When the laser shuttle enters the "light box" or lasing chamber, the shuttle activates two proximity sensors. It is the outer sensor or sensor 1 that is of concern. Both sensors must be triggered for the laser safety shutter to open. The laser safety shutter, located between the laser tube and marking head, is a solenoid controlled metal flap, spring loaded closed. voltage to the solenoid opens the shutter and allows the laser beam to enter the marking head and thus mark the device. Attached is a sensor adjustment procedure. If the sensor is intermittently triggered, then adjusting should solve the issue.
Please be sure that sensor 1 is adjusted as shown in the drawing. Additionally, the top of the sensors should be close but not touching the bottom of the shuttle. 0.020" of clearance, or as close as possible without touching.
When the laser nozzle shuttle is inside the laser box, both proximity sensors (which are wired in series) should activate. The activation can be witnessed in two locations, 1) at the sensors themselves with a yellow LED light at the base of each sensor body, and 2) at the corresponding relay in the Grayhill relay boards in the bottom section of the laser cabinet. There should be two red LEDs lit, one for each sensor.
Please refer to the attachment on adjusting the laser shuttle proximity sensors.
Refer to this diagram to understand the Grayhill relays:
Another factor to consider is shuttle 'bounce'. When the upper and lower transport air cylinders send the shuttle inside the light box, the air cylinders, if not adjusted correctly, can 'bounce' at their end of travel. This bounce can cause the same sensor to deactivate momentarily, which closes the laser safety shutter, again blocking the laser beam. See the attachment for adjusting the air cylinders.
Attached is a general pneumatic diagram of the laser along with adjustment details:
Old Style WHARAIR12 and CHARAIR12
http://www.bpmicro.com/web/helpandsupport.nsf/WebKeys/BPM-8QGN67?openDocument&Cat=Issue
New Style D04948AD with D04951PD (new sensor cable) general pneumatic diagram of the laser along with adjustment details:
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