Universal Laser Systems ULS-25E Service Manual

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SERVICE MANUAL

ULS-25E / ULS-25ER

LASER SYSTEM

Universal Laser Systems, Inc.

16008 North 81st Street

Scottsdale, AZ 85260

Phone: 602-483-1214

Fax: 602-483-5620

Revision C

January 1997

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Summary of Contents for Universal Laser Systems ULS-25E

Page 1 SERVICE MANUAL ULS-25E / ULS-25ER LASER SYSTEM Universal Laser Systems, Inc. 16008 North 81st Street Scottsdale, AZ 85260 Phone: 602-483-1214 Fax: 602-483-5620 Revision C January 1997...
Page 2 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.
Page 3 TABLE OF CONTENTS *NOTE: A=Adjustment, C=Cleaning, R&I=Removal and Installation Beam Window (C,R&I) ......................2 Cart Assembly (Assembly, Adjustment) ................... 4 Electronics 1 (Component Description)..................6 Electronics 2 (Description, Diagnostics)................... 8 Electronics 3 (EEPROM R&I)....................10 Exhaust (C,R&I) ........................12 Focus Tool (Calibration) ......................14 Front Door (Proximity Sensors, Actuators, Air Filter-C,R&I)...........
Page 4 Table of Contents BEAM WINDOW Description, Cleaning, Removal, and Installation Description The laser light enters the engraving area through the Beam Window. The Beam Window (window for short) is made of a solid piece of Zinc Selenide (ZnSe). This material allows the beam to pass through with very little loss of power or beam absorption.
Page 5 Table of Contents BEAM WINDOW...
Page 6 Table of Contents CART ASSEMBLY Description, Assembly, Adjustment Description The laser system is normally mounted on the Cart Assembly. The Cart Assembly is the only part of the laser system that needs to be assembled, and adjusted if necessary. Assembly Bolt the flat panel to the legs securely as the diagram indicates.
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Page 8 Table of Contents ELECTRONICS 1 Component Description Description These diagrams show the main electronic components of the laser system. Please refer to the Schematics section for the wiring diagram and the troubleshooting section for various troubleshooting procedures of these components. The following ONLY describes the function of each of the components: POWER INLET This receptacle is where the power cord plugs into the laser system.
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Page 10 Table of Contents ELECTRONICS 2 Description, Diagnostics Description On the left side of the Power Supply, there are the receptacles for the stepper motors. Next to the receptacles are their respective Diagnostic Red LED's. On the right side of the Power Supply are the connectors for the Limit Switches, the LAS4.0 Board Data Link receptacle and the AC Power Inlet receptacle.
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Page 12 Table of Contents ELECTRONICS 3 Component Description, EEPROM Removal and Installation Description Inside the Power Supply is the USTEP Board. This board is the controller board for the Limit Switches and the stepper motors. It receives motion system commands from the LAS4.0 Board, processes them, and turns them into stepper motor movements.
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Page 14 Table of Contents EXHAUST ASSEMBLY Removal, Cleaning, and Installation Removal If the exhaust plenum gets full of debris, it can be cleaned. In order to clean it, it must be removed. Remove the (4) screws, drop the engraving table all the way down, and pull out the plenum. Cleaning Clean it out with soap and water or ordinary household cleaners and dry it completely.
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Page 16 Table of Contents FOCUS TOOL Calibration NOTE: THE FOCUS TOOL THAT IS INCLUDED WITH THE LASER SYSTEM HAS ALREADY BEEN CALIBRATED AT THE FACTORY. THE FOLLOWING PROCEDURE IS ONLY NECESSARY IF THE TOOL COMES OUT OF ADJUSTMENT OR YOU ARE ADJUSTING THE TOOL TO A REPLACEMENT LENS.
Page 17 Table of Contents • Place the Focus Tool on top of the anodized aluminum and up against the side of the Focus Lens Holder. Loosen the Set Screw on the base of the Focus Tool. Adjust the base so that the top part of the bevel is touching the bottom of the Focus Lens Holder.
Page 18 Table of Contents FRONT DOOR Component Description, Air Filter Removal, Cleaning, and Installation Description The Front Door is safety interlocked by the Proximity Sensors and the Actuators. The Proximity Sensor Actuators are simply magnets. When the Actuators are close enough to the Sensors, it closes the electrical connection inside the Sensor thus creating a closed circuit to energize the Solid State Relay which in turn applies DC power to the laser tube.
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Page 20 Table of Contents KEYPAD Display Board Description, Removal, and Installation Keypad Description, Removal, and Installation Display Board Description The Display Board has and LED display that displays the menu system for the laser. It has a brightness/contrast control. To adjust, rotate the black knob on the back of the board while the laser system is on.
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Page 22 Table of Contents LASER TUBE ASSEMBLY 1 Description, Fan Enclosure Removal and Installation Fan Removal and Installation Description The laser beam is generated inside the Laser Tube Assembly. It has its own electronics located inside the assembly and are not user or technician serviceable. The Laser Tube is located inside the Laser Tube Assembly.
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Page 24 Table of Contents LASER TUBE ASSEMBLY 2 Laser Tube Removal and Installation Removal NOTE: This diagram only shows the proper screws to remove when replacing the Laser Tube Assembly. The alignment of the beam itself and the proper way to adjust it is covered in the “Motion System 15” section.
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Page 26 Table of Contents MOTION SYSTEM 1 Description, X&Y Bearing and Track Cleaning Description The lasers Motion System is an XY or plotter based, stepper motor motion system. The X-axis Motor drives the Focus Carriage left and right by means of the X-axis Belt. The Y-axis Motor drives the X-axis Arm towards the rear and front of the machine by the means of two Y-axis Belts.
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Page 28 Table of Contents MOTION SYSTEM 2 Mirror Description, Removal, Cleaning, and Installation Description The Mirrors must also remain clean otherwise the laser systems engraving power (depth) will be reduced, and eventually, the Mirrors and Focus Lens will burn up and have to be replaced. Mirrors #2 and #3 (as well as the #1 Mirror) are frontal surfaced mirrors meaning that the reflective surface is on the outside surface of the mirror.
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Page 30 Table of Contents MOTION SYSTEM 3 Focus Lens Description, Removal, Cleaning, and Installation Description The Focus Lens is composed of Zinc Selenide (ZnSe). It is yellow in color and allows the beam to pass through with very little laser heat absorption. It also focuses the beam to a very small spot size compared to the size of the beam that enters the lens.
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Page 32 Table of Contents MOTION SYSTEM 4 Limit Switch Description, Cleaning, Installation, and Adjustment Description The X&Y-axis Limit Switch (Home) Sensors are optical sensors that sense when the Focus Carriage and the X-axis Arm are in the Home Position (upper right hand corner). This occurs ONLY UPON POWER UP.
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Page 34 Table of Contents MOTION SYSTEM 5 X-axis Bearing Description and Adjustment Description The Motion System has been designed in such a way that the outer surface of the bearings will eventually wear out instead of the metal parts of the Motion System. In this way, it will be much less expensive to replace bearings than an anodized aluminum extrusion.
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Page 36 Table of Contents MOTION SYSTEM 6 X-axis Bearing Removal, Installation, and Adjustment Removal To replace the X-axis Bearings, remove the Lockdown Screws, the Tensioning Screws and Springs, and then the X-axis Bearing Tensioning Bracket. The Bracket has the top X-axis Bearing attached to it. The Focus Carriage Assembly will now hang only by the X-axis Belt.
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Page 38 Table of Contents MOTION SYSTEM 7 X-axis Belt Cleaning, Adjustment, Removal, and Installation Cleaning The X-axis Belt will need cleaning from time to time. Sometimes smoke or debris will settle on the teeth and that debris will transfer to the X-axis Drive Gear. If the X-axis Drive Gear accumulates too much debris, the X-axis Belt will start to slip.
Page 39 Table of Contents MOTION SYSTEM 7...
Page 40 Table of Contents MOTION SYSTEM 8 X-axis Belt Idler Pulley Description, Removal, Installation, and Adjustment Description The X-axis Idler Pulley (Idler for short) is mounted on the left side of the X-axis Arm and underneath the #2 Mirror Holder Bracket. The X-axis Belt is wrapped around the Idler. The X-axis Motor, Drive Gear, Belt, X-axis Bearings, and Idler work together to drive the Focus Carriage left and right.
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Page 42 Table of Contents MOTION SYSTEM 9 X-axis Motor Removal, Installation, and Adjustment Description The X-axis Motor and Drive Gear, along with the Belt and Idler, drive the Focus Carriage left and right. If the X-axis Motor wears out, it must be replaced. If the Drive Gear gets clogged with dirt, the X-axis Motor must be removed to facilitate cleaning.
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Page 44 Table of Contents MOTION SYSTEM 10 X-axis Arm Squaring, Y-axis Bearing Clearance Adjustment Description Over a long period of time and a lot of engraving, the X-axis Arm can start to come out of square and/or the Y-axis Bearings will start to get loose. To check if the X-axis Arm is square to the Motion System Rails, turn the machine off and pull the arm towards you until the arm contacts the front rail.
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Page 46 Table of Contents MOTION SYSTEM 11 Y-axis Bearing Removal, Installation, and Adjustment Description The Y-axis Bearings are mounted on the left and right side of the X-axis Arm. In order to change them, the X-axis Arm must be removed from the laser system. Turn the laser system OFF before performing this procedure.
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Page 48 Table of Contents MOTION SYSTEM 12 Y-axis Belt Removal, Installation, Adjustment Y-axis Belt Idler Pulley Removal and Installation Y-axis Drive Gear Removal and Installation Y-shaft Bearing Removal and Installation NOTE: Belts, Idlers, Drive Gears, and Shaft Bearings are the same on both sides of the Motion System. The following Procedure assumes that you will be changing all of the described parts.
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Page 50 Table of Contents MOTION SYSTEM 13 Y-axis Motor Description, Removal and Installation Description The Y-axis Motor has two shafts, one to drive the left side and one to drive the right side of the motion system. Most applications utilize the raster function which causes more wear on the X-axis Motor than the Y-axis Motor.
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Page 52 Table of Contents MOTION SYSTEM 14 X-axis Arm Description, Installation, Adjustment Description If installing a new X-axis Arm, the Assembly comes from the factory as shown. It does not include the #2 or # 3 mirrors or a focus lens in the holder as the diagram illustrates. Installation Refer to the procedure “Motion System 11”...
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Page 54 Table of Contents MOTION SYSTEM 15 Beam Alignment Theory The correct alignment between the Laser Beam and the Motion System is very critical to correct Laser System operation. The Laser Beam MUST strike each Mirror at a precise 45 degree angle to reflect 100% of the Laser Beam’s energy to the other Mirrors and Focus Lens.
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Page 56 Table of Contents MOTION SYSTEM 16 (Beam Alignment continued) Place a piece of Masking Tape over the #2 Mirror Holder and press the directional arrow key to position the Motion System at P1. Rub the masking tape with your finger, against the edge of the hole so that you can see an impression of the hole through the tape.
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Page 58 Table of Contents MOTION SYSTEM 17 (Beam Alignment Continued) changing). Tighten the lockdown screws and re-test alignment between P1 and P2. If the dots have separated, re-check to make sure that the M1 holder is flat against the lip of the mounting bracket. If not, re-adjust and re-test.
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Page 66 Table of Contents TICKLE ADJUSTMENT Description, Adjustment Description For maximum laser performance, and instantaneous response time, the laser must be supplied with a small pulse width and pulse rate signal at all times. This is what we refer to, in the laser industry, as the "Tickle".
Page 67 Table of Contents Adjustment To set the Tickle, go to the Preferences menu in the Control Panel of the laser system, then select “Tickle”. There are two numbers, the Tickle Rate in khz(or kilohertz) and the other is Tickle Width in us(or microseconds).
Page 68 Table of Contents TOP DOOR 1 Proximity Sensor Removal and Installation Top Door Window Cleaning Top Door Removal and Installation Proximity Sensor Actuator The Proximity Sensor Actuators are magnets that will close the circuit of the Safety Interlock System. This will allow the laser beam to fire only if the doors are closed and the circuit is completed. Removal Unscrew the two(2) small nuts that attach the Actuator to the Top Door.
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Page 70 Table of Contents TOP DOOR 2 Pressure Cylinder Removal and Installation Description The Top Door Pressure Cylinders help lift the Top Door when opening and also assist in keeping the door tightly closed when it is in the closed position. It also prevents the Top Door from slamming when closing it.
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Page 72 Table of Contents TOP DOOR INTERLOCK Proximity Sensor Description, Removal and Installation Description The Top Door is safety interlocked by the Proximity Sensors and the Actuators. The Proximity Sensor Actuators are simply magnets. When the Actuators are close enough to the Proximity Sensor Assembly (when the doors are closed), it closes the electrical connection inside the Sensor thus creating a closed circuit to energize the Solid State Relay.
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Page 74 Table of Contents TROUBLESHOOTING REMINDER Any removal of the electronic or electrical components of the laser system should be done with the power OFF and the system unplugged. Obviously, if you are testing voltages, you will need the system powered ON. This manual assumes that you have electrical and electronic skills. Please use common sense when servicing this equipment.
Page 75 Table of Contents SOLID STATE RELAY The Solid State Relay (relay for short) is an electronic switch that is directly connected to the safety interlock system. If the top or front door is open, the input DC power to the relay is turned off thus opening the output circuit between the DC power supply and the laser tube.
Page 76 Table of Contents Z-AXIS ASSEMBLY 1 Engraving Table Description, Adjustment, Removal, and Installation Description The Engraving Table (Z-axis Table or Stage) is a Honeycomb centered, aluminum laminated table. It is very lightweight and surface ground so that it is very flat. The levelness of the Engraving Table is a very important requirement for proper laser engraving.
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Page 78 Table of Contents Z-AXIS ASSEMBLY 2 Ruler Adjustment, Removal, and Installation Adjustment The rulers are bolted through the Engraving Table and secured on the back side with locknuts and washers. If a Beam Alignment has been performed, usually because the laser tube was replaced, or the Motion System had some components replaced, then the Rulers might need adjustment.
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Uls-25er