CO10A Laser Marking System

CO10A Laser Marking System – General Arrangements

SYSTEM OVERVIEW SYSTEM CONFIGURATION

The Telesis® CO10A is a 10-watt, RF-excited, continuous wave, The CO10A is available in several configurations. The system
sealed-tube, CO2 laser marking system that provides a galvo- computer, required for running the Merlin® II LS software, may
steered beam designed for marking. The CO10A laser marking be external device connected to the laser controller, or
system is excellent for marking substrates like wood, glass, embedded within the laser controller itself. Additionally, the
Plexiglas®, quartz, ceramics, fabrics, and other organic system may be configured to mark only stationary objects or for
materials. marking objects while they are moving (i.e., mark-on-the-fly
The CO10A laser offers these advantages: operation).
• Air-cooling – no external water or refrigerant needed The modular design allows for major components to be easily
replaced and returned to Telesis if required. The basic laser
• Compact laser marking head and simple mounting system system consists of the following components.
• Detachable laser head cable assembly for easy integration • Laser Marking Head – includes the laser tube, optics,
• Visible red aiming diode shutter assembly, galvanometer assembly, and flat-field
• Standard 115/230VAC operation lens. A coaxial red aiming diode is included for pin-point
marking alignment.
• Key switch, Laser Off button, interlocked safety shutter,
and emission indicators • Laser Controller – contains circuit boards, electrical
components, and the operator console
• DoD-compliant Unique Identification (UID) marking
• Cable Assemblies – power, control, and data cables
• Software – Merlin II LS Laser Marking Software
• System Computer – may be an external device connected
to the laser controller or embedded within the laser
controller itself. If external, the computer may be
supplied by Telesis or by the customer.
• Monitor, Keyboard, and Mouse – supplied by Telesis
for systems with embedded computers; may be supplied
by Telesis or by the customer for systems with external
computers.

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CO10A Laser Marking System

SYSTEM SPECIFICATIONS SYSTEM SETUP

Compliance.............................. CDRH The following procedures are listed for reference only to provide a
general overview of the installation process. Refer to the CO10A
Laser Type ............................... RF-excited, continuous wave, Installation & Maintenance Manual for complete installation details.
sealed-tube, carbon dioxide laser
Wavelength.............................. 10.6 micrometers (µm) Do not connect any power cable to power source
until all system connections are made.
Long Term Output
Power Drift .............................. < ±5% 1. All equipment must remain powered down and in the OFF
Power Requirements ............... 115 VAC, single-phase, position until mounting and connection are complete.
9.0A, 50/60Hz
230 VAC, single-phase, 2. Place the laser controller, monitor, keyboard, mouse, and if
4.5A, 50/60Hz applicable, the external system computer, in the desired
locations. Locate the laser controller as close as practical to
System Power (total) ............... approx. 480W, the laser marking head.
4.2A at 115 VAC
Maximum Supply Voltage ..... 264 VAC 3. Ensure sufficient clearance exists on all sides of the laser
controller to allow for proper air circulation and to permit
Supply Voltage Fluctuation .... < ±10% with clean ground proper installation of applicable cables. Refer to the C1030
Operational Temp ................... 15° to 30°C (59° to 86°F) Laser Controller Dimensions drawings for details.
Recommended Temp .............. 16° to 24°C (61° to 75°F) 4. Place the laser marking head on a suitable mounting
Ambient Relative Humidity ... 10% to 90% non-condensing surface.

5. Ensure sufficient clearance exists on all sides of the laser

marking head to allow for proper air circulation and to
permit proper installation of applicable cables.
SYSTEM OPTIONS
• External computer (desktop or notebook with powered 6. Mount the laser marking head with three M8-1.25 bolts and
cardbus-to-PCI expansion enclosure) to run the lock washers using the factory-tapped mounting holes
Merlin II LS Laser Marking Software provided. Refer to the CO10A Laser Marking Head
Dimensions drawing for details.
• Embedded computer within laser controller to run
Caution: Maximum mounting bolt penetration into
Merlin II LS Laser Marking Software
the laser marking head is 7.8 mm (.31 in.).
• Laser Controller Fuse/Connector Kit Note: Optionally, three M6 locating pins may be
• Remote pushbutton station (start/abort) used at the 0.2362 P6 hole locations for more
• Externally-mounted focus-finder diode precise marking head alignment.
• Mark-on-the-fly kit to interface with customer-supplied 7. Connect all cables remaining cables, as applicable.
encoder for marking objects in motion (linear or circular)
• I/O options (see Remote Communications for details):
8. Connect any optional or customer-supplied devices or
interface circuits as applicable.
TTL via PCI-DIO24 Board
Opto-isolated via Merlin DCIO Module 9. Refer to the CO10A Operation Supplement for proper
Two-axis Controller startup procedure. Refer to the Merlin II LS Operating
• Manually operated tool post for z-axis adjustment Instructions for complete information on using the system
• Programmable tool post for z-axis adjustment (requires
software.
two-axis controller)
• Programmable rotary drive fixture for theta-axis
adjustment (requires two-axis controller)
• Workstation / Work Area Enclosure
• Fume Extraction Systems

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 CO10A Laser Marking System

CO10A Laser Marking Head Dimensions

C1030 Laser Controller Dimensions

(external computer configuration shown – embedded computer configuration similar)

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CO10A Laser Marking System

CO10A LASER MARKING HEAD SAFETY LABELS

The following illustration shows the labels and their locations
on the CO10A laser marking head. Please familiarize yourself
with the laser labels and their locations prior to operating the
laser marking system.

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C1030 LASER CONTROLLER SAFETY LABELS

The following illustration shows the labels and their locations
on the C1030 laser controller. Please familiarize yourself with
the laser labels and their locations prior to operating the laser
marking system.

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CO10A Laser Marking System

CO10A LASER MARKING HEAD

The laser marking head incorporates the latest technology in Marking Field Size
sealed-tube, RF-excited, continuous wave, carbon dioxide The size of the marking field is dependent on type of lens
lasers, providing excellent output power, stability, and reliability installed on the laser marking head. See Flat-Field Lens.
in a rugged compact modular package.

Marking Depth
CO10A Laser Marking Head Specifications Simple laser parameters can be operator programmed to create
Dimensions (L x W x H) ....... 857.07 x 165.13 x 221.07 mm depths ranging from simple surface discoloration, shallow laser
(33.743 x 6.501 x 8.704 in.) etching, or deep laser engraving. Marking depth is dependent
on several factors including material, lens type selected, and
Surrounding Envelope ........... see CO10A Laser Marking Head laser marking parameters. Please contact Telesis for the proper
Dimensions drawing setting for your specific application.
Electrical Power ..................... 330 watts (approximate)
Mounting Weight .................. 19.1 Kg (42 lbs.) Flat-Field Lens
Mounting ................................ three factory-tapped The flat-field lens is key to the marking performance of the
M8-1.25 holes system. This is the final coated optical lens that the beam will
Positioning .............................. visible red aiming diode pass through before it strikes the marking target. This lens is
called a flat field lens because when the beam is focused, the
Field Resolution ..................... 16 bit (65535 data points) focus lies in a plane perpendicular to the optical axis of the lens.
Galvanometer The following chart outlines the available lenses, the resulting
Repeatability........................ < 22 micro radian image field (marking window) provided by the lens, and the
Marking Field Size ................ lens-dependent, see chart working clearance (in millimeters and inches) to properly focus
Laser Marking Head Cable.... 1.8 m (6 ft.), detachable the laser for marking.
Laser/Galvo Control Cable .... 3.6 m (12 ft.), detachable
Image Field Working
Cooling ................................... air cooled, fans Lens Marking Window Clearance
(mm) (in.) (mm) (in.)

75 mm 50 x 50 1.97 x 1.97 54 2.13

Dual-Sensor Shutter Circuit 100 mm 70 x 70 2.76 x 2.76 81 3.19
The CO10A laser marking head employs two separate sensors to
150 mm 100 x 100 3.94 x 3.94 131 5.16
detect the closed-state of the laser shutter mechanism. The
sensor signals can be monitored at the Outputs Connector on the 200 mm 140 x 140 5.51 x 5.51 184 7.24
back panel of the laser controller. When the shutter is open, the
sensor feedback signals are OFF. When the shutter is closed, the 250 mm 170 x 170 6.69 x 6.69 233 9.17
sensor feedback signals are ON.
300 mm 205 x 205 8.07 x 8.07 283 11.14

360 mm 250 x 250 9.84 x 9.84 351 13.82

Visible Red Aiming Diode

Laser marking head includes a visible red diode that can be
viewed on the work surface without the need for protective
safety goggles.
The aiming diode provides a safe and convenient aid for laser
setup and part programming. Since the red beam is located after
the shutter, the aiming beam may be used with the shutter
opened or closed. Additionally, the visible red beam may be
used with the lasing beam during the marking cycle. Note that
protective eyewear must always be worn when the laser is in
operation.

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C1030 LASER CONTROLLER Connector (Back) Panel for External Computer Usage
The laser controller is remotely connected to the laser marking The rear panel of the controller provides a power entry module
head by the laser marking head cable assembly. The cable with circuit breaker and connectors for the laser marking head
assembly carries power and control signals to the laser marking cable and the laser/galvo control cable. It also provides a remote
head. interlock connector and a remote pendant connector. An output
The laser controller provides the electrical control of the laser connector allows you monitor output signals reporting the status
marking system. The controller connects to the facility electrical of the shutter, laser emission, and fault conditions.
supply to provide power to the laser marking system. The laser
controller is also the electrical interface between the laser
marking software (installed on the system computer) and the
laser marking head. It provides buttons and indicators to control
and monitor the laser marking process.

C1030 Laser Controller Specifications

Dimensions (W x H x D) ...... 425.20 x 140.21 x 504.44 mm
C1030 Laser Controller
(16.74 x 5.52 x 19.86 in.)
Back Panel – External Computer
Surrounding Envelope........... see C1030 Laser Controller
Dimensions drawing
Weight .................................... approx. 8.14 Kg (17.9 lbs.)
Cooling................................... air cooled, fan/filter Connector (Back) Panel with Embedded Computer
The rear panel of the controller provides a power entry module
with circuit breaker and connectors for the laser marking head
Operator (Front) Panel cable and the laser/galvo control cable. It also provides a remote
The laser control panel includes the system enable key switch, a interlock connector and a remote pendant connector. An output
soft power on/off button, green power indicator, laser start push connector allows you to monitor output signals reporting the
button, laser off push button, safety shutter open and close status of the shutter, laser emission, and fault conditions.
controls, and a laser on (emission) indicator. An opto-isolated I/O connector and an I/O cable is provided for
connection to the remote I/O devices. Refer to Remote
Communications for more information.
Connections for the embedded system computer are mounted on
a sub-panel. The separate panel allows you to connect a monitor,
keyboard and mouse directly to the laser controller. Additional
RS-232, Ethernet, and USB ports are provide for other optional
connections and usage with Telesis software.

C1030 Laser Controller – Front Panel

C1030 Laser Controller

Back Panel – Embedded Computer

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CO10A Laser Marking System

SYSTEM COMPUTER SYSTEM SOFTWARE

The laser system requires an IBM-compatible computer for The powerful Telesis Merlin II LS Laser Marking Software is a
running the Merlin II LS Laser Marking Software. The system Windows® based software package that comes standard with the
computer may be an external device connected to the laser laser marking system. It is a graphical user interface that makes
controller, or it may be embedded within the controller itself. marking pattern design quick and easy. The WYSIWYG (what-
you-see-is-what-you-get) interface provides a to-scale image of
the pattern as it is created. Just “click and drag” for immediate
adjustment to field size, location, or orientation.
NOTICE
The Merlin II LS software includes tools to create and edit text
at any angle, arc text, rectangles, circles, ellipses, and lines.
Merlin II LS software and associated applications
Multiple fields may be grouped and saved as a block to form a
are pre-installed on the embedded computer. The
logo. Existing DXF files can also be imported for marking. Non-
embedded system supports Telesis-installed software
printable fields can be created to clearly display a graphical
only and does not support user-installed programs.
representation of the part being marked.
All system computers supplied by Telesis (external and
embedded) have the laser/galvo controller board and the
Merlin II LS software installed prior to shipment so the entire
assembly is tested as a laser marking system. Warranties for the
computer, keyboard, monitor, and peripherals default to the
original equipment manufacturer.

If the external system computer is supplied by anyone other than

Telesis it must use the following software:
Operating System ........ Windows®2000, XP, Vista® (Business),
7 (professional), or 8 (Professional)
Operator Interface........ Telesis Merlin II LS Laser Marking
Software

Additionally the system computer must, at a minimum, meet the

following specifications:
Processor ...................... Pentium® III with RAM as
recommended per operating system
Hard Drive ................... 2 GB Hard Disk Drive
External Drives ............ CD-ROM Drive Merlin-II LS User Interface
Comm Ports ................. One available RS-232 Serial Port,
Two available USB Ports,
Two available Ethernet Ports,
Two available full-height PCI Slots † Merlin II LS Laser Marking Software Specifications

Circuit Cards ................ Laser/Galvo Controller Board, Font Generation ............ True Type Fonts
Video Board Barcodes and Matrix ..... 2D Data Matrix, PDF417, BC 39,
Peripherals ................... SVGA Color Monitor, Mouse ‡, Interleaved 2 of 5, UPCA/UPCE
Keyboard ‡ BC 128, Maxi Code, Code 93, QR
Code and others
† One additional PCI slot required if
system is configured for mark-on-the-fly Graphic Formats............ Raster and Vector: BMP, GIF, JPG,
operation. If the system computer is a WMF, EMF, DXF, CUR, ICO
notebook, expansion must be used to Serialization .................. Automatic and Manual Input
provide the PCI slots.
Host Interface Capable
‡ Telesis recommends a USB mouse and a Linear Marking ............. Scalable w/ Letter Spacing Control
USB keyboard for system computers
that are embedded in the laser Arc Text Marking.......... Scalable and Adjustable
controller.
Drawing Tools .............. Line, Rectangle, Circle, Ellipse

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Remote Communications Communications Protocol

The communication capability of the laser marking software Two types of host interface are supported (RS-232 or TCP/IP) and
allows you to control the laser from a remote source. Remote two communication protocols are provided through the Merlin II LS
communications can be performed by connecting to a Host laser marking software: Programmable and Extended.
computer, an optional two-axis Auxiliary Controller, or to
remote I/O devices. Programmable Protocol. Programmable protocol provides
one-way (receive only) communication with no error checking
Host Communications. Remote communications may be or acknowledgment of the transmitted data. You may use
executed from a host computer using RS-232 or Ethernet Programmable protocol to extract a continuous portion of a
(TCP/IP) connections to the system computer running the message string to print. This can be used with a host computer
Telesis laser marking software. The software provides or a bar code scanner. Note that XON/XOFF Protocol applies
parameters to define the data transmitted to and from the host. even when Programmable Protocol is selected.
For more information on using and configuring these The Programmable Protocol Message Type identifies the type of
parameters, refer to the Merlin II LS Operating Instructions. message sent from the host. It determines how the marker uses
the data it extracts from the host message string when
Two-axis Controller. Telesis offers an optional two-axis
Programmable Protocol is used.
auxiliary controller for all laser marking systems that use the
Merlin II LS laser marking software. The Auxiliary Controller 49 Message type 49 (ASCII 1) overwrites the content of the
provides an interface for connecting the optional vertical (Z) first text-based field in the pattern with the data extracted
axis and the optional rotary (Theta) axis. The Auxiliary from the host message. Note that if the field contains
Controller may be configured with additional board to support message flags, they will be overwritten, not updated.
two additional linear axes (L1 and L2). For installation details, 65 Message type 65 (ASCII A) updates the Offset Angle
refer to the Auxiliary Controller Installation & Maintenance parameter with the data extracted from the host message.
Manual supplied with the controller. Syntax for the transmitted string is ±n where ± is a
positive or negative sign and n is an integer that
I/O Kits for Systems with External Computers. Telesis offers represents the offset angle for the marking window.
optional I/O kits that provide up to 12 additional, programmable 72 Message type 72 (ASCII H) updates the Offset X/Y
I/O signals (6 inputs and 6 outputs). All kits provide an I/O card, parameters with the data extracted from the host
pre-installed SIPs resistor packs, and software driver CD. For message. Syntax for the transmitted string is ±X.X,
details on connecting and using the additional I/O signals, refer to ±Y.Y where ± is a positive or negative sign, X.X
the Installation Supplement provided in each of the kits. represents the X-axis offset distance, and Y.Y represents
• Kit 53920 (1) provides a PCI-DIO24 card.
the Y-axis offset distance.
80 Message type 80 (ASCII P) indicates the data extracted
• Kit 53928 (2) provides a PCI-DIO24 card, from the host message is the name of the pattern to be
the Merlin I/O Interface Module, and loaded.
two cable assemblies. 81 Message type 81 (ASCII Q) updates the text in the first
• Kit 74445 (1) provides a PCIe-DIO24 card (PCIe x1). query text buffer (buffer 0) with the data extracted from
the host message.
• Kit 53928 (2) provides a PCIe-DIO24 card (PCIe x1),
86 Message type 86 (ASCII uppercase V) updates the text
the Merlin I/O Interface Module, and
in the first variable text field in the pattern with the data
two cable assemblies.
extracted from the host message.
1) This kit does not provide opto-isolated signals. Telesis does not 118 Message type 118 (ASCII lowercase v) updates the first
endorse direct connection of I/O signals to the I/O board. Direct
connections to high current/high voltage devices will damage the text field encountered in the pattern that contains a
board. variable text flag that matches the specified string length.
2) When using the Merlin I/O Interface Module in this kit, additional 0 Message type 0 (zero) indicates that host will provide
I/O racks or opto-isolated board assemblies are not required. message type, field number (if applicable), and data;. This
delegates message type selection to the host on message-
I/O Connector for Systems with Embedded Computers. by-message basis. The host message must use the format:
Controllers configured with an embedded computer provide an Tnn<string>
opto-isolated DB26P I/O connector. Separate I/O racks or opto-
where:
isolated board assemblies are not required. In addition to the
T = the message type (1, A, H, P, Q, V, or v)
standard input signals (Go, Abort, Input 1 through Input 4) and
standard output signals (Done, Ready, Paused, Output 1 through nn = the two-digit field number or query text
Output 3), this connector provides two programmable inputs and buffer where data will be placed.
two programmable outputs. For more information on connecting Note: Not used with Message Types A, H, P.
and using the opto-isolated I/O connector, refer to the CO30AF <string> = the pattern name to load (Message Type P).
Installation & Maintenance Manual. or
the data to be inserted into the field or the
query text buffer, as applicable
(Message Types 1, Q, V, or v ).

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Communications Protocol (continued)

Extended Protocol. Extended protocol provides two-way communication with error checking and transmission acknowledgment. It is
designed to provide secure communications with an intelligent host device using pre-defined message formats and response formats where
serial communication is a vital part of the marking operation.
All communications are carried out in a parent/child relationship with the host being the parent. Only the host has the ability to initiate
communications. The following describes the Extended Protocol message format as sent from the host to the Merlin II LS software.

SOH TYPE [##] STX [DATA] ETX BCC CR

where: STX ASCII Start of Text Character (002H).
SOH ASCII Start of Header character (001H). The system [DATA] Character string that may be required for certain
ignores all characters received prior to the SOH. message types (e.g., Type 1, A, E, H, P, Q, or V).
TYPE A single, printable ASCII character that defines the Typically, data is sent in the format:
meaning (type) and content of the message nn<string>
downloaded from the host, where: where:
1 Message Type 1 provides data to a text string nn = the two-digit field number or query
in the pattern or polls the pattern for data. text buffer where data will be placed.
See [DATA] for details. (Message Types 1, Q, or V).
A Message Type A provides data to the system <string> = the data to be inserted into the field or
Offset Angle parameter for the marking the query text buffer, as applicable
window or polls the system for data. (Message Types 1, Q, or V).
See [DATA] for details. or
E Message Type E allows the host to take the the pattern name to load
machine offline. It also provides the option of (Message Type P).
displaying an error message box with the or
provided data string. See [DATA] for details. the value of the X/Y Offset
(Message Type H).
G Message Type G initiates a print cycle.
or
H Message Type H provides data to the system the value of the Offset Angle
X/Y Offset parameters or polls the system for (Message Type A).
data. See [DATA] for details.
ETX ASCII end of text character (003H).
I Message Type I polls the system for the I/O
BCC Optional Block Check Code that is generated and
status.
sent to improve link reliability by providing fault
O Message Type O places the marker online. detection. The BCC is calculated by taking an eight
This allows a host computer to reset. For bit addition of the TYPE and DATA TEXT
example, this may be used to recover from a characters and transmitting them as a three digit
power outage when the marker is unattended. ASCII decimal number in the range from 000 to
P Message Type P loads a pattern or polls the 255. If the sum is greater than 255, the most
system for the current pattern name. significant bit overflows and is discarded.
See [DATA] for details. CR ASCII Carriage Return Character (00DH).
Q Message Type Q provides data to the system
query text buffer or polls the system for data.
See [DATA] for details.
S Message Type S polls the system for the
machine status. The machine status is
returned to the host in an eight-character
hexadecimal mask.
V Message Type V provides data to a variable TRADEMARKS
text string in the pattern or polls the pattern Telesis and Merlin are registered trademarks of Telesis
for data. See [DATA] for details. Technologies, Inc. in the United States and/or other countries.
[##] Optional two-digit ASCII number that specifies the Pentium is a registered trademark of Intel Corporation in the
Station ID of the system in multi-drop network United States and other countries.
applications. The ID may range from 00-31. Note Plexiglas is a registered trademark of Arkema, Inc.
that “00” is reserved for applications where only Windows and Vista are registered trademarks of Microsoft
one controller is used. In such applications, this Corporation in the United States and other countries.
field may be eliminated and “00” will be assumed.

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