ULS VLS Series User manual

VLS Service Manual

VLS Service Manual - REV2015.04 Table of Contents
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Table of Contents
Technical Assistance 5
Contact the ULS Technical Support Department ................................................................................... 5
Global Technical Support Department ..............................................................................................................5
Europe Technical Support Department .............................................................................................................5
Asia Technical Support Department..................................................................................................................5
Performing VLS Service Procedures...................................................................................................... 5
Safety ................................................................................................................................................................5
Difculty.............................................................................................................................................................5
Tools..................................................................................................................................................................5
Safety 6
Discription of Appropriate Use................................................................................................................ 6
General Safety........................................................................................................................................ 6
CO2 Laser Safety................................................................................................................................... 8
Tamper Proof Labels.............................................................................................................................. 8
Adjustments and Settings 9
Computer Power Management Conguration ........................................................................................ 9
Windows XP and Windows Vista:......................................................................................................................9
Windows 7 and Windows 8: ..............................................................................................................................9
Laser Power Upgrading........................................................................................................................ 11
CPU Initialization / Auto-Z Calibration .................................................................................................. 12
Cutting Table Calibration...................................................................................................................... 13
Rotary Calibration................................................................................................................................. 15
X-Axis Arm Alignment Check and Adjustment (Squaring).................................................................... 16
Adjustments.....................................................................................................................................................17
Laser Beam Check and Alignment....................................................................................................... 18
Z-Axis Leveling..................................................................................................................................... 20
Setting the Table Height..................................................................................................................................20
Manually Setting the Table Height...................................................................................................................21
Checking and Adjusting the Table Level .........................................................................................................22
Focus Tool Calibration.......................................................................................................................... 23
Component Removal and Replacement 25
Focusing Lens ...................................................................................................................................... 25
Replace Mirror #3................................................................................................................................. 26
Replace Beam Shaper (for HPDFO lens kit)........................................................................................ 27
Replace Mirror #2................................................................................................................................. 28
Beam Window ...................................................................................................................................... 29
Collimator ............................................................................................................................................. 29
Rear Cover Filter Media and Fan Guard .............................................................................................. 30
Enclosure and Cart............................................................................................................................... 31
Rear Cover Hinges..........................................................................................................................................31
Rear Cover Latches and Cover Latch Catch...................................................................................................32
Rear Cover Proximity Sensor Magnets ................................................................................................ 33
Rear Cover Cooling Fan....................................................................................................................... 33
Top Door and Window.......................................................................................................................... 34
Top Door Hinges .................................................................................................................................. 35
Hydraulic Pressure Cylinder................................................................................................................. 37
Top Door Proximity Sensors................................................................................................................. 37
Front Door Hinges ................................................................................................................................ 38

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Table of Contents
Y-Axis Drive Gears............................................................................................................................... 57
Y-Axis Bearings.................................................................................................................................... 58
Y-axis Motor ......................................................................................................................................... 58
Y-Axis Rail............................................................................................................................................ 59
Z-Axis 60
Z-Axis Motor, Drive Gear & Z-Axis Motor Belt...................................................................................... 60
Z-Axis Limit Switch ............................................................................................................................... 61
Z-Axis Belt ............................................................................................................................................ 61
Left Z-Axis Assembly............................................................................................................................ 62
Right Z-Axis Assembly ......................................................................................................................... 63
Lead Screw........................................................................................................................................... 64
Engraving Table (Stage)....................................................................................................................... 65
Electronics 67
Laser Source ........................................................................................................................................ 67
CPU ..................................................................................................................................................... 68
Keypad ................................................................................................................................................. 69
Upper Flex Board ................................................................................................................................. 70
Lower Flex Board ................................................................................................................................. 70
Flex Cable ............................................................................................................................................ 71
Thermal Sensor/Com Board................................................................................................................. 71
Thermal Snap Switch ........................................................................................................................... 72
Power Supply Module........................................................................................................................... 73
AC Power Inlet .................................................................................................................................... 74
Fuse ..................................................................................................................................................... 74
Front Door Latch................................................................................................................................... 38
Front Door Latch Catch ........................................................................................................................ 39
Front Door Proximity Sensors .............................................................................................................. 39
Exhaust Plenum ................................................................................................................................... 40
Rulers ................................................................................................................................................... 40
Cart....................................................................................................................................................... 41
VLS3.60 and VLS4.60.....................................................................................................................................41
VLS6.60...........................................................................................................................................................43
Cart Casters ......................................................................................................................................... 44
Front Door Interlocks............................................................................................................................ 45
Top Door Interlocks .............................................................................................................................. 45
Rear Cover Interlocks........................................................................................................................... 46
X-Axis 47
X-Axis Bearings.................................................................................................................................... 47
X-Axis Belt Replacement...................................................................................................................... 48
X-Axis Idler Pulley ................................................................................................................................ 50
X-Axis Motor and Drive Gear................................................................................................................ 51
X-Axis Drive Gear............................................................................................................................................51
X-Axis Motor....................................................................................................................................................52
X-Axis Arm Replacement ..................................................................................................................... 52
X-Axis Rail............................................................................................................................................ 53
Y-Axis 55
Y-Axis Belts .......................................................................................................................................... 55
Y-axis Idler Pulleys............................................................................................................................... 56

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Table of Contents
9V Battery Holder/Drawer .................................................................................................................... 75
Accessories 76
Air Assist Cone Alignment.................................................................................................................... 76
Air Track .............................................................................................................................................. 76
Air Assist Diffusers ............................................................................................................................... 77
#2 Mirror Diffuser.............................................................................................................................................77
Beam Window Diffuser....................................................................................................................................77
Cutting Table Insert ............................................................................................................................ 78
Rotary Cone/Cup ................................................................................................................................. 78
Rotary Belt/Motor ................................................................................................................................. 79
Rotary Clamp ...................................................................................................................................... 81

VLS Service Manual - REV2015.04
Table of Contents
Technical Assistance
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Contact the ULS Technical Support Department
Global Technical Support Department
16008 North 81st Street
Scottsdale, AZ 85260
Phone: [phone]
Fax: [phone]
Hours: M – F 7:00 a.m. to 5:00 p.m.
Web: http://www.ulsinc.com
Email: suppor[email protected]
Europe Technical Support Department
Lerchenfelder Gürtel 43
1160 Vienna, Austria
Phone: [phone]
Hours: M – Th 8:30 a.m. to 5:30 p.m.
F 8:30 a.m. to 2:30 p.m.
Web: http://www.ulsinc.com
Email: suppor[email protected]
Asia Technical Support Department
The Yokohama Landmark Tower
220-8115 Yokohama, Japan
Phone: [phone]
Hours: M - F 8:00 a.m. to 5:00 p.m.
Web: http://www.ulsinc.com
Email: [email protected]
Performing VLS Service Procedures
Safety
When performing the procedures in this manual, always be sure to read and understand the entire procedure
before operating the machine. Follow each step carefully. Pay special attention when steps require the VLS to be
unplugged.
Do not attempt to perform any of the procedures outlined in this manual until you have read and thoroughly
understand the Safety section.
Difficulty
The VLS is a very easy machine to maintain and repair. Most service procedures are simple to perform and
require minimal time and tools.
Tools
Nearly all the procedures described in this manual can be performed with a minimum of simple hand tools:
• Hex Key Set, Standard (SAE) including sizes:
• 9/64, 1/8, 7/64, 3/32, 5/64, 1/16, .050
• Screwdrivers, including Phillips #1, #0
• Lens Cleaning Solution, Cotton Swabs and/or Lens Tissue
• Needle Nose Pliers
• Bubble Level
• StaplerPerforming VLS Service Procedures
Technical Assistance

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Safety
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Discription of Appropriate Use
This device is designed for laser cutting and engraving of the materials listed in the VLS printer driver. Materials to be processed must fit completely inside the system for proper operation. Use of the equipment in a manner other than
that described in this manual may result in injury to yourself and others and may cause severe damage to the equipment and your facility.
CAUTION: This device is not designed, tested, intended or authorized for use in any medical applications, surgical applications, medical device manufacturing or any similar procedure or process requiring approval, testing or
certification by the United States Food and Drug Administration or other similar governmental entities.
General Safety
Use of the equipment in a manner other than described in this manual or failure to follow the operational instructions and safety guidelines listed in this manual can result in personal injury and may cause damage to the equipment
and surrounding property.
EXPOSURE TO THE LASER MATERIAL PROCESSING BEAM CAN RESULT IN BURNS TO THE SKIN AND CAN CAUSE SEVERE EYE DAMAGE. Proper use and care of this system are essential to safe
operation. Use of controls or adjustments or performance of procedures other than those specified herein may result in exposure to hazardous laser radiation.
Never operate the laser system without constant supervision of all cutting, marking, and engraving processes. Exposure to the laser beam may cause ignition of combustible materials which can lead to a fire. A
properly maintained fire extinguisher should be kept on hand at all times.
Never leave materials in the laser system after laser material processing. Always remove all material including scrap material from the machine after use. Scrap material left in the laser system, including materials
that collect in the removable Flow-Through Cutting Table, can be a fire hazard. Materials can be hot after laser material processing so caution should be used when handling material immediately after laser
material processing. A properly maintained fire extinguisher should be kept on hand at all times.
A properly configured, installed, maintained and operational particulate and fume exhaust system is mandatory when operating the laser system. Fumes and smoke from the laser material processing must be
extracted from the laser system and filtered or exhausted outside.
SOME MATERIALS, WHEN ENGRAVED, MARKED OR CUT WITH A LASER, CAN PRODUCE TOXIC AND CORROSIVE FUMES. Obtain the Material Safety Data Sheet (MSDS) from the manufacturer of every
material to be processed. The MSDS discloses all of the hazards when handling or processing a particular material. DISCONTINUE processing any materials that cause chemical deterioration of the laser system
such as rust, metal etching or pitting, peeling paint, etc. Damage to the laser system from corrosive fumes is NOT covered under warranty.
Safety

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Safety
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Safety
Do not attempt to move or lift the laser system by hand. It is recommended to use a fork lift or other mechanical assistance when moving the laser system. If unsure about how to move the equipment please
consult a professional rigging company or Universal Laser Systems Customer Support.
DANGEROUS VOLTAGES ARE PRESENT WITHIN THE ELECTRONICS ENCLOSURES OF THIS SYSTEM. Access to these areas (marked with warning labels) is not necessary during normal operation. If it
becomes necessary to open one of these enclosures for any reason, the power cord must first be disconnected from the electrical supply.
NEVER REMOVE THE GROUND LEAD TO THE ELECTRICAL CORD AND PLUG THE SYSTEM INTO A NON-GROUNDED OUTLET. A laser system that is not properly grounded is hazardous and can result in
severe or fatal electrical shock. Without proper grounding, the laser system may exhibit sporadic or unpredictable behavior. Always plug the system into a properly grounded (earthed) outlet.
The power supply cord is the main disconnect device; the equipment should be located close to an easily accessible power outlet. To disconnect the equipment from the supply main, the power cord should be
unplugged from the power outlet or main power inlet (appliance coupler) of the unit.
The laser system is designed as a Class I, Group A, pluggable device. It is also designed for connection to IT power systems.
The equipment should be connected to an AC power supply with Zmax = 0.049 Ohms or lower impedance. The end user should consult with their power supply authority to ensure the AC line impedance
requirement of EN 61000-3-11:2000 Annex B compliance is met.
THIS DEVICE IS SPECIFICALLY DESIGNED TO COMPLY WITH CDRH PERFORMANCE REQUIREMENTS UNDER 21 CFR 1040.10 AND 1040.11 AND TO COMPLY WITH EUROPEAN LASER SAFETY REGULATIONS
UNDER EN60825-1.
CDRH is the Center for the Devices of Radiological Health division of the Food and Drug Administration (FDA) in the USA. No guarantees of suitability or safety are provided for any use other than those specified by Universal Laser
Systems, Inc.

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Safety
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Safety
CO2 Laser Safety
ULS Laser systems are designed to support a sealed carbon dioxide (CO2) laser cartridge that produces intense invisible laser radiation at a wavelength of 9.3 microns and 10.6 microns in the infrared spectrum. For your protection,
the laser is contained within a Class 1* enclosure designed to completely contain the CO2 laser beam.
CAUTION: Use of controls or adjustments or performance of procedures other than those specified herein may result in exposure to hazardous levels of invisible laser radiation.
• Laminated safety glass is employed in the viewing window to block 10.6 and 9.3 micron laser radiation from CO2 lasers. This viewing window will block transmission of CO2 laser radiation allowing safe observation of laser
processing. Do not operate the laser system if the view port is damaged, with any of the doors removed or if any of the safety interlocks are defeated.
• The intense light that appears during the engraving or cutting process is the product of material combustion or vaporization. DO NOT STARE AT THIS INTENSE LIGHT FOR LONG PERIODS OF TIME OR VIEW DIRECTLY
WITH OPTICAL INSTRUMENTS SUCH AS BINOCULARS OR MICROSCOPES.
• This device contains a visible Red Diode Pointer (Class 2) to aid in positioning material to be cut or engraved. DO NOT LOOK DIRECTLY INTO THE RED LASER BEAM OR USE A REFLECTIVE SURFACE TO REDIRECT
OR VIEW THE RED LASER BEAM. NEVER ATTEMPT TO VIEW THE RED LASER BEAM USING OPTICAL INSTRUMENTS SUCH AS BINOCULARS OR MICROSCOPES.
• The user door(s) are safety interlocked which will prevent the CO2 laser beam from firing when the user door(s) are opened. The Red Diode Pointer is NOT safety interlocked and can be automatically activated with the
door(s) either open or closed.
• DO NOT OPERATE THE LASER SYSTEM IF ANY SAFETY FEATURES HAVE BEEN MODIFIED, DISABLED OR REMOVED. This may lead to accidental exposure to invisible CO2 laser radiation which may cause severe
eye damage and/or severe burns to your skin.
• Always use caution when operating a laser system.
Tamper Proof Labels
All laser cartridges are equipped with tamper proof labels. There are NO field serviceable parts inside a Universal Laser System, Inc. (ULS) laser cartridge. If your laser cartridge needs service, please contact the Customer Service
Team at 480-609-0297 (USA), [phone] (Austria), [phone] (Japan) or e-mail us at suppor[email protected].
*An enclosure which does not permit human access to laser radiation in excess of the accessible emission limits of Class 1 for the applicable wavelength and emission duration.

VLS Service Manual - REV2015.04
Table of Contents
Adjustments and Settings
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Computer Power Management Configuration
Power management is an option on computers and monitors to reduce engergy comsuption when not in active
use. However, the computer is a critical component in the operation of the VLS. Active Power Management
can cause interruption of communication between the PC and the VLS, resulting in failure of operation; so it is
recommended nthat this feature be disabled.
Windows XP and Windows Vista:
From the Windows XP home screen, right-clight on the desktop. Be sure you do not click on any icons as that
will open a different program.
1. From the list of options, select Properties. The Display Properties box will open.
2. In Display Properties, select the Screen Saver tab. Set the Screen saver to (None).
3. In the Monitor Power field, select Power…
4. Select the tab Power Schemes.
5. From the Power Schemes tab, in the Settings for Home/Office Desk Power Scheme, select Never
for all the setting options (Turn OFF monitor, Turn OFF hard disks, System standby, and System
hibernates).
6. Click Apply, then click OK on both open windows.
7. The configuration is complete.
Windows 7 and Windows 8:
1. Open the Control Panel by pressing the Windows
Key + R. The Run box will open. Type Control and
click OK.
2. In the Search Control Panel box, located in the
upper right-hand corner of the windows, type
Power Save. The Power Options are displayed.
3. Click the Edit power plan link.
4. Set every option to Never.
5. Click Change advanced power settings.
6. On the Power Options dialog box, click the Hard disk + symbol and the Turn off hard disk after +
symbol to expand the folder.
Adjustments and Settings

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Adjustments and Settings
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7. Set all Turn OFF hard disk after options to Never.
8. Click Apply.
9. Scroll to the Sleep settings and click the +symbol.
10. Set all Sleep options to Never or OFF.
11. Click Apply.
12. Scroll to USB settings and click the +symbol.
13. Set all USB selective suspend settings to Disabled.
14. Click Apply.
15. Click OK to close this window, then click Save Changes to close the Edit Plan Settings window.
16. In the still open Search Control Panel window type Screen Saver in the search box.
Adjustments and Settings