E-series/E15: Installation & Maintenance
E-series/E15: Installation & Maintenance
E-series/E15
Laser Marking Systems
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subject to change without notice.
E-series/E15 Installation & Maintenance
Foreword
Telesis Technologies, Inc. (hereinafter referred to as Telesis) reserves the right to change the information
and specifications contained in this document without prior notice. The reader should consult Telesis to
determine whether such changes have been made.
In no event shall Telesis be liable for any incidental, indirect, special, or consequential damages whatsoever,
including but not limited to lost profits, arising out of, or relating to this document or the information it
contains, even if Telesis has been advised, has knowledge, or should have knowledge of the possibility of
such damages.
Telesis expressly warrants the equipment it manufactures as set forth in the Standard Terms and Conditions
of Sale. Telesis makes no other warranties, expressed or implied, including and without limitation,
warranties as to merchantability or fitness for a particular purpose.
The information contained in this document is confidential and is proprietary to Telesis or its licensors.
Trademarks
Telesis and Merlin are registered trademarks of Telesis Technologies, Inc. in the United States and/or other countries.
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Windows and Vista registered trademarks of Microsoft Corporation in the United States and other countries.
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Contents
SECTION 1 LASER SAFETY 1-1
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For further guidance on the safe use of laser equipment, the following is a list of suggested reading:
American National Standard for the Safe Use of Lasers (ANSI Z136.1-2014)
Laser Institute of America
12424 Research Parkway
Orlando, Florida 32826-3249 USA
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Eye Exposure
EV4GDS: When the eye is exposed to Nd:YVO4 laser radiation or the pumping radiations, retinal damage,
corneal damage, and/or blindness may result. To avoid eye exposure to the Nd:YVO4 laser or the pumping
radiation it is mandatory that laser safety glasses or goggles attenuated for the Nd:YVO4 laser wavelength
(532nm) and the pumping radiation wavelengths (808nm and 1064nm), are worn any time exposure to
the laser is possible.
All Other E-series Lasers: When the eye is exposed to Nd:YVO4 laser radiation or the pumping
radiation, retinal damage, corneal damage, and/or blindness may result. To avoid eye exposure to the
Nd:YVO4 laser or the pumping radiation it is mandatory that laser safety glasses or goggles attenuated for
the Nd:YVO4 laser wavelength (1064 nm) and the pumping radiation wavelength (808 nm), are worn any
time exposure to the laser is possible.
Skin Exposure
Skin exposure to the Nd:YVO4 laser, the YAG laser, and the EV4GDS green laser, can result in thermal
burning of the skin, much like sunburn or a burn from an oven. To avoid this kind of hazard, it is very
important to know the laser beam path, enclose it when possible and avoid contact with the beam or
hazardous laser radiation.
Source of Ignition
EV4GDS: The Nd:YVO4 laser radiation and its harmonic wavelengths are sources of ignition and are
therefore unsuitable for use in a potentially explosive environment.
All Other E-series Lasers: The Nd:YVO4 laser radiation is a source of ignition and is therefore unsuitable
for use in a potentially explosive environment.
Chemical Hazards
Harmful particulate and vapor matter can be released as a result of any thermal process, including laser
processing. Certain metals and plastics release extremely toxic fumes, which must be properly ducted and
disposed of during processing. A fume extraction system should be considered when such materials are to
be processed.
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Power Supplies
Laser power supplies contain very high voltages and can easily be a shock hazard. To date, all known
laser-related deaths in the United States have been electrocutions. Extreme caution should be used when
working with laser power supplies and all general electrical safety practices should be adhered to.
Faulty Equipment
Many hazards may present themselves due to faulty equipment, such as X-radiation from a faulty power
supply (normally found in very high power lasers); electromagnetic emissions and RF emissions from Q-
switch drivers, etc. To avoid such hazards, it is imperative to perform maintenance procedures as
prescribed.
1.3.1 Operation
Operation is defined as the "performance of the laser or laser system over the full range of its intended
functions (normal operation). It does not include maintenance or service as defined in this section." (ANSI
Z136.1-2014 p. 13)
1.3.2 Maintenance
Maintenance is defined as "performance of those adjustments or procedures (specified in user information
provided by the manufacturer with the laser or laser system), which are to be performed by the user to ensure
the intended performance of the product. It does not include operation or service as described in this section."
(ANSI Z136.1-2014 p. 12)
1.3.3 Service
Service is defined as "the performance of those procedures or adjustments described in the manufacturer’s
service instructions which may affect any aspect of the performance of the laser or laser system. It does not
include maintenance or operation as defined in this section." (ANSI Z136.1-2014 p. 15)
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EV4GDS: Ensure that laser safety goggles attenuated for the Nd:YVO4 laser wavelength (532nm) and the
pumping radiation wavelengths (808nm and 1064nm) are available for all personnel present. Laser goggles
with an optical density greater than 6 at 532nm, 808nm*, and 1064nm are necessary for protection from
specular reflections.
* The 808nm laser light is not present under normal operation and maintenance procedures. Eye
protection for 808nm light must be worn whenever the fiber from the laser controller is not attached
to the EV resonator and there is a possibility the controller can be powered on. Under normal
operation and maintenance procedures, eyewear must be selected to provide adequate protection
from 532nm and 1064nm laser radiation.
All Other E-series Lasers: Ensure that laser safety goggles attenuated for the Nd:YVO4 laser wavelength
(1064 nm) and the pumping radiation wavelength (808 nm) are available for all personnel present. Laser
goggles with an optical density greater than 6 at 1064 nm and 808 nm are necessary for protection from
specular reflections.
1.5.3 Training
Ensure that all personnel operating the system have the proper training in laser safety and in operating the
laser. Appropriate training courses are available through the Telesis Customer Service Department.
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Remote access to safety interlocks is provided on the rear panel of the laser controller. Provisions for remote
control of the laser interlock and for shutter control are provided via a M12 and DB9 connector. An optional
work enclosure may be fitted with interlocks designed to stop lasing action when the interlock is activated
during operation or maintenance of the system.
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Questions regarding laser safety should be referred to the Telesis Customer Service Department.
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Section 2 Installation
2.1 Components
The typical E-series/E15 Laser Marking System is made up of the following components.
• E-series Laser Marking Head (EVCDS, EV4GDS, EV10SDS, or EV15DS)
• Lens (attached to marking head)
• E15 Laser Controller
• EV4GDS Temperature Controller (EV4GDS Systems Only)
• System Computer and OEM software (external device* or embedded in laser controller)
• Monitor*, Keyboard*, Mouse*
* for systems with external computers, these devices may be supplied by Telesis or by the customer.
• Laser/Galvo Controller Board (installed in system computer)
• Merlin II LS Laser Marking Software (installed on system computer)
• Software CD, Merlin II LS
• Laser Marking Head Cable (detachable)
• Fiber Optic Cable (pre-attached to laser controller)
– Wrench (for cable installation/removal)
– Small protective cap (for fiber optic cable end)
– Larger protective cap (for mating connector on laser marking head)
• Galvo Control Cable (detachable)
• RF (Q-switch control) Cable (detachable)
• EV4GDS Temperature Control Cable (pre-attached to temperature controller; EV4GDS Systems only)
• Serial Communications Cable (for systems using an external computer – detachable)
• I/O Cable (for systems using an embedded computer – detachable)
• Shutter Interlock Cable
• Power Cables (detachable)
• E-series/E15 Getting Started Supplement
• Telesis Product Documentation medium
• Optional:
Controller Fuse/Connector Kit (mating connectors for back panel interfaces and spare fuses)
Class 1 Enclosure (Class 1 System)
Marker Stand (Class 4 System)
See System Specifications for details on all components supplied by Telesis or required by the customer.
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RAM ................................................... 8 GB
(1) One additional PCIe slot required if system is configured for mark-on-the-fly operation. If the system computer is a
notebook, expansion must be used to provide the PCIe slots.
(2) Telesis recommends a USB mouse and a USB keyboard for system computers that are embedded in the laser
controller.
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2.3 Installation
The following procedures provide guidelines and instructions for installing the laser marking equipment.
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4. Secure the laser marking head to the mounting fixture using M5-0.80 bolts and M5 lock washers.
Torque to 47 in-lb (5.31 N-m). Do not over tighten the mounting bolts.
Note: See the optional EVC/EVCDS backwards compatibility mounting later in this section if replacing a
unit built prior to June 2018.
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1. Refer to the below Lens Kit Marking Head drawing for the lens kit needed.
2. On a clean, flat surface, carefully lay the laser head on its side.
3. Hold one spacer plate to the bottom of the laser head as shown below and tighten two M4 screws
provided.
5. Secure the laser marking head to the mounting fixture using M5-0.80 bolts and M5 lock washers
Torque to 47 in-lb (5.31 N-m). Do not overtighten the mounting bolts.
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1. An optional Controller Fuse/Connector Kit #70776 (available upon request) may have been supplied
with the laser controller. If supplied, locate and retain the kit for future use.
• The controller fuse/connector kit contains mating connectors for back panel interfaces and spare
fuses. Use the connectors when fabricating cables to connect optional interfaces such as
interlocks, I/O devices, and mark-on-the-fly encoders. See Optional Connections for details.
• Retain the fuses for future use. The spare fuses are replacements for those used inside the
controller. Only Telesis-approved technicians are authorized to access the internal components
of the laser controller.
2. For systems with a 2-meter cable set, the laser controller must be located within 1.50 m (5.00 ft) of
the laser marking head to allow for cable connections.
For systems with a 5-meter cable set, the laser controller must be located within 4.75 m (15.58 ft) of
the laser marking head to allow for cable connections.
Do not bend or kink fiber optic cable. The fiber optic cable will tolerate a 8.9 cm (3.5 in) bend
radius without damage.
Allow a minimum distance of 15 cm (6 in) at rear of the laser controller. This will provide
sufficient room for proper air flow and for connecting the remaining cables.
Do not block or obstruct exhaust vents. Note location of the exhaust vents on both sides of the
laser controller. These vents must have adequate clearance to ensure proper cooling.
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System Computer
A system computer is required to run the Merlin II LS software. The system computer may be a separate,
external device that connects to the laser controller, or it may be embedded within the laser controller itself.
External computers may be supplied by Telesis or by the customer. See System Specifications for details.
Perform this installation only if your system uses an external system computer.
2. Place the monitor, keyboard, and mouse on a sturdy, flat, and level surface.
Ensure their location allows for connection to the external system computer or to the laser controller,
as applicable.
1. Place the Temperature Controller atop the E15 Laser Controller with indicators toward front, cable
toward back.
2. Verify the controller is properly configured for use with the customer-supplied facility power (115 or
230 VAC). Refer to Controller Fuse Replacement (Section 3) for details.
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2.3.3 Exhaust
E-series laser marking heads require external exhaust if installed in a Class 1 configuration. The exhaust
tubing should be a smooth-walled, rigid duct and have as few bends as possible.
1. Obtain a suitable duct with a diameter that matches the exhaust unit.
2. Install the duct between the vacuum unit and the marking system.
Do not directly connect the rigid duct to the marking system.
Note: Blower vibrations can be isolated if a short piece of industrial-grade, wire-reinforced rubber
tubing is used at the end of the duct.
Note also that the EVCDS laser marking head is shown in the examples. These connections are similar to all
other E-series systems except the EV4GDS which uses a separate Temperature Controller (not shown).
Complete connection details for all E-series systems, their components, and optional interface connections are
provided in the following paragraphs.
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Preliminary Procedures
Verify the following are in the OFF (O) position.
Laser Controller power button (Front Panel)
Monitor power switch
Computer power switch (if an external computer is used)
If the marking system uses an external computer, proceed to External Computer Connections.
If the marking system uses an embedded computer, proceed to Laser Controller Connections – Embedded
Computer.
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2. Locate the Galvo Control cable (50545 or 57437), previously connected to the external computer.
Secure the DB9P connector to the 9-pin laser head connector ( ) on the laser controller.
5. Ensure Pendant Jumper Assembly #69737 is connected to the Pendant connector ( ) on the laser
controller.
Note: A remote control circuit may be connected to the controller. See Remote Pendant Connections for
details. If used, remove the Pendant Jumper Assembly and connect the customer-supplied
pendant cable.
6. An optional customer-supplied interface cable may be connected to the Outputs connector ( ) on the
laser controller. This allows monitoring of output signals generated by the marking system. See Output
Connections for details.
7. Connect a power cable to the laser controller. Do not connect cable to facility power at this time.
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6. Ensure Pendant Jumper Assembly #69737 is connected to the Pendant connector ( ) on the laser
controller.
Note: A remote control circuit may be connected to the controller. See Remote Pendant Connections for
details. If used, remove the Pendant Jumper Assembly and connect the customer-supplied
pendant cable.
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7. Connect the monitor, keyboard, and mouse (as applicable) to the sub-panel on the laser controller.
8. A quadrature shaft encoder may be used for mark-on-the-fly operations. See Encoder Connections for
details. If used, secure the customer-supplied interface cable to the DB15S MOTF connector on the
laser controller.
9. An optional Ethernet IP/ Profinet serial converter if used can be connected to one of the two Industrial
COMM ports on the back of the controller.
10. An optional customer-supplied interface cable may be connected to the MOTF Part Present connector
( ) on the laser controller. This is an industry standard M12 connector that can be used to directly
connect a variety of standard sensors to the Laser Controller. See MOTF Part Present Connections for
details.
11. An optional customer-supplied interface cable may be connected to the Outputs connector ( ) on
the laser controller. This allows monitoring of output signals generated by the marking system. See
Output Connections for details.
12. Connect a power cable to the laser controller. Do not connect cable to facility power at this time.
13. Connect a power cable to the monitor. Do not connect cable to facility power at this time.
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Do not touch the end of the fiber optic cable. If the fiber
becomes scratched or damaged from mishandling or from
contact with foreign objects, burning or other similar
malfunctions may occur.
Always wear powder-free, nitrile gloves when handling
the fiber optic cable.
If the fiber optic cable is already connected to the marker, proceed to Step 4.
Perform Steps 1 through 3 only if the fiber optic cables are disconnected from the marking head.
1. EVG4DS Only:
a. On the back panel of the laser marking
head, remove four M3 screws that attach
the fiber support top to the fiber support
bottom.
b. Remove two M5 screws that attach the fiber
support bottom to the back panel.
2. All Lasers:
a. Locate the Fiber Optic cable (71374-1 or
71375-1) attached to the laser controller.
b. Locate Telesis-supplied wrench (43172)
secured to fiber optic cable near the free end.
c. Carefully cut plastic wire-tie to remove
wrench.
d. Temporarily slide switch assembly away from
free end of fiber optic cable to allow room for EV4GS Only: Fiber Optic Cable Support
connection.
e. Remove protective caps from fiber optic cable and from mating connector on back of laser marking head.
f. To prevent scratching or any other damage to tip of fiber optic cable, gently insert fiber optic cable
straight into receptacle of laser marking head.
g. Using only the Telesis-supplied wrench, tighten cable connection finger tight, then no more than
1/16 turn.
h. Retain both protective caps and the wrench future use. These caps must be installed whenever the
fiber optic cable is disconnected. The bags attached to the fiber optic cables are provided for
storing the caps and wrench.
i. Carefully slide switch assembly over fiber cable and attach switch assembly securely to laser
marking head.
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3. EVG4DS Only:
a. Position the fiber support bottom onto the back panel such that the fiber cable/switch assembly
rests in the padded cradle of the support.
b. Secure the fiber support bottom to the back panel with two M5 screws. Tighten securely.
c. Secure the fiber support top to the fiber support bottom with four M3 screws. Tighten securely.
4. Locate the RF (Q-switch Control) cable (53980 or 57439), previously connected to the laser controller.
a. Remove cover plate from back panel of laser marking head where RF cable will attach.
b. Feed free end of RF cable through hole in cover plate and attach to RF connector on laser marking
head.
c. Attach cover plate securely to laser marking head.
5. Locate the Laser Marking Head cable (50546 or 57438), previously connected to the laser controller.
Secure the DB37S connector to the mating connector on the laser marking head.
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7. Locate the Shutter Interlock cable (78395-1 or 78395-2), previously connected to the laser controller.
Secure the M12P connector to the Shutter Interlock Output connector ( ) on the laser marking head.
8. Ensure the Shutter Interlock Jumper (78280) is connected to the Shutter Interlock Input connector ( )
on the laser marking head.
Note: A shutter interlock circuit may be connected to the controller. See Shutter Interlock Connections for
details. If used, remove the Interlock Jumper and connect the customer-supplied interface cable.
9. If your marking system uses an EV4GDS laser marking head, proceed to EV4GDS Temperature
Controller Connections. Otherwise, proceed to Power Cable Connections.
2. Attach the free end of the temperature control cable (or the temperature control extension cable)
to the DB9P connector on the laser marking head.
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1. Connect the power cables for the laser marking system equipment:
Laser controller power inlet receptacle (back panel)
Monitor power receptacle
Computer power receptacle (if an external computer is used).
EV4GDS Systems only: Temperature Controller power entry module (back panel)
Optional Connections
Proceed to the following section(s) as applicable:
• See Shutter Interlock Connections to connect a customer-supplied shutter interlock circuit.
• See Remote Communications to connect a host computer, remote I/O device, or to make use of the
optional I/O signals for the laser controller.
• See Output Connections to connect a circuit for monitoring output signals generated by the system.
• See Mark-on-the-Fly Configuration to enable operation and to connect a customer-supplied encoder.
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The customer/installer must supply the mating 7/8-inch Minifast connector and cabling to construct a cable for
the PC 24 VDC connector on the laser controller. Refer to the following table for pin assignments. Note if the
customer/installer does not use the provided connector, the pin assignment numbers on the connectors will
not match.
Pin # Signal/Function
1 + 24 VDC IN (6Amax)
2 +24 VDC OUT
3 24 V Return IN
4 24 V Return OUT
Pin # Signal/Function
1 24 V Return OUT
2 24 V Return IN
3 +24 VDC IN
4 +24 VDC OUT
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Note: The customer-supplied circuit must incorporate normally closed (NC), dry contact switches.
1. Remove the interlock jumper (P/N 78280) from the Shutter Interlock Input connector.
2. Connect the customer-supplied circuit to laser marking head Shutter Interlock Input connector.
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Note: Pins 11 and 12 are TTL-level contact closures for Pin 10 (TTL GND).
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Maximum Output
Minimum Input Voltage 11 VDC 0.25 amps
Current
Maximum ON
Maximum Input Voltage 28 VDC 0.50 ohms
Resistance
• READY and DONE are used to determine when the marker is available. The marker will acknowledge a
START PRINT command only when READY and DONE are both on.
• When the marker receives a START PRINT command, both READY and DONE go off.
• DONE will go on after printing is complete. READY will go on after the marker returns to the Park
position, provided all parameters to continue printing are within limits (e.g., serial number limits are not
exceeded).
• If the print cycle is aborted, DONE will go on, but READY will remain off.
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Customer-supplied I/O Cable. If you choose to use a customer-supplied interface cable to connect to the
I/O port, you must comply with the following requirements.
• Use only shielded cable.
• For I/O signals, terminate cable shield at either at the laser controller or at the source, but not both.
• For TTL signals, terminate cable shield only at the laser controller.
• For TTL signals, ensure cable length to contact closure does not exceed 6.0 ft (1.8 m)
• Ensure all signals are within limits. See I/O Signal Specifications for signal limitations.
The following illustrations show a simple contact closure for input signals using customer-supplied DC power.
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The following illustration shows connections for output signals using customer-supplied DC power.
To demonstrate differences in polarity, the graphic illustrates both sourcing outputs and sinking outputs.
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Telesis-optional I/O Cable. Telesis offers an optional I/O cable #70775 for all systems that use an
embedded computer. The cable provides access to all standard I/O signals. It allows easy connection of
optional Telesis-supplied I/O devices such as a remote pushbutton station.
The I/O cable has three connectors: a DB26HDS, DB9S, and DB15P.
• The DB26HDS connects to the laser controller I/O port.
• The DB9S and DB15P are provided for connecting the remote I/O devices or circuits.
The following illustration shows a simple contact closure for Start Print and Abort when connected to I/O Cable
#70775.
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The On/Off combinations of the four input signals generate binary codes ranging from 0000 through 1111.
Each code corresponds to a specific pattern name stored in the Remote Pattern lookup table. When the
remote pattern selection feature is enabled, the software interprets the code from the four input signals and
loads the corresponding pattern.
The default file assignments reference patterns named PAT00.TTP through PAT15.TTP. If you intend to use the
lookup table as is, you must ensure that the patterns you wish to remotely select are identified exactly as
named in this table. Optionally, you may assign different pattern names to the codes.
Refer to the Merlin-II LS Operating Instructions (supplied with the marking system software) for complete
details on configuring and using the Remote Pattern Selection features.
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The Output connector allows you to monitor output signals generated by the laser marking system. Refer to
the following table for pin assignments.
9 Out Common
10 Emission Signal ON when laser is on and emission of laser radiation can occur.
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Refer to the following illustration for output cable specifications, construction, and connections.
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Examples of Marking-on-the-Fly
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If an optional encoder will be used, you must fabricate an interface cable and connect the encoder to the
Laser/Galvo Controller board. Refer to the following information to for cable and connection details.
• For systems with an external computer, the encoder connector is located on the Laser/Galvo Controller
board itself.
• For systems with an embedded computer, the laser controller provides a DB15S connector labeled MOTF.
Required Equipment
• Laser/Galvo Controller board configured for mark-on-the-fly operations
• Customer-supplied quadrature shaft encoder
• Customer-supplied TTL-level Part Position Detector
Note: A TTL-level part position detector should be used to automatically trigger marking
at the required moment every time a moving object is under the marker.
• Customer-supplied interface cable. See Interface Cable Requirements (below) for details.
Refer to the Merlin II LS Operation Instructions to enable and configure the encoder parameters.
See Enabling Mark-on-the-Fly for details.
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The /Start2 signal from the MOTF Part Present connector is OR tied with the /Start2 signal on the MOTF DB15
connector.
• When MOTF is enabled, the /Start2 signal becomes the Part Present signal. This signal controls MOTF
operations as defined by the Part Present parameter setting in the software. Refer to the Merlin II LS
Operating Instructions (Marker Properties) to enable/disable MOTF operations and to configure the MOTF
parameters.
The /Start2 signal is a TTL input signal and should be treated accordingly.
The installer must ensure that only NPN style sensors are used so that no sourcing signal is placed on the
/Start2 signal.
1 +24 VDC
2 not used
3 24 VDC Return
4 /START2 MOTF Enabled: Initiates the on-the-fly-mark (after the print cycle has been
started) based on the settings of the Part Present parameter in the
software.
MOTF Disabled: Triggers a Start Print.
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2. All system computers supplied by Telesis are configured to use the default Windows® video driver.
If the system uses a separate, external computer and it was supplied by a source other than Telesis, it
is recommended that you disable any adapter-specific video driver which may be installed. You should
use the default Windows® video driver instead. Refer to the Windows® documentation for details on
using the Windows® Device Manager.
4. If applicable, configure the laser marking system software for mark-on-the-fly operations.
Refer to the Merlin II LS Operating Instructions for details. See Enabling Mark-on-the-Fly.
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Section 3 Maintenance
3.2 Inspection
When inspecting the system, please take notice of the following:
Turn the system OFF.
If the inspection is performed immediately after the using the system, ensure the surrounding
temperature around the working field is safe.
Do not do attempt operations not specified in this manual.
Inspection frequency depends on the system requirements, types of applications, and the frequency of
usage.
Inspect the following items regularly to ensure the system runs at its peak performance level.
1. Using a thermometer, measure the surrounding temperature. Ensure it is in the range of specifications.
2. Using a hydrometer, measure the surrounding humidity. Ensure it is in the range of specifications.
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E-series/E15 Installation & Maintenance
3.3 Cleaning
Basic cleaning of the system should be conducted on a daily basis. Dirt, debris, and other build up may cause
inaccurate operation and malfunction of the system. The marking system is composed of sensitive optical and
mechanical parts that are crucial for marking performance. Even minor damage to one of these parts may
jeopardize the performance of the entire system. If the laser marking system is exposed to excess dust, the
optical parts may become damaged by dirt that is burnt by the laser beam.
The frequency of cleaning depends on the number of operations and the types of materials being marked.
Consequently, increased use of the system and materials with higher levels of particles will require more
cleaning. Inspect the system and its applications to determine proper cleaning cycles.
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2. Disconnect power at the AC input cables from the laser controller and from the laser marking head.
5. Do not remove the lens. Clean the lens while installed in the laser marking head.
6. Clean as follows:
Always wear gloves or finger cots when handling laser optics.
Do not wipe in both directions.
Always wipe in one direction to avoid adhesion of dust and scratching of the lens surface.
This may need to be repeated several times to eliminate streaking.
Use a lens cleaning tissue and methyl alcohol or isopropyl alcohol (reagent grade 99.8%, low water
content).
Use tweezers and lens tissue for hard-to-reach locations.
7. After cleaning, install the lens cap. Keep the lens protected by securing the lens cover over the lens
when the system is not in use.
3. Clean the cover of the laser marking head with lint-free cloths and a mild detergent.
Do not use liquid detergent that is highly concentrated.
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E-series/E15 Installation & Maintenance
3.4 Maintenance
Power inlet fuses are installed in the power entry module located on the back panel of the EV4GDS
Temperature Controller. Systems using 115 VAC power require one fuse. Systems using 230 VAC require two
fuses since both sides of the incoming line voltage are not at ground potential.
Perform the following steps to remove and replace the controller fuses.
3. Insert a very small, flat-tip screwdriver into the slot on the top of the power entry module cover.
See illustration. Gently pry open the cover.
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5. Remove and discard old fuse(s). Obtain replacement fuse(s). See table.
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E-series/E15 Installation & Maintenance
Removal
The fiber optic cable assembly contains an interlock switch assembly that connects the back panel of the laser
marking head. The fiber optic cable must be connected to the laser marking head to close the laser interlock
circuit. If the cable is disconnected, the laser interlock circuit will open.
Follow these steps to remove the fiber optic cable from the laser marking head.
1. EVG4DS Only:
a. On the back panel of the laser marking
head, remove four M3 screws that attach
the fiber support top to the fiber support
bottom.
b. Remove two M5 screws that attach the fiber
support bottom to the back panel.
c. Retain the top and bottom fiber support
pieces and mounting screws for installation.
2. Remove three screws that secure the interlock switch assembly to the back of the laser marking head.
3. Carefully slide the switch assembly over the fiber cable and away from the laser marking head to allow
room for disconnection.
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E-series/E15 Installation & Maintenance
4. Locate the fiber cable wrench (43172) that was supplied with the marking system.
Do not touch the end of the fiber optic cable. If the fiber
becomes scratched or damaged from mishandling or from
contact with foreign objects, burning or other similar
malfunctions may occur.
Always wear powder-free, nitrile gloves when handling
the fiber optic cable.
5. Using only the Telesis-supplied wrench, loosen the cable connection where the fiber cable attaches to
the laser marking head. Carefully disconnect the fiber cable from the laser marking head.
6. Locate the fiber cable protective caps that were supplied with the marking system.
7. Install the protective caps onto the fiber optic cable and onto the mating connector on back of laser
marking head.
Installation
Follow these steps to connect the fiber optic cable to the laser marking head.
1. Locate the fiber optic cable (71374-1 or 71375-1) attached to the laser controller.
The free end of the fiber optic cable assembly contains an interlock switch assembly. The fiber optic
cable must be connected to the laser marking head to close the laser interlock circuit. If the cable is
disconnected, the laser interlock circuit will open.
2. Locate fiber cable wrench (43172) that was supplied with the marking system.
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E-series/E15 Installation & Maintenance
3. Temporarily slide the interlock switch assembly away from free end of fiber optic cable to allow room
for connection.
Do not touch the end of the fiber optic cable. If the fiber
becomes scratched or damaged from mishandling or from
contact with foreign objects, burning or other similar
malfunctions may occur.
Always wear powder-free, nitrile gloves when handling
the fiber optic cable.
4. Remove the protective caps from the fiber optic cable and from the mating connector on the back of
the laser marking head.
5. To prevent scratching or any other damage to tip of fiber optic cable, gently insert the fiber optic cable
straight into the receptacle of the laser marking head.
6. Using only the Telesis-supplied wrench, tighten the cable connection finger tight, then no more than
1/16 turn.
7. Retain both the protective caps and the wrench for future use. These caps must be installed whenever
the fiber optic cable is disconnected. The bags attached to the fiber optic cables are provided for storing
the caps and wrench.
8. Carefully slide the interlock switch assembly over the fiber cable and into position on the laser marking
head.
9. Using three screws, attach the interlock switch assembly to the laser marking head. Tighten securely.
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3.5 Troubleshooting
This section provides troubleshooting information for the laser system. Refer to the following table to identify
problems, their possible causes and some possible solutions. If these procedures fail to correct the problem,
contact Telesis Customer Support.
Merlin II LS software locks up Conflict between the Disable any adapter-specific video driver which may
Merlin II LS software and be installed and use the default Windows® video driver
the video adapter driver instead. Refer to the Windows® documentation for
details on using the Windows® Device Manager.
LASER ON lamp Laser Off button pressed Perform a normal system shutdown (see procedure).
extinguishes Investigate and resolve any abnormal conditions
before restarting the system.
Unit does not appear to Unit not plugged in, Ensure that all power cords are properly attached and
have power improper connections, unit connected to a functional electrical outlet. See
not turned on, main power Marking System Connections (Section 2).
inlet circuit breaker is off Ensure the System Lock/Unlock key switch on the
front of the laser controller is in the UNLOCK position.
Unit appears to have Improper connections, Ensure all cables are properly attached between
power but does not F-Theta lens cap in place, computer, laser controller and laser marking head.
respond to computer laser controller not turned See Marking System Connections (Section 2).
commands on. Ensure the F-Theta lens cap has been removed from
the bottom of the laser marking head.
Ensure the Emission and Shutter Open indicators are
illuminated on the front of the laser controller.
Check the LCD screen for Status message. Refer to
the various status messages (below) for possible
causes and solutions.
Unit does not mark Improper focal distance, Ensure the surface of the work piece to be marked is
improper work piece positioned in the focal plane of the laser beam and
positioning, loose cable that the work piece itself is located in the marking
connection. field. (Refer to the E-series/E15 Operation
Supplement for details on adjusting focal plane and
using the optional aiming diode.)
Check cable connections.
Unit marks with poor Improper work piece Ensure the surface of the work piece to be marked is
quality positioning, improper positioned in the focal plane of the laser beam and is
marking parameters, parallel to the bottom of the laser marking head (i.e.
improper work piece flat).
material, poor original Experiment with the various parameter settings in the
graphics file laser marking software to obtain the highest quality
mark. Refer to the Merlin II LS Operating Instructions
for details on using the laser marking software.
Ensure the laser is able to mark on the work piece
material (try marking the desired mark on a different
material). Verify the graphics files are of good quality
prior to importing them into the laser marking
software.
Unit does not mark or Defective, damaged or If none of the previously outlined solutions correct the
marks with poor quality misaligned unit problem(s), contact Telesis Customer Support.
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E-series/E15 Installation & Maintenance
No video is displayed on If a laser controller with an 1. Turn the laser controller OFF.
the external VGA monitor embedded computer is 2. Connect the external monitor to the VGA port on
powered up without an the laser controller sub-panel.
external VGA monitor 3. Turn the laser controller ON and allow the
attached, the system will Windows® operating system to fully start.
automatically disable the The BIOS flash screen will display on the external
VGA port and change the monitor when the controller initially powers up,
settings to Internal Monitor but will go blank once Windows® starts. Wait until
mode. With the VGA port the screen is blank or the Telesis logo displays.
disabled, it is impossible to 4. Press the Windows key on the keyboard once,
view the Merlin software. and then press the P key on the keyboard twice.
Video should be restored to the monitor. As long
as an external monitor is connected during laser
controller startup, this procedure should not need
to be performed again.
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INTERLOCK The interlock circuit is open. Investigate the circuit to determine the cause of the
open circuit. Ensure the fiber optic cable is securely
connected to the laser marking head. Resolve any
abnormal conditions before restarting the system.
SHUTTER INTERLOCK The shutter interlock circuit is Investigate the circuit to determine the cause of the
open. open circuit. Resolve any abnormal conditions before
restarting the system.
SHUTTER CLOSE FAIL The system attempted to close the Power down the laser marking system and contact
shutter and could not close it. Telesis Customer Support.
SHUTTER OPEN FAIL The system attempted to open the Power down the laser marking system and contact
shutter and could not open it. Telesis Customer Support.
CRYSTAL OVER TEMP The temperature inside the Check ambient temperature. Ensure temperature is
resonator chamber (where the within operating limits.
laser crystal resides) is too high.
CRYSTAL UNDER TEMP The temperature inside the Check ambient temperature. Ensure temperature is
resonator chamber (where the within operating limits.
laser crystal resides) is too low.
Insufficient temperature will result
in an insufficient lasing beam for
marking.
DIODE OVER CURRENT The current being delivered to the Power down the laser marking system and contact
pump diode (inside the laser Telesis Customer Support.
controller) exceeds the maximum
allowable amperage.
DIODE OVER TEMP The temperature of the pump Check ambient temperature. Ensure temperature is
diode (inside the laser controller) within operating limits.
is too high.
DIODE UNDER TEMP The temperature of the pump Check ambient temperature. Ensure temperature is
diode (inside the laser controller) within operating limits.
is too low.
RF DRIVER HI PWR The RF Driver output power is Inspect the RF cable. Ensure the cable is securely
more than the maximum allowable connected. Ensure the cable is not cut or damaged.
level. The module will not output If this message appears during power up, the
power when this status is RF Driver may have a blown fuse. Please contact
displayed. Telesis Customer Support for assistance.
RF DRIVER LOW PWR The RF Driver output power is less Inspect the RF cable. Ensure the cable is securely
than the minimum allowable limit. connected. Ensure the cable is not cut or damaged.
This status will be displayed even If this message appears during power up, the
if the driver has had its output RF Driver may have a blown fuse. Please contact
turned off by another fault Telesis Customer Support for assistance.
condition.
RF DRIVER HVSWR The RF Driver is connected to a Inspect the RF cable. Ensure the cable is securely
load that does not match 50 ohms connected. Ensure the cable is not cut or damaged.
(example: connecting wire If this message appears during power up, the
damaged or disconnected). The RF Driver may have a blown fuse. Please contact
module will not output power when Telesis Customer Support for assistance.
this status is displayed.
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E-series/E15 Installation & Maintenance
If you need parts or service for your marking system, be sure to specify the equipment model number and
serial number.
Contact Telesis at one of the following locations for more information on any of these services.
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