Synrad FH FLYER User manual

Flyer 3D Head
Operator’s
Manual
™
4600 Campus Place
Mukilteo, WA 98275
1.800.SYNRAD1
tel [phone]
fax [phone]
e-mail synr[email protected]
web www.synrad.com
FH
MARKING HEAD
FLYE
R

Flyer 3D Head
Marking System
Operator’s Manual
Version 3.4
SYNRAD©is a registered trademark of Novanta Corporation. ©Novanta Corporation
2018. All Rights Reserved. No reproduction without written authorization.
DATE: February 2019
FH
MARKING HEAD
FLYE
R

table of contents
ii
i
Synrad FH Flyer Marking Head Operator’s Manual Version 3.4
Getting Started 1
Laser Safety
Hazard information.....................................................................................................1
Terms...................................................................................................................................................1
General hazards...............................................................................................................................1
Label locations .............................................................................................................4
Agency compliance....................................................................................................5
Center for Devices and Radiological Health (CDRH) requirements..............................5
Federal Communications Commission (FCC) requirements...........................................5
European Union (EU) requirements.........................................................................................6
Declaration of Conformity .......................................................................................8
Introduction ..................................................................................................................1-2
Basic marking setup ......................................................................................................................1-2
FH Flyer features .............................................................................................................................1-3
Control modes.................................................................................................................................1-3
Unpacking......................................................................................................................1-4
Incoming inspection .....................................................................................................................1-4
Packaging guidelines ....................................................................................................................1-4
Inventory ........................................................................................................................1-5
FH Flyer marking head..................................................................................................................1-6
FLMK mounting kit ........................................................................................................................1-7
Laser ....................................................................................................................................................1-7
Mounting........................................................................................................................1-8
Mounting guidelines.....................................................................................................................1-8
Mounting Rail...................................................................................................................................1-8
L-bracket ............................................................................................................................................1-9
FH Flyer marking head..................................................................................................................1-10
Laser ....................................................................................................................................................1-11
Cooling............................................................................................................................1-12
Connecting....................................................................................................................1-13
DC Power cable ...............................................................................................................................1-13
Laser Control cable ........................................................................................................................1-14
USB Communication cable .........................................................................................................1-16
DB-25 User Interface connector................................................................................................1-17
Gas Purge port ................................................................................................................................1-17

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Synrad FH Flyer Marking Head Operator’s Manual Version 3.4
i
v
Tracking 4
Operation 2
Stand-alone Operation 3
WinMark Pro v6 conguration................................................................................1-19
System requirements ....................................................................................................................1-19
WinMark/Flyer conguration .....................................................................................................1-19
Ethernet conguration..............................................................................................1-21
Ethernet conguration via USB connection .........................................................................1-21
Ethernet conguration via peer-to-peer connection........................................................1-22
Ethernet security.............................................................................................................................1-23
Modbus I/P conguration............................................................................................................1-24
Controls and indicators.............................................................................................2-2
Initial start-up ...............................................................................................................2-3
Test ring the laser .........................................................................................................................2-3
Marking in WinMark control mode ..........................................................................................2-5
Getting Started (cont.) 1
Introduction ..................................................................................................................3-2
Stand-alone denitions................................................................................................................3-2
Control modes.................................................................................................................................3-2
Supported functions .....................................................................................................................3-3
WinMark Pro/FH Flyer interface .............................................................................3-4
Version requirements for stand-alone operation................................................................3-4
Stand-alone set-up.........................................................................................................................3-4
Stand-alone Toolbar ......................................................................................................................3-5
Filestore structure...........................................................................................................................3-6
Fonts....................................................................................................................................................3-13
Conguring a network share......................................................................................................3-15
Conguration................................................................................................................3-16
Stand-alone development ..........................................................................................................3-16
Stand-alone automation..............................................................................................................3-18
Stand-alone, Master Control File...............................................................................................3-20
Introduction ..................................................................................................................4-2
Tracking setup .................................................................................................................................4-2
Tracking denitions....................................................................................................4-3
Tracking mark criteria ................................................................................................4-7

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v
Synrad FH Flyer Marking Head Operator’s Manual Version 3.4
Technical Reference 5
Tracking hardware ......................................................................................................4-9
Position encoder.............................................................................................................................4-9
Part sensor.........................................................................................................................................4-14
DC power supply ............................................................................................................................4-18
WinMark Pro tracking setup....................................................................................4-19
Determining line speed ............................................................................................4-24
Line speed formula ........................................................................................................................4-24
Sample calculations.......................................................................................................................4-24
Tracking optimization................................................................................................4-26
Text ......................................................................................................................................................4-26
Graphics .............................................................................................................................................4-27
Mark placement ..............................................................................................................................4-28
Line speed optimization ..............................................................................................................4-28
Summary ...........................................................................................................................................4-29
Tracking (cont.) 4
FH Flyer technical overview.....................................................................................5-3
Marking head...................................................................................................................................5-3
Beam expansion..............................................................................................................................5-3
Lens specications .........................................................................................................................5-4
Input/Output circuitry ..............................................................................................5-5
User Interface overview ...............................................................................................................5-5
Internal +15 VDC supply ..............................................................................................................5-7
Digital input circuitry ....................................................................................................................5-7
Digital output circuitry .................................................................................................................5-14
FH Index/Tracker to Flyer conversion......................................................................................5-18
FH Smart to Flyer conversion .....................................................................................................5-21
USB port..........................................................................................................................5-25
USB connections.............................................................................................................................5-25
Electrical isolation/electrical noise...........................................................................................5-25
Ethernet port ................................................................................................................5-26
Ethernet overview..........................................................................................................................5-26
Ethernet port LEDs.........................................................................................................................5-26
Ethernet/Flyer cabling ..................................................................................................................5-26
Fast Acting Safety Interlock .....................................................................................5-29
Flyer web interface .....................................................................................................5-31

table of contents
Synrad FH Flyer Marking Head Operator’s Manual Version 3.4
vi
Maintenance/Troubleshooting 6
Technical Reference (cont.) 5
Firmware upgrades.....................................................................................................5-32
Clearing mark ...............................................................................................................5-33
Over-temperature warning .....................................................................................5-35
Custom test mark feature.........................................................................................5-36
Overview............................................................................................................................................5-36
Test Mark Control options ...........................................................................................................5-36
Creating a custom test mark.......................................................................................................5-37
Setting Test Mark Control options............................................................................................5-38
Downloading a custom test mark le.....................................................................................5-38
Custom test mark I/O ....................................................................................................................5-38
General specications ...............................................................................................5-40
FH Flyer package outline drawing ........................................................................5-42
FH Flyer/Model 48-1/48-2 package outline drawings ...................................5-43
FH Flyer/Model 48-5 package outline drawing................................................5-45
FH Flyer/Firestar v30 package outline drawing................................................5-46
FH Flyer/Firestar v40 package outline drawing................................................5-47
FH Flyer/Firestar t70i package outline drawing ...............................................5-48
FH Flyer/Firestar t-Series package outline drawing........................................5-49
FH Flyer/Firestar f100 package outline drawing..............................................5-50
FH Flyer/Evolution 100 package outline drawing...........................................5-51
FH Flyer/Evolution 125 package outline drawing...........................................5-52
FH Flyer/Model 48-1/48-2 mounting ...................................................................5-53
FH Flyer/Model 48-5/Evolution 100/125 mounting .......................................5-54
FH Flyer/Firestar v30 mounting..............................................................................5-55
FH Flyer/Firestar v40/t-Series/f100 mounting ..................................................5-56
FH Flyer packaging instructions ............................................................................5-57
FLMK-1A packaging instructions...........................................................................5-58
FLMK-2A packaging instructions...........................................................................5-59
Maintenance .................................................................................................................6-2
Daily inspections.............................................................................................................................6-2
Storage/shipping............................................................................................................................6-3
Lens mount removal/replacement...........................................................................................6-3
Cleaning optics................................................................................................................................6-5
Troubleshooting ..........................................................................................................6-8

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vii
Synrad FH Flyer Marking Head Operator’s Manual Version 3.4
Appendix C
Index
Appendix B
Appendix A
Maint/Troubleshooting (cont.) 6
Indicator LEDs..................................................................................................................................6-8
FH Series Flyer marking head.....................................................................................................6-9
Stand-alone mode..........................................................................................................................6-14
Tracking mode.................................................................................................................................6-15
Automation I/O................................................................................................................................6-16
Laser Marking FAQ .........................................................................................................................6-17
Cooling............................................................................................................................A-2
Cooling FH Flyer..............................................................................................................................A-2
Heat load factors.............................................................................................................................A-2
Calculating heat load ....................................................................................................................A-4
Mounting an auxiliary cooling fan ...........................................................................................A-8
Power measurements................................................................................................B-2
Setup...................................................................................................................................................B-2
Input measurements.....................................................................................................................B-2
Output measurements .................................................................................................................B-4
Alternate mounting congurations......................................................................C-2
Mounting guidelines.....................................................................................................................C-2
Standard mounting .......................................................................................................................C-2
In-line mounting.............................................................................................................................C-3
Oset mounting..............................................................................................................................C-3
Beam expansion/path length.................................................................................C-4

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Synrad FH Flyer Marking Head Operator’s Manual Version 3.4
viii
List of Figures
Figure 1 FH Series Flyer hazard label and CE mark locations ...............4
Figure 2 European compliance mark ............................................................7
Figure 1-1 Typical FH Flyer static marking setup ..........................................1-2
Figure 1-2 FH Flyer shipping kit contents........................................................1-5
Figure 1-3 Installing the Mounting Rail............................................................1-9
Figure 1-4 Mounting the L-bracket....................................................................1-9
Figure 1-5 Mounting the Flyer head..................................................................1-10
Figure 1-6 Installing the Beam Enclosure Tube .............................................1-10
Figure 1-7 Mounting the laser .............................................................................1-11
Figure 1-8 Connecting the DC Power cable ...................................................1-13
Figure 1-9 Polarity of Flyer’s Power jack ...........................................................1-14
Figure 1-10 Connecting the Laser Control cable.............................................1-14
Figure 1-11 Connecting the USB Communication cable..............................1-16
Figure 1-12 Creating a new Flyer device name................................................1-19
Figure 1-13 Flyer IP Address Ranges dialog ......................................................1-23
Figure 2-1 FH Flyer control panel .......................................................................2-2
Figure 2-2 Working distance measurement ...................................................2-3
Figure 2-3 Test pattern ...........................................................................................2-5
Figure 2-4 WinMark Pro’s Mark button .............................................................2-6
Figure 3-1 Stand-alone Toolbar...........................................................................3-5
Figure 3-2 Initial stand-alone Flyer Files window .........................................3-6
Figure 3-3 File operations indicator...................................................................3-7
Figure 3-4 Filestore containing saved les and folders ..............................3-9
Figure 3-5 Contextual menu—.mkh mark les .............................................3-9
Figure 3-6 Contextual menu—other les........................................................3-10
Figure 3-7 Contextual menu—folders..............................................................3-11
Figure 3-8 Contextual menu—Filestore...........................................................3-12
Figure 3-9 Master Control File owchart—continuous mode .................3-28
Figure 3-10 Master Control File owchart—strobed mode ........................3-29
Figure 4-1 FH Flyer tracking setup .....................................................................4-2

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ix
Synrad FH Flyer Marking Head Operator’s Manual Version 3.4
List of Figures (cont.)
Figure 4-2 Usable Field Size..................................................................................4-3
Figure 4-3 Mark Pitch greater than Usable Field Size..................................4-4
Figure 4-4 Tracking Window.................................................................................4-5
Figure 4-5 Target Area ............................................................................................4-5
Figure 4-6 Object Reference Point .....................................................................4-6
Figure 4-7 Checking Encoder Resolution ........................................................4-7
Figure 4-8 Usable Field Size comparisons .......................................................4-8
Figure 4-9 Maximum marking position in Tracking Window ...................4-8
Figure 4-10 Wiring diagram for current-sinking (NPN open
collector) encoders.............................................................................4-10
Figure 4-11 Wiring diagram for current-sinking (NPN open
collector) encoders using Flyer’s built-in power supply .......4-10
Figure 4-12 Wiring diagram for current-sourcing (PNP open
collector) encoders.............................................................................4-11
Figure 4-13 Wiring diagram for current-sourcing (PNP open
collector) encoders using Flyer’s built-in power supply ......4-11
Figure 4-14 Linestack mark .....................................................................................4-13
Figure 4-15 Wiring diagram for current-sinking (NPN open
collector) part sensors.......................................................................4-14
Figure 4-16 Wiring diagram for current-sinking (NPN open
collector) part sensors using Flyer’s built-in power supply..4-15
Figure 4-17 Wiring diagram for current-sourcing (PNP open
collector) part sensors.......................................................................4-15
Figure 4-18 Wiring diagram for current-sourcing (PNP open
collector) sensors using Flyer’s built-in power supply...........4-16
Figure 4-19 Part sensor setup.................................................................................4-17
Figure 4-20 Tracking properties on “Flyer device” tab...................................4-19
Figure 4-21 Drawing Canvas coordinates relative to FH Flyer....................4-20
Figure 4-22 Upstream part sensor, rising edge trigger .................................4-20
Figure 4-23 Downstream part sensor, rising edge trigger...........................4-21
Figure 4-24 X-Y position Object Reference Point coordinates....................4-21
Figure 4-25 Part sensor output waveforms.......................................................4-22
Figure 4-26 Tracker line speed calculation #1 ..................................................4-24
Figure 4-27 Tracker line speed calculation #2 ..................................................4-25

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Synrad FH Flyer Marking Head Operator’s Manual Version 3.4
xi
List of Figures (cont.)
Figure 4-28 Sample text mark ................................................................................4-26
Figure 4-29 Beam/mark motion ............................................................................4-27
Figure 4-30 Congure Marking Order dialog box...........................................4-28
Figure 5-1 Expander telescope location ..........................................................5-4
Figure 5-2 Physical layout of Flyer’s User Interface connection ..............5-5
Figure 5-3 FH Flyer’s equivalent input circuit.................................................5-9
Figure 5-4 Activating Flyer input with a current sinking device .............5-10
Figure 5-5 Activating Flyer input with a current sourcing device...........5-10
Figure 5-6 Driving Flyer from current sourcing switch or relay device.5-11
Figure 5-7 Driving Flyer from current sinking switch or relay device....5-11
Figure 5-8 Driving Flyer from high-speed encoder input..........................5-12
Figure 5-9 FH Flyer’s equivalent output circuit..............................................5-15
Figure 5-10 Flyer output to isolated I/O module.............................................5-16
Figure 5-11 Flyer output to PLC input module ................................................5-16
Figure 5-12 Physical wiring—straight-thru Ethernet connection.............5-27
Figure 5-13 Physical wiring—crossover Ethernet connection ...................5-28
Figure 5-14 Opening Flyer to enable FASI..........................................................5-29
Figure 5-15 Flyer DIP switch locations ................................................................5-30
Figure 5-16 Flyer’s Internet interface page........................................................5-31
Figure 5-17 Checking Flyer’s rmware version ................................................5-32
Figure 5-18 Clearing Mark properties..................................................................5-33
Figure 5-19 Clearing Mark Interval .......................................................................5-34
Figure 5-20 Test Mark Control dialog box..........................................................5-36
Figure 5-21 FH Flyer marking head package outline and mounting
dimensions ...........................................................................................5-42
Figure 5-22 FH Flyer/Model 48-1/48-2 package outline and mounting
dimensions, Sheet 1 of 2...................................................................5-43
Figure 5-23 FH Flyer/Model 48-1/48-2 package outline and mounting
dimensions, Sheet 2 of 2...................................................................5-44
Figure 5-24 FH Flyer/Model 48-5 package outline and mounting
dimensions ...........................................................................................5-45
Figure 5-25 FH Flyer/Firestar v30 package outline and mounting
dimensions ...........................................................................................5-46