Our Essential Guide to Common CO2 Laser Repairs
Last Updated - October 2024
From an ageing or damaged laser tube to a misaligned laser beam or inconsistent power supply due to wear and tear on internal components, understanding common CO2 laser repairs can save you time, money, and frustration, ensuring your machine stays in tip-top working condition and continues to deliver exceptional laser cutting and engraving results.
Some of the common CO2 laser repairs include:
All of which we'll explore in more depth below and how to identify which issue could be affecting your CO2 laser.
Laser Tube Replacement
Irrespective of the make and model of your laser machine, universally across the board, one of life's inevitabilities is at some point, your laser tube will need replacing. Your CO2 laser tube has an expected lifespan. Its energy and wattage will gradually decrease over time, eventually reaching a point where it can no longer generate a laser beam powerful enough for cutting and engraving.
How Can I Tell If My Laser Tube Needs Replacing?
Some of the common signs your laser cutter requires a laser tube replacement include:
Your laser cutter struggles to cut through materials it previously handled with ease.
Engraving lacks depth and clarity, even with increased power settings.
The laser beam appears weaker than usual, or it flickers and changes intensity during operation.
The tube itself may show cracks, discolouration, or other signs of physical damage.
When it's time for a laser tube replacement, we recommend prioritising quality and longevity by opting for a reputable brand like RECI. Manufactured with premium components, reci's laser tubes guarantee dependable performance and extend the operational life of your laser system, ensuring you get the most out of your investment.
Do Laser Tubes Degrade over Time?
During operation, the CO2 gas within the laser tube breaks down into Oxygen and Carbon Monoxide. Overdriving the tube by exceeding its recommended power settings speeds up this disintegration process and shortens its lifespan. As the tube ages, its performance inevitably deteriorates, leading to reduced power output, which forces users to either slow down cutting speeds or increase power levels to achieve the desired results.
What Is the Lifespan of a Laser Tube?
DC (glass) laser tubes typically last around four years, but this can vary based on usage and power settings. For optimal lifespan, we recommend operating your laser tube at or below 60% of its maximum power. This approach not only extends the tube's life but also ensures consistent performance, delaying the need for a replacement laser tube.
Can I Replace a CO2 Laser Tube Myself?
Replacing a laser tube can be a straightforward task for those with previous experience working with electrical components or handling delicate equipment technical experience. It's essential to test your laser tube's power supply unit to confirm it's delivering the correct mA output current and rule out any potential faults within the power supply that might be contributing to the power loss.
Prioritising safety is paramount when handling laser components. Adhering to proper procedures and exercising caution is essential to prevent any harm to yourself or damage to your valuable laser machine.
We recommend reaching out to a CO2 laser cutter repair specialist and booking a visit for the replacement of your laser tube.
At Focused Laser Systems, during a service visit or tube replacement call-out, we'll conduct a comprehensive laser tube and optics alignment to ensure precise results. We'll then perform a wattage test to verify your laser tube's output power. Additionally, we'll thoroughly examine your laser tube's power supply unit, ensuring it's delivering the correct mA output current and isn't contributing to any power loss. This meticulous approach guarantees your laser system is operating at its peak performance.
Timing Belt Replacements
The timing belts are responsible for moving the gantry and laser head around the laser bed by utilising the rotation of the motor. Your laser machine usually has three main timing belts that work with the linear guide rails: one belt for moving the laser head left and right (X-axis) and two belts on either side for moving it forward and backward (Y-axis). The teeth on the belts ensure that everything moves smoothly and precisely, allowing the laser to create accurate cuts and engravings.
How Do I Tell If My Timing Belt Needs Replacing?
Visible signs of wear and tear on the timing belt, such as cracks, fraying, missing teeth, or excessive stretching, are clear indicators that it's time for a replacement. These issues can directly impact the laser cutter's performance, leading to decreased accuracy in cutting or engraving, inconsistent or jerky movement of the laser head, and even slipping or skipping of the belt. You might also notice unusual noises like squeaking, grinding, or clicking sounds coming from the belt or motor area, further signalling the need for a new belt.
How Often Should a Timing Belt Be Replaced?
While the lifespan of timing belts can vary depending on usage and machine type, it's generally recommended to replace them every 2-3 years as part of preventative maintenance.
Faulty Electrical Cables
It goes without saying that the electrical cables in your laser machine are what powers the machine's capabilities. The most common cable errors are those in the gantry for the X & Y-Axis, as well as sensors/switches.
Your electrical cables for the X & Y-Axis motors will run through a cable track for guidance and to stop snagging. Constantly bending and straightening the cable will, over time, cause wear and, eventually, breaks in the cable. These may first appear as slight errors in the motor's performance when there is a slight break in the cable, but eventually, the cable will completely separate and cause a permanent error.
Most of the time, it is possible and most effective to repair the cable and fix the connections properly with soldered heat shrink sleeves. But on occasion, the best solution, either due to the cable itself, the location, or the extent of the damage, is to replace the whole cable.
Proximity Sensor Replacement
One common issue that can affect a CO2 laser's performance and safety is a faulty proximity sensor. These sensors play a crucial role in detecting the position of the laser head and other moving components, ensuring precise movements and preventing collisions.
What Is the Purpose of Proximity Sensors in CO2 Lasers?
Your CO2 laser engraver uses proximity sensors or switches to find its home/origin point. When the laser cutting machine starts up, both the X and Y axes will move toward a corner of the laser bed where the machine's proximity switches or sensors are located. They will activate once the gantry comes near or makes contact with them. This action lets the control board know that this is the starting point of the 0-0 coordinate. The machine's control board can then calculate the scale, position, and size of your design relative to the laser bed and relay this information to the motors to work within the machine's programmed parameters.
Why Do CO2 Laser Proximity Sensors Need Replacing?
Proximity sensors in CO2 laser machines can require replacement for several reasons. Constant exposure to dust, debris, and vibrations within the machine's environment can cause wear and tear, leading to degraded performance. Misalignment of the sensor can result in inaccurate detection of the laser head or other components, causing errors or malfunctions. Additionally, electrical surges can damage the sensor's internal components, causing it to fail. Lastly, like any electronic component, proximity sensors have a finite lifespan and may eventually fail due to age, even without any visible external cause.
Optical Misalignment
Even the slightest deviation in your laser tube's beam alignment, as it travels through a series of mirrors and lenses to the material's surface, can significantly impact laser cutting and engraving results.
Over time, the natural vibrations of your laser machine will throw the optical alignment off. Additionally, have you recently moved your laser engraver? Or perhaps the laser head has accidentally knocked into a rogue object left on the laser bed. If yes, then your laser optics may have become misaligned.
How to Tell If Your CO2 Laser Optics Are Misaligned?
When you fire a low-power laser pulse onto a material, the resulting burn mark should ideally be a perfectly centred dot within a clean, circular shape. Any deviation from this, like an off-centre mark or an irregularly shaped burn, could indicate misalignment in your optics. Additionally, it's worth checking your mirrors and lenses for any burn marks or damage.
How to Align a CO2 Laser Beam?
Achieve perfect laser performance with a complete laser tube and optics alignment using these step-by-step instructions.
Laser Tube Alignment:
Insert the alignment tool into the laser head.
Make sure the beam hits the centre of the target card.
If it's off-centre, gently adjust the laser tube itself until the beam is centred.
Mirror 3 Alignment:
Cover the laser head's output aperture with masking tape.
Briefly pulse the laser to mark the tape.
Adjust Mirror 3 so the reflected beam hits the centre of Mirror 2.
Mirror 2 Alignment:
Place tape on the centre of Mirror 2.
Pulse the laser and observe the mark.
Adjust Mirror 2 so the beam hits the centre of Mirror 1.
Mirror 1 Alignment:
Tape the centre of Mirror 1.
Pulse the laser.
Adjust Mirror 1 until the beam travels back through the centre of the laser tube's output aperture.
When it comes to fine-tuning your laser beam, remove the tape from the laser head and place the material at your desired focal point. Pulse the laser and make minor adjustments to all mirrors until the beam focuses precisely on the desired spot in a perfect circle.
Essential Laser Machine Repair Tips to Remember
CO2 laser machines, while powerful tools, can encounter various issues that impact their performance and longevity. Understanding these common repairs can help you proactively address problems, minimise downtime, and ensure optimal results.
Common CO2 Repairs to Watch For:
Laser Tube Replacement: The heart of your machine, the laser tube, will eventually need replacing due to natural wear and tear. Signs like decreased cutting power, poor engraving quality, or visible damage indicate it's time for a new one.
Timing Belt Replacements: Timing belts control the precise movement of the laser head. Cracks, fraying, or unusual noises signal the need for replacement, typically every 2-3 years.
Faulty Electrical Cables: Cables, especially those in the gantry, can wear out over time due to constant movement. Repair or replacement may be necessary if you experience motor performance issues or complete cable failure.
Proximity Sensor Replacement: These sensors are crucial for accurate positioning and collision avoidance. If your machine struggles to find its home position or exhibits erratic movements, a faulty sensor might be the culprit.
Optical Misalignment: Even slight bumps or machine movement can disrupt the laser beam's alignment, resulting in uneven cuts, poor focus, or power loss. Regular checks and realignment are essential.
Remember, proper maintenance and timely repairs are essential for maximising the lifespan and performance of your CO2 laser machine. If you encounter any of these issues, address them promptly to avoid further complications. Consult your laser machine's manual or seek professional assistance for complex repairs.
Looking for a CO2 Laser Cutter Repair Specialist?
At Focused Laser Systems, we're the UK's one-stop solution for all your CO2 laser repairs. Providing affordable co2 laser training, repairs, servicing and upgrades for all makes and models of CO2 laser machines, from desktops to industrial-sized laser machines.
Our goal is to resolve any issue you may be facing remotely, or if necessary, our engineers are always zipping up and down the UK, London and Ireland, enabling us to offer some of the fastest callout times in the industry. Whether you need a laser tube replacement, optical alignment, or help with a technical issue, our engineers are just a call away at 01271 626 406.
