Lesson Category: Fusion

Remove Panel

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

Remove the top access panel on the left side of the machine by using a 5/32” hex key to turn the black panel locks ¾ of the way counter-clockwise.

Adjust Belt Tension

Use a 7/64” hex key to loosen the x-axis pulley mounting screw located in front of the x-axis belt, accessible through a circular hole in the top of the x-axis assembly. Then loosen the second mounting screw located in the open channel behind the x-axis belt.

Next, loosen the two x-axis pulley mounting screws located on the top of the x-axis assembly.

Use a 5/32” hex key to adjust the tensioning screw accessible from the end of the x-axis assembly.

Loosening the screw will loosen the belt. Tightening the screw will tighten the belt.

Once you’ve achieved the ideal tension, use a 7/64” hex key to retighten the two pulley mounting screws.

Reinstall Panel

Replace the top access panel on the left side of the machine, using a 5/32” hex key to turn the black panel locks ¾ of the way clockwise.

Plug the machine in and turn it on.

Remove Panels

We’ll start by replacing the left sensor, then move on to the right sensor.

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

Remove the top access panels on both the left and right side of the machine by using a 5/32” hex key to turn the black panel locks ¾ of the way counter-clockwise.

Shift X-Axis Assembly Right

On both ends of the x-axis assembly, loosen the two green captive screws until they turn freely.

Carefully lift the assembly from its mounted position and shift it to the right, allowing the left end of the assembly to rest on the left side of the chassis so that all three screws on the left sensor housing are easily accessible.

Remove Old Left Sensor

Use a Phillips-head screwdriver to loosen the three screws securing the sensor housing.

Upend the sensor housing and catch the screws as they fall free.

Slide the sensor down out of the housing and set the housing aside.

Cut the zip tie securing the sensor wires to the x-axis assembly.

In the back of the x-axis assembly, disconnect the sensor’s black connector and slide it out through the hole where the Air Assist tube is also located.

Set the old sensor aside.

Install New Left Sensor

Take the new sensor and insert the black connector through the hole with the Air Assist tube.

Reconnect it with the black connector in the back of the x-axis assembly.

Slide the sensor into the slot on the sensor housing.

Hold the sensor housing upright, supporting the senor so that it doesn’t fall out, and insert the two screws that secure the sensor.

Align the sensor housing with the screw holes on the x-axis assembly and screw in the two screws.

Then screw in the third screw on the left end of the sensor housing.

Slide a new zip tie through the two small slots on the x-axis assembly and secure it around the sensor’s wires.

Cut off any excess length of the zip tie.

Shift X-Axis Assembly Left

Now shift the x-axis assembly to the left, allowing the right end of the assembly to rest on the right side of the chassis so that all three screws on the right sensor housing are easily accessible.

Remove Old Right Sensor

Use a Phillips head screwdriver to loosen the three screws securing the sensor housing.

Upend the sensor housing and catch the screws as they fall free.

Slide the sensor down out of the housing and set the housing aside.

Cut the zip tie securing the sensor’s wires to the other set of wires.

Disconnect the sensor’s black connector and set the sensor aside.

Install New Right Sensor

Connect the new sensor’s black connector.

Slide the sensor into the slot on the sensor housing.

Hold the sensor housing upright, supporting the senor so that it doesn’t fall out, and insert the two screws that secure the sensor.

Align the sensor housing with the screw holes on the x-axis assembly and screw in the two screws.

Then screw in the third screw on the right end of the sensor housing.

Secure the sensor’s wires to the other set of wires with a new zip tie. Cut off any excess length of the zip tie.

Reinstall X-Axis Assembly

Place the x-axis assembly back on its mountings and secure it by tightening its four green captive screws.

Reinstall Panels

Replace the top access panels on the left and right sides of the machine, using a 5/32” hex key to turn the black panel locks ¾ of the way clockwise.

Plug the machine in and turn it on.

Setting Up Your Page

We’ll start by creating a new file in CorelDRAW.

Click on the Get Started option on your Welcome screen, then click the New Document button. You can also use the shortcut keys Ctrl + N for opening a new document.

Now enter your page size. Enter 4” for the page width and 4” for the page height, then click OK.

Creating a Keychain Jig

For this project we’ll be engraving a wooden keychain, but first let’s create a cardboard jig to hold our keychain in place and reduce our setup time in the future.

To create a jig we need to create a hole the same size as the keychain so we can accurately place the keychain within the jig. Start by measuring the width of the keychain you received in your Training Suite packet. Use a set of calipers or a ruler to measure the keychain. The keychain should be 1.6”. We’ll use this later to set the diameter for the jig circle.

Now we’re going to draw a circle in CorelDRAW. Select the Ellipse tool in the toolbox on the left. While holding down the Ctrl key, click and drag across the page to create a circle. The size won’t matter as we are going to manually key in the width (diameter) for our jig circle.

Once you’ve drawn your circle, click on the Lock Ratio button in the Properties bar at the top of the screen. Turning on the Lock Ratio option will make sure that the width and height of the circle are the same when we change the width in the following step.

Now enter the Width (diameter) of the keychain you measured earlier into the Object Size box at the top of the screen. We’ll enter 1.6” here, then press Enter key.

Now, we need a spot in the jig for the eyelet and ring to rest. Select the rectangle tool in the toolbox. We’ll need the rectangle to start about 0.25” above the circle and be about 0.25” wide.

Click and drag from above the circle down into the circle to create the cutout for the eyelet and ring.

If you prefer you can align the rectangle to the center of the page horizontally by selecting Object > Align and Distribute > Center to Page Horizontally.

Printing to the Laser (Jig Cutting)

Now that we’ve completed the outline for our jig, we now want to print this file to the laser. Select File, then Print from the dropdown menu at the top of the screen. Select your Fusion laser from the printer options, and then click the Preferences button.

In the Laser Dashboard:

• Set the Job Type to Vector.
• Change the Piece Size to 4” x 4”.
• Set the Speed to 20%, Power to 100%, and Frequency to 10. (Refer to your laser manual for the suggested speed, power, and frequency settings for cutting cardboard with your wattage of laser.)
• Make sure Send to Laser is checked.
• Uncheck Send to Job Manager.

Then click the OK button.

The print preview should now look like our Corel file.

Finally, click Print to send the job to the laser!

Cutting the Jig at the Laser

At the laser, position your piece of cardboard in the Home Position at the top-left corner of the work area.

Hang your manual focus gauge on the optics assembly. Then select the Focus option on the keypad and press Up on the joystick to move the table up and bring the cardboard into focus. Once you’ve focused, remove the manual focus gauge and press the Reset button.

Now we’re ready to start the job. Press the Go button on the keypad to begin cutting your jig for the keychain engraving.

Importing Graphics

With the jig for the keychain cut, now it’s time to set up our graphic for the keychain. Keep your jig design open in CorelDRAW, as we are going to build from it and use the jig lines as a design template.

Now we’re going to import a graphic, resize it, and center the graphic to the jig circle for engraving on the wooden keychain. We’ll use a sea turtle graphic (sea-turtle.eps ) for this example, but you can use any graphic you prefer.

To import the file, select “File”, then “Import” from the drop-down menus at the top of the screen.

When the Import EPS options pop up you can leave the defaults as they are. Press the OK button to continue.

Now, click anywhere on the page to place the graphic in the work area.

Aligning and Resizing the Graphic

Now we need to align our turtle to the center of the circle and resize it to fit within the bounds.

Make sure the object is still selected, then click Object from the drop-down menu at the top of the screen, then Align and Distribute, then Center to Page. You can also use the shortcut option of pressing the letter ‘P’ on your keyboard to center the image to your page.

You’ll notice we have a little extra space to the bottom right of the turtle, so we’re going to click and drag the turtle down to the right a bit to visually center the turtle to the circle.

Printing to the Laser (Front Engraving)

With the graphic ready to go and still selected, we’re ready to print the graphic to the laser.

Select File, then Print from the dropdown menu, or press Ctrl + P on your keyboard.

Select your laser from the printer options.

Under Print Range, click Selection as the option. This setting will print only the graphic you had selected to the laser, and not the jig outline we are using as a template.

Then click the Preferences button.

In the Laser Dashboard:

• Set your Resolution to 600 dpi
• Select Raster from the Job Type options. (We’ll use Raster since we’re only engraving this file, not cutting.)
• Set the Speed to 60% and Power to 100%. (Refer to your laser manual for the suggested speed, power, and frequency settings for cutting cardboard with your wattage of laser.)
• Select Bottom-Up for the Engraving Direction.
• Select Stucki as the Image Dithering pattern. (The Stucki setting will randomize the dot pattern in the graphic and give us a consistent look to our wood engraving.)
• Set the piece size to match your page size. Set the horizontal and vertical size to 4.00 inches.
• Make sure Send to Laser is checked.
• Uncheck Send to Job Manager.

Then click the OK button.

The print preview should now look like our Corel file.

Finally, click Print to send the job to the laser!

At the Laser (Front Engraving)

At the laser, we’ll place the keychain into our jig located in the top-left corner of our work area.

Hang your manual focus gauge on the optics assembly. Then select the Focus option on the keypad and press Up on the joystick to move the table up and bring the keychain into focus. Once you’ve focused, remove the manual focus gauge and press the Reset button.

Now we’re ready to start the job. Press the Go button on the keypad to begin your wood keychain engraving job.

Engraving the Backside with a Name

There are great time-saving advantages to using jigs when you need to engrave multiple items, or need to engrave on the backside of an item.

Let’s go ahead and engraving the backside of our keychain with a name to personalize the keychain for someone.

Flip the keychain over in the jig to get started.

Back in CorelDRAW, we’re going to use the Text tool to add a name to our keychain. Select the text tool from the Toolbox options on the left side of your screen, and click anywhere on the page. Type out the name you would like to add to the keychain, and select the typeface you’d like to use for the name.

We’re going to use the name Charlotte in Birch Std (Standard) for our example.

Once you’re finished typing out the name and selecting the typeface, click and drag the turtle outside of the page bounds, because we don’t want the turtle to be included in our next engraving.

Then press the ‘P’ shortcut key on your keyboard to center the name to the page and the jig bounds.

If you need to, resize the name to better fit it to the keychain’s engravable area. Remember to hold down the Shift key while resizing to keep the proportions of the text the same as you resize it.

Printing to the Laser (Back Engraving)

Since we’ve already engraved one side of the keychain, the engraving settings we used from the previous turtle engraving job will be saved in the Print Driver Dashboard settings. All we need to do now is hold Ctrl, then press ‘P’ on the keyboard, or you can click File, then Print from the menus at the top of the screen to print the file to the laser.

Make sure the preview only shows the text you’ve selected to print, then click the Print button.

At the Laser (Back Engraving)

We’ve already flipped our keychain over to engrave the backside, and the laser’s focus is already set.

Simply press the Go button on the laser to engrave the name.

And then you’re done!

Setting Up Your Page

We’ll start by creating a new file in CorelDRAW.

Click on the Get Started option on your Welcome screen, then click the New Document button. You can also use the shortcut keys, Ctrl + N, for opening a new document.

Now enter your page size. Enter 3.5” for the page width and 3.5” for the page height, then click OK.

Adding Guides for Your Engraving Area

The glass coaster you received with your laser system includes four rubber feet on the bottom of the coaster ½” in from each side.

For this example, we are going to engrave on the bottom of the coaster, so we want to make sure we don’t engrave on the rubber feet.

To prevent from engraving on the coaster feet, we’ll set up a few guidelines to represent the bounds of our engraving area within our page.

Before we get started, we need to confirm that the top left corner of our page is set to the origin for both of the ruler bars. Look at your Horizontal and Vertical rulers to determine if the top left corner of your page is set to 0 for the Horizontal Ruler and 0 for the Vertical Ruler. If they are you’re all set. If not, locate the Origin Point tool at the top left corner of your work area

Then click and drag to the top left corner of your page to set the new Origin point.

To create our guidelines, we’ll start by creating two horizontal guides for the top and bottom boundaries.

Click on the ruler at the top of the page and drag one guide down to -1/2 inch and another to -3 inches.

You may find it easier to click and drag the guides to the approximate location, then type in the specific Y Object Position values for each of the guidelines in the Properties bar located at the top of the screen.

Next, we’ll create two vertical guides for our left and right boundaries.

Click on the ruler at the left side of the page and drag one guideline across to 1/2” and another to 3”.

Again, you may find it easier to drag the guidelines to the approximate locations, then key in the 1/2” value for the first guide and the 3” value for the second guide in the X Object Position box in the Properties bar.

Importing a Graphic

Now we’re going to import a graphic and center it to the page. Here we’ll use a fish graphic (fish.wmf ) for this example, but you can use any graphic you prefer.

Start by clicking File at the top of the screen, then select Import from the drop-down menu.

Navigate to the file you’d like to Import, then select the file and click the Import button.

Now, click anywhere on the page to place the graphic.

Centering

Next, we’ll center the image to the page.

Make sure the object is still selected, then click Object from the drop-down menu at the top of the screen, then Align and Distribute, then Center to Page.

You can also use the shortcut option of pressing the letter P on your keyboard to center the image to the page.

Resizing

Now we need to resize the fish image to fit inside our boundary guidelines.

To resize the graphic, we’ll click and drag on the top right resizing handle to resize the image and make it smaller.

By clicking on the top-right sizing handle, then holding the Shift key and dragging toward the center of the image, we can keep the proportions of the image the same as we make it smaller.

Drag the sizing handle until the right or left side of the fish graphic aligns with a vertical guideline.

Mirroring for Backside Engraving

As a final step before printing our graphic to the laser, we want to mirror the graphic for engraving on the bottom side of the glass coaster. Engraving the back of glass will give you the best result when viewed through the other side, and doing so will help protect your engraving from wear and tear.

For backside engraving on glass, it’s important to mirror your graphic. If there is text in your graphics, you want the text to read forward instead of backward once viewed from the top or other side of the piece.

To mirror the graphic, select the graphic with the Pick Tool, then click on the Mirror Horizontally button in the Properties bar at the top of the screen.

Printing to the Laser

Next, we’ll print the file to the laser.

Select File, then Print from the dropdown menu, or press Ctrl + P on your keyboard.

Select your laser from the printer options, then click the Preferences button.

In the Laser Dashboard:

• Set your Resolution to 300 dpi (When engraving glass we don’t need to use a high resolution to get a good engraving.)
• Select Raster from the Job Type options (We only need Raster since we’ll only be engraving this file.)
• Set the Speed to 55% and Power to 100% (Refer to your laser manual for the suggested speed, power, and frequency settings for etching glass with your wattage of laser.)
• Select Stucki as the Image Dithering pattern. (Since we are engraving this at a lower resolution, this will randomize the dot pattern in the graphics and give us a higher-quality frosted look to our engraving.)
• Set the piece size to match your page size. Set the horizontal and vertical size to 3.5 inches.
• Make sure Send to Laser is checked.
• Uncheck Send to Manager

Then click the OK button.

The print preview should now look like our Corel file.

Finally, click Print to send the job to the laser!

At the Laser!

At the laser, we’ll place the glass coaster into the top left corner of the work area.

Then press the Focus button on the keypad to bring the manual focus gauge out over the work area.

Hang the manual focus guage on the optics assembly, then press Up on the Joystick to move the table up and bring the material into focus.

Now we’re ready to start the job. Press the Go button on the keypad to begin your glass engraving job.

And then you’re done!

Setting Up Your Page

We’ll start by creating a new file in CorelDRAW. Click File in the menu bar at the top of the screen. Then select New from the drop-down list.

Now enter your page size. Enter 4.5” for the page width and 4.5” for the page height. Then click OK.

Importing and Resizing a Graphic

Now we’re going to import a graphic onto the page. For this example we will use trees.wmf , but you can use any graphic you prefer.

Start by clicking File at the top of the screen, then select Import from the dropdown menu.

Navigate to the file you’d like to Import and select the file, then click the Import button.

Now, click anywhere on the page to place your graphic.

To center the image on the page, select Object from the menu bar.

Then select Align and Distribute, then Center to Page.

Now we’ll click and drag on the bottom right sizing handle to resize the image, and make it smaller. By holding down the shift key then clicking on the handle and dragging, we can keep the proportions of the image the same.

Next we’ll reposition the image by moving it up by about 1” on the page by clicking on the graphic and dragging it up.

Importing a Second Graphic

Now let’s import another image. Go to File > Import, and we’ll choose the deer file (deer.wmf ). Then Press the Import button.

Click anywhere on the page to place the graphic.

This time we’ll use another way to resize the deer. Click the lock ratio button to keep the dimensions the same as we resize the graphic.

Enter 10% as the scale factor and press Enter to resize the image to 10% of its original size.

We’ll position the deer image to the bottom left side of the trees.

Adding Text to the Artwork

Now we’re ready to add text. Click on the text tool in the tool bar on the left.

Create a text box by clicking and dragging a rectangle next to the deer.

We’ll enter our text “The poetry of the earth is never dead.” Then press Enter and type “John Keats”.

Select the pick tool, select the text, and then change the font size to 8 pt.

Next select the right justify option to align the text to the right side of the text box.
8 pts. is a little small so we’ll go ahead and change that to 10 pts.

Before we move on let’s make the text box a little smaller. Select the Pick Tool, then click on the text box. Now click on the bottom middle sizing handle and drag it up to make the text box a little smaller.

Selecting, Grouping, and Resizing

Press Ctrl and A to select everything on the page.

Next we’ll group the items so they all stay together when we make changes. Click Object in the menu bar, then Group, then Group Objects.

Now we’ll center the images. Click Object, Align and Distribute, Center to Page.

Creating a Cut Line

Now let’s create a cut line. Click the rectangle tool, and then click and drag a rectangle around the image. We’ll center the box we’ve drawn by using the shortcut of pressing the letter P on the keyboard. This will center the box to the page.

Now select the pen tool drop down box at the top of your screen to set the line thickness. We’ll select ‘hairline’ from the dropdown menu. This is important; to laser cut a line you need to set the line width to under .004”. In Corel, hairline thickness will always cut.

Printing to the Laser

Next we’ll print the file to the laser. Select File, then Print from the drop-down menu.

Set your Zing laser as your printer and then click the Preferences button.

In the print driver, first set your resolution to 500 dpi.

Since we have both engraving (raster) and cutting (vector) parts of this file, choose combined as the job type.

Now we’ll set up the speed and power settings. You can find the suggested settings for your wattage in your manual’s appendix. We’ll set the speed to 70%, then set the power of the laser to 100%.

Next set your cutting speed and power. Use the 1/8” wood vector settings in your manual. We’ll set the speed to 30% and the power to 70%

Next, set the frequency to around 500. This is the pulse rate of the laser and a lower pulse rate is preferable for wood cutting to achieve less burning on the edge of the wood.

Set the piece size to match your page size. We’ll set the horizontal size to 4.5” and the vertical to 4.5” as well.

Make sure Send to Laser is checked, and for this example, we’ll go ahead and uncheck the Job Manager option. Then click the OK button.

The print preview should now look like our Corel file.

Finally, click Print to send the job to the laser!

At the Laser

At the laser, we’ll place the 4” square wood piece into the top left corner of the work area.

Hang your manual focus gauge on the optics assembly. Then use the down arrow on the keypad to select the Focus option. Now use the joystick to move the table up and bring the material into focus.

Once you’ve focused for your material, press the Reset button.

Now we’re ready to start the job. Press the Go button on the keypad to begin your laser engraving and cutting job.

Once the laser is finished, use a damp sponge or towel to remove any leftover residue or debris.

And then you’re done!

Remove Side Panels

With the machine powered on, use the control panel to scroll down to ‘Jog.’

Then use the joystick to move the x-axis assembly toward the middle of the machine to give you room to work.

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

Remove the top access panels on both sides of the machine by using a 5/32” hex key to turn the black panel locks ¾ of the way counter-clockwise.

Disconnect X-Axis Assembly

On the right side of the machine, locate the wire harness, which electronically connects the x-axis assembly to the rest of the system.

The wire harness and its plastic guard are held secure by the wire harness clamp.

With a screwdriver, remove the clamp screw on the side of the blue housing and loosen the clamp screw on top. Then remove the clamp and set it aside.

Next, disconnect the white connector from its socket by squeezing the lock tab on the bottom of the connector and pulling it away from the circuit board.

Remove the black connector as well.

Move the wire harness and its plastic guard to the side.

On both ends of the assembly, loosen the two green captive screws until they turn freely.

Carefully lift the assembly from its mounting position and shift it to the right, allowing the left end of the assembly to rest on the left side of the chassis.

Gain Access to the X-Motor

Remove the blue cable guard by unscrewing the top Phillips head screw near the rear of the guard and the two Phillips head screws at the front bottom edge of the guard.

Disconnect the large white connector by squeezing the lock tab on the side of the connector and pulling it away from the circuit board.

Using a 7/64” hex key, loosen, but do not remove, the four motor mounting screws.

Press the motor in toward the center of the machine, loosening the reducer drive belt.

Remove the belt.

Remove the Old Motor

Now it’s time to remove the x-motor. Remove the four motor mounting screws. The x-motor may move away from the machine slightly as the internal tensioning spring pushes it outward.

Hold the x-motor away from the x-axis assembly so you can see the black connector attaching the x-motor to the circuit board. Disconnect the black connector and set the old x-motor aside.

Install the New Motor

With the new x-motor, connect the black connector to the circuit board.

Attach the new x-motor to the x-axis assembly by inserting, but not completely tightening, all four motor mounting bracket screws.

Connect the x-motor’s large white connector to the circuit board.

Press the x-motor in toward the center of the machine and loop the reducer drive belt around both the x-motor and x-axis assembly pulleys. Release the x-motor and let the tensioning spring push it outward so the reducer drive belt goes taut.

Tighten all four motor mounting screws.

Reattach the blue cable guard by screwing in the top Phillips head screw near the rear of the guard and the two Phillips head screws at the front bottom edge of the guard.

Reconnect the X-Axis Assembly

Lift the x-axis assembly and shift it back to the left. Place it on its mounting points, lining up with the guide pins so there is no space between the bottom of the assembly and the screw mounts.

Use a screwdriver to tighten the green captive screws on both ends of the assembly.

Next, connect the wire harness by plugging in the black and white connectors.

Retrieve the wire harness clamp and position the wire harness and its plastic guard so that the harness is on top of the guard and both are under the clamp on the x-axis assembly. Be sure that the wires between the wire harness and the circuit board have some slack and are not drawn tight.

Secure the clamp by inserting the two screws with a screwdriver.

Reinstall Side Panels

Replace the top access panel on the right side of the machine, using a 5/32” hex key to turn the black panel locks ¾ of the way clockwise.

Plug the machine in and turn it on.

Once complete, run an engraving test to ensure the results look correct. If you notice any issues, check that everything is plugged in and positioned properly, and that the tension on the reducer driver belt is adequate.

Open the Box

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 the straps and the wooden box topper. Then lift and remove the cardboard box.

Note: As you’re removing the Fusion M2 box, be sure to pull out the foam and wood corner braces before taking the box all the way off the Fusion M2.

Remove the plastic bag.

Set up the Ramps

Unscrew and remove the raised wooden edge located on one side of the pallet.

Remove the wheel ramps from underneath the machine.

Affix the ramps to the side of the pallet by inserting the metal edges into the slits located where the wooden edge used to be. Make sure the ramps are aligned with the wheels.

Remove the Machine

Unlock the two wheels at the front of the machine.

The Fusion M2 32 and 40 systems range in weight from 500 to 679 lbs. so you may need the help of an additional person when pulling the Fusion off the pallet and down the ramps.

Slowly wheel the Fusion M2 off the pallet and down the ramps, taking care to make sure the wheels stay on the ramps. Be sure to pull the machine, not push.

Make sure not to discard the packaging material at this time.

Included Items and Materials

Open your Fusion M2 laser system’s top door, and remove the included items from the cabinet, then open the box of included items.

Your Fusion M2 laser system includes:

• Manual Focus Gauge (two if you have a dual source)
• Power cord
• Ethernet cord
• USB cord
• Exhaust Plenum connectors
• Driver Install CD
• Quick Start Guide
• Owner’s Manual
• Training Site Signup Card & Kit
• Laser Beam Alignment Target
• Lens Cleaner
• Bearing Lubrication Grease
• Vendor Material Sample Kit

Remove Panel

Remove the lower access panel on the right side of the machine by using a 5/32” hex key to turn the black panel locks ¾ of the way counter clockwise.

Remove Old Power Supply

Disconnect the power leads connecting the power supply assembly to the various components of the machine. There are four white connectors and two black connectors.

There are also two grounding wires attached via nuts to the side of the machine’s interior. Use a 5/16” nut driver to remove the first nut, then remove the first wire. Then remove the lock washer and the second nut, followed by the second wire. Leave the second lock washer on the grounding screw.

Next, use a 5/32” hex key to remove the two mounting screws attaching the top of the power supply assembly to the interior side of the machine.

Then use a 5/32” hex key to remove the two mounting screws attaching the back of the power supply assembly to the back of the machine.

Remove the power supply assembly from the machine.

Install New Power Supply

Place the new power supply housing inside the machine’s chassis, placing it as far to the rear of the machine as possible so the circuit breaker and socket are accessible through the chassis’ rear opening.

Use a 5/32” hex key to loosely install the two rear mounting screws.

Use a 5/32” hex key to install and tighten the mounting screws attaching the top of the power supply to the interior side of the machine.

Tighten the two rear mounting screws that were previously loosely installed.

Reconnect the power supply assembly’s black and white power leads to the various components of the machine. Each of these connectors is different, so there is no risk of connecting them incorrectly.

Also reinstall the grounding wires by first placing one wire onto the grounding screw against the lock washer. Use a 5/16” nut driver to install a nut to secure the wire. Install the second lock washer, then the second wire, then the second nut.

Reinstall Panel

Replace the lower access panel on the right side of the machine, using a 5/32” hex key to turn the black panel locks ¾ of the way clockwise.

Plug the machine in and turn it on.

Alignment Target

Place the alignment target in the round opening on the side of the lens assembly.

Then cover the alignment target with a small piece of masking tape.

On the control panel, use the arrow buttons to select ‘Jog.’

Then use the joystick to move the lens carriage to the front right corner of the machine.

Close the machine’s lid.

On the control panel, press and hold the “Laser On” button and tap the joystick to the left or right once or twice to fire the laser.

Then press the “Red Dot Pointer” button.

Align Red Dot to Laser

We’ll begin by aligning the red dot laser to the main laser.

Remove the top access panel on the left side of the machine by using a 5/32” hex key to turn the black panel locks ¾ of the way counter-clockwise.

Use a 5/32” hex key to remove the bottom main panel and the top right panel on the back of the machine.

Locate the red dot pointer mount in the rear of the machine. Use a 3/32” hex key to adjust the alignment screws on the red dot pointer mount.

Align the red dot to the burn mark on the alignment target. The two laser beams are now aligned with each other.

Align First Mirror

Remove the tape from the alignment target.

Use the control panel to jog the lens carriage to the back left corner of the machine.

Through the bottom panel on the left side of the machine, use a 3/32” hex key to adjust the alignment screws on the mirror at the bottom of the periscope.

Align the red dot to the center of the alignment target.

Align Second Mirror

Now jog the lens carriage to the front left corner of the machine.

Through the top right corner panel on the back of the machine, use a 3/32” hex key to adjust the alignment screws on the mirror at the top of the periscope.

Align the red dot to the center of the alignment target.

Jog the lens carriage back to the back left corner of the machine and make sure the red dot is still within the center circle of the alignment target.

If the red dot is not properly positioned, continue to adjust the alignment screws on the mirrors until you can jog between the front and back corners on the left side of the machine without the red dot leaving the center of the alignment target.

Align Third Mirror

Now jog the lens carriage to the back right corner of the machine.

Use a 3/32” hex key to adjust the alignment screws on the mirror at the left end of the x-axis assembly.

Align the red dot to the center of the alignment target.

Then jog the lens carriage to the front right corner of the machine.

Use a 3/32” hex key to adjust the alignment screws on the mirror at the left end of the x-axis assembly.

Align the red dot to the center of the alignment target.

Jog the lens carriage to the various corners of the machine and make sure the red dot is still within the center circle of the alignment target at all corners.

If the red dot is not consistently positioned at the center, go back to the first mirror alignment step and repeat the adjustment process until you can jog the lens carriage to all four corners without the red dot leaving the center of the target.

Once the red dot is properly aligned, remove the alignment target from the lens assembly.

Align Fourth Mirror

Hang your lens’s focus gauge on the lens assembly and position the alignment target directly beneath the gauge.

On the control panel, use the arrow buttons to select ‘Focus,’ then use the joystick to move the table vertically until the focus gauge just barely touches the alignment target.

On the control panel, press in the joystick once to set this table position as the origin.

Set the focus gauge aside.

With the red dot pointer still turned on, place the alignment target beneath the lens so that the red dot is directly in the center of the target.

With the control panel still set to ‘Focus,’ use the joystick to lower the table until the display reads around +3.000.

Check to see if the red dot has moved out of the center of the alignment target.

If it has, use a 3/32” hex key to adjust the alignment screws on the lens carriage mirror.

Align the red dot to the center of the alignment target.

With the control panel still set to ‘Focus,’ use the joystick to raise the table until the display reads approximately 0.000 again.

Make sure the red dot is still within the center circle of the alignment target.

If the red dot is not properly positioned, continue to adjust the alignment screws until you can lower and raise the table without the red dot leaving the center of the alignment target.

Reinstall Panels

Once the red dot is aligned, use a 5/32” hex key to replace the bottom main panel and the top right panel on the back of the machine.

Replace the top access panel on the left side of the machine by using a 5/32” hex key to turn the black panel locks ¾ of the way clockwise.

Plug the machine in and turn it on.

Remove Panel

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

Remove the top access panel on the right side of the machine by using a 5/32” hex key to turn the black panel locks ¾ of the way counter-clockwise.

Remove Old Safety Module

Locate the Laser Safety Module inside of the engraver.

The top of the Laser Safety Module can be seen on the top of the right side of the machine.

The module case and connections are accessible from below.

You will see four pairs of screws on the module.

Each pair consists of one case screw and one mounting screw.

The mounting screws are positioned toward the back of the machine relative to the case nuts.

Use a 5/16” nut driver to remove the four mounting screw nuts.

Carefully slide the module down off the screws.

On one end of the module are the laser tube connections.

If your machine has a CO2 laser tube, remove the 8-Pin connector that resembles an Ethernet or Telephone jack.

If your machine has a fiber laser tube, remove the larger connector using a Phillips head screwdriver.

On the other end of the module, use a flat head screwdriver to remove the two remaining connectors.

Set the old safety module aside.

Install New Safety Module

Attach the connectors to the new safety module.

Use a Phillips head screwdriver to attach the fiber laser tube connector.

Then insert the CO2 laser tube connector.

Use a flat head screwdriver to attach the two remaining connectors on the other end of the module.

Slide the module up onto the mounting screws and use a 5/16” nut driver to secure the module with the nuts you removed earlier.

Reinstall Panel

Replace the top access panel on the right side of the machine by using a 5/32” hex key to turn the black panel locks ¾ of the way clockwise.

Plug the machine in and turn it on.