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Rofin PowerLine E Air 10 Maintenance And Integration Manual

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PowerLine E Air
Maintenance and Integration Manual
Version 1.3.7
THE MARK OF EXCELLENCE

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Summary of Contents for Rofin PowerLine E Air 10

  • Page 1 PowerLine E Air Maintenance and Integration Manual Version 1.3.7 THE MARK OF EXCELLENCE...
  • Page 3 GENERALITIES Identification data Machine type: Model designation: Serial number: Order number: Parts list number: Manufactured on: Customer data Inventory number: Location:...
  • Page 4 ROFIN-SINAR Laser GmbH shall not be liable for damage and operating failure resulting from the non-observance of the operating instructions. The copyright on this manual is exclusively reserved to ROFIN-SINAR. This manual is only entrusted to the owner of the laser for his/her personal use.
  • Page 5 +44 (0) 1327 701100 +39-039-2141304 +44-(0)-1482-6500 22 +44 (0) 1327 701110 info@rofin.it info@rofin-uk.com sales@rofin-baasel.co.uk ROFIN-BAASEL China Co., Ltd ROFIN-BAASEL Japan Corp. ROFIN-BAASEL Korea Co., Ltd. Room 206, Bldg. 2 1042-4 Toda, Atsugi-shi 602 World Meridian Venture Center No. 1077 Zu Chongzhi Road...
  • Page 6 ROFIN sales & service ROFIN-BAASEL Benelux B.V. ROFIN-BAASEL España, S.L. ROFIN-BAASEL France S.A. Brussels Office Barcelona Office Sartrouville Office Rue Abbé Cuypers, 3 Plaza María Aurelia Capmany, 1-A 7, Rue d'Estienne d'Orves B-1040 Brussels, Belgium E-08970 Sant Joan Despí, Spain...
  • Page 7 PRC Europe N.V. WEGMANN-BAASEL PMB Elektronik GmbH Industriepark De Bruwaan Laser und elektrooptische Geräte Leutstettener Str. 28 GmbH 35C - B-9700 82319 Starnberg, Germany Münchner Str. 15b Oudenaarde, Belgium 85604 Zorneding, Germany +32-(0)55-30 31 96 +49-(0)-8106-30626-0 +49-(0)-8151 91691-0 +32-(0)55-30 94 96 +49-(0)-8106-30626-13 +49-(0)-8151 91691 66 sales@prc-europe.be...
  • Page 8 viii...

  • Page 9: Table Of Contents

    Table of contents Table of contents Safety ..........1 Operation according to regulations .
  • Page 10 Table of Contents Assignment of the -X42 integration interface ......47 Assignment of the -X42a integration interface ......47 Assignment of the -X42b integration interface .

  • Page 11: Safety

    This includes reading this manual and especially this chapter. Please contact ROFIN-SINAR Laser or the system manufacturer, if you have questions regarding this chapter or generally concerning the safety of the laser system.

  • Page 12: General Safety Instructions

    Safety – PTB Physical and Technical Federal Institute Braunschweig (UVV) – Technical Supervisory Associations (UVV) General safety instructions Danger The "Danger" notice is used in this manual in the case in which lethal danger or serious damage to health may occur if the relevant safety instructions are ignored or not sufficiently observed. Warning The "Warning"...
  • Page 13 Safety 1.4.1 Beam path The diode light is conducted from the 19" plug-in for electrical components, in which, according to the laser, one or two diode modules are located, to the resonator module in the laser head via a passive glass fiber (transport fiber). The passive glass fiber or transport fiber is surrounded by a metal tube that safely covers the glass fiber from the diode module in the 19"...
  • Page 14 Safety 1.4.1.1 PowerLine E Air 10 The dashed lines designate the beam path of the laser beam. FIG. 2 Beam path in laser head FIG. 3 Beam path in 19" plug-in for electrical components Diode module Adapter block Transport fiber in metal tube...
  • Page 15 Safety 1.4.1.2 PowerLine E Air 25/ 30 The dashed lines designate the beam path of the laser beam. FIG. 4 Beam path in laser head FIG. 5 Beam path in 19" plug-in for electrical components Diode module Fiber terminal box Transport fiber in metal tube PowerLine E Air...

  • Page 16: Other Dangers

    The safety equipment consists of a metal tube and an adapter block or a fiber terminal box. The safety equipment comprises the following: – In the case of the PowerLine E Air 10, the metal tube is permanently connected with the diode module via an adapter block. –...

  • Page 17: Personal Protective Measures

    Safety 1.5.2 Hazardous materials Warning Ensure that an appropriate working exhaust ventilation system is connected to the material processing laser. Hazardous fumes and dust may be given off during the marking process or when carrying out service tasks (e.g. replacing contaminated filters). Please observe the supplier’s directives concerning safety and wear a suitable respiratory mask and safety gloves when handling hazardous materials.

  • Page 18: Disposal

    Safety • Have authorised and purposely appointed persons check the effectiveness of integrated safety equipment (e.g. EMERGENCY STOP) according to defined test cycles. All relevant national safety regulations and guidelines must be observed (see Section "1.1, Operation according to regulations" on page 1). Utilize all available safety equipment while the system is running.

  • Page 19: Safety Equipment

    Safety 1.10 Safety equipment Both lateral covers of the laser head are monitored by the interlock switch (see 1). An open interlock switch leads to the emergency shutdown of the laser system. FIG. 6 Interlock switch of the laser head (electrical side) FIG.

  • Page 20: Labelling

    Safety 1.11 Labelling All locations which, under certain circumstances (such as when protective covers are opened), represent a potential risk, are labeled with the required warning labels. The location of the individual labels are shown in the following pictures. These labels must not be removed. 1.11.1 Warning labels for 1064nm The following warning labels are on top of the laser head.
  • Page 21 FIG. 9 19" plug-in for electrical components (outside) Caution ! Invisible laser radiation Class 4 when cover is open. Avoid eye or skin exposure to direct or scattered radiation. PowerLine E Air 10: PowerLine E Air 25/ 30: Fiber terminal box Metal tube Metal tube Adapter block FIG.
  • Page 22 Safety 1.11.2 Instruction labels 1.11.2.1 19"plug-in for electrical components The two labels below are on the top of the 19" plug-in for electrical components in addition to the warning label. "Disconnect before opening" label reminds you that the 19" plug-in for electrical components must be disconnected before the housing cover is removed or the mains plug is disconnected, since the inside of the 19"...
  • Page 23 Safety PowerLine E Air 10 In the 19" plug-in for electrical components, the "Do not remove" label is located on the adapter block between the diode module and metal tube. FIG. 14 "Dangerous electrical voltage" label The "Do not remove" label indicates that the...
  • Page 24 Safety "Electrostatically endangered components" label indicates that precautionary measures for the handling of components at risk of electrostatic discharge must be observed. FIG. 17 "Electrostatically endangered components" label 1.11.2.2 Marking head The "Plug-in connections" label is located on the top of the marking head. The "plug-in connection"...
  • Page 25 The pictures here show an example of the iden- tification label. For information on the technical data see Sec- tion "9, Technical data" on page 71. FIG. 20 Identification label - PowerLine E Air 10 FIG. 21 Identification label - PL-E Air 25/ 30 PowerLine E Air...
  • Page 26 Safety PowerLine E Air...

  • Page 27: Maintenance

    Maintenance ROFIN-SINAR lasers are designed to be operated with a minimum of maintenance. The maintenance measures include the following: – Changing the filter mat (19" plug-in for electrical components) – Cleaning and changing the optical components – Cleaning the exhaust air shaft, the fan unit, and the cooling block of the laser head For maintenance, you need the following aids: –...

  • Page 28: Changing The Filter Mat/S

    Depending on the laser, the 19" plug-in for electrical components has one or two filter mats, respectively, to protect it from soiling. PowerLine E Air 10 A white filter mat is located in the front behind the grille in the 19" plug-in for electrical components.

  • Page 29: Cleaning And Changing The Optical Components

    Maintenance Change the filter mat/s as follows: • Loosen the screws of the grille using an appropriate hexagon screwdriver. • Lift out the grille. • Take out the old filter mat/s. • Insert the new filter mat/s. • Rescrew the grille. FIG.
  • Page 30 Maintenance 2.2.2.1 Protective glass Depending on the system layout, different holders will be used for the protective glass as shown below: Version 1: Protective glass lies loosely in the protective glass support Version 2: Protective glass with clamping screws Version 3: Protective glass with grub screws Version 4: Protective glass in ring nut...
  • Page 31 Maintenance 2.2.2.2 Focusing optics Before changing the focusing optics, you must first dismantle the protective glass slide or the protective glass. The following versions of the protective glass slide are normally available and can vary according to system layout: Version 1: Protective glass slide with mounting plate and guiding plate Version 2: Protective glass slide with two-part mounting plate...
  • Page 32 Maintenance Remove the protective glass slide as follows (Version 2): • Loosen the four screws on the underside of the guiding plate with a suitable hexagon screwdriver. • Loosen the two screws on the front side of the mounting plate. •...

  • Page 33: Cleaning The Exhaust Air Shaft, The Fan Unit, And The Cooling Block

    Maintenance Cleaning the exhaust air shaft, the fan unit, and the cooling block Clean the exhaust air shaft, the fan unit, and the cooling block according to the maintenance schedule. Non-compliance might affect the cooling effect in the laser head. The exhaust air shaft is located on the side of the laser head.
  • Page 34 Maintenance • Blow fine dust particles from the surface of the exhaust air shaft using purified compressed air (max. 2 bar). As required, you can use a cleaning brush or a soft, dust-free, lint-free cloth. You may also use a slightly moist cloth for cleaning.

  • Page 35: Spare Parts

    Board;PL-E CAN Interface;Mod.2 120 108 376 Board; Safety Shutter Control, SSC3 120 300 913 PowerLine E Air 10 Resonator module; PL-E Air 10; HP; Vanadat; exchange 101 110 928 Resonator module; PL-E Air 10; HQ; Vanadat; exchange 101 110 929 PowerLine E Air 25/ 30 Resonator module;...

  • Page 36: Marking Heads

    Handle; 3 HE 110 400 211 Temperature sensor; NTC; 10K; with plug SMR-02V 101 109 357 Temperature sensor LM35DT-TO220 -B6/7/8 120 201 171 PowerLine E Air 10 Power supply;laser diodes;HN802PelCo;V2 120 108 618 Cooling unit -B1/2/3/4 & 101 107 633 -M3/4 Fan;ax;2x12VDC;5,8W;Set with plug...

  • Page 37: Parts Subject To Wear, 19" Plug-In For Electrical Components

    101 110 245 Parts subject to wear, 19" plug-in for electrical components Designation Art. No. PowerLine E Air 10 Filter mat; 180x100x10mm; EU; white 141 200 275 PowerLine E Air 25/ 30 Filter mat; 100x90; EU2, white 141 200 324 Filter mat;...

  • Page 38: Spare Parts, 19" Plug-In Pc

    Spare parts Spare parts, 19" plug-in PC Designation Art. No. PC 19";2HE;DualCore;2,4GHz;DVD 120 301 289 Board; ALI-3; V4.0S; slot bracket 120 301 181 Board; OPO 3; Version 2 120 300 906 Board; OPO 3; 16i/o 120 300 569 Spare parts, focusing axis FFM (Fast Focusing Module) (optional) Designation Part No.

  • Page 39: Cleaning Of Optical Surfaces

    Spare parts Designation Part No. Protective goggles for eyeglass wearers; 180-532nm; 1064nm 150 500 286 DI >315-532 L8, R >315-532 L6, D 1045-1100 L7, I 1045-1100 L8, R 1045-1100 L7, acc. to DIN EN 207 Standard protective goggles; 900-1400 nm; 150 500 511 DIR 900-1050 L6, D >1050-1400 L7, IR >1050-1400 L8, acc.
  • Page 40 Spare parts PowerLine E Air...

  • Page 41: Integrating The Laser System

    Integrating the laser system The following integration interfaces are available for integrating your laser system: -X28, -X42, -X42a, X42b and -X46. The interface -XC3a, located on the PC, is an extension of the I/O control signals which can be directly controlled in the marking program VisualLaserMarker (VLM). For information on the laser system's dimensions, see Section "4.12, Integration drawings"...

  • Page 42: Integration Interface -X42, -X42A, -X42B, -X46, -X3A

    Rofin Article number 120 104 416 Housing e.g. Harting; Article name D-Sub 37 Housing metallized; Article number 09670370443; Rofin Article number 120 104 809 Plug type -X42b: Plug e.g. Harting; Article name D-Sub 37 Male Multipoint connector IEC 60807; Article number 09670375604;...
  • Page 43 Max. input voltage: ..........+30V DC Explanation of symbols internal external (ROFIN) (Customer) +24V Plug : PIN no...
  • Page 44 Integrating the laser system 4.2.2.2 Marking stop This signal cancels a running marking program or marking job. +24V -X42b : 7 This signal input is also available on -X46 (see -X42b : 22 -X42b : 8 Section "4.3, External control panel -X46" on page 43).
  • Page 45 Integrating the laser system 8 Bit M-functions are available: – Bit 8 and 9 on -X42b -X42b: Bit 8 – Bit 10 to 15 on -XC3a -X42b: Bit 9 -XC3a: Bit 10 XC3a: Bit 11 XC3a: Bit 12 XC3a: Bit 13 XC3a: Bit 14 XC3a:...
  • Page 46 Integrating the laser system 4.2.3.4 Error PC (system error) Attention Effective as of VLM marking sofware version 4.4: As soon as an error occurs in the marking software, this output has logical signal 1 (+24V). +24V -X42b : 7 -X42b : 1 Signal logical 1 for galvo check error, program -X42b : 8 sequence error and external error.
  • Page 47 Integrating the laser system Attention Effective as of VLM marking software version 4.4: 7 Bit M-functions are available: – Bit 9 on -X42b -X42b: Bit 9 – Bit 10 to 15 on -XC3a -XC3a: Bit 10 Bit 11 -XC3a: -XC3a: Bit 12 -XC3a: Bit 13...
  • Page 48 Integrating the laser system 4.2.4.3 Shutter interlock, hardware circuit You can connect an interlock circuit, e.g. door check, by a safety switch on the laser class 1 +24V -X42a : 22 safety area. -X42a : 23 The output resistance must not exceed 6 Ohm per 0V24 -X42a : 24 channel.
  • Page 49 Integrating the laser system 4.2.5.3 Laser radiation possible This output will be set approx. 6 seconds before the laser beam can be generated and remains in +24V -X42b : 7 set condition while the laser beam is being gene- -X42b : 6 rated.
  • Page 50 -X42a : 1 stop circuit of the laser system. -X42a : 2 If no ROFIN control panel (control panel on the -X42a : 3 19" plug-in for electrical components or on the -X42a : 4...
  • Page 51 Integrating the laser system 2a. External motor contactor incorporated into the emergency stop circuit An external motor contactor can be incorporated into the emergency stop circuit of the laser sys- -X42a : 1 tem. -X42a : 2 The emergency stop relay can be set with the key -X42a : 3 switch on the control panel.
  • Page 52 Integrating the laser system 3. External emergency stop relay; Reset emergency stop system on the external emergency stop relay The laser control can be incorporated into an external emergency stop relay. The master is the ex- ternal emergency stop relay. The internal emergency stop relay still includes the network relay of the laser power unit in the feed- back loop.

  • Page 53: External Control Panel -X46

    Integrating the laser system External control panel -X46 4.3.1 Digital inputs marker control Target value: ............24V DC Contact: .
  • Page 54 Integrating the laser system 4.3.2 Digital outputs marker control Target value: ........... . . 24V DC Signal logical 1 corresponds to: .
  • Page 55 Integrating the laser system 4.3.3 Digital outputs laser control Target value: ............24V DC Signal logical 1 corresponds to: .
  • Page 56 Integrating the laser system 4.3.3.4 Shutter open This output will be set if the shutter is safely open and the laser is ready for operation. +24V -X46 : 11 -X46 : 13 -X46 : 16 4.3.3.5 Error laser system This output is set if an error is reported. +24V Note -X46 : 11...

  • Page 57: Assignment Of The -X28 Intergration Interface

    Integrating the laser system 4.3.3.9 Reset emergency stop relay A button can be integrated into this circuit to start the emergency stop relay (Reset). -X46 : 5 -X46 : 6 Assignment of the -X28 intergration interface The interface -X28 (D-Sub 15) is available on request. Assignment of the -X42 integration interface The 24V voltage is connected when the laser system is switched on (main switch in position I) and is not controlled by the emergency stop function.

  • Page 58: Assignment Of The -X42B Integration Interface

    Integrating the laser system Contact Signal direction Function Input (S22) Emergency stop push button channel 2 Output (S22) Emergency stop push button channel 2 Input (S21) Emergency stop push button channel 2 (31) Emergency stop relay auxiliary contact (NO) (32) Emergency stop relay auxiliary contact (NO) (33) Emergency stop relay Reset a *...
  • Page 59 Integrating the laser system Contact Signal direction Function Output Effective as of VLM version 4.4: Error PC (System Error) [ErrInt] Output M-Function Output GND 24V control voltage Output Shutter closed Output End of marking Output Laser radiation possible Output 24V DC control voltage [1L+] Output GND 24V control voltage Input...

  • Page 60: Assignment Of The -X46 Integration Interface

    Integrating the laser system Assignment of the -X46 integration interface 4.8.1 Plug -X46 D-Sub 25 female The voltage 24V DC [1L+] is not controlled by the emergency stop function and is equipped with the F2 fuse. The voltage is only available for the signal inputs of the laser system. Note The figures provided in brackets show the start location or the destination of the signal on the emer- gency stop relay.

  • Page 61: Assignment Of The -Xc3A Integration Interface

    Integrating the laser system Contact Signal direction Function Innput Reset Error Output GND 24V control voltage * The contact must be potential-free. Assignment of the -XC3a integration interface 4.9.1 Plug -XC3a D-Sub 15 female The voltage 24V DC [1L+] is controlled by the emergency stop function and is equipped with the F2 fuse.

  • Page 62: Laser Control Flow Diagrams

    Integrating the laser system 4.10 Laser control flow diagrams 4.10.1 Description of the flow diagram Interruption for a Plug name -X42 new situation and PIN number :32 Laser Power up Interruption for a Signal varying span of time potentially bound -X42b:3 Additional Signal via isolated...
  • Page 63 Integrating the laser system 4.10.3 Switch on laser with remote control If the laser system is switched on by remote control, the key switch must be at position II on the operating panel. Laser power up, remote-controlled Control panel keyswitch in pos. II 1L+ control voltage -X42b:7 -X42a:14...
  • Page 64 Integrating the laser system 4.10.4 Switch off laser with remote control Remote control – laser system shutdown, PC shutdown -X42a:17 Shutter (open) -X42a:20 enable -X42a:16 Laser on/off -X42a:18 Laser ready, 30sec -X42b:4 shutter closed Laser ready, -X42b:19 shutter open closed Shutter interlock open 1L+ control voltage...
  • Page 65 Integrating the laser system 4.10.5 Shutter Interlock Shutter Interlock Laser ready, -X42b:4 shutter closed Laser ready, -X42b:19 shutter open -X42a:22 Shutter interlock; channel 1 -X42a:23 closed closed closed -X42a:24 Shutter interlock; channel 2 closed closed -X42a:25 closed -X42a:17 Shutter enable and -X42a:20 keyswitch Pos II -X42a:16...
  • Page 66 Integrating the laser system 4.10.6 Shutter Interlock, troubleshooting FIG. 43 Flow diagram 'Shutter Interlock', troubleshooting' PowerLine E Air...

  • Page 67: Marker Control Flow Diagrams

    Integrating the laser system 4.11 Marker control flow diagrams 4.11.1 Marking flow diagram Run marking program, Stop marking Laser ready, -X42b:4 shutter closed Laser ready, -X42b:19 shutter open System ready -X42b:18 20msec. -X42b:16 Job end -X42b:5 Image end Image start -X42b:9 -X42b:22 Image stop...
  • Page 68 Integrating the laser system 4.11.2 Marking On The Fly Run marking program with „trigger (on the fly)“ One of several versions Laser ready, -X42b:4 shutter closed Laser ready, -X42b:19 shutter open System ready -X42b:18 20msec. = 30msec. = 30msec. -X42b:16 Job end -X42b:5 Image end...

  • Page 69: Integration Drawings

    Integrating the laser system 4.12 Integration drawings Note Refer to the information on dimensions and the cable bend radius of the electrical connection on the laser head in the following integration drawings. Note See also the "Setting up the laser system" chapter in the Operator’s Manual of the laser system. Note Information relating to hazard classes, dimensions and weights, etc.
  • Page 70 Integrating the laser system 4.12.1 Laser head and marking head FIG. 46 PowerLine E Air with RS.R10 marking head (example) PowerLine E Air...
  • Page 71 Integrating the laser system FIG. 47 PowerLine E Air with RS.RM10;G4 marking head PowerLine E Air...
  • Page 72 Integrating the laser system 4.12.2 19" plug-in units FIG. 48 19" plug-in for electrical components with control panel PowerLine E Air...
  • Page 73 Integrating the laser system FIG. 49 19" plug-in for electrical components without control panel PowerLine E Air...
  • Page 74 Integrating the laser system FIG. 50 19" plug-in PC, 2HE PowerLine E Air...
  • Page 75 Integrating the laser system FIG. 51 19” plug-in UPS (external component) Note The uninterruptible power system (UPS) is an external component. PowerLine E Air...
  • Page 76 Integrating the laser system PowerLine E Air...
  • Page 77 Index Index Numerics Marker control ......43 19" plug-in for electrical components Spare parts ......26 19"...
  • Page 78 Passive glass fiber (transport fiber) ....3 PowerLine E Air 10 ......4 PowerLine E Air 25/ 30 .

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