Universal Laser Systems ULS-25PS User manual

OPERATION MANUAL
ULS-25PS / ULS-25PSR
ULS-50PS / ULS-50PSR
Universal Laser Systems, Inc.
16008 North 81st Street
Scottsdale, AZ 85260
Phone: [phone]
Fax: [phone]
Volume I, Rev. B1
July 1996

This publication and its contents are proprietary to Universal Laser Systems Inc., and
are intended solely for the contractual use of Universal Laser Systems, Inc. customers.
This publication and its contents may not be reproduced or distributed for any other
purpose without the written permission of Universal Laser Systems, Inc.
© Universal Laser Systems Inc., 1996
All Rights Reserved
Notice
Universal Laser Systems, Inc. does not assume any liability arising out of the
application or use of any products, circuits or software described herein. Neither does
it convey a license under its patent rights nor the patent rights of others. Universal
Laser Systems Inc. further reserves the right to make any changes in any products
described herein without notice. This document is subject to change without notice.
HP is a registered trademark of Hewlett-Packard Company.
Windows is a registered trademark of Microsoft Corporation.
2

Table of Contents
Section 1 - Safety
1.1 Laser Safety.............................................................................................5
1.2 Safety Labels...........................................................................................6
1.3 The Safety Interlock System....................................................................7
1.4 EMI Compliance ......................................................................................8
Section 2 - Installation
2.1 Unpacking and Assembling the Laser System.........................................9
2.2 Operating Environment............................................................................9
2.3 Exhaust System Requirements................................................................10
2.4 Water Chiller Installation (50W CO2 only) ...............................................12
2.5 Computer Recommendations and Setup.................................................12
2.6 Laser System Installation.........................................................................13
2.7 Installing the ULS Printer Driver for Windows 3.1 or 3.11........................14
2.8 Installing the ULS Printer Driver for Windows 95.....................................17
2.9 Installing the ULS Printer Driver for Macintosh........................................18
Section 3 - Software Setup and Operation
3.1 Using Graphics Software.........................................................................21
3.2 The ULS Printer Driver for Windows........................................................26
3.3 Using DOS Based Programs...................................................................30
3.4 The ULS Printer Driver for Macintosh......................................................31
Section 4 - Laser System Operation
4.1 General System Overview.......................................................................35
4.2 The Control Panel....................................................................................36
4.3 Loading and Focusing the Laser System.................................................50
4.4 Running a Sample ...................................................................................54
4.5 Using the Optional Rotary Fixture ...........................................................54
4.6 The Optional Rubber Stamp Feature.......................................................59
4.7 Start-Up Parameters for Various Materials..............................................63
Section 5 - Basic Maintenance
5.1 General Cleaning and Maintenance Supplies..........................................85
5.2 System Cleaning......................................................................................87
5.3 Optics Cleaning (as necessary)...............................................................87
5.4 Bearing Clearance Adjustments (as necessary)......................................91
Section 6 - Appendices
Appendix A - Warranty .......................................................................................A
Appendix B - Laser System Specifications.........................................................B
Appendix C - Serial Port Cable Requirements....................................................C
Appendix D - Laser.ini Modifications ..................................................................D
Appendix E - Software Anomalies......................................................................E
3

Introduction
The ULS Performance Series are designed to combine flexibility and full featured
performance with simplicity and ease of use. Using advanced engineering and design,
these laser systems offer finer control, higher precision, more versatility, better
resolution, faster speed, and overall greater quality than any other laser system in its
class. It combines the performance of high speed engraving and cutting capabilities
with the ease of a user friendly, specially designed, Windows or Macintosh printer
driver interface. Actually, the Performance Series is such a breakthrough in technology
that it is more than just a laser system, it is a precision engraving and cutting device
used as a tool for the imagination.
To begin with, we highly recommend that this entire manual be read before attempting
to use the laser system. The manual includes important information about the safety,
assembly, use, and maintenance of the laser system. We cannot overemphasize
the importance of reading the owner's manual completely.
Where to get HELP:
If it is necessary to call for technical assistance, please call our TECHNICAL
SUPPORT at [phone]. Please be prepared to answer our questions by following
the procedures below, as this will allow us to provide assistance in a prompt and
efficient manner:
Take a moment to write down all of the pertinent information about the
computer being used with the laser cutting and engraving system such
as software, operating system and computer type.
Our technical support staff will ask you for your company name and the
laser systems serial number. The serial number tag is located on the
back of the machine in the lower right corner.
Try to recreate the problem and write down the circumstances in which
the problem occurred. This will help our technical staff tremendously.
If possible call from a phone that is close to the laser engraving system
so that the system can be operated while talking with our technical
support staff.
4

Section 1 - Safety
1.1 Laser Safety
The laser system contains a sealed carbon dioxide laser that produces intense and
invisible laser radiation (at a wavelength of 10.6 microns in the infrared spectrum). The
laser system is designed as a CLASS I device, meaning that the system is equipped
with a protective housing and safety devices to completely contain the laser under
normal use. Do not at any time attempt to modify or disassemble any part of the system
and do not attempt to operate a system that has been modified or disassembled.
Improper use of controls and adjustments or performance of procedures other than
those specified in this manual may invalidate the Class I rating and result in exposure to
the laser beam.
Please remember the following safety precautions when operating the laser system:
1. Exposure to laser radiation may produce physical burns and can cause severe eye
damage. Proper use and care of this system is very important to the safety of all
people in the surrounding area.
2. NEVER operate the laser system without constant supervision of the cutting and
engraving process. Exposure to the laser beam may cause ignition of combustible
materials. A properly maintained fire extinguisher should be kept on hand at all
times.
3. Operation and care of the laser system must be performed in accordance with this
manual.
4. Dangerous voltages are present within the electronics and laser enclosures of this
system. Although access to these areas is not necessary during normal use, if it
becomes necessary to open one of these enclosures for service reasons please
remember to UNPLUG THE MACHINE FIRST.
5. Never operate the laser system without properly exhausting the fumes generated
by the cutting and engraving process.
6. Please contact Universal Laser Systems Inc. with any questions concerning laser
safety before operating this system.
Note: The laser system is specifically designed to comply with CDRH performance
requirements under 21CFR 1040.10 and 1040.11. No guarantees of suitability
or safety are provided for any use other than those specified by Universal Laser
Systems Inc.
5

1.2 Safety Labels
According to CDRH standards, all interlocked and non-interlocked covers that allow
access to a laser beam MUST have appropriate laser safety labels attached to them.
These labels must be visible to personnel prior to the removal of the covers. Additional
labels must be installed inside the machine and be visible if the covers are removed
from the machine. Labels that provide the manufacturer's name, date of manufacture,
description of product, model number, serial number and compliance statement must
also be visible on the outside of the machine.
All CDRH required labels are properly affixed to the machine in the appropriate
locations at the time of manufacture. These labels are not to be removed. If they
become damaged or removed for any reason, please request additional labels from
Universal Laser Systems (they will be provided free of charge). Below is a list of all the
labels and their locations on the system.
Manufacturer's Label
Location: On the back of the machine in the lower right corner.
CDRH Compliance Label
Location: On the back of the machine above the Manufacturer's Label.
Warning Label for Interlocked Panels and Doors
Location: On the outside of the top door, on the inside of the top door (visible when
door is open), on the outside of the front door, on the inside of the front door (visible
when door is open) and to the left of the interlock defeat tool receptacle.
6

Exposure Warning Label
Location: To the right of the beam window inside the
system where the laser beam enters the work area. On the
laser mounting bracket before the first mirror and next to the
aperture where the beam exits the laser tube.
Warning Label for Non-interlocked Panels
Location: 25 Watt - On the inside and outside of the first mirror cover (visible when the
fan cover is removed). 50 Watt - On the inside and outside of the laser cover and inside
the laser cover on the laser backplate where the laser tube attaches to the system.
1.3 The Safety Interlock System
The laser cutting and engraving system incorporates a safety interlock circuit that
automatically shuts off the power supplied to the laser whenever the front or top door is
opened. This interlock system is connected in series with a switch and a red indicator
light on the control panel of the system. The switch allows the power to the laser to be
manually turned on and off. The red indicator light will light up when power is being
supplied to the laser. If at any time the red indicator light remains ON when the front or
top door is open, IMMEDIATELY unplug the system and call Universal Laser Systems
Inc. for service instructions.
The laser system comes equipped with a safety interlock defeat tool. Do not use this
tool unless you have been properly trained by Universal Laser Systems Inc. This tool is
only to be used for maintenance and repair procedures and should only be used when
instructed to do so by Universal Laser Systems Inc. and all safety precautions have
been followed.
WARNING:
Do not attempt to modify or defeat the safety interlock system for any
reason as this could result in exposure to hazardous laser radiation.
When using the interlock defeat tool, wear appropriate laser safety
goggles. Failure to wear appropriate goggles can result in severe eye
damage.
7

1.4 EMI Compliance
This ULS laser system has been tested and found to comply with both Federal
Communication Commission (FCC) and European Union (EU) directives regarding
Electromagnetic Compatibility (EMC). In accordance with these directives ULS is
required to provide the following information to its customers.
FCC Compliance Statement and Warnings
This device Complied with FCC Rules Part 15. Operation is subject to the following two
conditions:
1. This device may not cause harmful interference, and
2. This device must accept any interference received, including interference that
may cause undesired operation.
This equipment has been tested and found to comply with the limits for a Class A digital
device as set forth in Part 15 of the FCC Rules. These limits are designed to provide
reasonable protection against harmful interference when the equipment is operated in a
commercial environment. This equipment generates, uses and can radiate radio
frequency energy and, if not installed and used in accordance with manufacturer’s
instructions, may cause harmful interference to radio communications. Operation of this
equipment in a residential area is likely to cause harmful interference in which case the
user will be required to correct the interference at his or her own expense.
Users should be aware that changes or modifications to this equipment not expressly
approved by the manufacturer could void the user’s authority to operate the equipment.
This equipment has been type tested and found to comply with the limits for a
Computing Device per FCC part 15, using shielded cables. Shielded cables must be
used in order insure compliance with FCC regulations.
EU Declaration of Conformity
Universal Laser Systems, Inc. hereby declares that the equipment specified
below is in conformity with Directive 89/336/EEC based on test results using the
harmonized standards listed.
Product Identification: ULS-25 or 50 PS laser cutting and engraving system
Manufacturer: Universal Laser Systems, Inc.
16008 N. 81st St.
Scottsdale, AZ 85260
USA
Standards Used: EN 50081-1, EN 50082-1, EN55022
8

Section 2 - Installation
2.1 Unpacking and Assembling the Laser System
The laser system is shipped in one crate and is fully assembled. Remove the top and
four sides of the wooden crate. With the help of an assistant, roll the laser system off
the base of the crate and onto the floor. Store the flattened crate in a dry place. Save
the shipping crate in case the machine needs to be shipped. Remove all packing
materials such as Rubber bands, foam, and tie straps.
2.2 Operating Environment
Before the system is installed, choose a suitable location. Follow these guidelines:
Avoid places where the system may be exposed to high
temperatures, dust, or high humidity (humidity exceeding
70% or where the temperature is near the dewpoint). The
laser system should be installed in an office type environment.
Avoid places where the system may be exposed to high levels
of vibration or electrical noise. We recommend using a high
quality surge protector to protect the laser engraving system's
electronics.
Avoid small enclosed areas where ventilation is poor.
Choose a place where the ambient operating temperature will
remain between 60 and 80 degrees Fahrenheit(15 to 25
degrees Celsius).
Choose a place which provides a short and direct path to the
exhaust duct work (not provided).
If planning to connect the laser engraving system to a
computer through the parallel port, choose a location where
the computer can be placed within 10 feet(3 meters) of the
machine since this is the maximum recommended parallel
cable length.
If planning to have another laser system or other type of
printer connected to the same computer, we recommend
installing an additional parallel port into the computer system.
DO NOT use a manual A/B type switch box. This creates
electrical noise which can cause an engraving problem or can
damage the laser system’s electronics.
9

Try to have a work table or storage area next to or nearby.
This prevents the operator from using this precision machine
as a table or storage facility.
Make sure that the floor where the laser system will be located
is flat within 1/8” (3 mm). It is not necessary that the floor be
level, it simply should not dip or rise in the areas where the
casters will rest.
2.3 Exhaust System Requirements
To properly exhaust fumes and smoke from the laser system during operation, it is
necessary to provide an exhaust unit moving a minimum of 235 CFM at 6 inches of
static pressure. Many industrial supply companies carry blowers that should meet these
requirements.
THROUGH OUR RESEARCH WE HAVE ESTABLISHED GUIDELINES ON THE PROPER
CFM RATINGS REQUIRED FOR THE EXHAUST SYSTEM. THESE RATINGS ARE BASED
ON THE MEASURED DISTANCE BETWEEN THE EXHAUST OUTLET ON THE LASER
SYSTEM AND THE INLET OF THE EXHAUST BLOWER. WE HAVE FOUND A SUITABLE
SUPPLIER FOR THIS TYPE OF EQUIPMENT IF YOU CHOOSE NOT TO USE THIS
SUPPLIER, PLEASE ENSURE THAT THE BLOWER THAT YOU PURCHASE MEETS OR
EXCEEDS THE FOLLOWING SPECIFICATIONS.
DISTANCE BETWEEN
BLOWER AND LASER CFM RATING AT 6 INCHES STATIC PRESSURE
UP TO 10 FEET 235 @ 6 INCHES STATIC PRESSURE
11 - 20 FEET 410 @ 6 INCHES STATIC PRESSURE
21 - 30 FEET 535 @ 6 INCHES STATIC PRESSURE
31 - 40 FEET 625 @ 6 INCHES STATIC PRESSURE
The blower must be mounted on the OUTSIDE of the building either on the roof or on a
cement pad next to the building. Rigid duct work should be used between the blower
unit and the laser system. The exhaust tubing should be smooth walled and have as
few bends as possible. Use duct work with a diameter that matches the blower unit and
reduce the duct work to four inches just before the point where it attaches to the laser
system. Also consider installing a gate to control air flow and to close off the exhaust
from the outside environment when the laser is not in use. This is especially useful in
colder climates where it is not good to have cold air coming into the laser from the
outside. Do not connect the rigid duct work directly to the laser system. Use a short
piece of industrial grade, wire reinforced rubber tubing to connect the end of the gate,
or tubing, to the laser system. This will provide mobility and will dampen blower
vibrations. Do not use a very long piece because it’s spiral construction reduces air
flow. Install a hose clamp on both ends of the hose to prevent leaks and to prevent the
hose from slipping off.
10

We recommend installation of the exhaust system by a licensed contractor to meet
safety and local code requirements. Please contact a local air quality control specialist.
Having the blower wired to a wall switch, by a licensed electrician, in the same room
will make it easy to turn it off and on.
WARNING
Do not attempt to operate the laser engraving system without a properly
installed and operating exhaust system. Some materials when cut or
engraved can produce fumes that are hazardous in concentrated amounts.
Sample Exhaust System Layouts
11

2.4 Water Chiller Installation (50 Watt CO2 Only)
Set up the chiller next to the laser system and connect the tubes between the chiller and
the laser system. Press the tubes into the connectors and twist the tubes slightly to
seat them. Gently tug on the tubes to make sure that they do not come out.
Chiller Connections
Fluids will have to be added to the chiller. Please follow the chiller’s instruction manual
on it’s installation and use. Turn the chiller on and allow it to run for a few minutes to
purge the air that is trapped in the lines. Set the chiller’s temperature between 20 - 22
degrees Celsius. The laser system will not fire the laser beam unless the chiller has
been turned on.
2.5 Computer Recommendations and Setup
The following computer configuration is the minimum requirement necessary to operate
in the Windows environment. Using a computer with more speed, memory and storage
capacity will enable the graphic images to be produced faster. A faster computer will
perform calculations quicker and will shorten download time to the laser.
486-33 Mhz or higher PC compatible computer
8 MB of RAM
250 MB hard drive
One floppy disk drive
Color VGA monitor
Mouse
Microsoft Windows version 3.1
Windows compatible graphics program
The following is our recommended computer configuration:
Pentium 90 or higher(Pentium 120 Mhz system if doing rubber stamps
or full field engraving)
32 MB of RAM
1 Gigabyte hard drive or bigger
17 inch color VGA monitor
One floppy disk drive
CD-ROM Drive
Mouse
Microsoft Windows 3.11 for Workgroups or Windows 95
12

CorelDraw 3.0, 4.0, 5.0 (see appendices for anomalies)
600 DPI Optical Resolution Scanner
Adobe Photoshop 2.5LE or 3.0
Adobe Streamline (for raster to vector conversion)
CAD users do not necessarily need Windows or Windows compatible programs. The
laser system is compatible with any program that can output HPGL commands whether
it is Windows based or not. Check with your salesperson for specific details on DOS
based CAD programs compatibility and recommendations.
The following is our recommended Macintosh computer configuration:
Any system capable of running System 7.0 or higher.
32 MB of RAM or higher
1 Gigabyte hard drive or bigger
17 inch color monitor
600 DPI Optical Resolution Scanner
Adobe Photoshop
Aldus Freehand
2.6 Laser System Installation
CAUTION: Please make the following connections in the exact order
described otherwise static electricity can damage the computer and/or the
laser system’s electronics.
1. Connect the laser system power cord to a good quality surge suppresser and then
the surge suppresser to a grounded outlet. Do the same for the computer system.
2. Make sure both the computer and laser system are plugged in and turned OFF,
then connect the laser system to the computer using either a serial or parallel
connection.
Cabling Connections
13

2.7 Installing the ULS Printer Driver for Windows 3.1 or 3.11
Installation of the ULS Printer Driver will allow Windows to interface with the laser
system. This driver is installed the same way as most other Windows 3.1 or 3.11 printer
drivers and a simple step-by-step installation procedure is outlined below. Complete
understanding of how Windows works is essential to the operation of the laser system.
Please consult the Windows owner's manual on its installation, use, and operation
before continuing.
1. Start Windows, double click on “Main” in “Program Manager” and double click on
“Control Panel”.
2. Double click on “Printers” from inside “Control Panel”. The “Printers” dialog box
will now appear.
Printers Dialog Box
3. Click on the “Add” button if other drivers are present in the “Installed Printers”
dialog box.
4. Click on “Install Unlisted or Updated Printer” and click on “Install”.
Add Unlisted Printers Dialog Box
14

5. The “Install Driver” dialog box will appear asking for the location of the new driver.
6. Insert the floppy disk containing the ULS Printer Driver into the appropriate disk
drive and type in the correct drive letter.
7. Click on “OK” and a new dialog box called “Add Unlisted or Updated Printer” will
appear.
Add Unlisted or Updated Printer Dialog Box
8. Select the appropriate laser system from the list (or the “R” version if you
purchased the Rubber Stamp Option) and click on the “OK” button. The driver will
now install itself to your Windows System directory and the laser system will
appear in the “Installed Printers” section of the “Printers” Dialog Box.
Printers Dialog Box
9. Select the laser system and click on “Connect” if connecting to a port other than
LPT1. Now select the appropriate port.
NOTE: A check box named “Fast Printing Direct to Port” located on the bottom of the
Dialog Box should NOT be checked, otherwise file transmission errors can occur.
15

Connect Dialog Box
10. Click on “OK” and the “Printers” Dialog Box will re-appear.
Printers Dialog Box
11. Selecting “Set As Default Printer” and “Use Print Manager” are of personal
preference. Refer to the Windows manual on how to use Print Manager, if
desired. We recommend that you do not use Print Manager because it serves no
use to the laser system and it can become a nuisance.
12. Now you MUST click on “Setup” to initiate the installation of the driver. If you do
not, the driver will not store your power settings correctly. The driver settings
dialog box will now appear.
16

Driver Settings Dialog Box
13. How to adjust the settings will be covered in a later chapter. Now you MUST click
on “OK” in order for the driver to create a file called “Laser.ini” which the driver will
install to your c:\windows directory. This file stores all of the driver settings as you
change them. If you do not perform this procedure, any settings that get changed
later on will not be stored in when the computer gets shut down. Upon reboot, the
default settings like the ones shown above will appear instead of the settings you
used before computer shut down. To prevent this, make sure that the “OK” button
is clicked and NOT the “Cancel” button.
14. At this point, exit the “Printers” dialog box and the “Control Panel” window. Printer
driver installation is now complete. Store the driver disk in a safe place.
2.8 Installing the ULS Printer Driver for Windows 95
Installation of the ULS Printer Driver will allow Windows 95 to interface with the laser
system. This driver is installed the same way as most other Windows 95 printer drivers
and a simple step-by-step installation procedure is outlined below. Complete
understanding of how Windows 95 works is essential to the operation of the laser
system. Please consult the Windows 95 owner's manual on its installation, use, and
operation before continuing.
1. Power ON your PC.
2. From the Task Bar click “Start”.
3. Point the mouse to the “Settings” icon, and then click the “Printers” icon.
17

4. Double-click on the “Add Printer” icon.
5. When the “Add Printer Wizard” appears click “Next”.
6. Select “Local Printer” and click “Next”.
7. When the “Manufacturer” and “Printers” menu list appears click “Have Disk”
(Do not look for the printer in the menu)
8. Insert the driver disk.
9. Make sure the dialog box matches the floppy drive you are using: “A:\” or “B:\”.
10.Click on “OK”.
11.When the list of “Printers” appears choose the appropriate laser system (or the “R”
version if you purchased the Rubber Stamp Option).
12.Click on “Next”.
13.Choose the port your laser system is connected to and click on “Next”.
14.If you would like to name the laser system a different name then rename it now.
15.Choose if you would like to set it as your default printer and click on “Next”.
16.Select “No” when it asks to print a test page, and then click on “Finish”.
17.Click on the laser system, then click on “File” and drag the mouse to “Properties”.
18.Click on “Details” and then click on “Setup”.
19.The driver settings screen will appear. Click on “OK” and then “OK” once again.
This step is important because it will allow the driver to write the Laser.ini file to your
c:\windows subdirectory. This file is essential for proper driver operation.
20.Driver installation is now complete. Store your driver disk in a safe place.
2.9 Installing the ULS Printer Driver for Macintosh
Installation of the ULS Printer Driver for Macintosh will allow Macintosh computers
running system 7.0 or higher to interface with the laser engraving system. This driver is
installed in the same way most other Macintosh printer drivers are, and a simple step-
by-step installation procedure is outlined below. A complete understanding of how the
Macintosh operating system works is essential to the operation of the laser system.
Please consult your Macintosh owner's manual for answers to any question you might
have on operating your Macintosh computer.
18

1. Turn on your Macintosh computer and insert the ULS Macintosh driver disk in the
computer’s disk drive.
2. Copy the appropriate laser system driver (or the “R” version if you purchased the
Rubber Stamp Option) and Engrave Monitor onto your Macintosh computer by
dragging these items from the floppy disk folder into the “Extensions” folder located
inside the “System” folder on your computers hard drive.
3. Copy the “Preferences” file (if present) from the floppy disk onto your Macintosh
computer by dragging this item from the floppy disk folder into the “Preferences”
folder also located inside the “System” folder on your computers hard drive.
4. Click on the “Apple” menu and drag the mouse pointer to “Chooser”. Click on the
appropriate laser system as your output device by clicking on it with the mouse.
5. Click on the “Modem Port” in the “Connect To” dialog box and close the “Chooser”
dialog box.
Chooser Dialog Box
6. Make sure that AppleTalk is set to “Inactive”.
7. Driver installation is now complete. Store the driver disk in a safe place.
19

20