained in the Coupler. It is powered at low voltage (2-4 Vdc)
and medium-high current (up to 50A). Its operating temperature is detected by a temperature
sensor and adjusted so that it stays between 20°C and 30°C. The Laser Diode provides the
pump radiation at a 808nm wavelength, transported in Optical Fibre and necessary to supply
the Resonator (optical pumping).
Peltier cell
The Peltier cell is placed in direct contact with the base of the Coupler unit and is located
exactly below the power laser diode. It is supplied with 24Vdc voltage and transfers the
generated heat from the laser diode to be eliminated by the Dissipater.

Schilling Marking Systems GmbH
In Grubenäcker 1 DE-78532 Tuttlingen [phone] [phone] [e-mail]
www.schilling-marking.de
MegaLight Installation
Technical modifications reserved 19 Edition 2004
Aiming laser diode
The aiming diode laser with 635nm wavelength (visible in red) is supplied at low voltage (2.5-
4Vdc) and is located in the Resonator unit. This visible radiation overlaps with the power laser
beam and makes it possible to indirectly view the optical path, as well as the operating field at
the output of the scanner head.
Display
Display provides the Operator with information on the status of the laser and is the first
diagnostic tool in the event of a fault
Laser resonator
The laser Resonator is basically composed of a pair of lenses able to gather the radiation
pumped at 808nm output from the optical fibre and focalized inside the crystal of active
material (Nd:YAG) by a pair of aligned mirrors which act as an oscillator for the laser radiation
at 1064nm and a Cr4+:YAG, which acts as a passive Q-switch and is used to generate
instantaneous high power laser impulses suitable for engraving. The final stage carried out a
beam-expander function: it increases the diameter of the output laser beam and improves the
collimation in order to be able to improve the focalization of the beam in a spot of reduced
dimensions, to obtain elevated irradiation on the engraving plane.
Picture 6: Laser Resonator
CRYSTAL Nd:YAG
CRYSTAL Cr4+:YAG
BEAM EXPANDER
FOCUSING OPTICS
MIRROR HR@1064nm
EXIT COUPLING
λ=808 nm CW
RED DIODE PILOT
BEAM
DICHROIC MIRROR
λ=1064 nm
PULSED
+
λ=635 nm/CW

Schilling Marking Systems GmbH
In Grubenäcker 1 DE-78532 Tuttlingen [phone] [phone] [e-mail]
www.schilling-marking.de
MegaLight Installation
Technical modifications reserved 20 Edition 2004
The aiming red diode is also situated in the Resonator unit, returned by a dichroic mirror so
that it overlaps the laser beam exactly and can be used to learnt he main path of the invisible
radiation, even if indirectly. The architecture of the laser head created in this manner is used
to obtain an output laser beam of a very high modal quality, with high performance and very
little heat to dissipate.
The connection for the optical fibre is located in the rear wall of the Resonator (see
Appendix A: Technical Specifications):
Engraving scanner head
DRIVER X-axis
D/A
CONVERTER
DSP2 (PC)
Power supply
Picture 7: Galvanometric scanning head to direct the laser beam
FOCUSING
LENS
DRIVER Y-axis
GALVO
MOTORS X-Y
MIRRORS X-Y
OPTICAL FIBER
CONNECTOR SOCKET