Universal Laser Systems ULTRA X6000 User manual

ULTRA X6000 Laser System
User Guide
www.ulsinc.com
Version 2020.06.0102

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Dear Customer:
Thank you for choosing Universal Laser Systems®. We appreciate innovative customers like you who
have made us an integral part of your business. Universal Laser Systems®(ULS) is committed to
providing the highest level of customer satisfaction and support. To ensure a favorable customer
experience, we urge you to thoroughly read the documentation provided with your equipment.
Your satisfaction is essential to us, and we welcome your feedback. Tell us about your experience
with Universal Laser Systems and our products at [email protected].
Should you have any questions, please email the ULS Support Team at:[e-mail] or call:
[phone] (USA)
[phone] (Austria)
[phone] (Japan)
Again, thank you for choosing ULS.
Sincerely,
Universal Laser Systems
© 20
20 Universal Laser Systems. All Rights Reserved.
Universal Laser Systems,
Inc.™ name and logo are registered trademarks. Digital Laser Material Processing (DLMP™) technology,
Rapid Reconfiguration™ technology, 1
-Touch Laser Photo™, MultiWave Hybrid™ technology and SuperSpeed™ are trademarks of
Universal Laser Systems. All other company and product names mentioned herein are trademarks or registered trademarks of thei
r
respective companies.
Universal laser systems are
protected under one or more U.S. Patents: 5,051,558; 5,661,746; 5,754,575; 5,867,517; 5,881,087;
5,894,493; 5,901,167; 5,982,803; 6,181,719; 6,313,433; 6,342,687; 6,423,925; 6,424,670; 6,983,001; 7,060,934; 7,415,051; 7,46
9,000;
7,715,454; 7,723,638; 7,947
,919; 8,101,883; D517,474 S; 8,294,062; 8,599,898; 8,603,217 plus other U.S. and international patents
pending.

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Table of Contents
1. ULTRA X6000 Platform Overview ...........................................................................5
2. Safety ...................................................................................................................13
3. Meet the ULTRA X6000 Platform ..........................................................................27
4. Laser System Manager (LSM) Overview ...............................................................33
5. The ULTRA X6000 Workflow ................................................................................77
6. Maintaining the Laser System ..............................................................................81

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ULTRA X6000 Platform Overview 1
The ULTRA X6000 Platform offers laser material processing for the widest possible range of
materials. It is designed and ideally suited for precision material processing in manufacturing,
research and development, academic research, and prototyping environments. With its unique
modular architecture, the platform can be easily reconfigured with a wide array of options for
enhancing performance, capability, and safety to meet present and future business needs.
The ULTRA X6000 Platform has a materials processing envelope of 36 x 24 in. (914 x 610 mm), with
support for materials with a thickness up to 12 in. (305 mm) and may be configured with up to
three laser sources.
When the ULTRA X6000 Platform is configured with two interchangeable CO2lasers and one fiber
laser, users may take full advantage of MultiWave Hybrid™ technology, enabling up to three
wavelengths – 9.3 µm, 10.6 µm, and 1.06 µm – to be simultaneously combined into a single coaxial
beam. In this configuration, each spectral component of the beam is independently controlled and
may be modulated in real time.
Major features include multiple laser support, rapid high-accuracy laser beam positioning, precision
material-independent autofocus, controllable laser power density, an automation interface,
intelligent camera registration, an integrated touch screen control panel, over-temperature
detection, and support for fire suppression.

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Specifications, Features, and Options
FEATURE
DESCRIPTION
Processing Area
36 x 24 in. (914 x 610 mm)
Multiple Laser Support
Supports up to three laser sources of different wavelengths.
Compatible Laser Sources:
•CO210.6 µm | 10, 30, 50, 60, 75, and 150W power single sources
[150-watt CO2 laser source available 2021]
•CO29.3 µm | 30, 50, 75W power single laser sources
•Fiber 1.06 µm | 50W power single laser sources
Laser Source Combinations:
Any combination of the three laser sources above, up to two CO2laser
sources and one fiber laser source (permanently mounted). The three
laser sources can be used individually or in combination.
Laser Configurations
Single Wavelength Laser Configurations: (1) 10.6 µm, (1) 9.3 µm, or (1) 1.06 µm
Multiple Wavelength Laser Configurations:
(2) 10.6 µm OR
(2) 9.3 µm OR
(1) 10.6 µm and (1) 9.3 µm OR
(1) 10.6 µm and (1) 1.06 µm OR
(1) 9.3 µm and (1) 1.06 µm OR
(2) 10.6 µm and (1) 1.06 µm OR
(2) 9.3 µm and (1) 1.06 µm OR
(1) 10.6 µm and (1) 9.3 µm and (1) 1.06 µm
Maximum Laser Power
CO
2
: 150W
Fiber: 50W
Rapid Reconfiguration™
(CO2Laser Sources only)
Patented technology that enables users to install and reinstall any
supported ULS laser source onto any ULS laser system without tools or
optical alignment.
MultiWave Hybrid™
Technology*
Patented technology that enables any combination of the 3 laser
wavelengths to be focused to the same focal point within the same focal
plane and used either sequentially or simultaneously.
SuperSpeed™ Technology*
SuperSpeed produces two focal spots (one for each laser beam) that
enable the system to deliver two independently controlled raster lines at
a time. SuperSpeed requires a laser system equipped with two CO2lasers
of the same wavelength and power.
Minimum Addressable Beam
Positioning 2 micron (.00008 in.) beam position addressability
Mechanical Positioning
Repeatability
2
± 10 micron (.00039 in.) repeatability
Maximum Positioning Speed
175 in./sec (4445 mm/sec)

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Maximum Effective Raster
Material Processing Speed
Equivalent to more than 300 in. /sec (equivalent to more than 7620
mm/sec) −Requires the SuperSpeed module.
Maximum Functional Vector
Processing Speed
75 in./sec (1905 mm/sec)
Precision Material-
Independent Autofocus
Repeatability of ± .0025 in. (63.5 micron) using motorized focus assembly
and high-resolution touch sensor.
Integrated Touch Screen
Control Panel
A fully integrated 21 in. (533 mm) touch panel command and control
console used to control laser system operation.
Controllable Laser Power
Density*3
The unique ability to control laser power densities while maintaining a
high degree of alignment accuracy of the focal plane with the material
surface as well as a Gaussian beam distribution. Power Densities: 1X*, 4X
(included) or 13X* for 10.6 µm and 9.3 µm wavelengths; 52X for 1.06 µm
wavelength (included with fiber laser configuration).
Dynamic Energy Delivery
Stabilization
Maintains even laser energy delivery regardless of the speed of the
motion system.
Design File Geometry
Preservation
Curves in a design file, i.e., circles, ellipses, b-splines, Beziers, and NURBS,
kept throughout the path planning process rather than linearly
interpolated.
True Position Laser Pulsing
Optimal laser pulse placement driven by positional feedback from
synchronized multi-axis linear encoders.
Intelligent Path Planner
Comprehensive path planning algorithm that minimizes laser processing
completion time.
Multifunction Material
Support Structure
A built-in aluminum honeycomb work surface designed to keep materials
stationary and in focus during laser processing. Reduces back reflection
and enables exhaust of laser processing byproducts from underneath
materials. Available in two versions: manually adjustable, with vertical
range < 3 in. (76.2 mm) and motorized adjustable, with vertical range
< 12 in. (304.8 mm). Includes a full-field masking material dispenser.
Machined Aluminum Tiles*
Provides a rigid and smooth work surface for laser material processing.
Also compatible with Material Support Pins (Not recommended for laser
cutting unless configured with Material Support Pins).
Material Support Pins*
Custom machined pins for laser cutting that can be inserted into either
the Multifunction Material Support Structure or the Machined Aluminum
Tiles. Pins add sufficient space between the target material and the work
surface to eliminate back reflection.
Rotary Axis Module*
Enables 360° rotation laser processing of cylinders, spherical-shaped, and
tapered objects. Addressable resolution of 13 arc seconds.
Class 4 Pass-Through*
Patented technology that enables the laser system to facilitate material
pass-through in compliance with CDRH and international safety
regulations for operating Class 4 laser systems. This optional device
converts a fully enclosed Class 1 system into an open Class 4 system.

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Traveling Exhaust*
Collects laser processing byproducts at the location of laser processing
(required with Class 4 Pass-Through).
Vacuum Booster*
Dedicated vacuum booster that increases the pressure differential
between the chamber and the ambient/atmospheric pressure at the work
surface. Keeps a material stationary on the Multifunction Material
Support Structure.
Programmable Gas Assist Allows the user to program gas type and flow rate on a process-by-
process basis within a control file.
Optics Protection A barrier of clean air that protects optical components during processing.
Coaxial Gas Assist
A breakaway gas assist attachment that directs air (or gas) perpendicular to
the material’s surface.
Lateral Gas Assist*
An adjustable, breakaway, gas assist attachment that directs air (or gas)
laterally or at an angle to the material’s surface.
Air Compressor*
A compressed air source that delivers optimally conditioned, clean, dry,
and oil-free air for Optics Protection and gas-assisted laser processing.
Intelligent Air Filtration*
(UAC 2000/4000)
Intelligent Air Filtration uses a patented dual carbon filter and sensor
suite (for CO and VOCs) that filters out laser processing byproducts,
monitors filtration performance at every stage, and alerts the operator
when predefined contaminant thresholds have been reached. Connects
directly with the laser system to turn filtration on and off with laser
processing and communicates the status of all aspects of the UAC
2000/4000.
Automation Interface
Addressable device that can receive input signals and provide output
signals. Enables the laser system to control external devices and for them
to initiate laser system functions.
Light Tower
A set of color-coded lights mounted atop a pole used to indicate the
laser system’s status to personnel in visual proximity of the laser system.
E-STOP
Highly visible standards-compliant pushbutton. Once depressed, DC
power to all laser sources, the motion system, and other control
mechanisms is immediately shut off, while aborting all system operations.
Collision Detection
In the event an obstruction from any direction or axis interferes with the
motion system, the ULTRA X6000 laser system immediately stops and
disables its servo motors.
Laser Safety Classification
Class 1 for material processing lasers. Class 2 overall due to red laser
pointer. Can convert to Class 4 with optional Class 4 module.
Safety Interlocks Safety feature that disables the laser source when interlocks are open as
required by all major international safety standards.

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Over-Temperature Detection
The system is designed to disable all laser sources, home the motion
system, and trigger an audible alarm in the event it detects an unusually
high temperature in the laser processing area.
Warning:All laser processing requires constant supervision while the
laser system is in use; exposure to the laser beam may cause combustible
materials to ignite, which may lead to a fire hazard.
Laser Blocking Laminated
Safety Glass
Shatterproof multi-layer laminated safety glass with appropriate
wavelength filter media. Meets laser safety requirements OD 5+ for
10.6 µm, 9.3 µm, and 1.06 µm wavelength laser radiation.
Metal Enclosure with
Labyrinth Seals
All enclosure doors or access panels have overlapping flanges to prevent
direct line of sight into the enclosure, as required by international safety
regulations.
Fire Suppression*
Deploys fire suppressant into the laser material processing area if self-
sustained combustion is detected.
Warning:All laser processing requires constant supervision while the
laser system is in use; exposure to the laser beam may cause combustible
materials to ignite, which may lead to a fire.
System External
Dimensions
•Width: 63.09 in. (1603 mm) with Control Panel folded
•Width: 87.75 in. (2229 mm) with Control Panel extended
•Depth: 50.07 in. (1272 mm)
•
Height: 47.67 in. (1211 mm)
Maximum System Weight
4
550 lb (250 kg). Weight is approximate and varies with laser selection.
Power Requirements
220 – 240 V / 20A
Exhaust Requirements
Intelligent Air Filtration (UAC 2000/4000) OR
External Exhaust Blower Capable of >700 CFM at 6 in. WG Static Pressure
(1190 m3/hr. at 1.5 kPa)
Note: *Denotes Optional Feature
Disclaimers
1. Universal Laser Systems® reserves the right to change these specifications at any time, and without notification.
2. Material processing results are affected by ambient temperature, material temperature, processing environment
temperature, humidity, laser processing settings, and material characteristics.
3. Normalized power density (watts/cm2) = power density coefficient x 103 x average laser power (watts). Normalized
power density is the power of the material processing laser(s) divided by the area of the focal spot measured
at 1/e2.
4. Weight is approximate and varies with laser source selection.

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Laser System Manager Control Software
FEATURE DESCRIPTION
Intelligent Materials
Database
The Intelligent Materials Database generates laser processing
parameters for a wide variety of material and laser system configurations.
If the system configuration changes, the database automatically
recalculates the parameter values.
Design File Relocation and
Duplication Controls User controls to reposition or duplicate design files anywhere within the
material processing field.
Intelligent Camera
Registration Aligns a control file to registration marks or features on a material’s
surface. Compensates for scale, skew, and perspective.
True Width Raster
Processing Eliminates the need for motion system over-travel beyond the edges of
the raster image.
Vector Acceleration Control User control to define acceleration for vector motion for each control file.
Kerf Compensation Compensates for material width removed during laser cutting in order
to achieve desired dimensions without changing the design file. It
maintains true arc and circle geometry if present in the design.
Path Deviation Control User control to adjust the allowable deviation from the intended path.
Line Segment Reduction User control to reduce excessive line segmentation contained in some
design files.
Industry Standard
Interchange Format Support
Supports industry standard graphics interchange formats including DXF,
PDF, and G-Code.
Flexible Connectivity Enables remote design file transfer and monitoring over Ethernet or
Wi-Fi via a web browser.
User Access Administration Administration tool for managing multiple user accounts and permissions.
Automatic Update
Notification Notifications of system software updates automatically sent to the
laser system.