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- Page 1 SERVICE MANUAL 8015 Rayjet 07/09/2010 Trotec Produktions- und Vertriebs GmbH_Linzer Strasse 156, A-4600 Wels, Austria, Technical Support 1 / 53 tel_+43 (0)7242 239-7000, fax_+43 (0)7242 239-7380, mailto: rayjet@troteclaser.com www.rayjetlaser.com...
- Page 2 TROTEC PRODUKTIONS UND VERTRIEBS GmbH Linzer Strasse 156 A – 4600 Wels AUSTRIA Ph.: ++43/7242/239-0 Fax: ++43/7242/239-7380 E-Mail: trotec@troteclaser.com www.troteclaser.com This publication and it´s contents are proprietary to Trotec Wels and are intended solely for the contractual use of Trotec customers. This publication and it´s contents may not be reproduced or distributed for any other purpose without the written permission of Trotec Wels.
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Page 3: Table Of Contents
Service Manual Rayjet Table of contents MAIN COMPONENTS ..................5 SAFETY INFORMATION..................6 General ............................6 Laser Safety ..........................8 2.2.1 Safety Interlock System ....................... 9 Dangers of Electricity......................10 Emission indication and safety labeling ................11 2.4.1 Light Emitting Diodes......................11 2.4.2... - Page 4 Hardware feedback........................39 RECOMMENDED SERVICE INTERVALS............40 RECOMMENDED TOOLS ................. 41 10 RECOMMENDED SPARE PARTS RAYJET - STARTER KIT ......42 11 FAQ’S ........................ 43 11.1 Problems you can see in the engraving or cutting result ........... 43 11.1.1 Trotec test routine......................43 11.1.2...
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Page 5: Main Components
Service Manual Rayjet Main components General 1 Main components Top view Back view keypad power supply units top lid electronics maintenance panel connection for PC and exhaust unit service access panel connection for exhaust hose lasertube product ID lable on/off switch / power socket... -
Page 6: Safety Information
Please read this chapter before operating or servicing a Rayjet laser system! 2.1 General The Rayjet is an apparatus with a high level of security. To guarantee a safe operation it is necessary to know potential dangers and avoid risks. The dangers can be classified in three... - Page 7 Service Manual Rayjet General Safety information responsibility to ensure the safe removal and disposal of the smokes and particles from the laser machine according to the national and regional threshold values. In the US reference should be made to Section 7.3 in the ANSI Z136.1-1993 Standard...
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Page 8: Laser Safety
The safety of a laser machine is defined by one of five safety classes. The Rayjet without laser pointer would be safety class 2 in the EU safety class 2. With an installed laser pointer it would be laser class 2M. Therefore it presents no hazard to personnel when properly used during normal operation or routine maintenance. -
Page 9: Safety Interlock System
Laser Safety Safety information 2.2.1 Safety Interlock System Your Rayjet is equipped with an integrated safety interlock system which cuts off the power of the laser tube immediately as soon as one of the interlocked doors/panels is opened. CAUTION Do not attempt to alter the interlock system as that could result in hazardous radiation exposure. -
Page 10: Dangers Of Electricity
2.3 Dangers of Electricity When you open the covers of the engraving system there is the danger to get in contact with parts under high voltage. Therefore it is absolutely necessary that service and repair work is only done while the power supply is unplugged. In any case all safety laws and standards in connection with electricity must be obeyed. -
Page 11: Emission Indication And Safety Labeling
Service Manual Rayjet Emission indication and safety labeling Safety information 2.4 Emission indication and safety labeling 2.4.1 Light Emitting Diodes There is a red LED (light emitting diode) on the left hand side of the keypad which is illuminating when laser radiation is emitted. -
Page 12: Beam Alignment
3 Beam alignment 3.1 Laser beam alignment Attention: To do the laser pointer adjustment it is absolutely necessary to wear laser protection glasses! What you need laser protection glasses (for CO lasers) part number 69300 the toolbox enclosed to the engraver beam alignment tools (BAT) for mirrors #2 &... - Page 13 Service Manual Rayjet Laser beam alignment Beam alignment Beam path of the Rayjet: Mirror 3 Mirror 1 Mirror 2 Illustration is with removed service and maintenance panel. What you have to do Put on your laser protection glasses. Remove the three screws shown below on the right inside of the working area and disassemble the panel.
- Page 14 Put the BAT for mirror #1 & 2 on the holder of mirror #2. Turn on the Rayjet. Connect the Rayjet to the Manager and ensure that the testpulse the options of the Mini manager is set to a low level (~10%) before doing the beam alignment. You find this menu...
- Page 15 Seal the adjustment screws by putting some varnish to them. Put the cover for mirror #1 back on. Now your engraver is aligned properly. Put the maintenance panel back to the Rayjet and close it. 07/09/2010 Trotec Produktions- und Vertriebs GmbH_Linzer Strasse 156, A-4600 Wels, Austria, Technical Support...
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Page 16: Laser Pointer Adjustment
3.2 Laser pointer adjustment Attention: To do the laser pointer adjustment it is absolutely necessary to wear laser protection glasses! What you need: laser protection glasses (for CO lasers) part number 69300 the toolbox enclosed to your engraver beam alignment tool (BAT) for mirror #3 What you have to know: Connect the laser to the Manager and ensure that the testpulse setting within the Manager is set to a low level (~10%) before doing the beam alignment. -
Page 17: Replacing The Laser Tube
(of the motion system) and software adjustment are OK. When you receive a new lasertube for the Rayjet, the tube is mounted on a plate and already adjusted in a way, that it should not be necessary to adjust the beampath. If there are some missalignments, do the alignment as described before in chapter 3. -
Page 18: Measuring The Laser Power
4.1 Measuring the laser power: To measure the laser power you need: 1. laser protection glasses (for CO lasers) part number 69300 2. Laser power meter CAUTION To make sure that there is no laser emission out of a controlled area establish a limited access area by using non flamable beam blocking curtains, temporary walls or other enclosures. - Page 19 1. Open the mini manager and connect to the engraver. 2. Enter the Options via right-click on the small red rayjet icon on the left side of the task-bar. Choose “Service” and set “Power test pulse” to 100%. Press Apply.
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Page 20: Replacement Of The Lasertube
4.2 Replacement of the lasertube The concerned parts in replacement of lasertubes are placed on the backside of the machine. holding plate cover of mirror #1 cover of lasertube fans power supplies Do the following steps to exchange the lasertube. 1. -
Page 21: Adjusting The Mini-Manager Options
Adjusting the Mini-Manager Options Tab „Options“ 5 Adjusting the Mini-Manager Options You enter the options menue via right-click on the small red rayjet-icon on the left side of the task bar when minimanager is active. 5.1 Tab „Options“ Here you can set preferred language and the used unit. Additionally you can set the maximum number of Jobs which are shown in the Job Queue of the Minimanager ang decide if you want to suppress warnings of the (Trotec) exhaust system. -
Page 22: Tab „Service
Power test puls defines, with which power the lasertube fires when initiating a test pulse by pressing the STOP and PAUSE button simultaneously on the keypad on the Rayjet. The following parameters are responsible for achieving good engraving quality. Trotec uses a patented algorithm for compensating imperfections of the laser tube behaviour. -
Page 23: Tab „Information" - Firmware Update
Service Manual Rayjet Adjusting the Mini-Manager Options Tab „Information“ – Firmware Update 5.3 Tab „Information“ – Firmware Update Engraver shows the model actually connected to the computer. Power shows the power of the laser tube in W. Firmeware shows the actually installed firmware version of the laser machine. To update the firmware follow the following steps: 1. - Page 24 2. Choose the firmwareupdate-file (.TUZ oder update2.ttu) in your directories and click on OPEN.
- Page 25 Service Manual Rayjet Adjusting the Mini-Manager Options Tab „Information“ – Firmware Update 3. In the following you can observe the progress of the update… 4. … untill the MiniManager asks you to turn your laser off and on again. 07/09/2010...
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Page 26: Hardware
6 Hardware Whenever you are servicing a machine, turn the machine off and unplug it! Most of the described procedures are explained in detail on the Rayjet Video DVD. Please consult the DVD for additional information. 6.1 X- and Y-axis The axes are the most strained mechanical components in a laser engraver. -
Page 27: Exchange Of The Reels On X-Axis
To correct the belt tension follow the next steps: 1. Turn off the Rayjet and unplug it from the electrical outlet. 2. Remove the service panel at the left side of the machine. -
Page 28: Exchange Of X-Motor
6. Let the motor plate glide into the position enforced by the tensioning device. 7. Tighten the two screws fixing the motor plate. 8. Replace the small metal plate mounted on the motor. 9. Replace the service panel at the left side of the machine. 6.1.5 Exchange of x-motor 1. - Page 29 Service Manual Rayjet Hardware X- and Y-axis 1. Open the cover of the machine. 2. Remove service and maintenance panel on left and right side of the machine. 3. Remove the three upper screws holding the front panel and remove the panel.
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Page 30: The Electric System
6.2 The electric system The Rayjet contains the following electrical components: 1. IO board 2. CPU board 3. Motor prints 4. Power supplies 5. Laser tube 6. Motors 7. Keypad For checking the system we recommend to use an electronic multimeter (Voltage check,... -
Page 31: I/O Board With Cpu Board And Motor Prints
Service Manual Rayjet Hardware The electric system Pictures 6.2.1 I/O board with CPU board and motor prints 6.2.2 CPU board 07/09/2010 Trotec Produktions- und Vertriebs GmbH_Linzer Strasse 156, A-4600 Wels, Austria, Technical Support 31 / 53 tel_+43 (0)7242 239-7000, fax_+43 (0)7242 239-7380, mailto:... -
Page 32: Motor Prints
6.2.3 Motor prints 6.2.4 Power supplies 30 W 12 W... -
Page 33: Lasertube
Service Manual Rayjet Hardware The electric system 6.2.5 Lasertube 6.2.6 Motors X-axis motor Y-axis motor Z-axis motor 07/09/2010 Trotec Produktions- und Vertriebs GmbH_Linzer Strasse 156, A-4600 Wels, Austria, Technical Support 33 / 53 tel_+43 (0)7242 239-7000, fax_+43 (0)7242 239-7380, mailto:... -
Page 34: Keypad
(0.5 Hz) Rayjet is ready green, flashing fast (2 Hz) Cover has been opened green permanent light / Data available in the Rayjet Pause mode red permanent light Laser beam is being emitted Cover open during switch-on process,... -
Page 35: Wiring Diagrams
Service Manual Rayjet Hardware Wiring diagrams 6.3 Wiring diagrams 6.3.1 12W air-cooled 07/09/2010 Trotec Produktions- und Vertriebs GmbH_Linzer Strasse 156, A-4600 Wels, Austria, Technical Support 35 / 53 tel_+43 (0)7242 239-7000, fax_+43 (0)7242 239-7380, mailto: rayjet@troteclaser.com www.rayjetlaser.com... -
Page 36: Air-Cooled
6.3.2 30W air-cooled... -
Page 37: Error Codes
Service Manual Rayjet Error codes Software feedback 7 Error codes The following error codes can be generated by the Trotec Minimanager, whenever it recognizes a machine or computer problem. In many cases these codes are a helpful information which makes it easier to sort out problems. - Page 38 Number Text -811 // Could not create bitmap -812 // No trotec info found -812 // Error retrieving color table -900 // could not initialize rubber -901 // could not initialize bmp line -902 // could not retrieve line from CRubber -903 // invalid (NULL) job specified -904 // move of file failed -905 // copy of file failed...
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Page 39: Hardware Feedback
Service Manual Rayjet Error codes Hardware feedback 7.2 Hardware feedback Machine errors are shown after 30 seconds! Error Code 123 A device on the CAN bus is not working properly Error Code 124 Switching Point density is too high Error Code 125... -
Page 40: Recommended Service Intervals
8 Recommended service intervals Due to safety reasons we recommend to check the interlock mechanismen on a yearly basis. Nevertheless any fault on an interlock will switch off the laser tube to prevent personell of any injuries. For any service technician it´s important to have information about the life expectancy of the different components. -
Page 41: Recommended Tools
Service Manual Rayjet Recommended tools 9 Recommended tools laser protective goggles for CO Allen key set inch Allen key set metric set of screw drivers set of screw drivers phillips side cutting pliers combination pliers adjustable wrench cutter knife set of hexagon wrenches... -
Page 42: Recommended Spare Parts Rayjet - Starter Kit
10 Recommended spare parts Rayjet - Starter Kit Lens 1,5” 32550 Lens 2,0” 32551 Lens 2,5“ 32553 Mirror #1 & #2 32481 Mirror #3 32448 Motorboards (3x) 31498 CPU Board 84809 I/O Board 31497 X-Axis belt 30846 Y-Axis belt (2x) -
Page 43: Faq's
Service Manual Rayjet FAQ’s 11 FAQ’s 11.1 Problems you can see in the engraving or cutting result 11.1.1 Trotec test routine Trotec has developed special test files for quality checks. Start the following tests if you recognize troubles in the engraving result on your laser system:... -
Page 44: Customer Experience
11.1.2 Customer experience Problem description: Possible reason: Solution: imprecise focusing check focus too low engraving dirty optics clean optics depth table misaligned check table adjustment too low laser power replace tube dirty beam output window on tube clean output window imprecise focusing check focus blurred edges... -
Page 45: Machine Malfunctions
Service Manual Rayjet FAQ’s finished correctly on the computer -Raster correction ON Switch off raster correction in Engraved or cut job JobControl (settings/advanced size doesn’t match Wrong size settings in the printer options/laser tab) with size in Corel driver Use the same size as in Corel... -
Page 46: Error Code Is Created
acceleration too high reduce acceleration engraving jobs and cut lines Destroyed FRAM parameters Refresh F-Ram parameters The machine makes Damaged firmware Update the firmware unusual things The Axis make the The jumpers on the motor boards are Use the right codification on each wrong movements interchanged Axis... -
Page 47: Problems With The Software
Service Manual Rayjet FAQ’s 11.3 Problems with the Software Problem description: Possible reason: Solution: spool settings don’t match link the spool directory in Job After installation it control to the spool folder in is not possible to the explorer send jobs to Job... - Page 48 Skipped cut lines or skipped Set the right functions in the No engraving or engraving parameter window (double cutting click on the plate) Printer settings Go to the TROTEC printer Problems with properties (start/settings/fax printing jobs to and printers). the JobControl Choose the “Port”...
- Page 49 Service Manual Rayjet FAQ’s CorelDraw message “Printer paper Always prevent from automatic Job size orientation orientation does not match one or adjusted page sizes by does not match more document pages. Adjust selecting “No”. the chosen printer automatically?” was settings.
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Page 50: Laser Quick Check
11.4 Laser Quick Check The laser quick check is thought for situations where you don’t see an obvious problem, but want to do check the temporary condition of your machine. check the optical components (lens, mirror#1, mirror#2, mirror#3, beam combiner) check the grade of soiling (engraving area) verify home position listen carefully to eventual noise generation... -
Page 51: Samples
Service Manual Rayjet FAQ’s 11.5 Samples Good shoulder settings Bad shoulder settings 07/09/2010 Trotec Produktions- und Vertriebs GmbH_Linzer Strasse 156, A-4600 Wels, Austria, Technical Support 51 / 53 tel_+43 (0)7242 239-7000, fax_+43 (0)7242 239-7380, mailto: rayjet@troteclaser.com www.rayjetlaser.com... - Page 52 Shadow on the edges Blurred edges Waviness of lines...
- Page 53 Service Manual Rayjet FAQ’s Big shift in the engraving result Engraving quality in the center is different to the edges Bad power correction 07/09/2010 Trotec Produktions- und Vertriebs GmbH_Linzer Strasse 156, A-4600 Wels, Austria, Technical Support 53 / 53 tel_+43 (0)7242 239-7000, fax_+43 (0)7242 239-7380, mailto:...