Usage of CO2 laser marking machines (typically referring to Galvanometer-based systems, though sometimes Gantry-based) can present specific operational challenges.
The following are the common faults and their corresponding solutions, categorized by the system they affect.
1. Optical & Laser Output Issues
These are the most common issues, usually manifesting as a weak beam, no beam, or blurred markings.
Fault Symptom
Possible Cause
Solution
Weak Laser Beam / Shallow Marking
Focal Distance Incorrect
The distance between the lens and the material is critical. Adjust the lifting pillar until the “two red lights overlap” (if equipped) or find the focal point manually where the marking sound is loudest and sparks are brightest.
Dirty Optics
Dust or smoke on the F-theta lens (the bottom lens) or beam expander. Gently clean with a cotton swab and alcohol/optical cleaner.
Laser Tube Aging
CO2 glass tubes have a lifespan (typically 2,000–10,000 hours). If the tube is old, it may need replacement. RF metal tubes last longer but may need gas refilling.
Laser Power Supply
Check if the power supply is outputting the correct current. If the voltage is unstable or too low, the power supply may be damaged.
No Laser Output
Water Protection Error
The chiller or water pump isn’t sending a signal. Check if water is flowing and if the chiller alarm is on. The laser will not fire if it detects no cooling.
Control Card/Software
The software may not be sending the “Mark” signal. Check if the “Laser” button is checked in the software (e.g., EzCad) and if the drivers are installed.
Door Interlock
If the machine has a safety enclosure, ensure the door is fully closed and the sensor is engaging.
Blurred / Unclear Marking
Focus Incorrect
(See “Focal Distance” above). This is the #1 cause of blurry marks.
Lenses Loose
Check if the F-theta lens or beam expander is loose. Tighten them gently.
2. Galvanometer (Scanner Head) Issues
The galvanometer is the head that directs the laser beam.
Problems here usually affect the shape or geometry of the mark.
Fault Symptom
Possible Cause
Solution
Wavy / Trembling Lines
Signal Interference
Heavy machinery nearby or poor grounding can cause electrical noise. Ensure the machine is properly grounded (Earth wire).
Galvo Power Supply
The power supply for the galvo head (usually ±15V or ±24V) may be failing. Check connections or replace the power supply.
Distorted Shapes (Square looks like Trapezoid)
Calibration Data Lost
The “Cor file” (correction file) in the software (EzCad) might be wrong or corrupted. You may need to perform a “9-point calibration” in the software parameters.
Galvo Mirror Stuck
One of the mirrors inside the head is not moving correctly. This requires professional repair or replacement of the galvo head.
Whistling Noise from Head
Galvo Servo Fault
A high-pitched squeal usually indicates the galvanometer motor or driver board inside the head is failing or tuning parameters are off.
3. Software & Control Issues
Fault Symptom
Possible Cause
Solution
“Can not open card” Error
Driver / USB Connection
The computer isn’t communicating with the board. 1. Re-plug the USB cable. 2. Re-install the laser board driver (USBLM driver) in Device Manager. 3. Check if the board is powered on.
Size is Wrong (10mm marks as 12mm)
Calibration Parameters
Go to the software settings (F3 parameters). Check the “Scale” or “Galvo 1 = X / Galvo 2 = Y” settings. You can calibrate by entering the Goal Size vs. Real Size.
Marking is uneven (Left side deep, right side shallow)
Fixture/Table Not Level
The machine head is not perfectly perpendicular to the table. Use a spirit level to check or shim the fixture so the material is flat relative to the lens.
4. Cooling System Issues (Critical for CO2)
Fault Symptom
Possible Cause
Solution
Chiller Beeping / Alarm
Water Flow blocked
Check for kinked tubes or a clogged filter.
High Temperature
If the room is too hot (>30°C), the chiller can’t cool the tube. Ensure proper ventilation.
Low Water Level
Add distilled water to the chiller.
Routine Maintenance Checklist
To prevent these faults, perform the following regularly:
Clean the Field Lens: Wipe the bottom lens daily if marking materials that produce smoke (wood/leather).
Check Water: Ensure distilled water is clean and flowing. Replace water every month to prevent algae growth which blocks the tube.
Dust Removal: Keep the control cabinet and fans free of dust to prevent electrical shorts.
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The technology is a perfect match because the wavelength of light from a CO2 laser (10,600 nm) is readily absorbed by organic materials like the paper fibers in cardboard. Instead of adding ink, the laser works by rapidly heating and vaporizing the top layer of the cardboard, creating a permanent mark.
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