P100/flyer 3d Installation Guide 4600 Campus Place Mukilteo, Wa 98275

Transcript

p100/Flyer 3D installation guide 4600 Campus Place Mukilteo, WA 98275 1.800.SYNRAD1 tel 1.425.349.3500 fax 1.425.349.3667 e-mail [email protected] web www.synrad.com Pulstar p100/Flyer 3D Installation Guide Version 1.0 Released August 2014 Part number 900-20818-08 ® 4600 Campus Place Mukilteo, WA 98275 1.800.SYNRAD1 tel 1.425.349.3500 fax 1.425.349.3667 e-mail [email protected] web www.synrad.com 2 Synrad Pulstar p100/Flyer 3D installation guide Table of Contents Trademark/copyright information..............................................................6 Contact information...................................................................................7 Worldwide headquarters............................................................................................. 7 European headquarters............................................................................................... 7 Hazard information.....................................................................................8 Terms........................................................................................................................... 8 General hazards.......................................................................................................... 8 Agency compliance....................................................................................11 Inventory.....................................................................................................12 Flyer 3D marking head............................................................................................... 12 Pulstar p100 laser........................................................................................................ 13 Flyer 3D/p100 subsystem............................................................................................ 14 Power supply............................................................................................................... 14 Mounting....................................................................................................15 Mounting guidelines................................................................................................... 15 Flyer 3D/p100 subsystem............................................................................................ 16 Connecting.................................................................................................17 Cooling connections.................................................................................................. 17 Power connections...................................................................................................... 21 Control connections................................................................................................... 23 Gas purge connections............................................................................................... 26 Initial configuration and start-up................................................................28 Initial power-up.......................................................................................................... 29 Peer-to-peer Ethernet set-up...................................................................................... 30 WinMark Pro v7 configuration.................................................................................. 32 Ethernet configuration................................................................................................ 33 Mark field configuration............................................................................................. 35 Test firing (WinMark control mode).......................................................................... 36 Marking operation...................................................................................................... 38 Synrad Pulstar p100/Flyer 3D installation guide 3 List of Figures Figure 1 Flyer 3D’s mark field orientation............................................15 Figure 2 Mounting the Flyer 3D/p100 rail assembly............................16 Figure 3 Pulstar p100/Flyer 3D cooling connections............................20 Figure 4 Flyer 3D/p100 power supply connections ..............................22 Figure 5 Flyer 3D/p100 Laser Control connection...............................24 Figure 6 Flyer 3D Ethernet crossover cable connection.......................25 Figure 7 Pulstar p100 gas purge kit assembly........................................26 Figure 8 Flyer 3D/p100 Gas Purge port connections............................27 Figure 9 Local Area Connection Properties dialog..............................31 Figure 10 Internet Protocol (TCP/IPv4) Properties dialog....................31 Figure 11 Creating a new Flyer 3D device name....................................32 Figure 12 Flyer IP Address Ranges dialog...............................................34 Figure 13 Working distance measurement.............................................35 Figure 14 WinMark Pro’s Mark button...................................................36 Figure 15 Diode pointer On/Off button.................................................36 Figure 16 Factory Test Mark pattern......................................................37 4 Synrad Pulstar p100/Flyer 3D installation guide List of Tables Table 1 Flyer 3D ship kit contents.......................................................12 Table 2 Pulstar p100 ship kit contents................................................13 Table 3 Flyer 3D/p100 subsystem ship kit contents............................14 Table 4 Power supply ship kit contents...............................................14 Table 5 Dew point temperatures..........................................................19 Table 6 Purge gas specifications...........................................................27 Synrad Pulstar p100/Flyer 3D installation guide 5 Trademark/copyright information SYNRAD is a registered trademark of SYNRAD, Inc. All other trademarks or registered trademarks are the property of their respective owners. © 2014 by SYNRAD, Inc. All rights reserved. 6 Synrad Pulstar p100/Flyer 3D installation guide Contact information Worldwide headquarters SYNRAD’s worldwide headquarters are located north of Seattle in Mukilteo, Washington, U.S.A. Our mailing address is: SYNRAD, Inc. 4600 Campus Place Mukilteo, WA 98275 U.S.A. Phone us at: Outside the U.S.: Fax: E-mail: 1.800.SYNRAD1 (1.800.796.7231) +1.425.349.3500 +1.425.349.3667 [email protected] Sales and Applications SYNRAD’s Regional Sales Managers work with customers to identify and develop the best CO2 laser solution for a given application. Because they are familiar with you and your laser application, use them as a first point of contact when questions arise. Regional Sales Managers also serve as the liaison between you and our Applications Lab in processing material samples per your specifications. To speak to the Regional Sales Manager in your area, call SYNRAD at 1.800.SYNRAD1. Customer Service For assistance with order or delivery status, service status, or to obtain a Return Authorization (RA) number, contact SYNRAD at 1.800.SYNRAD1 and ask to speak to a Customer Service representative. Technical Support SYNRAD’s Regional Sales Managers are able to answer many technical questions regarding the installation, use, troubleshooting, and maintenance of our products. In some cases, they may transfer your call to a Laser, Marking Head, or Software Support Specialist. You may also email questions to the Technical Support Group by sending your message to [email protected] or to [email protected]. Reference materials Your Regional Sales Manager can provide reference materials including Outline & Mounting drawings, Operator’s Manuals, Technical Bulletins, and Application Newsletters. Most of these materials are also available directly from SYNRAD’s web site at http://www.synrad.com. European headquarters For assistance in Europe, contact SYNRAD’s European subsidiary, Synrad Europe, at: Synrad Europe Münchener Straße 2A D-82152 Planegg, Germany Phone: +49 (0) 89 31 707-0 Fax: +49 (0) 89 31 707-222 E-mail: [email protected] Synrad Pulstar p100/Flyer 3D installation guide 7 Hazard information Hazard information includes terms, symbols, and instructions used in this manual or on the equipment to alert operating and service personnel to the recommended precautions in the care, use, and handling of Class 4 laser equipment. Terms Certain terms are used throughout this manual or on the equipment labels. Please familiarize yourself with their definitions and significance. Danger: Imminent hazards which, if not avoided, will result in death or serious injury. Warning: Potential hazards which, if not avoided, could result in death or serious injury. Caution: Potential hazards or unsafe practices which, if not avoided, may result in minor or moderate injury. Caution: Potential hazards or unsafe practices which, if not avoided, may result in product damage. Important Note: Important information or recommendations concerning the subject under discussion. Note: Points of particular interest for more efficient or convenient equipment operation; additional information or explanation concerning the subject under discussion. General hazards Following are descriptions of general hazards and unsafe practices that could result in death, severe injury, or product damage. Warnings and cautions not appearing in this section are found throughout this manual. Danger serious personal injury This Class 4 laser marking subsystem emits invisible infrared laser radiation in the 10.6 µm CO2 wavelength band and emits visible laser radiation from a Class 3R laser in the 630–680 nm wavelength band. Do not allow laser radiation to enter the eye by viewing direct or reflected laser energy. CO2 laser radiation can be reflected from metallic objects even though the surface is darkened. Direct or diffuse laser radiation can inflict severe corneal injuries leading to permanent eye damage or blindness. All personnel must wear eye protection suitable for 10.6 µm CO2 radiation when in the same area as an exposed laser beam. Eyewear protects against scattered energy but is not intended to protect against direct viewing of the beam—never look directly into the laser output aperture or view scattered laser reflections from metallic surfaces. Enclose the beam path whenever possible. Exposure to direct or diffuse CO2 laser radiation can seriously burn human or animal tissue, which may cause permanent damage. This product is not intended for use in explosive, or potentially explosive, atmospheres. 8 Synrad Pulstar p100/Flyer 3D installation guide Hazard information Warning serious personal injury Warning serious personal injury For laser systems being used or sold within the U.S.A., customers should refer to and follow the laser safety precautions described in the American National Standards Institute (ANSI) document Z136.12007, Safe Use of Lasers. For laser systems being used or sold outside the U.S.A., customers should refer to and follow the laser safety precautions described in European Normative and International Electrotechnical Commission documents EN 60825-1:2007, Safety of Laser Products – Part 1: Equipment Classification and Requirements and IEC/TR 60825-14:2004, Safety of Laser Products – Part 14: A User’s Guide. Materials processing with a laser can generate air contaminants such as vapors, fumes, and/or particles that may be noxious, toxic, or even fatal. Safety Data Sheets (SDS) for materials being processed should be thoroughly evaluated and the adequacy of provisions for fume extraction, filtering, and venting should be carefully considered. Review the following references for further information on exposure criteria: ANSI Z136.1-2007, Safe Use of Lasers, section 7.3. U.S. Government’s Code of Federal Regulations: 29 CFR 1910, Subpart Z. Threshold Limit Values (TLV’s) published by the American Conference of Governmental Industrial Hygienists (ACGIH). It may be necessary to consult with local governmental agencies regarding restrictions on the venting of processing vapors. Warning possible personal injury Caution possible personal injury The use of controls or adjustments or performance of procedures other than those specified herein may result in exposure to hazardous invisible laser radiation, damage to, or malfunction of the laser. Severe burns will result from exposure to the laser beam. A risk of exposure to toxic elements, like zinc selenide, may result when certain optical or beam delivery components are damaged. In the event of damage to laser, marking head, or beam delivery optics, contact SYNRAD, Inc. or the optics manufacturer for handling instructions. Synrad Pulstar p100/Flyer 3D installation guide 9 Hazard information SYNRAD® CO2 lasers should be installed and operated in manufacturing or laboratory facilities by trained personnel only. Due to the considerable risks and hazards associated with the installation and operational use of any equipment incorporating a laser, the operator must follow product warning labels and instructions to the user regarding laser safety. To prevent exposure to direct or scattered laser radiation, follow all safety precautions specified throughout this manual and exercise safe operating practices per ANSI Z136.1-2007 and IEC/TR 60825-14:2004 at all times when actively lasing. Thoroughly review the Pulstar OEM p100 Operator’s Manual and the Flyer 3D Operator’s Manual for information about product specific hazards and safe operating instructions. Always wear safety glasses or protective goggles with side shields to reduce the risk of damage to the eyes when operating the laser. A CO2 laser is an intense heat source and will ignite most non-metallic materials under the proper conditions. Never operate the laser in the presence of flammable or explosive materials, gases, liquids, or vapors. Safe operation of the laser requires the use of an external beam block to safely block the beam from traveling beyond the desired work area. Do not place your body or any combustible object in the path of the laser beam. Use a water-cooled beam dump or power meter, or similar non-scattering, noncombustible material as the beam block. Never use organic material or metals as the beam blocker; organic materials, in general, are apt to combust or melt and metals act as specular reflectors which may create a serious hazard outside the immediate work area. Other hazards The following hazards would be typical for this product family when incorporated for intended use: (A) risk of injury when lifting or moving the unit; (B) risk of exposure to hazardous laser energy through unauthorized removal of access panels, doors, or protective barriers; (C) risk of exposure to hazardous laser energy and injury due to failure of personnel to use proper eye protection and/or failure to adhere to applicable laser safety procedures; (D) risk of exposure to hazardous or lethal voltages through unauthorized removal of covers, doors, or access panels; (E) generation of hazardous air contaminants that may be noxious, toxic, or even fatal. Disposal This product contains components that are considered hazardous industrial waste and must be disposed of properly. If a situation occurs where the laser is rendered non-functional and cannot be repaired, it may be returned to SYNRAD, Inc. who, for a fee, will ensure compliant disposal of the product. Additional laser safety information The SYNRAD web site (http://www.synrad.com/LaserFacts/lasersafety.html) contains an online laser safety handbook that provides information on (1) Laser Safety Standards for OEM’s/System Integrators including product classification, product housing, product features, and other CDRH requirements; (2) Laser Safety Standards for End Users including Class 1 installations, Class 4 installations, laser hazards, ANSI Standard, U.S. State requirements, and OSHA; (3) References and Sources including CDRH, ANSI/OSHA; and (4) Assistance with Requirements. In addition, the Occupational Safety and Health Administration (OSHA) provides an online Technical Manual (located at http://www.osha.gov/dts/osta/otm/otm_iii/otm_iii_6.html). Section III, Chapter 6 and Appendix III are good resources for laser safety information. Another excellent laser safety resource is the Laser Institute of America (LIA). Their comprehensive web site is located at http://www.laserinstitute.org. 10 Synrad Pulstar p100/Flyer 3D installation guide Agency compliance SYNRAD lasers and Flyer 3D marking heads are designed, tested, and certified to comply with certain United States (U.S.) and European Union (EU) regulations. These regulations impose product performance requirements related to electromagnetic compatibility (EMC) and product safety characteristics for industrial, scientific, and medical (ISM) equipment. The specific provisions to which systems containing SYNRAD lasers and Flyer 3D heads must comply are identified and described in the Pulstar OEM p100 Operator’s Manual and the Flyer 3D Operator’s Manual. These Operator’s Manuals provide detailed information regarding compliance to Center for Devices and Radiological Health (CDRH), Federal Communications Commission (FCC), and European Union (EU) requirements (including RoHS compliance and Declaration of Conformity statements). In the U.S., laser safety requirements are governed by the Center for Devices and Radiological Health (CDRH) under the auspices of the U.S. Food and Drug Administration (FDA) while radiated emission standards fall under the jurisdiction of the U.S. Federal Communications Commission (FCC). Outside the U.S., laser safety and emissions standards are governed by European Union (EU) Directives and Standards. In the matter of CE-compliant products, SYNRAD, Inc. assumes no responsibility for the compliance of the system into which the product is integrated, other than to supply and/or recommend laser components that are CE marked for compliance with applicable European Union Directives. Because OEM products are intended for incorporation as components in a laser processing system, they do not meet all of the Standards for complete laser processing systems as specified by 21 CFR, Part 1040 or EN 60825-1. SYNRAD, Inc. assumes no responsibility for the compliance of the system into which OEM laser products are integrated. Important Note: Pulstar p100/Flyer 3D subsystems are OEM products intended for incorporation as components in a laser processing system and as such do not comply with 21 CFR, Subchapter J or EN 60825-1 without additional safeguards. Synrad Pulstar p100/Flyer 3D installation guide 11 Inventory The Inventory section includes subsections:  Flyer 3D marking head  Pulstar p100 laser  Power supply Our Flyer 3D/p100 laser subsystem concept ensures the Flyer 3D head is precisely aligned to the laser without the need to perform time-consuming alignment procedures in the field. Table 1 through Table 4 list the items shipped with each subsystem component. Please notify SYNRAD immediately if any item listed below was not received with your shipment. Flyer 3D marking head Table 1 lists items included in the Flyer 3D ship kit. Table 1 Flyer 3D ship kit contents Ship Kit Contents Qty Ship Kit Contents Qty SYNRAD Flyer 3D Marking Head.............. 1 Final Test Report............................................1 DC Power Cable........................................... 1 Flyer 3D Operator’s Manual (on CD)...........1 Laser Control Cable...................................... 1 p100/Flyer 3D Installation Guide (CD).........1 DB-25 User Interface Connector.................. 1 WinMark Pro Hardlock (USB)....................1 Ethernet Crossover Cable.............................. 1 WinMark Pro Laser Marking Software CD....1 Spare Power Connector w/ Pins.................. 1 Flyer 3D ship kit contents Each item listed in Table 1 is described below: SYNRAD Flyer 3D Marking Head – this large-format, three-axis head marks, cuts, and drills a wide variety of products and materials in either index or tracking mode. DC Power Cable – connects power from the 48 VDC power supply to the Flyer 3D head. Laser Control Cable – sends PWM Command signals generated by Flyer 3D to the laser. DB-25 User Interface Connector – allows you to connect I/O field wiring directly to the Flyer 3D head. Ethernet Crossover Cable – provides a robust Ethernet communications link between the host computer or network and the Flyer 3D head. Spare Power Connector w/ Pins – allows you to fabricate a custom length DC Power cable, if required. Final Test Report – contains data collected during the Flyer 3D head’s final pre-shipment tests. Flyer 3D Operator’s Manual (on CD) – a PDF version of the Flyer 3D Operator’s Manual is available on the WinMark Pro v7 software CD. 12 Synrad Pulstar p100/Flyer 3D installation guide Inventory Pulstar p100/Flyer 3D Installation Guide (on CD) – a PDF version of this guide is available on the WinMark Pro v7 software CD. WinMark Pro Hardlock (USB) – enables the personal computer (PC) running WinMark Pro v7 Laser Marking Software to communicate with Flyer 3D during file transfers and WinMark-controlled mark sessions. WinMark Pro v7 Laser Marking Software CD – contains the latest build of WinMark Pro v7 Laser Marking Software and PDF versions of the WinMark Pro v7 User’s Guide, the Flyer 3D Operator’s Manual and all Flyer 3D Installation Guides. Pulstar p100 laser Table 2 lists items included in the Pulstar p100 ship kit. Table 2 Pulstar p100 ship kit contents Ship Kit Contents Qty Ship Kit Contents Qty Pulstar p100 Laser/Rail Assembly................ 1 SYNRAD CO2 Lasers Manual CD................1 DC Power Cable Set.................................... 1 Gas Purge Kit................................................1 Quick Start Plug............................................ 1 Spare Fuses....................................................2 12 mm Cooling Tubing................................ 1 Final Test Report............................................1 Mounting Bolts............................................ 6 Pulstar p100 ship kit contents Each item listed in Table 2 is described below: Pulstar p100 Laser/Rail Assembly – a 100 W water-cooled laser for cutting, welding, drilling, and marking a wide variety of products and materials. The p100 laser is carefully mounted and aligned on a mounting rail assembly before shipment. DC Power Cable Set – carry DC power from the 48 VDC power supply to the p100 laser. Quick Start Plug – connects to the p100’s User I/O connector and allows easy connection to Flyer 3D’s Laser Control cable. 12 mm Cooling Tubing – carries cooling water from your chiller to the laser and back. This clear polyethylene tubing is 12 mm O.D. by 30 feet and must be cut to length. Mounting Bolts – These three M6 × 1.0 × 16 mm and three 1/4–20 × 3/4" UNC Allen capscrews are not used in the p100/Flyer 3D assembly. SYNRAD CO2 Lasers Manual CD – contains a Pulstar OEM p100 Operator’s Manual that provides setup, operation, and maintenance information for your p100 laser. Gas Purge Kit – provides a filtering and connection point to the laser from your facility’s purge gas system. Spare Fuses – fast-acting mini blade fuses protects Pulstar’s internal circuitry. Final Test Report – contains data collected during the laser’s final pre-shipment test. Synrad Pulstar p100/Flyer 3D installation guide 13 Inventory Flyer 3D/p100 subsystem Table 3 lists items included in the Flyer 3D/p100 subsystem ship kit. Table 3 Flyer 3D/p100 subsystem ship kit contents Ship Kit Contents Qty Ship Kit Contents Qty Reducing Tee, 12 mm to 10 mm Tube......... 2 “Y” Union, 1/4" Tube...................................1 10 mm Cooling Tubing................................ 1 1/4" Purge Tubing.........................................1 Flyer 3D/p100 subsystem ship kit contents Each item listed in Table 3 is described below: Reducing Tee, 12 mm to 10 mm Tube – connects the laser’s 12 mm diameter cooling tubing to the 10 mm tubing leading to Flyer 3D’s water-cooled input aperture. 10 mm Cooling Tubing – connects Flyer 3D’s water-cooled input aperture into the laser’s cooling system. “Y” Union, 1/4" Tube – connects Flyer’s Gas Purge port into the supply for the laser’s Gas Purge port. 1/4" Purge Tubing – connects Flyer 3D’s gas purge system into the laser’s gas purge system. Power supply Table 4 lists items included in the power supply package. Table 4 Power supply ship kit contents Ship Kit Contents Qty PS-48 DC Power Supply.............................. 1 Power supply contents Each item listed in Table 4 is described below: Important Note: The PS-48 power supply is not included with international orders unless specifically included on your Sales Order. PS-48 DC Power Supply – provides 48 VDC (at 2400 W) to power both the p100 laser and Flyer 3D Marking Head. 14 Synrad Pulstar p100/Flyer 3D installation guide Mounting The Mounting section includes subsections:  Mounting guidelines  Flyer 3D/p100 subsystem SYNRAD’s integrated subsystem design means the Flyer 3D/p100 laser subsystem is mounted to a rail assembly and then aligned and tested before leaving the factory. Follow the steps in each section below to mount the subsystem rail assembly into your laser processing system. Mounting guidelines Before mounting your p100/Flyer 3D subsystem, please ensure the following guidelines are met:  When positioning the Flyer 3D head in your laser system, be aware that Flyer 3D’s mark field (WinMark Pro’s Drawing Canvas as seen in Figure 1) is oriented in a horizontal (landscape) view. 270° 0° 180° 90° WinMark Pro’s Drawing Canvas orientation relative to Flyer 3D/laser Figure 1 Flyer 3D’s mark field orientation  Mount the Flyer 3D/p100 subsystem so the working distance, measured from the bottom of the Flyer 3D housing to the top of the marking surface (see Figure 13), matches the distance specified in Flyer 3D’s Final Test Report.  Surround the beam path around the marking area with a beam enclosure shield to confine any reflected laser radiation.  Flyer 3D’s built-in heat sink includes an attached cooling fan. Allow at least 57.2 mm (2.25") of unobstructed fan clearance between the outside edge of the fan housing and any mounting surface or enclosure. Synrad Pulstar p100/Flyer 3D installation guide 15 Mounting Flyer 3D/p100 subsystem As shown in Figure 2, the p100 laser is already mounted and aligned before it is shipped. To mount the Flyer 3D/p100 subsystem into your laser processing system, perform the following steps: Warning possible personal injury Lifting or moving the combined Flyer 3D/p100 laser subsystem poses a potential for injury. Use appropriate lifting techniques and/or equipment to prevent a risk of injury. You may require the assistance of additional personnel and/or lifting equipment to safely unpack and move this equipment. 1 Remove the Flyer 3D/p100 subsystem from the shipping container. 2 Position the Flyer 3D/p100 subsystem so it is parallel to the part marking surface with the Flyer 3D head positioned at the specified working distance and then fasten it to a rigid support structure. Use four M6 or 1/4" fasteners to attach the rail assembly to the mounting surface. Four each M6 or 1/4” user-supplied fasteners Figure 2 Mounting the Flyer 3D/p100 rail assembly Important Note: The p100 laser is precisely aligned with the Flyer 3D head and rail assembly at the factory. Do not loosen, adjust, or remove the Allen capscrews fastening the laser to the rail assembly! 3 16 Remove the protective cover from Flyer 3D’s output aperture window. Synrad Pulstar p100/Flyer 3D installation guide Connecting The Connecting section includes subsections: ■ Cooling connections ■ Power connections ■ Control connections ■ Gas purge connections Cooling connections Adapting laser cooling fittings for 1/2" tubing Pulstar p100 cooling fittings are designed to accept 12 mm polyethylene tuning. If your integrated laser application uses 1/2" cooling tubing, you can install metric-to-imperial tubing adaptors on a short section of 12 mm tubing on the chiller side of the 12 mm to 10 mm reducing Tee. These adaptors are available from many suppliers including McMaster-Carr (P/N 51495K416). Caution possible equipment damage Do not overtighten the water IN/OUT cooling fittings. Overtightening the cooling fittings may crack the cooling manifold, causing coolant leakage, or partially block the cooling channel, leading to reduced coolant flow and premature laser failure. If you must install new fittings, wrap the threads with Teflon tape and carefully tighten the fittings, making sure the maximum insertion depth is no more than 6.6 mm (0.26") into the cooling manifold. Guidelines for cutting and installing tubing ■ Cut tubing lengths generously to allow for trimming. ■ Cut tubing squarely; diagonal cuts may not seal properly. Carefully trim any burrs if the cut is “ragged”. ■ Avoid excessive stress on fittings; create gentle bends when routing tubing close to connectors. Excessive stress from sharp bends will compromise the sealing properties of the fitting. ■ Never allow the tubing to kink, since kinking severely restricts coolant flow. ■ Push tubing completely into the fitting, then pull the tubing to verify that it is locked into place. ■ If tubing must be disconnected from a fitting, first push and hold the tubing slightly into the fitting. Next push the white release ring evenly towards the fitting, and then pull the tubing free. ■ After disconnecting tubing from a fitting, trim 12.7 mm (1/2") from its end before reconnecting. Trimming the end of the tubing before reconnecting the fitting provides an undisturbed sealing surface. Synrad Pulstar p100/Flyer 3D installation guide 17 Connecting Chiller preparation guidelines ■ You must provide fittings to adapt the laser’s 12 mm O.D. polyethylene cooling tubing to your chiller’s Inlet and Outlet ports. These fittings can be “quick disconnect” or compression type fittings. ■ Because the p100’s factory-installed fittings and tubing are metric (12 mm), do not use 1/2 inch size tubing or fittings unless you have installed the appropriate adaptors. Mixing inch and metric size tubing or fittings will lead to coolant leaks or may allow the pressurized tubing to blow-off the fitting. Coolants SYNRAD recommends the laser’s cooling fluid contain at least 90% distilled water by volume. In closedloop systems, use a corrosion inhibitor/algaecide such as Optishield® Plus or equivalent as required. Avoid glycol-based additives because they reduce the coolant’s heat capacity and high concentrations may affect power stability. For SYNRAD lasers, the minimum coolant setpoint is 18 °C (64 °F) so glycol is not necessary unless the chiller is subjected to freezing temperatures. If tap water is used, chloride levels should not exceed a concentration of 25 parts per million (PPM) and total hardness should be below 100 PPM. Install a filter on the chiller’s return line and inspect frequently. Pulstar p100 lasers incorporate the following wetted materials in the coolant path—nickel-plated brass, copper, acetal, nitrile, and stainless steel. Note: DO NOT use de-ionized (DI) water as a coolant. DI water is unusually corrosive and is not recommended for mixed material cooling systems. Setting coolant temperature Choosing the correct coolant temperature is important to the proper operation and longevity of your laser. When coolant temperature is lower than the dew point (the temperature at which moisture condenses out of the surrounding air), condensation forms inside the laser housing leading to failure of laser electronics as well as damage to optical surfaces. The greatest risk of condensation damage occurs when the laser is in a high heat/high humidity environment and the chiller’s coolant temperature is colder than the dew point of the surrounding air or when the system is shut down, but coolant continues to flow through the laser for extended periods of time. The chiller’s temperature setpoint must always be set above the dew point temperature. In cases where this is not possible within the specified coolant temperature range of 18 °C to 22 °C (64 °F to 72 °F), then the following steps MUST be taken to reduce the risk of condensation damage. ■ Use the Gas Purge port to introduce nitrogen or dry, filtered air into the laser housing. ■ Air-condition the room or the enclosure containing the laser. ■ Install a dehumidifier to reduce the humidity of the enclosure containing the laser. ■ Stop coolant flow when the laser is shut down. ■ Increase coolant flow by an additional 3.8 lpm (1.0 GPM). Do not exceed a coolant pressure of 414 kPa (60 PSI). ■ Refer to Table 5 and gradually increase coolant temperature until it is above the dew point temperature and condensation disappears. Do not exceed a coolant temperature of 30 °C (86 °F). Note: Pulstar p100 lasers can be operated at coolant temperatures up to 30 °C to reduce condensation; however, these elevated temperatures may result in decreased laser performance and/or reduced laser lifetime. 18 Synrad Pulstar p100/Flyer 3D installation guide Connecting Table 5 provides dew point temperatures for a range of air temperature and relative humidity values. The laser’s coolant temperature must be set above the dew point temperatures shown in the chart; however, for best results and performance, use a coolant temperature in the range of 18–22 °C (64–72 °F). Table 5 Dew point temperatures Dew Point Temperature Chart °F (°C) Relative Humidity (%) 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 Air Temp °F (°C) 60 (16) — — — 32 36 39 41 44 46 48 50 52 54 55 57 59 (0) (2) (4) (5) (7) (8) (9) (10) (11) (12) (13) (14) (15) 65 (18) — — 33 37 40 43 46 48 51 53 55 57 59 60 62 64 (1) (3) (4) (6) (8) (9) (11) (12) (13) (14) (15) (16) (17) (18) 70 (21) — 33 37 41 45 48 51 53 56 58 60 62 64 65 67 69 (1) (3) (5) (7) (9) (11) (12) (13) (14) (16) (17) (18) (18) (19) (21) 75 (24) — 37 42 46 49 52 55 58 60 62 65 67 68 70 72 73 (3) (6) (8) (9) (11) (13) (14) (16) (17) (18) (19) (20) (21) (22) (23) 80 (27) 35 41 46 50 54 57 60 62 65 67 69 71 73 75 77 78 (2) (5) (8) (10) (12) (14) (16) (17) (18) (19) (21) (22) (23) (24) (25) (26) 85 (29) 40 45 50 54 58 61 64 67 70 72 74 76 78 80 82 83 (4) (7) (10) (12) (14) (16) (18) (19) (21) (22) (23) (24) (26) (27) (28) (28) 90 (32) 44 50 54 59 62 66 69 72 74 77 79 81 83 85 87 88 (7) (10) (12) (15) (17) (19) (21) (22) (23) (25) (26) (27) (28) (29) (31) (31) 95 (35) 48 54 59 63 67 70 73 76 79 81 84 86 88 90 92 93 (9) (12) (15) (17) (19) (21) (23) (24) (26) (27) (29) (30) (31) (32) (33) (34) 100 (38) 52 58 63 68 71 75 78 81 84 86 88 91 93 95 97 98 (11) (14) (17) (20) (22) (24) (26) (27) (29) (30) (31) (33) (34) (35) (36) (37) To use Table 5, look down the Air Temp column and locate an air temperature in Fahrenheit or Celsius (°C values are shown in parentheses) that corresponds to the air temperature in the area where your laser is operating. Follow this row across until you reach a column matching the relative humidity in your location. The value at the intersection of the Air Temp and Relative Humidity columns is the Dew Point Temperature in °F (or °C). The chiller’s temperature setpoint must be set above the dew point temperature. For example, if the air temperature is 85 °F (29 °C) and the relative humidity is 60%, then the dew point temperature is 70 °F (21 °C). Adjust the chiller’s temperature setpoint to 72 °F (22 °C) to prevent condensation from forming inside the laser. Caution possible equipment damage Operating the laser at coolant temperatures above 22 °C (72 °F) may result in decreased performance and/or premature failure of electronic components. Synrad Pulstar p100/Flyer 3D installation guide 19 Connecting Cooling tubing connections To connect cooling tubing to the p100 laser, refer to Figure 3 and perform the following steps. Water In Water Out to chiller Figure 3 Pulstar p100/Flyer 3D cooling connections 1 Locate the 12 mm O.D. polyethylene cooling tubing in the ship kit. 2 Cut two short lengths of tubing. Connect one to the upper WATER IN port and one to the lower WATER OUT port on the rear of the Pulstar p100 laser. 3 Connect a 12 mm – 10 mm reducing Tee fitting to each short length of tubing on the WATER IN/ WATER OUT ports. 4 Cut and connect a length of 12 mm tubing to fit between the chiller’s Outlet port and the Tee fitting on the upper WATER IN port on the rear of the Pulstar p100 laser. 5 Cut and connect a length of 12 mm tubing to fit between the Tee fitting on the lower WATER OUT port and the chiller’s Inlet port. Note: If your system uses imperial (1/2") cooling tubing, install two 12 mm to 1/2" adaptors (not included) in the cooling lines between the chiller and the Tee fittings. 6 Locate two lengths of 10 mm tubing in the ship kit. Connect one end of each tubing section to the center (10 mm) connector on each reducing Tee. The 10 mm sections should extend towards the front of the p100 laser. 7 Connect each 10 mm tubing section to the 10 mm to 1/4" straight tubing adaptors connected to Flyer 3D’s water-cooled aperture. 20 Synrad Pulstar p100/Flyer 3D installation guide Connecting Caution possible equipment damage Inlet cooling water temperature must always be maintained above the dew point to prevent condensation and water damage to your Pulstar laser. 8 Turn on the chiller and adjust the temperature setpoint to 18 °C to 22 °C. Regulate coolant flow between 5.7–7.6 lpm (1.5–2.0 GPM) at less than 414 kPa (60 PSI) of pressure. 9 Closely examine all cooling connections to verify that there are no leaks and then turn off the chiller. Power connections The following procedures describe how to complete electrical connections to the p100 laser and Flyer 3D head. Pulstar p100 DC power cables are manufactured from #8 AWG wire and measure 1.8 meters (72 inches) in length while Flyer 3D DC power cables are made with #18 AWG wire and are 1.8 meters (72 inches) in length. PS-48 DC power supply Caution possible equipment damage Do not reverse polarity when connecting DC Power cables to your DC power source. Reversed DC polarity may damage the laser’s internal RF power supply. Carefully follow the directions below to ensure that DC Power cable leads are properly connected to the correct DC output terminals. The p100 laser/Flyer 3D subsystem requires a 48 VDC power supply. We recommend a SYNRAD PS-48 DC supply that can provide a maximum of 50 A at 48 VDC. AC input requirements for the PS-48 supply are 180–264 VAC, single-phase (1Ø), 11.2 A max (@ 208 VAC), 47–63 Hz. To connect the PS-48 supply, refer to Figure 4 and perform the following steps: Synrad Pulstar p100/Flyer 3D installation guide 21 Connecting Flyer 3D DC Power cable Earth ground - Green –48 VDC - Black +48 VDC - Red Figure 4 Flyer 3D/p100 power supply connections 1 Verify that input AC power to the DC power supply is physically locked out or disconnected. Note: The negative (–) side of the DC input to the laser is internally connected so the laser chassis serves as DC power ground. You should isolate the laser’s DC power supply so the only grounded connection is at the laser. Alternatively, you can mount the laser chassis on an insulating pad or film in order to electrically isolate the DC return from the machinery’s chassis ground. 2 Position the PS-48 supply so it is within 1.8 meters (72 inches) of the laser and Flyer 3D head. 3 Locate Flyer 3D’s DC Power cable in the ship kit. Connect the 3-pin connector on the end of the cable to the Power jack on the rear panel of the Flyer 3D head. Caution possible equipment damage 4 Do not attach or remove the DC Power cable while DC power is applied to the Flyer 3D head. This “hot-plug” action causes arcing that will damage the connector pins and may damage Flyer 3D circuitry. Always switch AC power to the PS-48 supply to energize and deenergize the Flyer 3D head. Locate the 48 VDC output terminals on the PS-48 power supply’s output section and connect the black (–) DC power cable from the laser to the Negative (V–) output terminal. Crimp a properly sized ring terminal to the black (–) wire on Flyer’s DC Power cable and connect it to the supply’s Negative (V–) output terminal. 22 Synrad Pulstar p100/Flyer 3D installation guide Connecting 5 Connect the red (+) DC power cable from the laser to the Positive (V+) 48 VDC output terminal. Crimp a properly sized ring terminal to the red (+) wire on Flyer’s DC Power cable and connect it to the supply’s Positive (V+) output terminal. 6 Crimp a properly sized ring terminal to the green (ground) wire on Flyer’s DC Power cable and connect it to an earth ground, such as the DC power supply chassis. Note: Because AC input connections and requirements vary from facility to facility, customers must provide the AC power cable or wiring. 7 On the AC section of the PS-48 power supply, connect one side of the 180–264 VAC line to the input terminal labeled “AC/L”. 8 Connect the other side of the AC line to the input terminal labeled “AC/N”. 9 Connect the ground wire, typically green, to the input terminal labeled with the ground symbol. Control connections Pulstar p100 laser Control connections to Pulstar p100 lasers are made through the 15-pin User I/O port on the laser’s rear panel. This port receives power commands from the Flyer 3D head and also serves as the connection point for auxiliary signals between the laser and any parts handling, automation, or monitoring equipment. The User I/O port includes three optoisolated signal inputs, along with a dedicated optoisolated PWM input, +5 and +24 VDC auxiliary power outputs (limited to 0.5 A each), and five optoisolated status outputs. See the Pulstar OEM p100 Operator’s Manual for specific details about the p100 User I/O interface. Flyer 3D marking head On Flyer 3D, control connections are made through the 25-pin User Interface port on the rear control panel. The DB-25 User Interface connection provides an isolated +15 VDC, 400 mA internal supply for powering externally-connected I/O devices; two high-speed optoisolated inputs; six bipolar optoisolated inputs; and eight bipolar optoisolated outputs that allow you to automate your marking operation. Important Note: Flyer 3D inputs and outputs (I/O) are not intended for use as general purpose I/O. Instead, they were designed to communicate with the control system before or after, but not during, the actual marking process. In applications where external devices must be monitored and controlled while lasing is in progress, we recommend using an automation controller or discrete I/O modules to perform this function. Synrad Pulstar p100/Flyer 3D installation guide 23 Connecting Quick Start Plug Warning serious personal injury The use of the Quick Start Plug bypasses the laser’s safety interlock function, potentially exposing personnel in the area to invisible infrared laser radiation. Because this plug jumpers Remote Interlock and Shutter Open Request signals, the laser will fire immediately on application of a PWM Command signal. Your integrated control system should provide interlock and shutter signals directly to the DB-15 User I/O connector only after safe operating conditions are established. The Quick Start Plug is intended only for initial testing and troubleshooting by qualified personnel. In normal operation, the laser’s Remote Interlock input should be connected to the machine’s safety interlock circuitry. The Quick Start Plug has factory-installed shorting jumpers wired into it to enable Remote Interlock and Shutter Open Request input signals. Connect the Quick Start Plug to the User I/O connector when performing initial start-up and testing of your laser. To connect the Quick Start Plug, refer to Figure 5 and perform the following steps: 1 Plug the Quick Start Plug into the User I/O port on the rear of the laser. Tighten the screws to fasten it in position. Laser Control cable The Laser Control cable is a 1.8 m (6 ft) long coaxial cable with male BNC connectors on each end. To connect the Laser Control, refer to Figure 5 and perform the following steps: Quick Start Plug Laser Control cable with ferrite bead Figure 5 Flyer 3D/p100 Laser Control connection 24 Synrad Pulstar p100/Flyer 3D installation guide Connecting 1 Attach the end of the coaxial cable with the ferrite bead to the Laser Control BNC on Flyer 3D’s rear panel. 2 Attach the other end of the coaxial cable to the Quick Start Plug attached to the rear of the laser. If using a customer-supplied DB-15 connector instead of the Quick Start Plug to access laser I/O, wire the DB-15 so Pin 9 (PWM Input) is connected to the Laser Control cable’s center conductor and Pin 1 (PWM Return) is connected to the shielded outer conductor. Ethernet Crossover cable All communication with Flyer 3D heads is over an Ethernet communications link. An Ethernet connection also allows Flyer 3D to operate over a network in WinMark control mode or access a network share file in Stand-alone mode. An Ethernet crossover cable (included in the Flyer 3D ship kit) is required when connecting Flyer 3D directly to a computer using a peer-to-peer connection. When connecting to a local network, use a straightthru (patch) Ethernet cable between Flyer 3D and your Ethernet router or hub. To connect the Ethernet Crossover cable, refer to Figure 6 and perform the following steps: Ethernet port Ethernet Crossover cable to computer Figure 6 Flyer 3D Ethernet crossover cable connection 1 Locate the Ethernet Crossover cable in the Flyer 3D ship kit. This shielded CAT 5e Ethernet cable is approximately 3 meters (10 ft) long with RJ45 plugs on each end. 2 Connect the crossover cable between your computer and Flyer 3D’s Ethernet port. See Peer-to-peer Ethernet set-up and Ethernet configuration topics in the Initial configuration and start-up section for details on creating a peer-to-peer Ethernet connection and setting an IP address that is compatible with your facility’s networking scheme. Synrad Pulstar p100/Flyer 3D installation guide 25 Connecting Input/Output (I/O) p100 User I/O connector The User I/O connection is only required when you are wiring input or output automation signals to the Pulstar p100 laser. See the Technical Reference chapter in the Pulstar OEM p100 Operator’s Manual for detailed information on using the p100 User I/O interface. Flyer 3D User Interface connector The User Interface connection is only required when you are wiring input or output automation signals to Flyer 3D. See Getting Started and Technical Reference chapters in the Flyer 3D Operator’s Manual for detailed information on using the Flyer 3D User Interface. Gas purge connections A gas purge is highly recommended when operating the p100 laser Flyer 3D head. Purging laser and marking head housings creates positive pressure that prevents dirt and debris from accumulating on optical surfaces and prevents condensation from damaging electrical components. To connect p100/Flyer 3D Gas Purge ports, refer to Figure 7 and Figure 8 and perform the following steps: B A W O FL 2 OW FL 1 Figure 7 Pulstar p100 gas purge kit assembly 1 Locate the gas purge kit in the p100 ship kit. The kit consists of one male/female 90° quick-disconnect fitting, a straight fitting, and a low-flow gas filter. 2 Assemble the 90° fitting, straight fitting, and filter as shown in Figure 7A. Be sure to orient the directional arrow on the filter body as shown. 3 Refer to Figure 7B and plug the filter assembly into the Gas Purge connector. 4 Connect a short section of 1/4” tubing to the inlet of the gas filter as shown in Figure 8. 5 Connect the “Y” union fitting to the tubing from the laser’s Gas Purge port. 6 Connect a length of 1/4” tubing between the “Y” union fitting and the Gas Purge port on the rear of the Flyer 3D housing. 26 Synrad Pulstar p100/Flyer 3D installation guide Connecting Gas Purge port Gas Purge port W O FL Connection to nitrogen or instrumentgrade filtered & dried air source Figure 8 Flyer 3D/p100 Gas Purge port connections 7 Connect 1/4" tubing between your nitrogen or instrument-grade air source and the “Y” union connected to the rear of the p100 laser. Caution possible equipment damage Do not exceed a gas purge pressure of 34.5 kPa (5 PSI). Excessive pressure may damage the purge assembly or other internal laser components. Do not use argon as a purge gas. Use only nitrogen or clean, dry air as described in Table 6, Purge gas specifications. 8 Set a flow rate of 0.85–1.7 m3/hr (30–60 SCFH, Standard Cubic Feet per Hour) at a pressure not to exceed 34.5 kPa (5 PSI). If a flowmeter is not available, set a purge pressure between 13.8–34.5 kPa (2–5 PSI) to provide just enough positive airflow to prevent dust from entering the Flyer 3D head. The Flyer 3D Gas Purge port must be connected to a source of nitrogen or clean, dry air only; do not use any other gases for purging. Purge gas specifications are listed in Table 6 below. Table 6 Purge gas specifications Purge Gas Specification Nitrogen High Purity Grade > 99.9500% purity; filtered to ISO Class 1 particulate level Air Breathing Grade > 99.9996% purity; filtered to ISO Class 1 particulate level Air Compressed Instrument-grade air filtered and dried to ISO 8573-1:2010 Class 1, 2, 1 (< 10 1.0–5.0 µm particles/m3; < –40 °F dew point; < 0.01 mg/m3 oil vapor) Synrad Pulstar p100/Flyer 3D installation guide 27 Initial configuration and start-up The Initial configuration and start-up section includes subsections: ■ Initial power-up ■ Peer-to-peer Ethernet set-up ■ WinMark Pro v7 configuration ■ Ethernet configuration ■ Mark field configuration ■ Test firing (WinMark control mode) ■ Marking operation Danger serious personal injury This product is designed to emit invisible infrared laser radiation from a Class 4 laser in the 10.6 µm CO2 wavelength band. This product emits visible laser radiation from a Class 3R laser in the 630–680 nm wavelength band. Since direct or diffuse laser radiation can inflict severe corneal injuries, always wear eye protection when in the same area as an exposed laser beam. Do not allow the laser beam to contact a person. CO2 lasers emit an invisible beam that is capable of seriously burning human tissue. Always be aware of the beam path and always use a beam block while testing or operating this product. Warning serious personal injury Warning serious personal injury 28 On p100 OEM lasers, remote interlock (INT) faults are not latched. Clearing the fault condition enables the RDY indicator and the laser will fire immediately provided the SHT indicator is lit and a PWM Command signal is applied. Because exposure to 10.6 µm CO2 laser radiation can inflict severe corneal injuries and seriously burn human tissue, the OEM or System Integrator must ensure that appropriate safeguards are in place to prevent unintended lasing. The use of the Quick Start Plug bypasses the laser’s safety interlock function, potentially exposing personnel in the area to invisible infrared laser radiation. The Quick Start Plug is intended only for initial testing and troubleshooting by qualified personnel. In normal operation, the laser’s Remote Interlock input should be connected to the machine’s safety interlock circuitry. Synrad Pulstar p100/Flyer 3D installation guide Initial configuration and start-up Caution possible equipment damage Caution possible equipment damage Contamination on the laser’s output window, or on the surface of any beam delivery optic, can absorb enough energy to damage the optic. Periodically inspect the laser’s output window and all other beam delivery optics for signs of contaminants, and then carefully clean as required. In dirty environments, purge laser optics using filtered air or nitrogen to prevent vapor and debris from accumulating on optical surfaces. FH Flyer 3D’s operating system requires approximately 20 seconds to boot up. Repeatedly cycling power during the boot up sequence may cause corruption of Flyer 3D’s flash memory and operating system. Initial power-up Starting auxiliary equipment 1 If you have not already done so, install WinMark Pro v7 Laser Marking Software onto your Windows® computer. See the WinMark Pro User Guide or v7 Release Notes for installation instructions. 2 Ensure that all personnel in the area are wearing protective eyewear. Caution possible equipment damage 3 Inlet cooling water temperature must always be maintained above the dew point temperature to prevent condensation and water damage to your Pulstar laser. Turn on the chiller (set in the range of 18–22 °C) and verify it is delivering a coolant flow between 5.7–7.6 lpm (1.5–2.0 GPM) at less than 414 kPa (60 PSI) of pressure. Caution possible equipment damage Do not exceed a gas purge pressure of 34.5 kPa (5 PSI). Excessive pressure may damage the purge assembly or other internal laser components. Do not use argon as a purge gas. Use only nitrogen or clean, dry air as described in Table 6, Purge gas specifications. Synrad Pulstar p100/Flyer 3D installation guide 29 Initial configuration and start-up 4 Set a purge gas flow rate of 0.85–1.7 m3/hr (30–60 SCFH, Standard Cubic Feet per Hour) at a pressure not to exceed 34.5 kPa (5 PSI). If a flowmeter is not available, set a purge pressure between 13.8–34.5 kPa (2–5 PSI). This will provide enough positive airflow to prevent dust from entering Flyer 3D and p100 housings. 5 Turn on the +48 VDC power supply. p100 laser: The INT (Remote Interlock) LED will illuminate green and the SHT (Shutter) LED will illuminate blue. The TMP (Temperature) LED will illuminate green if laser temperature is within safe operating limits. The RDY (Ready) LED illuminates yellow when INT and TMP LEDs are green. Flyer 3D: The head’s Power LED will illuminate green. Flyer’s operating system requires approximately 20 seconds to boot up. Flyer is operational when the Status LED illuminates solid green and the Lase indicator illuminates a dim red to indicate tickle signals are applied to the laser. Peer-to-peer Ethernet set-up Flyer 3D heads are preset at the factory to an IP address of 192.168.100.100. This allows you to make a simple peer-to-peer Ethernet connection to a non-networked marking computer. If you intend to run Flyer over a network, first use the peer-to-peer connection to connect to the head and change its IP address to one compatible with your network’s addressing scheme. The procedure described below may require the assistance of your IT Department if your facility’s Ethernet settings are determined automatically using Dynamic Host Configuration Protocol (DHCP). The Flyer peer-to-peer Ethernet connection must be connected to a computer with a static IP address that is not connected to a local network. To setup Flyer 3D for the Ethernet using a peer-to-peer Ethernet connection, perform these steps: Set your computer’s static IP address Note: The exact steps may vary depending on your operating system. The description below applies to a Windows® 7 operating system (OS). 1 Remove the WinMark computer from the local network by unplugging network cables. 2 In the Windows Control Panel, double-click Network and Sharing Center. 3 In the Network and Sharing Center dialog, click the Local Area Connection option. 4 In the Local Area Connection Status dialog, click the Properties button. 5 In the Local Area Connection Properties dialog (Figure 9) select Internet Protocol Version 4 (TCP/IPv4) and click the Properties button. 30 Synrad Pulstar p100/Flyer 3D installation guide Initial configuration and start-up Figure 9 Local Area Connection Properties dialog 6 When the Internet Protocol Version 4 (TCP/IPv4) Properties dialog opens, first write down your current settings so they can be restored later. Then select “Use the following IP address:” and enter the following information as shown in Figure 10: IP Address: Subnet Mask: 192.168.100.101 255.255.255.0 Figure 10 Internet Protocol (TCP/IPv4) Properties dialog 7 Click OK to submit the changes. Connect to the Flyer head 1 Connect Flyer to your computer using an Ethernet crossover cable. 2 Power up the Flyer marking head and wait approximately 20 seconds for it to boot-up. Synrad Pulstar p100/Flyer 3D installation guide 31 Initial configuration and start-up 3 Open WinMark Pro and perform either Step A or Step B: a When WinMark’s Device Simulation dialog opens, click “Enter IP Address for Flyer Head”, click in the text box and type 192.168.100.100, and then click OK. b If WinMark Pro launches, go to the Devices menu and select Connect to Ethernet Flyer. In the Select Ethernet Flyer IP Address dialog, click in the text box and type 192.168.100.100, and then click OK. For additional Ethernet-related information, refer to the Flyer 3D Operator’s Manual. To set-up a network share folder, refer to WinMark Pro/Flyer 3D interface in the Stand-alone operation chapter. For details on accessing Flyer’s web page, see Flyer 3D web interface in the Technical Reference chapter. Important Note: The Ethernet cable included in the ship kit is a shielded crossover-type cable. If your application requires a straight-thru (patch) cable or you supply your own crossover cable, be sure the Ethernet cable is an industrially-shielded CAT 5e or CAT 6 cable. WinMark Pro v7 configuration The label of the Flyer 3D tab corresponds to the Object Name given to the Flyer head. Each Flyer 3D head is assigned a unique name based on it’s serial number in the form “Flyerxxxxxx”; where “xxxxxx” denotes the last six digits of the head’s serial number. In facilities operating multiple Flyer/Flyer 3D heads, you can give each Flyer head a unique identity based on location or process. To edit Flyer’s Object Name property, refer to Figure 11 and perform the following steps: Figure 11 Creating a new Flyer 3D device name 1 Power up Flyer and then open WinMark Pro. 2 On the Tools menu, select General Settings… . 3 Verify that the label on the Flyer 3D tab, refers to the Flyer head you wish to rename. If not, go to the Devices menu and from the drop-down menu, point to Flyer3D Ethernet to select the correct device from the list of recognized Flyer/Flyer 3D heads. 32 Synrad Pulstar p100/Flyer 3D installation guide Initial configuration and start-up 4 In the General Settings dialog, click the Flyer 3D tab and then select Object Name. Type in a descriptive name for the currently active Flyer head This new name is written into Flyer’s non-volatile memory and will remain until overwritten by a new entry. Note: An alternate method to access the Flyer 3D tab is to right-click the Mark button. In addition to Object Name, the Flyer 3D tab provides other head-related setup and status properties including firmware version, IP addresses, clearing mark, tracking parameters, and Stand-alone settings. Ethernet configuration Changing Flyer 3D’s IP address You can change Flyer’s Ethernet IP address as required to conform to your facilities network numbering convention. To change Flyer’s factory-default IP address, perform the following steps: Important Note: We do not recommend using Dynamic Host Configuration Protocol (DHCP) with Flyer marking heads. Under the DHCP scheme, Flyer’s IP address and DNS name will change each time the head is turned off for a time period that exceeds the DHCP lease. By default, Flyer’s Use DHCP property is set to No at the factory. Note: The following procedure may require the assistance of your IT Department to ensure Flyer’s Ethernet settings are unique and not in use by another device on your facility’s network. 1 Establish a connection between the Flyer marking head and the WinMark computer as described in the Connecting section. 2 Open WinMark Pro and go to the Flyer 3D tab under Tools/General Settings… . 3 Scroll down the Flyer 3D tab and enter values for the following properties: Ethernet IP Address or Host Name IP Netmask IP Gateway If you are required to use DHCP, then set the Use DHCP property to Yes. When DHCP is enabled, Flyer automatically queries your DHCP server for a valid IP address and other network parameters. 4 Click OK to apply the new settings and then remove power from the Flyer head. 5 If necessary, reset your computer to its original Ethernet/local network configuration. 6 Disconnect the Ethernet crossover cable from Flyer and connect the Ethernet cable required by the local network—straight-through or crossover—as determined by your IT department. 7 Reapply DC power to Flyer and wait approximately 20 seconds for the head to boot-up. 8 Open WinMark Pro and perform either Step A or Step B: a When the Device Simulation dialog opens, click “Enter IP Address for Flyer Head” and type the value you entered for Ethernet IP Address or Host Name. Click OK. b If WinMark Pro launches, go to the Devices menu and select Connect to Ethernet Flyer. In the Select Ethernet Flyer IP Address dialog, type the value you entered for Ethernet IP Address or Host Name and then click OK. Synrad Pulstar p100/Flyer 3D installation guide 33 Initial configuration and start-up Ethernet security configuration WinMark allows you to restrict the range of IP addresses that connect with Flyer marking heads. If there are no restrictions, Flyer head’s will connect to any Ethernet address. Entering one or more IP address ranges (up to ten) allows Flyer to communicate only to devices within those ranges and prevents all other connections. To setup Ethernet security, refer to Figure 12 and perform the following steps: Figure 12 Flyer IP Address Ranges dialog 1 In WinMark Pro under the Tools menu, click Flyer IP Address Range. 2 Enter your user password. The default factory password is “pass” (without the quotes). 3 Once the Flyer IP Address Ranges dialog opens, enter a range of authorized IP addresses. The beginning IP address should be “less than” the ending IP address. For example, 190.160.90.100 is considered less than 190.160.100.100. To allow access by only a single IP address, set the beginning IP address equal to the ending IP address. Clear a range of addresses by entering 0.0.0.0 for both beginning and ending addresses. 4 To enable the Ethernet security feature, click the “On” button in the IP Address Security section. 5 If you wish to change the Ethernet Security Password from the factory default, enter a new case-sensitive password. 6 Click OK when done with changes. 34 Synrad Pulstar p100/Flyer 3D installation guide Initial configuration and start-up Mark field configuration Software configuration Because the Flyer 3D system is configured at the factory with a fixed mark field, no software setup is required. The Working Distance property (on the Tools/General Settings… /Flyer 3D tab) is preset to match the field size specified when the system was ordered. Field Width and Field Height values are readonly properties that reflect the fixed mark field dimensions. Important Note: Flyer 3D is driven by advanced algorithms that compensate for barrel and pin-cushion effects common to three-axis heads. This unique design eliminates the need for correction tables and user calibration to achieve accurate large-area flat-field marks. Hardware set-up 1 Place the material or part to be marked (a sheet of anodized aluminum is ideal) on your marking surface centered underneath Flyer 3D’s output aperture. 2 Consult the Final Test Report shipped with your Flyer 3D head (or in WinMark Pro, look on the Tools/General Settings… /Flyer 3D tab) and locate the Working Distance value. 3 Use a ruler marked in millimeters or a precision distance gauge to set the working distance from the bottom surface of the Flyer 3D head to the mark surface as shown in Figure 13. Important Note: Do not allow any measuring device or object to contact the protective window! Scratches or pits may damage the optical surface enough to affect mark quality. Tip: Create a distance gauge (from an acrylic, wood, or aluminum rod), by precisely measuring and cutting the rod to the working distance length specified on the head’s Final Test Report. Distance Gauge (user supplied) Part Surface Figure 13 Working distance measurement Synrad Pulstar p100/Flyer 3D installation guide 35 Initial configuration and start-up Test firing (WinMark control mode) Verify Flyer 3D/WinMark Pro communication 1 Open WinMark Pro and verify the Mark button displays the name of the Flyer 3D head you are operating (see Figure 14). WinMark Pro “Mark” Button Figure 14 WinMark Pro’s Mark button The head name is grayed out if Flyer 3D is disconnected or unavailable. If this occurs, see the Maintenance/Troubleshooting chapter in the Flyer 3D Operator’s Manual for possible causes. Diode pointer operation The Flyer 3D marking head includes a built-in visible diode pointer that is useful for locating the center of the mark field or “tracing” the mark on the part surface prior to actual lasing. 1 To trace a mark, add mark objects to a blank Drawing Canvas or open an existing .mkh mark file. For convenience, open FactoryTestMark1.mkh located in the C:\Program Files\WinMark folder 2 Click the Diode Pointer button (Figure 15), or select Diode Pointer from the File menu. The diode pointer turns on, and automatically moves to the center of the mark field, and the Synrad WinMark (Launcher) dialog opens. When the diode pointer is activated, the Diode Pointer button appears depressed as seen in Figure 15. Because laser marking is disabled, the red laser starburst icon does not appear on the Mark button. Diode Pointer Button Figure 15 Diode pointer On/Off button 36 Synrad Pulstar p100/Flyer 3D installation guide Initial configuration and start-up Important Note: Lasing cannot occur while the diode pointer is activated. 3 Press F1 or click the Start-F1 button. The visible diode pointer beam will trace the mark path including off-vector (laser off) moves. When complete, the visible beam remains at its last commanded position, it does not return to center. If you opened the factory test mark file, the visible beam will trace the path shown in Figure 16. Figure 16 Factory Test Mark pattern 4 Click the Diode Pointer button, or select Diode Pointer from the File menu, to turn the diode pointer off and enable lasing. Lase a mark 1 Place the material or part to be marked in position on the marking surface at the proper working distance. 2 Check that a beam block (an anodized aluminum plate is ideal) is in place to prevent the laser beam from traveling beyond the work area. The beam block should be slightly larger than the mark field. Note: Flyer 3D’s mark field (the WinMark Pro Drawing Canvas as seen in Figure 1) is oriented in a horizontal (landscape) view, not a vertical (portrait) view. 3 In WinMark Pro, create a new mark file, open an existing .mkh file, or use the “FactoryTestMark1. mkh” file. Important Note: 4 Default settings for the test mark file include a power level determined by the 50% duty cycle of your laser and a mark speed of 40 inches per second. To prevent overburning, you should adjust these settings as required depending on your laser’s output power and marking substrate. Check that all safety precautions discussed earlier such as safety glasses for personnel and shielding around the beam area are in place. Synrad Pulstar p100/Flyer 3D installation guide 37 Initial configuration and start-up Warning serious personal injury 5 Pressing the F1 function key on the computer keyboard causes WinMark Pro to mark immediately without opening the Launcher dialog! When using WinMark Pro, the F1 key is designated as a “quick mark” key meaning that the mark is lased immediately. To prevent injury, always ensure that all personnel in the area are wearing the appropriate protective eyewear and are physically clear of the mark area before beginning a mark session. Click the Mark button, or select Mark from the File menu. After the Synrad WinMark (Launcher) dialog opens, click the Start-F1 button to begin marking. The Lase Indicator on the Flyer 3D head becomes brighter as PWM Command signals are sent to the laser during marking. If the Flyer 3D head fails to mark properly, refer to the Maintenance/Troubleshooting chapter in the Flyer 3D Operator’s Manual for possible causes. If the Pulstar p100 laser fails to lase, refer to the Maintenance/Troubleshooting chapter in the Pulstar OEM p100 Operator’s Manual for troubleshooting information. Note: When the optical scanners are activated on boot up, they are automatically positioned in the center of the mark field. After any marking is performed, the scan mirrors remain at the end of mark location; they do not return to the center point of the mark field. 6 To power down the marking system, save any open mark files, close WinMark Pro, shut off AC power to the PS-48 DC power supply, and then shut off the chiller or otherwise stop coolant flow through the laser. Caution possible equipment damage Do not flow coolant through the laser for an extended period of time when the laser is shutdown. This causes condensation to form inside the laser that may result in catastrophic damage to internal optics and electronic circuits. Marking operation Marking operation is the same as with previous Flyer marking heads. Open existing WinMark Pro .mkh mark files or create new mark files. The polylines comprising each mark object are marked in the plane of the Drawing Canvas at the specified working distance. Important Note: 38 Backup existing mark files before opening them in WinMark Pro v7. If an existing file is inadvertently saved in the latest v7 build format, it cannot be opened by earlier WinMark builds. Synrad Pulstar p100/Flyer 3D installation guide Initial configuration and start-up Determine the operating method 1 To operate Flyer 3D using a method other than WinMark control, refer to the following sources of information in the Flyer 3D Operator’s Manual on Flyer 3D’s many control methods: Chapter 3, Stand-alone operation, to setup stand-alone control or access a network share. Chapter 4, Technical reference, to use hard-wired I/O between Flyer and your automation controller. Appendix C, Master Control File, for information on creating a Master Control File scheme. Appendix D, Tracking, to set-up Flyer 3D’s tracking (on-the-fly part marking) function. Also see WinMark Pro Application Note # 5 for information on controlling Flyer 3D via Ethernet MODBUS® TCP/IP. Open/create a mark file 1 Open an existing WinMark Pro .mkh mark file or create a new drawing and set drawing/object automation, marking, and format parameters to suit your needs. Tip: When using file automation, test the file under WinMark control first before running in Stand-alone mode or with a .NET application. Begin marking 1 Place the material or part to be marked in position on the marking surface at the proper working distance. 2 Check that a beam block (an anodized aluminum plate is ideal) is in place to prevent the laser beam from traveling beyond the work area. The beam block should be slightly larger than the mark field. Danger serious personal injury This product is designed to emit invisible infrared laser radiation from a Class 4 laser in the 10.6 µm CO2 wavelength band. This product emits visible laser radiation from a Class 3R laser in the 630–680 nm wavelength band. Since direct or diffuse laser radiation can inflict severe corneal injuries, always wear eye protection when in the same area as an exposed laser beam. Do not allow the laser beam to contact a person. CO2 lasers emit an invisible beam that is capable of seriously burning human tissue. Always be aware of the beam path and always use a beam block while testing or operating this product. Synrad Pulstar p100/Flyer 3D installation guide 39 Initial configuration and start-up 3 Ensure that all safety precautions discussed earlier such as safety glasses for personnel and shielding around the beam area are in place. 4 Start up the laser and marking head as described earlier. 5 Verify that Flyer 3D is configured for the desired operating method—WinMark control mode, Standalone control mode, or automation mode. 6 Enable marking. This step will vary depending on the control method you are using. In WinMark control mode, click the Mark button, or select Mark from the File menu. After the Synrad WinMark (Launcher) dialog opens, click the Start-F1 button to begin marking. Warning serious personal injury 40 Pressing the F1 function key on the computer keyboard causes WinMark Pro to mark immediately without opening the Launcher dialog! When using WinMark Pro, the F1 key is designated as a “quick mark” key meaning that the mark is lased immediately. To prevent injury, always ensure that all personnel in the area are wearing the appropriate protective eyewear and are physically clear of the mark area before beginning a mark session. Synrad Pulstar p100/Flyer 3D installation guide