Monport Laser Rotary Attachment User Manual

Introduction

The Monport Laser Rotary Attachment is designed for laser cutters and engravers to engrave cylindrical objects. It temporarily replaces the Y-Axis and is compatible with most Ruida type controllers. Note that due to ongoing design improvements, the physical appearance of your rotary attachment may slightly differ from the illustrations in this guide.

Table of Contents

This document covers the following topics:

• Main Diagram and Components
• Dimensions
• Pre-use Checks
• Installation
• Software Settings (RDWorks, LightBurn)
• Fine Tuning and Testing
• Basic Operations (Loading/Unloading, Focusing, Alignment)
• Usage Guides and Suggestions (Safety, Speed, Y-coordinates, Slipping)
• Sizing and Aligning Artwork
• Maintenance and Alignment

Main Diagram

The rotary attachment consists of several key components:

• Headboard: Houses the motor and drive mechanism.
• Front Rollers/Wheels: Support the object being engraved.
• Clamp: Secures the object to the rotary.
• Motor Pulley: Connects the motor to the belt.
• Magnetic Front Foot: Provides stability and magnetic attachment.
• Footboard: The base structure of the rotary.
• Clamp Lock Screw: Secures the clamp.
• V-Wheels: Guide the carriage along the rails.
• Eccentric Spacer: Used for adjusting V-wheel tension.
• Carriage: The movable part that holds the object.
• V-slot rails (Vertical & Horizontal): Guide the carriage.
• Magnetic Back Foot: Provides rear stability.
• Carriage Lock Thumbscrew: Locks the carriage position.
• Vertical Adjustment Hand Wheel: Adjusts the height of the headboard.
• Back End-stop Wheel/Roller: Provides rear support and limit sensing.
• Back End-Stop Lock Thumb Screw: Secures the back end-stop.
• Back End-Stop Platform: The base for the back end-stop.
• V-slot rail cap: Covers the end of the V-slot rail.

Refer to the diagrams in the original document for visual identification of these parts.

Dimensions

The rotary attachment has the following approximate dimensions:

• Length: 530 mm (20.86 inches)
• Height: 161.4 mm (6.35 inches)
• Width/Depth of main body: 204.6 mm (8.05 inches)
• Roller Diameter: 67.5 mm (2.66 inches)

Before Using: Check for Loose Items

Before initial use, it is crucial to check for any loose components, particularly the red silicone O-rings and the back stopper thumb screw. Due to packaging and shipping vibrations, O-rings can sometimes detach from the wheels. Ensure the front wheels have three large O-rings each, and the back wheels have two smaller O-rings each. Also, check that the "back stopper with wheel" is securely attached. If it's missing, it may have fallen off during transit or be included separately in the packaging.

Chapter I: Installation

Plug in the Rotary to Your Machine

The method for connecting the rotary attachment varies by laser machine model. Some machines (e.g., newer Boss Lasers, Aeon Mira/Nova, Thunder Laser) have a dedicated rotary port. For machines without a dedicated port (e.g., older Boss Lasers, OMTech), you will typically unplug the Y-axis motor and plug the rotary in its place.

For Machines Without Dedicated Rotary Port:

1. Locate the Y-Axis plug, usually found in the machine's "work chamber" after lifting the main cover.
2. Lower the laser bed to ensure sufficient clearance for the rotary.
3. Move the laser head to your preferred homing position (e.g., top right) and save it using the "Origin" button on the control panel before powering off. This prevents unexpected rapid movement of the laser head upon restart.
4. Power down the machine.

For Machines With Dedicated Rotary Port:

1. Power on the laser and allow it to auto-home.
2. Locate the dedicated Rotary port. On some machines, you may need to lower the Z-axis table to access it.
3. If your laser machine has a rotary switch, engage it to the rotary position.

Install the Rotary

When placing the rotary inside the laser machine, you have three primary options:

• On top of the honeycomb table.
• On the "knife blades" (if applicable).
• Directly on the laser floor.

If using magnetic feet, a ferrous metal honeycomb table is ideal. For aluminum tables, the cork pads on the magnetic feet still offer benefits. The rotary can also be placed directly on its feet on knife blades or a honeycomb table. If space is limited or blades are wide, use a flat piece of material like plywood or acrylic. For added stability, the rotary with simple feet can be screwed into a wooden surface, or a custom-fit plywood piece can be made to align with the laser gantry.

For larger objects, if your machine allows, you can remove the knife blades and place the rotary directly on the laser bed. If the bed is sloped, adjust the magnetic feet angle to match the slope, ensuring the surfaces are clean for better grip.

2. Plug in the rotary as previously described.
3. Arrange the wiring and the rotary to prevent interference with the laser bed's movement. Ensure wires are not pinched.
4. Turn on the machine.

Homing Machine with Rotary Attachment

Upon startup, the laser machine performs a homing sequence to find its starting position, typically moving the gantry and head to an end-stop limit switch. If plugging in the rotary disables the Y-axis motor, preventing it from reaching the limit switch, you may need to manually home the gantry.

To manually home:

• Push the gantry all the way back to trigger the Y-axis limit switch. The rotary rollers may rotate in the opposite direction as the laser attempts to move the gantry back slightly.
• Gently pull the gantry towards you to disengage the limit switch, then push it fully back again.

This manual process simulates the automatic homing sequence, preparing the machine for software setup.

Chapter II: Main Software Settings

To configure the rotary, you need two main settings: "Diameter (mm)" and "Steps Per Rotation" (also known as Circle Pulse).

• Diameter (mm): This typically refers to the diameter of the front rollers, usually around 62-63 mm.
• Steps Per Rotation: This value tells the laser machine how many steps its motor needs to complete a full 360-degree rotation. Incorrect settings can lead to squished or elongated engravings. This value depends on your specific laser engraver setup.

Known "Steps Per Rotation" Values

• Monport CO₂ Laser Machines: 5000 (60W, 80W, 100W); 12500 (130W, 150W)
• Other Brands:
  • Boss Laser LS/HP-1630s, 2436s & 3655s: 12,500
  • Boss Laser LS1420/1416: 6,000 (sometimes 8,000)
  • AEON Mira 7/9 and Nova: 25,000
  • Thunder Laser Nova: 8,000
  • OMTech: 5,000 (some 12,500)

For other machines, you may need to determine this value by examining the Stepper Driver DIP switches. Warning: Ensure the machine is powered off, unplugged, and discharged before accessing internal electronics.

Procedure to find "Steps Per Rotation":

1. Access the internal electronics compartment.
2. Locate the Stepper Motor Driver for your Y motor.
3. Identify the driver's Make and Model Number.
4. Note the position of the DIP switches (usually 6-8 tiny switches).
5. Determine the "Pulse/Rev" setting based on the DIP switch positions, often found on a table printed on the driver or in its manual.
6. Calculate "Steps Per Rotation" by multiplying the "Pulse/Rev" value by 2.5 (this accounts for the laser's gear ratio). For example, if Pulse/Rev is 5000, Steps Per Rotation = 5000 * 2.5 = 12,500.

Chapter III: Configuring Software

This section details how to configure your laser software (RDWorks or LightBurn) to use the rotary attachment.

Using RDWorks (or LaserWorks)

1. Ensure the rotary is installed and connected, and the laser machine is powered on and homed.
2. Connect the machine to your computer.
3. In RDWorks, navigate to the "User" tab and click "Read" to retrieve current settings. Resize the window if Read/Write buttons are not visible.
4. Scroll to the "Rotating" section (or click "Other" if separated).
5. Set "Enable Rotating" to "Yes".
6. Enter the calculated "Circle Pulse" (Steps Per Rotation) value.
7. Set "Diameter (mm)" to 63.
8. Click "Write" to save the settings.

Using LightBurn

5. Open LightBurn and go to "Tools" > "Rotary Setup".
6. Set "Rotary Type" to "Roller".
7. Enable the rotary by clicking the switch to make it green.
8. Set "Rotary Axis" to "Y Axis".
9. Enter your determined "Steps Per Rotation" value.
10. Set "Roller Diameter" to 62 or 63 mm.
11. Disregard "Object Diameter" and "Circumference" as they do not affect rotary operation.

Adjusting Speed and Acceleration

It is recommended to lower idle and acceleration speeds when using the rotary to prevent objects from flying off or shifting. These settings are found in the machine's settings within LightBurn (or RDWorks "User" tab).

• Set "Idle Speed (mm/s)" to 30.
• Set "Idle Acceleration (mm/s²)" to 30.
• Set "Min Acceleration (mm/s²)" to 20.
• Set "Max Acceleration (mm/s²)" to 30.

Note: It's advisable to back up your default settings before making changes.

Thunder Laser Specific Note

For Thunder Laser machines, change the "Job Origin" setting in LightBurn to anything other than "Absolute Coordinates" for the rotary to function correctly. Selecting "Absolute Coordinates" will cause the Y gantry to move instead of the rotary.

Chapter IV: Fine Tuning and Testing

This chapter guides you through testing and fine-tuning the rotary attachment's settings.

Testing Procedure

1. Find a cylindrical object (e.g., a tumbler) for testing.
2. Cut a piece of masking tape and wrap it around the object, marking a 100 mm (or 4-inch) line with start and end points.
3. In RDWorks or LightBurn, create a square or a vertical line with the same length as your marked line (e.g., 100 mm). Ensure the "padlock" icon (constrain proportions) is unlocked.
4. Set the layer power to 1% (to prevent actual laser firing) and speed to 20 mm/sec. Name this file "square" and upload it to the laser machine.
5. On the laser machine's control panel, set the default speed to 20 mm/sec.
6. Place the object with the marked tape onto the rotary.
7. Align the Y-axis gantry above the starting mark on the tape.
8. Adjust the laser bed height for focus, ensuring you can see the laser dot clearly on the object.
9. Load the "square" file and press the "Frame" button. The rotary will rotate the object.

Adjusting Settings

Observe where the rotary stops after the "Frame" operation:

• If the rotary stops before the end mark, decrease the "diameter (mm)" setting.
• If the rotary stops past the end mark, increase the "diameter (mm)" setting.
• Save the new setting and repeat the "Frame" test.
• Alternatively, you can fine-tune the "Steps Per Rotation" value for more precise adjustments.

Tip for Machines Without a Laser Pointer: If your laser lacks a visible pointer, you will need to burn the line onto the object at a minimal power setting to see the endpoint.

Error: "SLOP Y Over" This error indicates the Y-axis position is too close to the machine's maximum or minimum limits. Rotate the rotary wheels using the control panel arrows to bring the Y position within range (e.g., 150 mm), then reposition the object and press "Origin" again.

Chapter V: Basic Operations

Loading/Unloading Object

1. Remove any lid from the object to allow clamp access. If the clamp cannot be used, remove the clamp arm.
2. Loosen the horizontal lock thumb screw to allow the back wheels carriage to move freely.
3. Loosen the back end-stop lock screw and move the back end-stop out of the way.

Focusing and Beam Alignment

Proper alignment ensures accurate engraving:

• Position the Y gantry by hand above the rotary.
• Move the laser head left or right using the control panel arrows until it is centered over the clamp's alignment mark (often triangular).
• Move the laser head until it is directly over the center of the red thumb screw on the back stopper.
• Rotate the rotary until the laser's gantry path is parallel to the rotary's rail. This is achieved when the laser dot hits both the clamp's alignment mark and the center of the back stopper's thumb screw.

Focusing

If your laser has auto-focus, use it as normal, focusing on the area closest to the motor. Be prepared to use the emergency stop button if the autofocus malfunctions, as it can potentially damage the rotary or the object being engraved.

Chapter VI: Usage Guides and Suggestions

Rule #1: BE SAFE!

Never operate the laser machine with the cover open. Always wear protective goggles and keep hands clear of the laser beam path. Remember that infrared laser light is invisible and can cause severe burns.

Rule #2: Rotate SLOW!

Laser machines are designed for fast movements for efficiency. However, the rotary attachment is not built for such speeds. Rapid rotation can cause the object to fly off or shift. Before starting, set your machine's default movement speed to 20 mm/s or lower via the "Speed" button on the control panel. This affects manual movements and framing, not the lasering speed itself. Also, lower idle speed and acceleration settings as described in Chapter III.

Y Coordinates Position

The rotary replaces the Y-axis but has no inherent limit. The laser machine, however, has physical Y-axis limits. If you attempt to engrave beyond these limits (e.g., trying to engrave an object that extends past the machine's maximum Y-coordinate), you may encounter a "Slope" error. To fix this:

1. Use the UP arrow key on the control panel until the Y-axis reading is close to 0 mm.
2. Disengage the clamp and rotate the object by hand to your desired starting position.
3. Fine-tune the position using the UP/Down arrow keys, staying within the machine's safe Y-axis range (e.g., below 300 mm in a 400 mm Y-axis machine).
4. Press the "Origin" button to save this as the new starting position.

Slipping/Jumping Off

For very light objects, adding weight (e.g., a small bag of rice or sand inside the object) can help prevent slipping from the back rollers.

Sizing and Aligning your Artwork

Aligning

The rotary's stepper motor is mounted externally, simplifying image orientation. Your artwork will engrave as it appears on screen. Typically, you'll rotate artwork by -90 degrees if the object is laid sideways in the rotary. Sideways engraving requires no artwork rotation.

Sizing Artwork

Measure the object's length (X-direction) and circumference (Y-direction). To find the circumference, measure the diameter and multiply by π (approximately 3.1415926). For example, a tumbler with a 6-inch (152 mm) diameter and 10-inch (254 mm) length can accommodate artwork up to 152x254 mm, allowing for margins.

Uneven Surfaces

Maintain a consistent distance between the laser head and the object for optimal engraving quality. For curved objects, average the focal distance across the surface. If height differences are significant, consider engraving in sections or sizing the artwork to cover a smaller area lengthwise.

Bottle Objects or Help my image is getting stretched!

Engraving stretching on objects with varying diameters (like bottles with necks) occurs because different parts of the object rotate at different rates relative to the drive wheels. The software settings primarily affect the part of the object in contact with the drive wheels. To address this:

1. Remove the clamp arm and flip the bottle around. Uniform objects often engrave well without the clamp.
2. Temporarily adjust "Steps Per Rotation" or "Roller Diameter" settings experimentally (e.g., using the 100mm test) and remember to revert them for standard objects.
3. Resize your artwork, "squishing" its height until the engraving appears correct.

Note on Threads: Tumblers with threaded necks can cause movement against stoppers, leading to rotation issues. Laser-cut adapters can smooth the neck for better stability.

Switching to Regular Laser Operations

After using the rotary, remember to disable the rotary function in your software (e.g., LightBurn's Rotary Setup) and revert acceleration settings. It's recommended to save separate configuration files for rotary and flat work.

Chapter VII: Maintenance and Alignment

O-rings

If using metal marking sprays (Laserbond 100, Cermark), clean the O-rings with a paper towel and alcohol to ensure good traction. O-rings can be removed and cleaned as needed. Ensure they are not twisted when reinstalled for smooth rotation. Spare O-rings are available for purchase.

Belt

Check belt tension by powering off the rotary and trying to rotate the main wheel by hand. If it engages the second wheel smoothly, tension is good. If the belt skips teeth, increase tension. Tension can be adjusted by moving the idler pulley or the stepper motor itself. Loosen the M4 nut for the idler pulley or the M5 screws for the motor, adjust, and retighten. Avoid overtightening, which could crack the frame.

V-Slots and Roller Wheels

Periodically clean the V-slots and V-wheels. If the carriage feels loose, adjust the eccentric nut on the V-wheel to tighten it against the V-slot extrusion.

Roller Alignment

Check front-to-back roller alignment by moving the carriage close to the front rollers. Ensure both back rollers are equally spaced relative to the front wheels. Tighten the M5 screws securing the headboard, checking alignment as you go, and then fully tighten them.

Repair and Support

The modular design of the rotary attachment makes it easy to repair. Most parts can be disassembled using an Allen hex key and pliers. For any questions or assistance, contact Monport support via phone at +1 (213)554-8829 or email at support@monportlaser.com.