Contour Trac™ with Ultrasense™ · 2017-04-19 · PLMNL0247 REV. A Effective Date: 12/21/16 1 Contour Trac™ with Ultrasense™ Operation Manual 1 Introduction The Contour Trac™

Contour Trac™

with Ultrasense™

PLBDS1136 Operation Manual

PLMNL0247 REV. A Effective Date: 12/21/16 i Contour Trac™ with Ultrasense™ Operation Manual

WARNING

WORKING AROUND HIGH-POWERED LASERS CAN BE DANGEROUS

Laser Mechanisms, Inc.’s cutting heads must be operated with the cutting head interlock switch connected. The switch must be CLOSED when the head is properly attached. In the event of a crash and the cutting head becoming dislodged from its normal operating position, the switch must be OPEN. This interlock switch must be connected in a circuit in such a way that it will immediately turn off the laser and stop all machine motion. Check the wiring diagrams for your system.

Serious personal injury and/or equipment damage can occur if the head becomes dislodged and:

The head interlock is not connected properly.

Any interlock in the Laser Mechanisms’ product or laser system is defeated.

Laser Mechanisms, Inc. assumes no responsibility or liability for interlock switches or circuits and all interlocks are the sole responsibility of the purchaser of this head.

It is the responsibility of the integrator or end user to install, connect and activate all interlocks in compliance with the applicable ANSI, CEN, DIN, etc. standard.

All wiring should be done by personnel knowledgeable in electrical wiring and in accordance with the national and local electrical codes.

DISCLAIMER

The information in this manual is subject to change without notice.

Laser Mechanisms, Inc. makes no warranty of any kind with regard to the material in this manual, including but not limited to, the warranties or merchantability and fitness for a particular purpose.

Laser Mechanisms, Inc. shall not be liable for errors contained herein or for incidental or consequential damages in connection with furnishing, performance or use of this product.

Laser Mech® is a registered trademark of Laser Mechanisms, Inc.

Corporate names and trademarks stated herein are the property of their respective companies.

COPYRIGHT

©2016 Laser Mechanisms, Inc. All rights reserved. No part of this publication may be reproduced in any form, or by any means without the prior written permission of Laser Mechanisms, Inc.

PRODUCT WARRANTY

Laser Mechanisms, Inc. warrants this product against defects in material and workmanship for a period of one year from the date of shipment from Laser Mechanisms Inc. or an authorized distributor. During the warranty period, Laser Mechanisms, Inc. will at its option, repair or replace products that prove to be defective.

For all products returned to Laser Mechanisms, Inc. for warranty service the customer must:

Call Laser Mechanisms, Inc. for a Return Material Authorization (RMA) number.

Properly pack the product with the RMA number on the outside of the package. Include in the package, all cables, and all accessories shipped with the product along with a description of the problem.

Prepay shipping charges to Laser Mechanisms, Inc.

Insure the shipment in case of loss or damage. Laser Mechanisms, Inc. will not accept any liability in case of damage or loss.

Laser Mechanisms, Inc. will pay the shipping charges, duties and taxes for the products returned to Laser Mechanisms, Inc. from outside the United States.

The foregoing warranty will not apply if damage is incurred resulting from improper or inadequate maintenance by the customer, unauthorized modifications or misuse, operation of the product outside its specifications, interlocks not connected properly, improper site preparation, parts or assemblies not supplied by Laser Mechanisms, Inc. or unauthorized repair by non-Laser Mechanisms, Inc. authorized personnel.

For complete warranty information visit our web site at www.lasermech.com.

PLMNL0247 REV. A Effective Date: 12/21/16 ii Contour Trac™ with Ultrasense™ Operation Manual

INITIAL INSPECTION

Inspect all shipping containers for damage as soon as the device arrives. It is your responsibility, the recipient, to notify the freight company of any damage. The freight company will require you to provide the container that any goods were shipped in, all shipping documentation and a list of all damages. Photographs of the damage are helpful in settling a freight claim.

Do not return damaged goods to the factory without a Return Material Authorization Number (RMA number).

Although it is Laser Mechanisms, Inc.’s intent to insure you are up and running as soon as possible, damage incurred during shipment must be settled with the freight company before arranging for repairs or replacement. No return shipments will be accepted without an RMA number clearly printed on the outside of all shipping containers. Failure to follow this procedure could void any warranty coverage on your head. Call your sales engineer at Laser Mechanisms, Inc. for a RMA number.

Carefully remove the device from its shipping container and all packing material to avoid damage. Save all packaging material, including hole plugs and caps, in the event the head requires shipping or storage.

Check all items received against the packing list to verify that all the items were received.

Please note the product you receive may differ slightly from the illustrations in this manual. While the drawings may differ, the basic procedures described within remain the same.

TERMS USED IN THIS MANUAL

WARNING: The user could be injured if the warning is not followed.

CAUTION: The device or system could be damaged if the CAUTION is not followed.

NOTE: Clarification of a step or steps.

SAFETY

WARNINGS: Follow all warnings in this manual.

SAFETY GLASSES: Everyone in the area where the laser is being used must wear laser safety glasses designed for the laser being used.

SECONDARY REFLECTIONS: Secondary reflections are dangerous; never expose any part of your body to a reflected laser beam.

INTERLOCKS: Interlocks are safety devices and should never be defeated.

ADJUSTMENTS: Always turn off or put the laser in standby before making any adjustments to beam delivery components.

BEAM DUCT: Never open any component of the beam duct while the laser is operating. Always turn the laser off before servicing any beam duct components.

MANUALS: Always read the instruction manuals before attempting to install or make adjustments to any beam delivery component.

PLMNL0247 REV. A Effective Date: 12/21/16 iii Contour Trac™ with Ultrasense™ Operation Manual

TABLE OF CONTENTS

1 Introduction ........................................................................................................................................................1

2 Mechanical Installation ......................................................................................................................................3 2.1 Mounting the Beam Input .................................................................................................................... 3

2.2 Mounting the Cutting Head ................................................................................................................. 3

2.3 Plumbing – Purge Gas and Assist Gas .............................................................................................. 4

2.4 Aligning the Beam at the First Beam Bender Assembly ..................................................................... 4

2.5 Aligning the Beam at the Second Beam Bender Assembly ............................................................... 6

2.6 Aligning the Beam at the Third Beam Bender Assembly.................................................................... 9

2.7 Aligning the Beam Through the Head............................................................................................... 13

2.8 Aligning the Beam Through the Tip Retainer Assembly ................................................................... 15

2.9 Aligning the Beam Through the Gas Jet Tip ..................................................................................... 17

2.10 Locating the Gas Jet Tip ................................................................................................................... 19

2.10.1 Setting the Angle for Operation ..................................................................................... 19

2.10.2 Fine Tuning the Angle for Operation ............................................................................. 20

2.10.3 Setting Focus Position................................................................................................... 20

3 Electrical Installation and Operation ............................................................................................................. 22 3.1 Electrical Wiring ................................................................................................................................ 22

3.2 Electrical Grounding and Noise ........................................................................................................ 23

3.3 Customer Interface ........................................................................................................................... 23

3.4 Power ................................................................................................................................................ 24

3.4.1 Motor Bus (+/-) .............................................................................................................. 24

3.4.2 Ethernet Interface .......................................................................................................... 24

3.5 Digital Inputs ..................................................................................................................................... 25

3.5.1 Height Select Bits (HSB1 – HSB3) ................................................................................ 25

3.5.2 Motion Inhibit (HOLD).................................................................................................... 25

3.5.3 Reset ............................................................................................................................. 25

3.5.4 Programmable Home Position ...................................................................................... 25

3.5.5 Amp Enable / Servo Disable ......................................................................................... 26

3.5.6 Input Common (IN-COM) .............................................................................................. 26

3.5.7 Calibrate ........................................................................................................................ 26

3.6 Analog Inputs .................................................................................................................................... 27

3.7 Digital Outputs .................................................................................................................................. 27

3.7.1 In-Position (IN-POS) ...................................................................................................... 27

PLMNL0247 REV. A Effective Date: 12/21/16 iv Contour Trac™ with Ultrasense™ Operation Manual

3.7.2 Tip Touch (TIP-TOUCH) ............................................................................................... 27

3.7.3 Crash/Fault (CRASH) .................................................................................................... 27

3.7.4 Retract Limit (RETRACT LIMIT) ................................................................................... 27

3.7.5 Extend Limit (EXTEND LIMIT) ...................................................................................... 27

3.7.6 Output Common (OUT-COM) ....................................................................................... 27

3.7.7 Crash Interlock Relay (INT1, INT2) ............................................................................... 27

3.8 Analog Outputs ................................................................................................................................. 27

3.9 Ethernet I/P Interface ........................................................................................................................ 28

3.10 Operation .......................................................................................................................................... 28

3.10.1 Power Up/Initialization ................................................................................................... 28

3.10.2 Calibration Sequence Timing Diagram ......................................................................... 28

3.10.3 Example of Cut Sequence Timing Diagram .................................................................. 29

4 Contour Trac™ Monitor .................................................................................................................................. 30 4.1 System Requirements ...................................................................................................................... 30

4.2 Installation ......................................................................................................................................... 30

4.3 Connecting ........................................................................................................................................ 31

4.4 Manage Connections ........................................................................................................................ 31

4.4.1 Add an Address ............................................................................................................. 32

4.4.2 Modify an Address ......................................................................................................... 32

4.4.3 Reassign an Address .................................................................................................... 32

4.4.4 Rearrange Addresses ................................................................................................... 32

4.5 Position Display ................................................................................................................................ 32

4.6 Home Position ................................................................................................................................... 32

4.7 Stand Off Voltage Display ................................................................................................................. 32

4.8 Inputs ................................................................................................................................................ 33

4.9 Outputs ............................................................................................................................................. 33

4.10 Status Display / Fault History ............................................................................................................ 33

4.11 Contour Trac™ Monitor Settings ...................................................................................................... 33

4.11.1 Unlock Settings ............................................................................................................. 33

4.11.2 Gain ............................................................................................................................... 34

4.11.3 Retract ........................................................................................................................... 34

4.11.4 Service .......................................................................................................................... 35

4.11.5 Simulated Inputs ............................................................................................................ 35

4.11.6 Stand Off Voltages ........................................................................................................ 35

4.12 Contour Trac™ Monitor System Identification Information ............................................................... 36

PLMNL0247 REV. A Effective Date: 12/21/16 v Contour Trac™ with Ultrasense™ Operation Manual

5 Service.............................................................................................................................................................. 37 5.1 Replacing the Gas Jet Tip ................................................................................................................ 37

5.2 Servicing the Lens Holder ................................................................................................................. 37

5.3 Optic Cleaning .................................................................................................................................. 38

5.4 Servicing the Lens ............................................................................................................................ 39

5.5 Servicing the Lens Seal .................................................................................................................... 40

5.6 Remounting the Head After Separation ............................................................................................ 41

5.7 Crash Protection Device Interlock Switches ..................................................................................... 42

5.7.1 Crash Protector Device Interlock Switch Removal and Replacement .......................... 42

5.7.2 Adjusting the Crash Protector Device Interlock Switches ............................................. 42

5.7.3 Wiring the Crash Protector Device Interlock Switches .................................................. 44

5.8 Servicing the Large (2 Inch) Mirrors ................................................................................................. 44

5.9 Servicing the Small (1.1 Inch) Mirror ................................................................................................ 45

6 Specifications .................................................................................................................................................. 47

7 Troubleshooting .............................................................................................................................................. 48

8 Appendix A – Coolant Specifications ........................................................................................................... 49

9 Appendix B – Beam Delivery Purging ........................................................................................................... 49

10 Appendix C – Assist Gas Specifications ...................................................................................................... 49

11 Appendix D – Recommended User-Serviceable Parts List ........................................................................ 50

PLMNL0247 REV. A Effective Date: 12/21/16 1 Contour Trac™ with Ultrasense™ Operation Manual

1 Introduction

The Contour Trac™ line of surface follower cutting solutions provides a complete system from the laser output to the work surface.

The systems are customized, as needed, to fit each customer's needs.

Contour Trac™ can be configured to work with any wavelength laser.

At the heart of the system is a motorized Z-slide and control interface.

The slide is protected from vertical crashes by utilizing a type of slip mechanism.

Contour Trac™ is made up of (5) main assemblies (see Figure 1):

1. Beam Delivery

2. Slide and controller

3. Crash Protector

4. Cutting Head

5. Height Sensing Unit (HSU) with Ultrasense™

1. Beam delivery

The beam delivery portion of the system connects the laser to the slide and controller. Typically, it consists of a series of customized path enclosure tubes and beam benders.

In fiber delivered applications, the collimator and fiber input are usually mounted directly to the slide and controller.

Laser Mechanisms will supply each customer with an overall configuration drawing to show the beam delivery (e.g. PLBDSxxxx).

Since each system can be unique, addition manuals may be required.

Figure 1


2. Slide and controller

The slide and controller are two assemblies in one.

o The slide houses the drive motor and pulleys, slide mechanisms, position sensor, and limit switches.

o The drive system has 127mm of travel.

o The linear slide is equipped with "slip" capability in case of Z-axis crashes.

o The slide motor has a holding brake.

o The controller is a servo motor controller that has multiple feedback inputs:

Absolute slide position

Height sensor feedback

A user configurable input for custom sensors.

o The controller is connected using either discrete I/O, or EtherNet I/P.

o There is an Ethernet interface to PC.

o Contour Trac™ Monitor software is provided for:

Manual control

User preferences

Diagnostics.

3. Crash protector

The crash protector is a magnetically coupled device to protect the motion system from damage when a collision occurs.

It is easily resettable. Often, it can be reseated and processing can resume without realignment of tip centering.

4. Cutting head

The cutting head is made up of a number of configurable components, including

o The tip retainer assembly

o The focusing lens

o The cover glass (where applicable).

The tip threads into the end of the tip retainer and controls gas flow to the work piece.

The tip retainer assembly also provides the electrical feedback to maintain a constant gap between the tip and part.

The tip retainer assembly comes in various focal lengths and configurations, allowing the end user to optimize the cutting head configuration.

5. HSU (Height Sense Unit) with Ultrasense™

The Height Sensor Unit (HSU) provides the electrical feedback information to accurately control the distance between the tip and the work piece.

The sensor is mainly configured to work on conductive materials, but some non-conductive material can be sensed too. Contact Laser Mechanisms for more information.

Ultrasense™ is an option for the Laser Mech® HSU used to sense non-conductive materials. It is a special mode and materials must be verified with Laser Mech® prior to using this option.


2 Mechanical Installation

2.1 Mounting the Beam Input

The beam delivery system is attached to the beam source using an adapter plate and (3) 1/4-20 SHCS. See Figure 2.

Figure 2

2.2 Mounting the Cutting Head

The beam delivery system is attached to the cutting head source using an adapter plate and the 2-1/4 – 20 thread at the bottom of the vertical slide. See Figure 3.

See Laser Mechanisms’ manual (PLMNL0246) on the motor driven slide for more details on the vertical slide.

Figure 3

To mount the adapter plate (along with any other components that lead to the cutting head) to the motor driven slide:

1. Loosen, but do not remove the 1/4-28 SHSS in the adapter plate.

2. Thread the adapter ring up onto the vertical side to the desired position.

3. Tighten the 1/4-28 SHSS to lock the position of the adapter plate (along with any other components that lead to the cutting head).


2.3 Plumbing – Purge Gas and Assist Gas

There are (2) purge gas connections and (1) assist gas connection. See Figure 4 for the locations.

The purge gas ports are located

1. Near the beam input.

2. Just above the lower beam bender assembly.

The flow rate is >50 SCFH (>1.4 l/min).

The maximum pressure is 3 psi (0.2 Bar).

The purge gas must be high purity nitrogen. See Appendix A for more information.

3. The assist gas port is located just before the tip retainer assembly.

The maximum pressure is 100.0 psi (6.9 Bar).

See Appendix B for more information.

Figure 4

2.4 Aligning the Beam at the First Beam Bender Assembly

For steps 1 to 5, see Figure 5.

1. Remove the adjustable mirror holder from the second beam bender assembly.

To remove the adjustable mirror holder, see steps 2 to 5:

2. Using a 1/8-inch hex wrench turn one of the spring loaded captive shoulder bolts three turns counterclockwise.

3. Turn the next spring loaded captive shoulder bolt three turns counterclockwise.

4. Turn the remaining spring loaded captive shoulder bolt three turns counterclockwise.

5. Repeat this sequence of turning each spring loaded captive shoulder bolt three turns counterclockwise until the adjustable mirror holder can be removed.

Figure 5


6. Insert the alignment target (PLBBT0004) into the input aperture of the beam bender with the O-ring end in first. See Figure 6.

It may be necessary to lubricate the O-rings with a very light film of Parker Super O-LUBE® Laser Mechanisms part number PLLUB0002.

To aid the alignment procedure, rotate the target so that one of the crosshairs is parallel to the base of the beam bender.

Figure 6

Verify that everyone in the area is wearing laser safety glasses designed for the wave length of the laser being used before continuing. This alignment procedure produces smoke. An exhaust fan is recommended to keep the smoke away from the operator and the optical components.


7. Set up a nonflammable, nonreflecting beam stop such as a fire brick as close as possible, approximately 152 mm (6 inches) from the beam output is a good goal.

8. Determine which is the coated side of the thermal card (PLBRN0001).

Scratch, but do not rip, a small portion of the card, near the edge. You can use your fingernail.

o If the scratch leaves a black mark, that side is the coated one.

o It the scratch leaves an indentation, but not a black mark; the other side is the coated one.

9. Tape a thermal image card to the beam stop.

Orient the thermal card vertically with the coated side facing toward you.


The laser beam should be on long enough to make a burn spot the full diameter of the raw beam, but not long enough to set the target on fire.

10. Fire a single shot.


Figure 7

11. Examine the burn spot on the thermal image card.

The burn spot should be centered on the crosshairs.

If the burn spot is centered on the crosshairs, proceed to Section 2.7.

If the burn spot is NOT centered on the crosshairs, align the beam according to the laser manufacturer’s instructions.

Then repeat steps 8 to 11 to verify the burn is centered on the crosshairs.

12. Remove the beam bender target (PLBBT0004) from the first beam bender assembly. See Figure 6.

Two 8-32 screws can be installed in the tapped holes of the target to aid removal.

13. Replace the adjustable mirror holder. See the steps 14 to 19 and Figure 5.

14. Align the adjustable mirror holder so that the (3) spring loaded captive shoulder bolts are in-line with the (3) 10-24 tapped holes in the face of the second beam bender assembly at a 45° angle.

15. Using a 1/8-inch hex wrench turn one of the spring loaded captive shoulder bolts three turns clockwise.

16. Turn the next spring loaded captive shoulder bolt three turns clockwise.

17. Turn the remaining spring loaded captive shoulder bolt three turns clockwise.

18. Repeat this sequence of turning each spring loaded shoulder bolt three turns clockwise until the bolts are bottomed out and the adjustable mirror holder is replaced securely.

19. Back each of the spring loaded captive shoulder bolt out one turn (counterclockwise) to allow the adjustable mirror holder to tilt when using the adjuster screws.

2.5 Aligning the Beam at the Second Beam Bender Assembly


1. Remove the adjustable mirror holder from the second beam bender assembly.







Figure 8

6. Insert the alignment target (PLBBT0004) into the input aperture of the beam bender with the O-ring end in first. See Figure 9.



Figure 9














Figure 10



If the burn spot is centered on the crosshairs, proceed to Section 2.8.

If the burn spot is NOT centered on the crosshairs, proceed to step 12.

12. Use the adjustment screws on the first beam bender assembly to align the beam in the second beam bender assembly and center the beam in the crosshairs. See Figure 11.

Figure 11

13. After adjustments have been made, repeat steps 8 to 12 in this section until the burn is centered in the crosshairs.

14. Remove the beam bender target (PLBBT0004) from the second beam bender assembly.



15. Replace the adjustable mirror holder. See the steps 16 to 21 and Figure 8.

16. Align the adjustable mirror holder so that the (3) spring loaded captive shoulder bolts are in-line with the (3) 10-24 tapped holes in the face of the second beam bender assembly at a 45° angle.






2.6 Aligning the Beam at the Third Beam Bender Assembly


1. Remove the adjustable mirror holder from the third beam bender assembly.






Figure 12


6. Insert the alignment target

(PLBBT0004) into the input aperture of the beam bender with the O-ring end in first. See Figure 13.



Figure 13


7. Move the beam delivery system so it is in the fully retracted position.

The motor driven slide will be at the top of travel.












Figure 14



If the burn spot is centered on the crosshairs, proceed to step 15.

If the burn spot is NOT centered on the crosshairs, proceed to step 13:

13. Use the adjustment screws on the first beam bender assembly to align the beam position and center the beam in the cross hairs. See Figure 15.

Figure 15

14. After the adjustments have been made, repeat steps 8 to 13 in this section until the spot is centered.

15. Move the beam delivery system so it is in the fully extended position.

The motor driven slide will be at the bottom of travel.

16. Repeat steps 8 to 12.





17. Use the adjustment screws on the second beam bender assembly to align the beam angle and center the beam in the cross hairs. See Figure 16.

Figure 16


19. Remove the beam bender target (PLBBT0004) from the third beam bender assembly.


20. Replace the adjustable mirror holder.

See the steps 21 to 26 and Figure 12.

21. Align the adjustable mirror holder so that the (3) spring loaded captive shoulder bolts are in-line with the (3) 10-24 tapped holes in the face of the third beam bender assembly at a 45° angle.







2.7 Aligning the Beam Through the Head

1. Turn off the purge and assist gas.


2. Unthread and remove the tip retainer nut.

The adapter plate, fourth beam bender assembly and tip retainer assembly (PLTRA0458) will be removed too.

3. Unthread and remove the adjustable lens holder retainer nut.

4. Pull the adjustable lens holder (PLALH0115) straight out of the slot in the lens manifold block.

Figure 17

5. Thread the alignment target

(PLMAT0010) into the gas jet manifold. See Figure 18.

Figure 18













Figure 19






11. Use the adjustment screws on the third beam bender assembly to align the beam position and center the beam in the cross hairs. See Figure 20.

Figure 20



For steps 13 and 14, see Figure 17.

13. Push the adjustable lens holder (PLALH0115) straight into the slot in the lens manifold block.

14. Thread the adjustable lens holder retainer nut into the gas jet manifold.

15. Repeat steps 6 to 10, see Figure 19.





17. Use the adjustment screws on the lens manifold block to align the beam position and center the beam in the cross hairs. See Figure 21.

Figure 21

18. After the adjustments have been

made, repeat steps 16 and 17 in this section until the spot is centered.

19. Unthread and remove the alignment target (PLMAT0010) from the gas jet manifold. See Figure 18.


20. Place the tip retainer nut so it is centered over the gas jet manifold.

The 1.5-12 female thread in the tip retainer nut faces the 1.5-12 male thread on the gas jet manifold.

21. Thread the adapter block – along with the tip retainer nut, fourth beam bender assembly and tip retainer assembly (PLTRA0458) – onto the gas jet manifold.

22. Thread the tip retainer nut onto the gas jet manifold.

2.8 Aligning the Beam Through the Tip Retainer Assembly



2. If necessary, unthread and remove the tip transformer wire.

3. Unthread and remove the tip retainer assembly (PLTRA0458).

Figure 22


4. Thread the alignment target

(PLSAT0023) into the adapter plate. See Figure 23.

Figure 23












Figure 24






If the burn spot is NOT centered on the crosshairs, proceed to step 10.

10. Use a 0.050-inch hex wrench to adjust the screws inside the fourth beam bender assembly to align the beam position and center the beam in the cross hairs. See Figure 25.

The set screws must be moved one at a time. So, there is a back and forth pattern to the mirror adjustment.

Figure 25


12. Unthread and remove the alignment target (PLSAT0023) from the adapter plate. See Figure 23.

13. Thread the tip retainer assembly (PLTRA0458) into the adapter plate. See Figure 22.

2.9 Aligning the Beam Through the Gas Jet Tip



2. Press a piece of translucent tape, or equivalent, over the opening of the gas jet tip.

Press the tape so the impression of the opening is visible.

NEVER PLACE YOUR FINGER OVER THE BEAM EXIT HOLE. USE A TOOL OR A SCREW DRIVER HANDLE TO MAKE THE IMPRESSION ON THE TAPE.

3. Use a marker to put a dot on the tape to reference the front of the head.

Figure 26


BEFORE CONTINUING, VERIFY EVERYONE IN THE AREA IS WEARING LASER SAFETY GLASSES DESIGNED FOR THE WAVE LENGTH OF THE LASER BEING USED.












Figure 27

8. Remove the tape and observe the small hole in the impression of the gas jet tip opening.

If there is no hole, repeat steps 4 to 7 with an increased power setting.

If the hole is centered in the impression, then the beam is centered in the gas jet tip.

If the hole is not centered in the impression, proceed to step 9.


9. Use a 0.050-inch hex wrench to adjust the screws inside the fourth beam bender assembly to align the beam position and center the beam in the cross hairs. See Figure 28.

The set screws must be moved one at a time. So, there is a back and forth pattern to the mirror adjustment.

Figure 28


11. Remove any tape residue.

2.10 Locating the Gas Jet Tip

The gas jet tip orientation is customizable. There are (2) angle controls and (1) position control. So, the gas jet tip can be rotated to any desired orientation.

2.10.1 Setting the Angle for Operation

See Figure 29.

1. Rotate the locking handle up 90°.

2. Turn the swivel center plate to the desired angle.

All of the components from the swivel center plate to the tip retainer assembly will rotate.

3. Turn the locking handle down 90°.

Figure 29


2.10.2 Fine Tuning the Angle for

Operation

See Figure 30.

1. Turn the tip retainer nut slightly counterclockwise until the fourth beam bender assembly and tip retainer assembly rotate freely.

2. Rotate the fourth beam bender assembly, tip retainer assembly and tip transformer wire to the desired angle.

3. Turn the tip retainer nut clockwise until the fourth beam bender assembly, tip retainer assembly and tip transformer wire are secure.

Figure 30

2.10.3 Setting Focus Position

Turning the knurled ring of the gas jet manifold will adjust the focus point vertically. See Figure 31.

The focus location adjustment:

o Allows up to 3.2 mm (0.12 inch) of travel above or below the gas jet tip orifice.

o Moves the gas jet manifold, fourth beam bender assembly, tip transformer wire and tip retainer assembly along the axis of the laser beam.

Figure 31

Turn the gas jet manifold ring clockwise to raise the focus location above the gas jet tip orifice.

o The entire tip area assembly will move along the laser path axis.


Turn the gas jet manifold ring counterclockwise to lower the focus location toward or below the gas jet tip orifice.

The focus location is marked on the gas jet manifold. See Figure 32.

Figure 32


3 Electrical Installation and Operation

Figure 33

3.1 Electrical Wiring

There can be three electrical wires connected to the cutting head. See Figure 34.

PLCAB0625 is a 3 pin M8 cable for HSU and tip touch signal.

PLCAB0624 is a 4 pin M8 cable for the crash protector.

PLCAB0623 is a 5 pin M8 cable for calibration, communication and power to the HSU.

Figure 34


3.2 Electrical Grounding and Noise

The capacitive sensing circuitry contained in the cutting head measures minute changes in electrical capacitance between the tip and earth-ground to determine tip-to-part stand off distance. In order for the circuit to function properly the part and the cutting head need to be connected to a good earth ground.

Ideally the ground should be established from a ground rod, approximately 2 meters in length driven into the ground located near the base of the laser or machine.

Run a large gauge (1.6mm diameter or larger) ground wire from the ground rod to the part.

Run a separate wire from the ground rod to the mount of the Contour Trac™.

Electrical noise can create sensing issues. Large electric motors, arc welders and other devices may be a source of significant electrical noise. In order to eliminate this noise, it may be necessary to connect a ground wire to the chassis of any such device near the process.

In order to minimize noise when sensing non-conductive materials, some experimentation is typically necessary to find the optimum ground termination.

3.3 Customer Interface

See Chart below and Figure 35.

PIN NAME DESCRIPTION

INPUTS

1 M+ 48 VDC Servo Power/ Motor Bus +

2 M- 48 VDC Servo Power/ Motor Bus – (GND)

3 24 VDC +24 VDC Supply Voltage to Interface

4 0 VDC 0 VDC Supply Voltage to Interface (GND)*

OUTPUTS

5 OUTCOM +V-Sourcing, 0V-Sinking

6 RETRACT

LIMIT Slide Reached Upper Limit

7 EXTEND

LIMIT Slide Reached Lower Limit

8 TOUCH Tip Touch

9 READY System Ready

10 IN POSITION In-Position

11 A OUT+ Configurable Output Voltage/Position Output 12 A OUT-

INPUTS

13 INCOM Input Common

14 CALIBRATE Calibrate HSU

15 AMP

ENABLE Servo Drive Enabled

16 HOLD Motion Inhibit/Hold

17 RESET Reset

18 HSB3 Height Select Bit 3 (MSB)

19 HSB2 Height Select Bit 2

20 HSB1 Height Select Bit 1 (LSB)

21 A IN+ External Sensor Input

22 A IN-

INTERLOCK

23 INT1 Crash Interlock Relay N/O, 60V, .5A Max

24 INT2 Crash Interlock Relay N/O, 60V, .5A Max


Figure 35

3.4 Power

3.4.1 Motor Bus (+/-)

Power to the servo drive is connected by pins 1 and 2 of the customer connector (see Figure 35).

The servo accepts a minimum of 20VDC and a maximum of 80VDC. The voltage required is based on the motor type used inside the slide. The standard configuration is 48VDC.

A linear power supply is recommended for optimum performance.

The motor power requirements vary based on the cutting head and motor configuration.

o The controller is equipped with an 800W servo drive.

o At 48V the current can peak at 16A.

o The standard configuration requires <3A continuously.

Power to the support electronics and customer I/O is connected to pins 3 and 4 of the customer connector (see Figure 35).

o 24VDC/GND at 1A.

3.4.2 Ethernet Interface

The Ethernet port provides a means of interfacing to the Contour Trac™ controller with all of the capabilities of the discrete I/O with the addition of fault descriptions.

Connect the Ethernet port to your motion system using a crossover or null modem Ethernet cable, or to a network hub by a straight through Ethernet cable.

The controller has been assigned the IP Address 169.254.99.133.

Download Laser Mechanisms’ Contour Trac™ Monitor software to communicate with the controller at:

http://www.lasermech.com/contourtracupdates.asp



3.5 Digital Inputs

Specifications: 5 to 24VDC, 10mA at 24V

The inputs are configurable for connection to either sourcing or sinking outputs depending on the connection made to the INCOM.

3.5.1 Height Select Bits (HSB1 – HSB3)

The three discrete height select bits activate seven stand off heights. When all height select bits are off, the head will return to its retracted position.

The • symbol indicates ON.

HSB1 HSB2 HSB3 STAND OFF

HEIGHT

• 0.5mm

• 0.75mm

• • 1.0mm

• 1.25mm

• • 1.5mm

• • 1.75mm

• • • 2.0mm

Head Retracted

*When using Ultrasense™ for nonconductive material, the stand off values can be grossly different than the default parameter set.

Manually enter height values to accurately determine the proper stand off values.

Present the target work piece to the tip assembly at a desired stand off.

In the Settings ContourTrac™ Monitor dropdown menu, select Stand Off Heights.

Enter in the value displayed on the monitor software in the Stand Off Voltage field.

That value corresponds to a HSB location and is persistent.

3.5.2 Motion Inhibit (HOLD)

The HOLD input holds the head at the current position regardless of the measured stand off height.

HOLD is useful when the cutting path must start in a location that is not over the work piece.

HOLD has precedence over HS1, HS2, and HS3.

HOLD is available while in the absolute positioning mode.

3.5.3 Reset

RST allows the head to be reset if an error/crash occurs.

When RST is activated, the head will retract fully and reference itself to the retracted limit switch.

After this step, the head will automatically move to the saved retracted position.

There is no need to maintain RST. Toggle it to activate the recovery routine.

If there is no error and it is active, RST is ignored.

3.5.4 Programmable Home Position

The Contour Trac™ controller has the ability to position the head at an offset retracted position.

The feature is always enabled.

The programmed Home position is set by the Contour Trac™ Monitor software. See Section 4.6 for details.

This value is maintained even if power is reset.


When the head has reached the Home position, the IN-POS output will become active.

This feature can reduce cycle time by minimizing the amount of travel that the head has to move in-between cuts.

3.5.5 Amp Enable / Servo Disable

AMP ENABLE allows activation of the head.

When AMP ENABLE is activated for the first time after power up, the head will automatically perform a homing sequence.

When the AMP ENABLE input is deactivated, the head will stop immediately.

o If the AMP ENABLE has been deactivated, the RESET input will have to be toggled to initiate the homing sequence after the AMP ENABLE input has turned on again.

o It is also necessary to toggle the AMP ENABLE input if a crash fault occurs.

3.5.6 Input Common (IN-COM)

Connect +V to IN-COM when the inputs are connected to sinking (active low) customer outputs.

Connect 0V to IN-COM when connecting to sourcing (active high) customer outputs.

18 – 24 VDC < 10 mA

3.5.7 Calibrate

The Calibrate input is a request for sensor calibration.

The calibration should take place with the tip about 12mm away from a grounded metallic surface at least 100mm in diameter.

The calibration must be performed at power up and preferably every cycle.

o Calibrating at a stand off distance greater than 12mm will result in stand off readings that are slightly less than the optimum level.

o Calibrating at a stand off distance less than 12 mm will result in stand off readings that are slightly more than the optimum level.

It is recommended the tip be calibrated EVERY time the head is in a retracted position.

The calibration procedure takes ~150ms and will ensure proper tip stand off is maintained.

The height sense electronics are designed to operate with dynamic stability control of the nozzle stand off.

To achieve nozzle stand off control:

o Reset the calibration as frequently as possible.

o Reset the calibration before there are any significant changes in any of the environmental conditions.

Nozzle stand off control is stable through varying environmental conditions, such as temperature, humidity and cutting debris deposits.

Dynamic control is more effective than methods that try to passively stabilize the stand off.

Calibration pulse frequency varies with each process and machine. It is very important to recalibrate the head more often than environmental changes occur.


3.6 Analog Inputs

The analog input (differential) AIN+, AIN- allows the user to implement their own feedback sensor to the head.

The input range is 0 to 10 VDC.

See Contour Trac™ Monitor in Section 4 to adjust the target and gain settings.

If analog inputs is selected, the user can select 6 different target values.

o The values will correspond to the HSB bits.

o This input is generally used for special applications.

o Contact Laser Mechanisms® for more information.

3.7 Digital Outputs

Specifications: 5 to 24VDC, 400mA per output

All outputs are configurable for sourcing or sinking depending on the connection made to OUTCOM.

3.7.1 In-Position (IN-POS)

IN-POS indicates that the tip is within range of the selected stand off height/slide position.

Typically, IN-POS provides a handshake back to the motion system that the tip has reached the part and is ready to begin processing.

The IN-POS signal occurs when the head reaches its commanded “At Home Position.”

3.7.2 Tip Touch (TIP-TOUCH)

The TIP-TOUCH signal indicates that the tip has electrically contacted the part or object. This can occur during normal processing and does not produce a fault.

3.7.3 Crash/Fault (CRASH)

CRASH indicates that the head is currently in a crash or fault condition. Check the head and/or cabling for damage.

3.7.4 Retract Limit (RETRACT LIMIT)

This output is active when the head / slide reaches maximum retracted position.

3.7.5 Extend Limit (EXTEND LIMIT)

This output is active when the head / slide reaches maximum extended position.

3.7.6 Output Common (OUT-COM)

Connect +V to OUT-COM for sourcing (active high) outputs

Connect 0V to OUT-COM for sinking (active low) outputs.

3.7.7 Crash Interlock Relay (INT1, INT2)

Solid state relay rating: 400 mA at 0-60 VDC, 0-48 VAC

A solid state relay opens to indicate a fault or crash condition on the cutting head.

This signal should be part of your laser permissive circuit. If this interlock circuit is open, the laser must be unable to fire.

3.8 Analog Outputs

The analog output AOUT+,AOUT- is a voltage level to represent the actual position of the Z-slide.

Its scale is 25mV/mm. 0-10V = 0 to 200mm.


3.9 Ethernet I/P Interface

This RJ45 connection is intended for use in the future with a field bus interface. Contact Laser Mechanisms® for more information.

3.10 Operation

3.10.1 Power Up/Initialization

Prior to applying power to the controller verify:

1. The head is connected to the control with the proper cables.

2. The customer interface to the head is connected and powered on.

3. The head is mounted securely.

After power is applied, the controller:

1. Turn on the AMP ENABLE input.

The motion system will start to move.

2. The slide will establish the reference position of the head.

3. The head goes to the saved Home position.

Verify the head is positioned away from any objects.

4. Once the head is at the Home position, the height sensor MUST be calibrated.

Do not touch the tip while the head is calibrating, as this affects the calibration of the height sensor.

See Calibrate in Section 3.5.7.

The power-up sequence takes a few seconds to complete.

The head is now ready for operation.

3.10.2 Calibration Sequence Timing Diagram

See Figure 36.

Move the sensor head or material so there is a physical gap of 12mm between the gas jet tip and the target material.

It is important for the target material to be at least 100mm x 100mm.

Activate the CALIBRATE input for at least 40ms.

o There is no need to maintain this input.

During calibration, the READY output will turn off.

o When the sensor has completed its calibration cycle, the READY output will turn back on.

Figure 36


3.10.3 Example of Cut Sequence Timing Diagram

See Figure 37.

Figure 37


4 Contour Trac™ Monitor

Contour Trac™ Monitor is a very useful tool for use with your Contour Trac™ head. Contour Trac™ Monitor runs on a standard PC and connects to the controller with an Ethernet cable. It provides real time monitoring of the tip stand off, head position, and I/O of your Contour Trac™ on a single, easy-to-read screen. See Figure 38.

Figure 38 Standard View Panel

4.1 System Requirements

Windows 7 or later

Screen Resolution: Minimum 800 x 600

Ethernet Port

4.2 Installation

Download the latest copy of Contour Trac™ Monitor and Contour Trac™ Controller Firmware Update (Contour Trac™ Update) from the Contour Trac™ Updates web page:


Once the compressed folders are downloaded from the web site they only need to be decompressed.

1. Right-click on each compressed folder and select Extract All....

2. Follow the on-screen instructions to complete the decompression (extraction) of the compressed files.

The Contour Trac™ Monitor folder will have a single ContourTrac™Monitor.exe file and a folder named ContourTracMonitor Libs.

It is important that the Libs folder remain at the same location as Contour Trac™ Monitor.

The parent folder for these files can be moved and copied as needed. No license key is needed.




4.3 Connecting

All communications between Contour Trac™ Monitor and the Contour Trac™ head are made using an Ethernet cable. See Figure 39.

Figure 39

The Contour Trac™ controller can be directly connected to a PC or multiple Contour Trac™ controllers can be connected to a PC using an Ethernet Switch.

Verify the cable is connected to the Ethernet, NOT the EtherNet/IP port.

o Connecting the Contour Trac™ controller to a wider network, which may include an internet connection, is also possible. This type of connection adds a level of complexity due to the high level of network traffic.

Contour Trac™ controllers are set at the factory to a static IP address of 169.254.99.133. Typically, it is necessary to set the IP address of your PC to the same range as the IP address of your Contour Trac™ controller.

o For example; to connect to the Contour Trac™ controller at the default address, set your PC to an address of 169.254.99.1 with a subnet mask of 255.255.255.0. Refer to your Windows documentation on how to set your IP address.

To connect to the Contour Trac™ controller, select the IP address from the pull down menu and press the connect button. Once a connection is established, the display will change to an image representing the Contour Trac™ being used.

4.4 Manage Connections

To add, modify and rearrange IP addresses in Contour Trac™ Monitor, select the Manage Connections… option under the Connections Menu. The Manage Connections screen appears. See Figure 40.

Figure 40


4.4.1 Add an Address

1. Click the + button to create a new entry with the default IP address.

2. Modify the IP address to match the address of the Contour Trac™.

3. Assign a name to the Contour Trac™ and add an optional description.

4. Click Add & Test to verify the connection and save the address.

To add an address for a Contour Trac™ that is currently offline, click Add Without Testing instead.

4.4.2 Modify an Address

To change the address only within Contour Trac™ Monitor:

1. Click on the row of the address you would like to change.

2. Modify the IP address as desired.

3. Click Modify & Test to verify the connection and save the address.

If the Contour Trac™ is currently offline, click Modify Without Testing instead.

4.4.3 Reassign an Address

To change the address both on the Contour Trac™ and within Contour Trac™ Monitor:

1. If the address of the Contour Trac™ you would like to reassign is not currently listed within Contour Trac™ Monitor, add it by following the procedure in Step 4.4.1.

2. Click on the row of the address you would like to reassign.

3. Modify the IP address as desired.

4. Click on Reassign and confirm the change.

If the change is successful, the new address will be saved.

4.4.4 Rearrange Addresses

The order of the addresses in the list is the same as the order they appear in the drop-down list. See Figure 38.

To rearrange the order of the addresses, click on a row and drag it to the desired position in the list.

You may also sort the addresses by number, name, or description by clicking on the appropriate header.

4.5 Position Display

The Position Display indicates the physical position of the head within its travel. The retracted position is zero with the positive direction toward the extended limit.

4.6 Home Position

The Home Position determines the final position the head retracts to when height sensing is disabled. To adjust the setting, move the slider up or down to the desired position and click Set.

4.7 Stand Off Voltage Display

The Stand Off Voltage Display indicates the measured stand off voltage as determined by the capacitive height sensor. The closer to the part, the lower the voltage will be.

When the head is not actively tracking a surface (no stand off is selected) the message Height Sensing Disabled is displayed.


4.8 Inputs

The seven inputs displayed indicate the real time status of the command signals to the Contour Trac™ controller. See Section 3 of this document manual for a detailed description of these signals.

4.9 Outputs

The five outputs displayed indicate the real time status of key operating parameters. Note that some of these signals are only displayed in Contour Trac™ Monitor and not as digital outputs. See Section 3 of this document for a detailed description of available digital output signals.

* BRAKE OFF – The head is capable of moving up and down.

IN POSITION – If height sensing, the head is positioned at the proper stand off from the part. If height sensing is disabled, the head is positioned at the Home position.

READY – The system is operational and free of faults.

* EXT ANALOG – The head is configured to use the analog input as a feedback source to determine position.

TOUCH – The tip is making contact with the part.

* – Only available through Contour Trac™ Monitor.

4.10 Status Display / Fault History

This indicates the current alarm status of the Contour Trac™. Any alarms that may occur while Contour Trac™ Monitor is connected will be recorded in the Fault History. The history can be cleared by clicking the Clear button.

See Figure 38 and Figure 41.

Figure 41

4.11 Contour Trac™ Monitor Settings

The Contour Trac™ software is available for download. See Section 4.2 for details.

This section lists the settings that must be specified before operating Contour Trac™.

Before adjusting any settings:

The software must be installed on your PC. See Section 4.2 for more details.

The head and control box must be connected properly. See Section 3.1 for more details.

4.11.1 Unlock Settings

1. Click the Settings menu in the upper left corner of the Main screen and select Unlock Settings. See Figure 42.

In the pop up that appears, enter the password:

tracsetup.

Figure 42


4.11.2 Gain

1. Click the Settings menu in the upper left corner of the Main screen and hover over Gain. See Figure 43.

2. Click one of the three available parameters, as desired.

Figure 43

The screen shown in Figure 44 will appear.

Figure 44

3. Enter the desired value within the stated range in the provided field.

4. Click OK to apply the settings.

The current Gain is displayed.

The Gain value must be within the stated range.

4.11.3 Retract

The retract settings are used to set a distance above the part that the head will retract to at a reduced speed immediately after height sensing is disabled.

Once that position is reached, the head will continue retracting to the home position at full speed.

1. Click the Settings menu in the upper left corner of the Main screen and hover over Retract. See Figure 45.

2. Click Distance or Speed as desired.

Figure 45

A screen similar to Figure 46 will appear.

Figure 46

3. Enter the desired distance or speed within stated range using the provided field.

4. Click OK to apply the settings.


The current Retract setting is displayed. The Retract setting must be within the stated range. A distance setting of 0 disables this function.

4.11.4 Service

The Service menu contains advanced features that should only be used under the direction of Laser Mechanisms support staff.

4.11.5 Simulated Inputs

When selected, a second set of inputs is displayed in Contour Trac™ Monitor.

The inputs are designated by orange circles and may be set and cleared by clicking on them. See Figure 47.

The input seen by the Contour Trac™ is the OR value of the Actual Input and Simulated Input.

Figure 47

4.11.6 Stand Off Voltages

Contour Trac™ allows three groups of up to seven different stand off voltages to be programmed at a given time.

The voltages are then activated depending on the operating mode, active curve and height selection bits. 1. Click the Settings menu in the

upper left corner of the Main screen and select Stand Off Voltages...

A screen similar to Figure 48 will appear.

Figure 48


2. Click on the value you would like

to change.

3. Enter the desired value in the provided field.

4. Click Refresh to verify the values were properly stored.

5. Click OK to exit the Stand Off Voltages screen.

The current Stand Off Voltages are displayed.

The Stand Off Voltages must be greater than 0V and less than 10V.

Opt. values are used with even-numbered curves (standard operation).

Linear values are used with odd-numbered curves.

Cust. values are used when EXT ANALOG is active.

4.12 Contour Trac™ Monitor System Identification Information

The hardware and interface are specific to your system. So, version and serial numbers are critical in order for Laser Mechanisms to provide support.

To display system information:

1. Click the Display menu in the upper left corner of the Main screen and select About Contour Trac™… See Figure 49.

Figure 49

2. Click on the View Hardware Information

drop down menu in the pop up box that appears and the image shown in Figure 50 will appear.

Figure 50

3. Click on the appropriate line to view the identifying information for the desired item.

4. Repeat steps 2 and 3 as needed.

5. Click OK to exit the About Countour Trac™ screen.


5 Service

Regular maintenance is required for the Contour Trac™ Head. The operating environment has a critical impact on the frequency of maintenance procedures. Consult your Laser Mechanisms representative for guidance.

5.1 Replacing the Gas Jet Tip

See Figure 51.

1. Turn off the laser.


3. Unthread the gas jet tip from the tip retainer assembly.

Do not drop or dent the gas jet tip.

Figure 51

4. Thread a new gas jet tip into the tip retainer nut.

5. Verify the beam alignment according to Section 2.

5.2 Servicing the Lens Holder

To remove the adjustable lens holder: (see Figure 52):

1. Turn off the laser.

2. Turn off the assist gas.

3. Wipe all debris from the head, especially in the area around the adjustable lens holder.

4. Unthread and remove the adjustable lens holder retainer nut.

5. Pull the adjustable lens holder straight out of the lens manifold block slot.

Figure 52

6. Wipe any debris out of the adjustable

lens holder in the lens manifold block.

7. Inspect both sides of the lens. If there is any debris on the lens, blow it off with dry nitrogen.

8. If the lens is not clean after step 7, remove it according to Section 5.4 and clean it according to Section 5.3.

9. If the lens is not clean after step 8, replace it according to Section 5.4.


To replace the lens holder (see Figure 52):

10. Verify that the seal is in position in the bottom of the adjustable lens holder and that there is no debris or any nicks on the seal. Replace the seal as necessary according to Section 5.5.

11. Press the adjustable lens holder all the way into the lens manifold block slot.

12. With one hand hold the adjustable lens holder so it remains seated in the lens manifold block, with the other hand tighten the retainer nut finger tight.

Do not tighten the retainer nut with a wrench.

The lens holder retainer nut must be tight to prevent the adjustable lens holder from being forced out when assist gas is applied.

5.3 Optic Cleaning

Optics are very sensitive to dust and debris. It is extremely important to take every possible precaution to ensure the optics remain pristine.

NEVER install optics without performing this cleaning procedure.

Clean optics in a dust free air-conditioned room.

Before opening any part of the head, clean off the dust and/or process debris using an exterior cleaning towel (PLTLS0023) or equivalent.

ALWAYS handle optics by their edges, never touch the optical surfaces.

ALWAYS wear powder free gloves or finger cots when handling optics and optic holders.

Inspect the optics with high power illumination, such as Laser Mechanisms pen light (PLTLS0021) under 2X magnification.

The following instructions are only a guide. Always follow cleaning instructions supplied by optics manufacturers.

If installing a new optic, inspection and cleaning are still recommended.

Laser Mechanisms Inc. cannot be held responsible for any damage to optics resulting from improper cleaning or handling.

1. Wash hands with soap to remove all oils, and then put on powder free gloves or finger cots.

2. If necessary, remove the optic(s) according to the appropriate section of this document.

3. Hold the optic by the edge and inspect it.

If you see any scratches or pits, replace the optic.

4. Hold the optic by its edges and blow any dust off each side with low-pressure dry nitrogen (2 to 5 PSI) or air from a blow bulb.

DO NOT USE AN AIR COMPRESSOR.

5. Secure the optic by its edge with the curved side facing up.

A fixture may be helpful. Consult your Laser Mechanisms Sales Engineer for assistance.

6. Dampen a clean lens tissue (PLOCK0014 – Texwipe Absorband Wipes – or equivalent) or absorbent cotton ball with acetone or reagent grade isopropyl alcohol.

7. Use the damp lens tissue or cotton ball, wipe the optic in ONE direction.

8. Repeat steps 6 and 7 three (3) times using a clean lens tissue or cotton ball each time.


Dampen a fresh lens tissue or absorbent cotton ball each time you wipe the lens.

9. Inspect the optic:

If it is clean, proceed to step 10.

If it is not clean, repeat steps 4 to 8.

10. Turn the optic over onto a clean lens tissue (PLOCK0014 – Texwipe Absorband Wipes – or equivalent) and repeat steps 4 to 8 to clean the other side.

11. Reassemble the optic according to the appropriate section of this document.

Recommended best practices include:

o Blow any dust, lint, debris, etc. off the seals and rings using low-pressure dry nitrogen (2 to 5 PSI) or air from a blow bulb.

o Shake the assembled optic near your ear to verify no components are loose.

o Tighten any components as necessary.

o Before reinstalling, inspect the assembled optic again to verify it is clean and unscratched.

5.4 Servicing the Lens

To remove the lens:

1. Remove the adjustable lens holder (PLALH0115) according to Section 5.2 and take it to a clean environment.


2. Remove the lens retainer nut (PLLRN0030) with the lens insertion tool (PLLIT0001).

ALWAYS wear powder free gloves or finger cots when handling optics and optic holders.

3. Using a lens tissue, push the lens (PLYFS0012) from the side opposite of the removed retainer nut.

4. If the adjustable lens holder is not going to be installed in the head immediately, protect the lens by taping a clean lens tissue over both lens surfaces.

Take care to only put tape on the lens tissue. DO NOT allow any adhesive from the tape on the lens surface.

Figure 53


To replace the lens:

5. Inspect the indium lens seal ring. If it needs to be replaced use:

Lens seal ring PLLSR0002

6. Insert the lens into the adjustable lens holder with the flat surface toward the indium seal.

To determine the flat surface of the lens, look at both sides of the lens. Your whole face will be visible in the curved surface. Your face will overfill the flat surface.

7. Push the lens using a clean lens tissue until it is resting on the indium seal.

8. Use the lens insertion tool to install the lens retaining nut and tighten ONLY finger tight.

5.5 Servicing the Lens Seal

To install a new seal:

See Figure 54.

1. Install the seal (PLMSR0002) with the radial wedge as shown below.

2. Gently press the seal into the groove in the lens holder.

3. Gently press along the radial edge until the seal is completely in the groove.

Do not press down on the face of the seal, as this can cause permanent damage.

Figure 54


5.6 Remounting the Head After Separation

When a crash occurs the head will break away from the crash protector and it will be hanging by the safety cable.

1. Examine the bottom of the crash protector and the top of the breakaway flange for debris. See Figure 55.

If there is any debris on either surface wipe it off with a clean cloth.

Extreme care must be taken not to let any debris fall into the beam aperture in the head.

DO NOT USE AIR TO BLOW OFF THE DEBRIS.

Figure 55


2. Raise the head up so the dowel pin on the breakaway flange is aligned with the drill bushing in the crash protector and the aperture boss on the breakaway flange is aligned with the aperture counterbore in the crash protector.

3. Position the head so the breakaway flange is flush against the bottom of the crash proctor.

If the head wobbles, it is not seated properly on the crash protector.

Repeat steps 2 and 3 to reseat the head properly.

Never run the machine if the head is not seated properly.

Figure 56

4. If necessary, replace the gas jet tip according to Section 5.1.


5.7 Crash Protection Device Interlock Switches

The interlock switch on the crash protection device may become damaged. If this is the case, it must be replaced.

DO NOT OPERATE THE HEAD IF THE INTERLOCK SWITCH(ES) IS NOT OPERATING PROPERLY.

5.7.1 Crash Protector Device Interlock Switch Removal and Replacement

See Figure 57 to remove an interlock switch (PLCPS0002 or PLCPS0005):

1. Disconnect the interlock cable (PLCAB0325).

2. Remove the (2) 4-40 SHCS that secure the interlock switch to the crash protection device. Use a 3/32-inch hex wrench.

Figure 57

See Figure 57 to replace an interlock switch (PLCPS0002 or PLCPS0005):

1. Place the new interlock switch into position on the crash protection device.

2. Secure the switch to the crash protection device with the (2) 4-40 SHCS removed earlier.

3. Reconnect the interlock cable.

4. Adjust the switch according to Section 5.7.2.

5.7.2 Adjusting the Crash Protector Device Interlock Switches

There are two interlock switch scenarios that require adjustment (See Figure 58). If the interlock switch:

A. Is not closed when the head is in place

B. Does not open when the head is dislodged

A. To adjust an interlock switch if it does not close when the head is in place:

1. Remove the interlock switch according to Section 5.7.1.

2. CAREFULLY, bend the hook slightly down (0.010 – 0.020 inch, 0.25 – 51 mm). Use needle nose pliers.

3. Verify that the hook moves up and down freely. It should not rub on the switch plate or dowel pin.

4. Replace the interlock switch according to Section 5.7.1.

5. Test the interlock switch:

Connect and ohm meter between pin 2 and pin 4 of the interlock connector.


Verify that the interlock switch is CLOSED WHEN THE HEAD IS IN PLACE.

o If the interlock switch is closed proceed to step 5 in Procedure B.

o If the interlock switch is open repeat steps 1-5 in this section.

Figure 58

B. To adjust an interlock switch when it does not open when the head is dislodged

1. Remove the interlock switch according to Section 5.7.1.

2. CAREFULLY, bend the hook slightly up (0.010 – 0.020 inch, 0.25 – 51 mm). Use needle nose pliers.

3. Verify that the hook moves up and down freely. It should not rub on the switch plate or dowel pin.

4. Replace the interlock switch according to Section 5.7.1.

5. Test the interlock switch:

Connect and ohm meter between pin 2 and pin 4 of the interlock connector.

Verify that the interlock switch is OPEN WHEN THE HEAD IS DISLODGED.

o If the interlock switch is open proceed to step 5 in Procedure A.

o If the interlock switch is closed repeat steps 1-5 in this procedure.

Adjusting the switch hook during one procedure has an effect on the hook operation in the other procedure.

The interlock switch(es) MUST operate properly according to step 5 of both Procedure A and Procedure B above.

DO NOT OPERATE THE HEAD IF THE INTERLOCK SWITCH(ES) IS NOT OPERATING PROPERLY.


5.7.3 Wiring the Crash Protector Device Interlock Switches

In the event that an interlock switch (PLCPS0002 or PLCPS0005) or interlock cable (PLCAB0125) must be rewired, see Figure 59 for the necessary wire connections.

Figure 59

5.8 Servicing the Large (2 Inch) Mirrors

The procedure below is to service the

mirror (ᴓ 2 inch) in all (3) of the larger

beam bender assemblies. See Figure 60.

Figure 60

Always wear powder free gloves or finger cots when handling optics.


The beam bender mirror is located under the adjustable mirror holder cap. See Figure 61.

1. Loosen the (2) #6 – 32 SHCS to remove the adjustable mirror holder cap from the adjustable mirror holder base.

2. Remove the mirror from the adjustable mirror holder cap.

The mirror is located on the inside of the adjustable mirror holder cap.

DO NOT TOUCH THE REFLECTIVE SURFACE OF THE MIRROR.

Clean the mirror according to Section 5.3.

OR

Proceed to step 3 to replace it.

Figure 61

3. Put a small amount of thermo compound (PLTHC0001) on the back of the 2-inch diameter mirror (PLZRS0002).

Orient and attach the mirror centered on the adjustable mirror holder cap.

4. Orient the adjustable mirror holder cap so that the #6-32 SHCS are aligned with the #6-32 tapped holes in the adjustable mirror holder base.

5. Tighten the #6-32 SHCS to replace the adjustable mirror holder cap.

5.9 Servicing the Small (1.1 Inch) Mirror

The procedure below is to service the

mirror (ᴓ 1.1 inch) in the small beam

bender assembly near the laser output. See Figure 62.

Figure 62

Always wear powder free gloves or finger cots when handling optics.

The beam bender mirror is located under the knuckle mirror cap. See Figure 63.

Removing the knuckle cap does not necessarily require realignment. Take care not to disturb any hardware that is unrelated to this procedure.


1. If necessary, unthread and remove the tip retainer wire.

2. Loosen the (2) #2 – 56 SHCS to remove the knuckle mirror cap (PLKMC0018) from the fourth beam bender assembly.

3. Remove the mirror from the inside of the knuckle mirror cap.

DO NOT TOUCH THE REFLECTIVE SURFACE OF THE MIRROR.

Clean the mirror according to Section 5.3.

OR

Proceed to step 4 to replace it.

Figure 63

4. Put a small amount of thermo compound (PLTHC0001) on the back of the 1.1-inch diameter mirror (PLTRS0035).

Orient and attach the mirror so it is seated in the knuckle mirror cap.

5. Orient the knuckle mirror cap so that the (2) #2-56 SHCS are aligned with the #2-56 tapped holes in the fourth beam bender assembly.

6. Tighten the (2) #2-56 SHCS to replace the knuckle mirror cap.


6 Specifications

Cutting Head

Focal Length ................................................................................................................................... 5.0 Inch

Lens Diameter .................................................................................................................................. 1.1 Inch

Clear Aperture .................................................................................................................................. 1.0 Inch

Assist Gas Pressure ................................................................................................................ up to 100 psi

Purge Gas .................................................................................................................... High Purity Nitrogen

Height Sensing Unit

Stand Off Distance Range (1 mm Recommended) ........................................................ 0.2 mm to 8.0 mm

Calibration .................................................................................................................. Calibrating @ 12 mm

Response Time .............................................................................................................................. <1 msec.

Temperature Stability ....................................................................... ±5% of Stand Off Setting, 0° to 45° C

Power Requirement ................................................................................................................... 24VDC, 1A

Digital Inputs ............................................................................................................. Sourcing, 5 VDC 1mA

Digital Outputs ........................................................................................... Sinking, 12-28VDC 100mA MAX

Height Sense Output ............................................................................................................. 0-10 V Analog

Communication Protocol ...................................................................................................................RS-485

Controller

Communication ........................................................................................................... Ethernet/Discrete I/O

Power ...................................................................................................................... 48 VDC/3A, 24 VDC/1A

Digital Inputs ........................................................................................... Sink/Source 18 – 24 VDC <10mA

Digital Outputs .......................................................................................... Sink/Source 5 – 24 VDC 400 mA

Analog Input ..................................................................................................................................... 0 – 10V

Analog Output .......................................................................................................... 0 – 10 V, 100 mA MAX

Slide

Range ......................................................................................................................................... 0 – 127 mm

Speed ............................................................................................................................................ 150 mm/s

Specifications are subject to change without notice.


7 Troubleshooting

Most of the faults can be cleared by toggling the AMP ENABLE input then activating the RESET input. These actions clear faults and re-reference the head/slide.

Move all parts away from the head before toggling the AMP ENABLE input.

SYMPTOM CAUSE REMEDY

No Motion The AMP ENABLE input is not active.

Activate the AMP ENABLE input. It may also be necessary to toggle the RESET input.

Crashed One or both of the crash protection switches are open.

Verify the head is properly mounted. Verify ALL cables are connected. Verify the crash protection switches are operational.

Extended Limit Switch Head reached a limit. Reset the AMP ENABLE input, then toggle the RESET input.

Retracted Limit Switch Head reached a limit. Reset the AMP ENABLE input, then toggle the RESET input.

Head retracts when HSB1, HSB2, or HSB3 is active.

The height sensor has a fault or is not calibrated.

Verify ALL cables are undamaged and connected. Verify the tip assembly is not damaged. Calibrate the HSU.

System becomes unresponsive after a crash or hitting a limit.

In certain cases, the motor can be mechanically bound up due to the crash protection slip mechanism.

In this case, the user must: 1. Launch the Contour Trac™ Monitor software and click the Service menu and select “Release Brake.” 2. Manually release the motor brake 3. Use the manual knob on the Z slide to move the head away from the limit.

No signal is present on the analog output.

The controller has an internal error. Reboot the system.

The system is unresponsive at power up.

The motor is unable to commutate.

In this case, the user must: 1. Launch the Contour Trac™ Monitor software and click the Service menu and select “Release Brake.” 2. Manually release the motor brake 3. Use the manual knob on the Z slide to move the head away from the limit.


8 Appendix A – Coolant Specifications

The cooling manifolds are designed to be operated on either a closed-loop cooling system or facility tap water. For either type of system the requirements in the table below must be met.

Minimum Flow Rate 1.6 liter/minute @ 2 BAR minimum

Inlet Pressure 170 to 520 kPa

Inlet Temperature ≥room temperature / >dew point

Hardness (Equivalent to CaCO3) <250mg/liter

pH 6 to 8

Particulate Size <200 microns in diameter

9 Appendix B – Beam Delivery Purging

The beam delivery system must be purged with clean, dry air {specification to meet or exceed ISO 8573.1:2001 Class 1.5.2}; Solids <100 particles per cubic meter of 0.1-0.5 µm size, and <1 particle per cubic meter of 0.5-0.1 µm; Water dewpoint <+7º C; Oil <0.1 mg per cubic meter. Purge flow rate is 1400 liters/hr (50 SCFH) @ 20 kPa. A self-regenerating desiccant air dryer filter unit (PLKIT0188) is available as an option from Laser Mechanisms.

10 Appendix C – Assist Gas Specifications

Impurities in the assist gas such as hydrocarbons (THC) and moisture (H2O) can damage optics, cause power fluctuations and result in inconsistent cuts. See the table below for recommended assist gas specifications.

Impurities can also be picked up in the supply lines. Non-metallic materials can allow oxygen and moisture to permeate the system and can be a source of dust and hydrocarbons. Stainless steel lines and fittings are recommended. Use filters that remove particles down to .01 microns and purifiers that guard against oil or water from getting into the optical system.

Regulators with a stainless steel diaphragm are recommended. Industrial regulators can aspirate air and the neoprene diaphragm can be a source of hydrocarbons.

GAS PURITY MAX H2O ppm MAX THC ppm

Oxygen 99.8% <5 ppm <1 ppm

Nitrogen 99.998% <5 ppm <1 ppm

Argon 99.998% <5 ppm <1 ppm

Helium 99.998% <5 ppm <1 ppm


11 Appendix D – Recommended User-Serviceable Parts List

For recommended user-serviceable spare parts, please call Laser Mechanisms at (248) 474-9480. If your head requires service beyond the instructions outlined in this manual, please contact Laser Mechanisms for further assistance.

ITEM PART # DESCRIPTION

FITTINGS

1 PLFTG0012 Right Angle Fitting for 1/4 Inch OD Tubing (1/8 Inch NPT)

2 PLFTG0019 Right Angle Fitting for 1/4 Inch OD Tubing (10-32 Threads)

BEAM BENDER ASSEMBLY MIRRORS

3 PLZRS0002 2.0 Inch Diameter Mirror (Use with 3 Larger Beam Bender Assemblies)

4 PLTRS0035 1.1 Inch Diameter Mirror (Use with Small Beam Bender Assembly)

CRASH PROTECTION DEVICE

5 PLCAB0303 Crash Protection Safety Cable

6 PLCAB0320 Y-Cable

7 PLCAB0624 Interlock Cable (300 mm Long)

8 PLCPS0002 Crash Protection Interlock Switch

9 PLCPS0005 Crash Protection Interlock Switch

ADJUSTABLE LENS HOLDER

10 PLALH0115 Adjustable Lens Holder (Complete Assembly)

11 PLLRN0030 Lens Retainer Nut

12 PLLPZ0009 1.1 Inch Diameter Focusing Lens

13 PLLSR0002 Lens Seal Ring (Indium Seal)

14 PLMSR0002 Manifold Seal Ring (Wedge Seal)

TIP RETAINER ASSEMBLY

15 PLTRA0458 Tip Retainer Assembly (Complete Assembly)

16 PLGJT0327 Gas Jet Tip (1.5 mm Orifice)

17 PLTTW0003 Tip Transformer Wire (Not Included in PLTRA0458)

TOOLS (NOT SHOWN)

18 PLBBT0004 Beam Bender Target

19 PLMAT0010 Alignment Target

20 PLSAT0023 Alignment Target

21 PLBRN0001 Burn Card

22 PLLIT0001 Lens Insertion Tool

23 PLTHC0001 Thermo Compound


Figure 64

Laser Mechanisms, Inc.

25325 Regency Drive • Novi, Michigan 48375 USA

Phone: (248) 474-9480 • Fax: (248) 474-9277

In Europe: Phone: +32(0)92 18 70 70 • Fax: +32(0)92 18 70 79

Web: www.lasermech.com • E-Mail: [email protected]

Documents

Contour Trac™ with Ultrasense™ · 2017-04-19 · PLMNL0247 REV. A Effective Date: 12/21/16 1 Contour Trac™ with Ultrasense™ Operation Manual 1 Introduction The Contour Trac™