Lesson Category: Fusion Pro

Setup Files

Here we have a sheet of keychains to cut out of an acrylic sheet we had preprinted with the flower design.

In CorelDRAW, you can also see the file we printed, along with the four registration marks printed at the corners of the design.

First, we’ll turn on the Objects docker by going to Window > Dockers > Objects.

We’ll turn off the printing objects layer and turn off printing of that layer.

Next, we’ll turn on the view of the cutting objects and printing of that layer.

And repeat this process for the registration marks.

The registration marks for the laser are an outline of the printed black circles.

We’ll just use two here to save time when setting up the job.

Print the file to the laser.

Define Laser Settings

There are two processes: Engrave and Vector.

Click the Registration marks symbol for the Engrave layer.

On the Vector layer, import the settings for acrylic cutting 1/8”.

Click Send to Job Manager to continue with your project using the registration camera.

Connect Registration Marks

In the Job Manager, select the flower-keychains.cdr file in the uncategorized files section.

In the job preview window you will see a pink registration mark highlighted.

Find the corresponding mark in the camera view and select it.

Once selected, the second registration mark is highlighted. Choose the corresponding mark.

Now confirm that the outlines are roughly positioned over the actual cut lines and click Confirm.

The hunting routine will begin with the camera exactly positioning the artwork using the registration marks.

When the screen closes, it has been sent to the laser.

Run the Job

Select the flowers-keychain job at the laser and press the start button.

The laser will cut the keychains out of the acrylic precisely regardless of where the sheet is on the table.

And you have great personalized keychains ready to sell!

X-Axis Assembly Removal

First, power off and unplug the machine.

Using a 5/32” Allen Key, remove the right side panel from the machine.

Using a 5/32” Allen Key, remove the left side panel from the machine.

Manually move the x-axis assembly to the middle of the engraver.

Remove the lens tube by using a Philips head screwdriver to unscrew the captive screw securing the front lens clamp.

Remove the left and right bellows on both sides of the machine by loosening the six (6) 5/16” nuts which secure them in place.

Put on the anti-static wrist strap. Clip the strap on to any metal part of the machine. Always wear the anti-static strap to avoid damaging the unit through static discharge.

Using a Phillips screwdriver, remove the 4 screws that secure the x-axis motor drive board cover and set the cover to the side.

Now, disconnect the 7 electrical connectors from the drive board and set the board to the side.

Remove the 4 mounting screws supporting the drive board using a Phillips Screwdriver.

Take off the anti-static wrist strap until needed when replacing the motor drive board.

Remove the four 5/32” fasteners that secure the x-axis assembly to the y-axis bearings. There are two on the right side and two on the left side.

Slide the x-axis assembly out of the engraver through the right side of the machine, taking care to clear the carriage assembly through the opening without damage.

X-Axis Assembly Installation

Insert the x-axis assembly through the right side of the engraver, taking care to clear the carriage assembly through the opening without damage.

Once fully inserted, place the x-axis assembly onto the y-axis bearing blocks. On the y-axis bearing blocks is a locating pin that ensures the correct placement on the x-axis assembly. These pins fit into an opening on both the left and right side of the x-axis assembly.

Install and/or tighten the four 5/32” fasteners that secure the x-axis assembly to the y-axis bearings. There are two on the right side and two on the left side.

Put on the anti-static wrist strap, clipping the strap to any metal part of the machine.

Replace the 4 mounting screws supporting the drive board with a Phillips Screwdriver.

Reconnect the seven (7) electrical connectors from the drive board. The electrical connectors on the drive board are all unique and as such, will only fit into one receptacle.

Replace the x-axis motor drive board cover and tighten the 4 screws securing it.

Reconnect the left and right bellows on both sides of the machine and tighten the six 5/16” nuts which secure them in place.

Install the lens tube by tightening the Phillips screw on the retaining collar which secures it, ensuring that it does not fall.

Replace both the left and right panels of the engraver.

Plug in and power on the machine.

After installation of a new x-axis assembly, confirm the home position is accurate and recalibrate it if needed.

Open the Packaging

Begin by moving the pallet and machine into the center of a room or open space.

Start by using scissors or a utility knife to cut the box straps. Stand clear of the straps, as they are under high tension and may pop out at high speed when cut.

Remove any smaller boxes from the top of the large, primary box (which contains your Fusion Pro). These smaller boxes will contain any optional accessories you purchased with your machine. Set them aside for later use.

Now remove the strapping and the wooden box topper.

Cut the tape that is securing the box, then open the box.

Remove the foam topper and the foam corner inserts.

With the foam inserts removed, pull the box up and away from the pallet.

Cut the tape that’s holding the bag closed, then spread the bag over the sides of the machine.

Remove the Machine

With the help of an additional person, lift your Fusion Edge laser system from the pallet and place it on a sturdy, level surface.

Included Items and Materials

Once you’ve removed the machine from the pallet, remove the plastic bag

You’ll find the included items and materials stored underneath.

Your Fusion Pro laser system includes:

• Power cord
• Ethernet cord
• USB cord
• Software Installation USB
• Quick Start Guide
• Owner’s Manual
• Training Suite Signup Card and Kit
• Vendor Material Sample Kit
• Lens Cleaner
• Laser Beam Alignment Target
• Bearing Lubrication Grease, and
• Camera Calibration Sheet

Cleaning the Focusing Lens

The mirrors in the periscope housing are enclosed, and will likely require cleaning less often than the other components of the optics system.

Let’s start by jogging the laser assembly toward the front of the machine for access to the optics, then we’ll turn off the machine.

The focusing lens is mounted inside the lens tube, so we’ll need to remove the lens tube for access to clean the focusing lens.

To remove the lens tube, we’ll start by slightly loosening the captive screws holding the lens assembly face plate in place.

Then rotate the face place to the left until you can see the top section of the lens tube and optics mirror. Now tighten the upper left captive screw to hold the faceplate in a upward position. This will allow for better access to the lens tube and mirror during the cleaning process.

Using the tip of the focus gauge, place it into one of the holes in the ridged ring at the top of the lens tube and rotate it to the left to loosen the lens tube.

Unplug the air assist tube from the top of the lens assembly, then slide the lens tube forward toward the front of the machine and away from optics assembly.

With the lens tube removed, twist off the cone piece at the bottom of the tube to reveal the bottom side of the lens.

To clean the lens, use a high-quality cotton swab moistened with the optics cleaner supplied in the accessory kit, then use the dry side of the cotton swab to remove any excess moisture.

NOTE: Never use Isopropyl Alcohol or Hardware grade Acetone, they contain impurities which can damage the optics in your machine. If you run out of the cleaner supplied by Epilog, Reagent or laboratory grade Alcohol can be substituted. Also, if “Golden Grain” or “Everclear” are available in your area these are also good substitutes for the optical cleaning solution.

Once the optics have been cleaned allow the optics time to dry, then twist the cone piece securely back on to the bottom of the lens tube.

Slide the lens tube back into the lens assembly making sure the air assist port is facing the right side. Then connect the top of the air assist tube back to the port on the lens assembly.

Tighten the ridged ring at the top of the lens tube by rotating it to the right using the manual focus gauge.

Cleaning the Mirror

Now we’ll move on to cleaning the optics assembly mirror. The mirror is located on the front side of the assembly and is also simple to clean.

Start by twisting the knob on the top right side of the assembly counterclockwise to loosen the mirror.

Now remove the mirror from the assembly by sliding it out towards the front of the machine.

To clean the mirror, use a high-quality cotton swab moistened with the optics cleaner supplied in the accessory kit, and use the dry side of the cotton swab to remove any excess moisture.

After the mirror has been cleaned and is completely dry, place it back into the assembly with the mirror angled down towards the table. Tighten the knob that secures the mirror in place. Lastly, close the optics assembly face plate by sliding it back into position and tightening the captive screws.

As a final note, and again, never use Isopropyl Alcohol or Hardware grade Acetone, as they contain impurities which can damage the optics in your machine.

Remove Panels

First, power off and unplug the machine.

Using a 5/32” Allen Key, remove the right side panel from the machine.

Using a 5/32” Allen Key, remove the left side panel from the machine.

Manually move the x-axis assembly to the middle of the engraver.

Remove the X-axis assembly from the machine.

Remove the lens tube by using a Philips head screwdriver to unscrew the captive screw securing the front lens clamp.

Remove the left and right bellows on both sides of the machine by loosening the six (6) 5/16” nuts which secure them in place.

Put on the anti-static wrist strap. Clip the strap on to any metal part of the machine. Always wear the anti-static strap to avoid damaging the unit through static discharge.

Using a Phillips screwdriver, remove the 4 screws that secure the x-axis motor drive board cover and set the cover to the side.

Now, disconnect the 7 electrical connectors from the drive board and set the board to the side.

Remove the 4 mounting screws supporting the drive board using a Phillips Screwdriver.

Take off the anti-static wrist strap until needed when replacing the motor drive board.

Remove the four 5/32” fasteners that secure the x-axis assembly to the y-axis bearings. There are two on the right side and two on the left side.

Slide the x-axis assembly out of the engraver through the right side of the machine, taking care to clear the carriage assembly through the opening without damage.

Loosen the four 2.5 mm x-axis motor mounting screws and move the x-axis motor towards the center of the x-axis assembly.

Remove the X-Axis Reducer Belt

Using a 7/64” Allen Key, remove the four screws that secure the x-axis reducer assembly in place.

At the left side of the engraver, loosen the four 7/64” idler mounting screws located on the front side of the x-axis assembly, and the four idler mounting screws at the rear of the x-axis assembly.

Remove the tension from the x-axis belt by loosening the two 7/64” screws on the idler assembly body.

Remove the x-axis reducer from the reducer/motor housing.

Pull the x-axis belt away from the center of the x-axis assembly.

Place the reducer assembly in the reducer/motor housing. Ensure that the notch on the reducer baseplate is pointing towards the x-axis motor.

Install the x-axis reducer assembly and the four 7/64” Allen screws that secure it to the x-axis assembly.

Install the X-Axis Reducer Belt

Using your hands, manually apply tension to the reducer drive belt by pulling the x-axis motor away from the reducer.

Once the slack has been removed from the reducer belt, tighten the four 2.5 mm x-axis motor mounting screws.

Now it’s time to tension the x-axis belt, begin to apply tension to the belt by tightening the two 7/64 belt tensioning screws that were loosened earlier, until there is no slack left on the belt.

Now you may re-install the X-axis Assembly.

Insert the x-axis assembly through the right side of the engraver, taking care to clear the carriage assembly through the opening without damage.

Once fully inserted, place the x-axis assembly onto the y-axis bearing blocks. On the y-axis bearing blocks is a locating pin that ensures the correct placement on the x-axis assembly. These pins fit into an opening on both the left and right side of the x-axis assembly.

Install and/or tighten the four 5/32” fasteners that secure the x-axis assembly to the y-axis bearings. There are two on the right side and two on the left side.

Put on the anti-static wrist strap, clipping the strap to any metal part of the machine.

Replace the 4 mounting screws supporting the drive board with a Phillips Screwdriver.

Reconnect the seven (7) electrical connectors from the drive board. The electrical connectors on the drive board are all unique and as such, will only fit into one receptacle.

Replace the x-axis motor drive board cover and tighten the 4 screws securing it.

Reconnect the left and right bellows on both sides of the machine and tighten the six 5/16” nuts which secure them in place.

Install the lens tube by tightening the Phillips screw on the retaining collar which secures it, ensuring that it does not fall.

Plug in and power on the machine.

After installation of a new x-axis assembly, confirm the home position is accurate and recalibrate it if needed.

Plug in and power on the machine.

Once the slack is removed, you will need to run an engraving test.

Plug in and power on the machine.

Open your preferred illustrating program and create a black raster box on an artboard that is:

• • For Pro 48: 46” or 1100mm wide
• • For Pro 32: 30” or 800mm wide
• • and Roughly 4” or 100mm tall

Set the speed to 100%. The power setting is unimportant, since we will be running the job with the machine lid open and the laser will not be firing.

Send the job to the engraver and start the job.

At the display panel, press the gear icon in the upper right-hand corner of the display to open the Settings menu.

Press and hold the word “Settings” that appears at the touch of the touchpad to gain access to the Advanced Settings menu.

Once in the Advanced Settings menu, enter the Diagnostics menu and locate the RMS Current reading for the X-Axis Motor/Drive.

While the job is running, the x-axis motor RMS current should be between 5.2 – 6.2A.

If the RMS current is lower than this, pause the job and increase the tension on the x-axis belt by tightening the two (2) 7/64” tensioner screws on the x-axis idler assembly.

If the RMS current is higher than this, pause the job and decrease the tension on the x-axis belt by loosening the two (2) 7/64” tensioner screws on the x-axis idler assembly.

Once the optimal RMS current value has been achieved, tighten the four 7/64” idler mounting screws at the front of the x-axis assembly and the four 7/64” idler mounting screws at the rear of the x-axis assembly.

Replace both the left and right panels of the engraver.

You have now completed replacing the Reducer Drive Assembly on the Fusion Pro.

Loosen X-Belt

Start by powering of and unplugging the machine.

Using a 5/32” Allen Key, remove the left side panel from the machine.

At the left side of the engraver, loosen the four idler mounting screws located on the front side of the x-axis assembly, and the four idler mounting screws located on the rear of the x-axis assembly.

Remove the tension from the x-axis belt by loosening the two 7/64” screws on the idler assembly body.

Now it’s time to remove the Belt Clamps. Manually move the lens carriage to the right side of the machine.

Locate the x-axis belt clamps, just to the left and right side of the lens carriage assembly. Using a 3/32” Allen key, remove the four inner x-axis belt clamp mounting screws.

Connecting Old X-Belt to New X-Belt

Now we will connect the old belt to the new belt to ensure successful installation of the new X-axis belt.

Thoroughly clean the outer (smooth) side of the belt that is currently installed in the engraver.

Pull the right side of the belt away from the lens assembly and place it next to the new belt end-to-end.

Using Duct Tape, or a similar, heavy-duty tape, join the old and new belts together by placing a strip of tape on the outer (smooth) sides.

Before securing both the old and new belts together, ensure that the orientation of the teeth match. The teeth of the belt just face towards the rear of the engraver, while the smooth side should face the front of the engraver.

Place an additional piece of tape around the connection point of the new and old belts.

Once the new and old belts have been joined together, attach the right-side belt clamp to the untaped side of the new belt. This will prevent the new belt from being pulled into the reducer housing.

Ensure that the belt clamp is centered on the belt before tightening the clamp.

Replace Old X-Belt with New

Slowly pull on the left side of the old belt to remove it while subsequently threading the new belt through the x-axis assembly.

Once the connection point between the new and old belts has exited the idler assembly on the left side of the x-axis assembly, disconnect the belts by removing the tape.

Install the belt clamps by connecting the remaining belt clamp to the left side of the x-axis belt, ensuring that it is centered on the belt before tightening the clamp.

Place the belt clamps in position. Install and tighten the four 3/32” inner x-axis belt clamp mounting screws.

Tension New X-Belt

Now it’s time to tension the X-axis belt. Begin to apply tension to the X-axis belt via the two 7/64” x-axis belt tensioning screws that were loosened earlier until there is no slack left on the belt.

Once the slack is removed, you will need to run an engraving test.

Engraving Test

Plug in and power on the machine.

Open your preferred illustrating program and create a black raster box on an artboard that is:

• • For Pro 48: 46” or 1100mm wide
• • For Pro 32: 30” or 800mm wide
• • and Roughly 4” or 100mm tall

Set the speed to 100%. The power setting is unimportant, since we will be running the job with the machine lid open and the laser will not be firing.

Send the job to the engraver and start the job.

At the display panel, press the gear icon in the upper right-hand corner of the display to open the Settings menu.

Press and hold the word “Settings” that appears at the touch of the touchpad to gain access to the Advanced Settings menu.

Once in the Advanced Settings menu, enter the Diagnostics menu and locate the RMS Current reading for the X-Axis Motor/Drive.

While the job is running, the x-axis motor RMS current should be between 5.2 – 6.2A.

If the RMS current is lower than this, pause the job and increase the tension on the x-axis belt by tightening the two (2) 7/64” tensioner screws on the x-axis idler assembly.

If the RMS current is higher than this, pause the job and decrease the tension on the x-axis belt by loosening the two (2) 7/64” tensioner screws on the x-axis idler assembly.

Once the optimal RMS current value has been achieved, tighten the four 7/64” idler mounting screws at the front of the x-axis assembly and the four 7/64” idler mounting screws at the rear of the x-axis assembly.

Replace the left side panel of the engraver.

You have now completed replacing the X-axis belt on the Fusion Pro.

Lens Tube

With the machine powered on, select the Jog icon.

Then use the joystick to move the laser head toward the front and middle of the machine to provide you easier access to the lens assembly.

Select the Focus icon, then use the joystick to lower the table to give you a little room to work.

Open the top and front doors.

Shut off the laser and remove the power cord from the machine.

Remove the lens tube by using a Philips head screwdriver to unscrew the captive screw securing the front lens clamp.

Support the lens tube from the bottom, as the tube may come out easily.

Unscrew the lens tube cap on the end of the lens tube to give you access to one side of the lens inside the tube.

Apply some lens cleaning solution to a cotton swab, then use it clean the side of the lens you just exposed. Use a dry cotton swab to dry the lens.

Turn the lens tube around and clean and dry the other side of the lens.

Screw the lens tube cap back onto the lens tube.

Place the tube back into the assembly, making sure that the hole near the bottom of the tube lines up with the air assist hole on the assembly.

Make sure the notch at the top of the lens tube lines up with the insert on the assembly as well.

When the tube is in place it should only shift slightly when twisted side to side.

Secure the front lens clamp using a Philips screwdriver.

Lens Assembly

Next, open the housing at the top of the lens tube by pivoting the plate located on the back side of the housing.

Loosen the mirror screw, then carefully slide the mirror out of the housing.

Clean and dry the mirror.

While the housing is open, clean and dry the interior and exterior of the lens assembly window.

Carefully reinsert the mirror, tighten the mirror screw, and pivot the plate to close the housing.

The plate should click into place.

Internal Mirrors

Next we’ll clean the mirrors at the top and bottom of the periscope at the rear of the machine.

Use a hex key to remove the top access plate on the left side of the machine and reveal the top mirror housing.

Also remove the bottom access plate to reveal the bottom mirror housing.

To give yourself more room to work, you may want to remove the bottom panel on the back of the machine.

Use a hex key to remove the six screws, then remove the panel and set it aside.

Let’s start with the top mirror.

Remove the magnetic housing plate.

Loosen the mirror screw, then carefully slide the mirror out of the housing.

Clean and dry the mirror.

Reinsert the mirror, tighten the mirror screw, and put the magnetic housing plate back in position.

Follow the same process for the bottom mirror.

Remove the magnetic housing plate.

Loosen the mirror screw, then carefully slide the mirror out of the housing.

Clean and dry the mirror.

Reinsert the mirror, tighten the mirror screw, and put the magnetic housing plate back in position.

Reattach the bottom panel on the back of the machine by reinserting the six screws.

Reattach the top and bottom access panels on the left side of the machine as well.

X-Axis Assembly Mirror

Finally, use a hex key to loosen the black panel locks on the blue side panel on the left side of the machine.

Set the panel aside.

Loosen the mirror screw on the mirror housing at the end of the x-axis.

Carefully slide the mirror out of the housing.

Clean and dry the mirror.

Reinsert the mirror and tighten the mirror screw.

Clean and dry the outside of the window at the top of the periscope near the back of the machine.

Reattach the blue side panel by securing the panel locks.

Plug the machine in and turn it on.

Whenever you move or adjust the lens or mirrors, we suggest you run the laser alignment procedure to ensure everything is still properly aligned.