Add laser-safety and regulatory documentation; scrub bench identity

- LIGHTBURN.md: mandatory "Before you cut" safety section; the
  walkthrough now reflects the firing machine (dry runs need the
  layer output off or M5; live first-cut instructions); the homing
  entry documents homing_mode and the gfcloud method; the machine
  address is a placeholder.
- README.md: condensed safety section linking the full text and the
  regulatory notes.
- INSTALL.md: "Regulatory and legal" section ahead of the install
  steps; routine updates route through the panel updater rather than
  the installer.
- BRINGUP.md: the release signing key is described as held offline
  (no on-disk path); bench address and credential notes removed;
  Next-work item 7 corrected (the installer embeds the production
  release key); status entry for audit remediation Phases 0-1; the
  GATE A kernel drills join the pending image-flash checklist.
- bench scripts: the target host comes from GF_HOST (or argv) instead
  of a hardcoded address.
- laser_stream_test.py: per-session controller runs with a hermetic
  cooling-verdict publisher; new assertions that every stream
  terminates with FIRE clear (including M3 held to stream end) and
  that no FIRE bit rides a zero-step gap; a cycle-churn session
  exercises the stop/start seams.

Audit findings D-1, D-2, D-3, D-5, D-10, D-12, B-10, and the harness
half of D-4/G-1.
This commit is contained in:
ScottW514
2026-08-14 15:38:24 -04:00
parent 5dddea12ee
commit cc927aca5f
13 changed files with 361 additions and 63 deletions
+66 -11
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@@ -1,5 +1,28 @@
# LightBurn setup & operation (ForgeFIRM)
## Before you cut — safety (read this first)
ForgeFIRM replaces the factory software, **not** the factory safety rules. The
machine contains a Class 4 CO₂ laser emitting invisible 10.6 µm infrared at
roughly 45 W. **Jobs sent from LightBurn fire the laser.**
- **Eyes.** The enclosure and lid glass are the eye-safety barrier. Never
defeat the lid switches or the Pro's remote-interlock plug, and never
operate with any cover removed. Direct or reflected 10.6 µm radiation
blinds and burns.
- **Fumes.** Vent the exhaust to the outdoors, always. Laser-cutting fumes
are toxic and flammable.
- **Materials.** Never cut PVC, vinyl, or any chlorinated plastic — they
release chlorine gas that corrodes the machine and injures your lungs.
Know what your material is before you cut it.
- **Fire.** Never leave a running job unattended. Small flare-ups are normal
with some materials; sustained flame is not. Keep a fire extinguisher
(CO₂ preferred) within reach and know how you will open the lid and
smother a fire before you start.
- **Stop means stop.** The big button, LightBurn's Stop, and opening the
lid each halt the job. If anything looks wrong, stop first and diagnose
second.
The laser fires only inside an operator-armed window:
- **Starting a job that fires: press the button.** At the first
@@ -26,21 +49,30 @@ The laser fires only inside an operator-armed window:
## One-time device setup
Prerequisite: the controller is running on the board (see BRINGUP.md;
`grblHAL_glowforge` on TCP port 23 at 172.16.1.97).
`grblHAL_glowforge` on TCP port 23 at your machine's IP address, shown
below as `<machine-ip>`).
1. **Laser window → Devices → Create Manually** (skip auto-find; it
scans serial ports).
2. Device type: **grblHAL** if your LightBurn version lists it,
otherwise **GRBL** — both speak the right protocol.
3. Connection: **Ethernet/TCP**. IP address: **172.16.1.97** (LightBurn
uses TCP port 23 for GRBL devices, which is exactly where the
controller listens).
3. Connection: **Ethernet/TCP**. IP address: **`<machine-ip>`**
(LightBurn uses TCP port 23 for GRBL devices, which is exactly where
the controller listens).
4. Name: e.g. `Glowforge ForgeFIRM`. Work area: **X 495 mm, Y 279 mm**.
5. **Origin**: pick the corner where the head sits after parking at
home — **rear-left as you face the machine** (the top-left dot in
the selector). This is what keeps jobs un-mirrored: machine +X runs
right, +Y runs from the rear rail toward you.
6. **Auto-home on startup: NO.** Homing is not wired yet; `$H` errors.
6. **Auto-home on startup: NO** — LightBurn would issue `$H` at every
connect, and the working homing method runs a multi-minute session.
`$H` itself works and is selected by the `homing_mode` setting in the
machine's web control panel: `gfcloud` (Glowforge web-service vision
homing — the working method; X/Y home to the factory corner, Z to the
hall sensor; requires a signed-in Glowforge session), `switches`
(physical limit switches, once installed), or `none` (`$H` is
rejected). Run `$H` deliberately from the Console tab when you want a
true machine origin.
7. Finish. If a stale device profile already exists, edit its IP
instead of creating a new one.
8. Device Settings (wrench icon): **S-Value Max = 1000** (matches $30).
@@ -54,12 +86,12 @@ In the Laser window set **Start From: Current Position**, and set the
**Job Origin** dot to the same corner as the machine origin (top-left
dot). The job then runs into the bed from wherever the head currently
sits — absolute machine zero never matters, which is the forgiving mode
while the machine has no homing switches.
when you have not homed.
(`Absolute Coords` also works, but only if the head was parked at the
home corner when the controller started; after any Stop/alarm the
absolute frame is stale until the controller is restarted with the head
re-parked.)
(`Absolute Coords` also works after a successful `$H`, or if the head
was parked at the home corner when the controller started. After any
Stop/alarm the absolute frame is stale until you re-home with `$H` or
restart the controller with the head re-parked.)
## Operating basics
@@ -90,15 +122,38 @@ full, exhaust and intake fans to factory run speeds, then a ~15 s
cooldown after the layer before returning to idle. Leave it ON for
anything that will eventually involve the beam; expect real fan noise.
## Dry runs (motion only, no fire)
**Setting a low power value does NOT make a job inert — any laser layer
prompts for the arm button and then fires.** The motion-only modes are:
- **Frame** and jogging — never fire.
- A job whose layers emit no laser-on command: turn the layer's
**Output** off in the cut settings, or send gcode that stays in `M5`.
- A job run with the laser latch left locked (never press the arm
button): the job pauses at the white-button prompt and aborts after
`laser_button_timeout_s` — useful only to confirm the prompt itself.
If the white arm prompt appears and you did not intend to fire, press
**Stop** in LightBurn.
## A good first job
First a dry run, then a light cut on scrap:
1. Draw a rectangle (~100 × 60 mm) with a circle inside.
2. Double-click the layer color bar (bottom): mode **Line**, speed
**50 mm/s** (= 3000 mm/min; check Edit → Settings for your speed
units), power anything (ignored — nothing fires).
units). For the dry run turn the layer's **Output** off.
3. Park the head where the job's rear-left corner should be (or leave
it at home), **Frame**, watch the perimeter trace, then **Start**.
Expected behavior: darting travels at up to 200 mm/s, smooth 50 mm/s
tracing of the shapes, silky and near-silent motion (factory currents +
decay mode), and the head finishing per the job's return setting.
4. For the live pass: put scrap material on the bed (never an empty
honeycomb over the fan grill), re-enable the layer's **Output**, set
power to **30 %** or more (below ~30 % the tube barely marks), turn
the layer's **Air Assist** on, close the lid, **Frame**, **Start**,
and press the white button when it lights. Watch the whole job.