Synrad Firestar i401 Series Operator'S Manual Download

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i401
operator’s
manual

4600 Campus Place

Mukilteo, WA 98275

1.800.SYNRAD1

tel

1.425.349.3500

fax

1.425.349.3667

e-mail

[email protected]

web

www.synrad.com

Summary of Contents for Firestar i401 Series

Page 1: ...i401 operator s manual 4600 Campus Place Mukilteo WA 98275 1 800 SYNRAD1 tel 1 425 349 3500 fax 1 425 349 3667 e mail synrad synrad com web www synrad com ...

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Page 3: ...01 Operator s Manual Version 1 0 Released December 2011 Part number 900 20150 01 4600 Campus Place Mukilteo WA 98275 1 800 SYNRAD1 tel 1 425 349 3500 fax 1 425 349 3667 e mail synrad synrad com web www synrad com ...

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Page 5: ...nclature 1 2 Unpacking 1 3 Incoming inspection 1 3 Packaging guidelines 1 3 Unpacking the i401 laser 1 4 Removing the lifting handles 1 5 Inventory 1 6 i401 contents description 1 7 Mounting 1 8 Top down mounting 1 8 Bottom up mounting 1 9 Connecting 1 11 Cooling connections 1 11 48 V power supply connections 1 15 Control connections 1 19 Other connections 1 20 Operation 2 Controls and indicators ...

Page 6: ... Firestar safety features 3 28 Keyswitch functions 3 28 Shutter functions 3 28 Remote interlock functions 3 29 Firestar i401 general specifications 3 30 Firestar i401 package outline mounting drawings 3 32 Firestar i401 packaging instructions 3 34 Maintenance 4 2 Disabling Firestar 4 2 Daily inspections 4 2 Storage shipping 4 3 Cleaning optical components 4 3 Troubleshooting 4 6 Introduction 4 6 O...

Page 7: ...Figure 2 2 Firestar i401 rear panel controls and indicators 2 3 Figure 3 1 Hybrid waveguide unstable resonator design 3 2 Figure 3 2 Firestar i401 beam ellipticity 3 3 Figure 3 3 Converting 45 linear polarization to circular polarization 3 4 Figure 3 4 PWM Command signal waveform 3 7 Figure 3 5 User I O connector pinouts 3 10 Figure 3 6 Auxiliary DC power diagram 3 13 Figure 3 7 Quick Start Plug w...

Page 8: ...nting dimensions mounting feet removed 3 33 Figure 3 21 Firestar i401 packaging instructions 3 34 Figure 4 1 Firestar i401 operational flowchart 4 7 Figure 4 2 Firestar i401 functional block diagram 4 8 Figure 4 3 Enable Java script in browser 4 19 Figure 4 4 Add IP addresses to list of authorized trusted websites 4 19 ...

Page 9: ...able 3 3 User I O pin descriptions 3 11 Table 3 4 Input circuit specifications 3 16 Table 3 5 Output circuit specifications 3 18 Table 3 6 Firestar i401 general specifications 3 30 Table 4 1 Required cleaning materials 4 4 Table 4 2 Status signals 4 9 Table 4 3 Effect of Remote Interlock input on operating parameters 4 10 Table 4 4 Normal operating condition 4 10 Table 4 5 Quick Start Plug or inte...

Page 10: ...tor s manual Trademark copyright information SYNRAD and Firestar are registered trademarks of SYNRAD Inc All other trademarks or registered trademarks are the property of their respective owners 2011 by SYNRAD Inc All rights reserved ...

Page 11: ...ser fails within the first 45 days after purchase SYNRAD Inc will pay all shipping charges to and from SYNRAD when shipped as specified by SYNRAD Customer Service After the first 45 days SYNRAD will continue to pay for the costs of shipping the repaired unit or replacement parts back to the customer from SYNRAD The customer however will be responsible for shipping charges incurred when sending the...

Page 12: ...th order or delivery status service status or to obtain a Return Authorization RA num ber contact SYNRAD at 1 800 SYNRAD1 and ask to speak to a Customer Service representative Technical Support SYNRAD s Regional Sales Managers are able to answer many technical questions regarding the installa tion use troubleshooting and maintenance of our products In some cases they may transfer your call to a La...

Page 13: ...tions of general hazards and unsafe practices that could result in death severe injury or product damage Specific warnings and cautions not appearing in this section are found throughout the manual Danger Warning Caution Important Note Caution Note Danger serious personal injury This Class 4 laser product emits invisible infrared laser radiation in the 10 6 µm CO2 wavelength band Do not allow lase...

Page 14: ...d the adequacy of provi sions for fume extraction filtering and venting should be carefully considered Review the following references for further information on exposure criteria ANSI Z136 1 2007 Safe Use of Lasers section 7 3 U S Government s Code of Federal Regulations 29 CFR 1910 Subpart Z Threshold Limit Values TLV s published by the American Confer ence of Governmental Industrial Hygienists ...

Page 15: ...materials in general are apt to combust or melt and metals act as specular reflectors which may create a serious hazard outside the immediate work area Other hazards The following hazards are typical for this product family when incorporated for intended use A risk of injury when lifting or moving the unit B risk of exposure to hazardous laser energy through unauthorized removal of access panels d...

Page 16: ...IAL i401214110006 TESTED AT 48V MFG Aug 02 2011 This laser component does not comply with standards for complete laser products as specified by 21 CFR 1040 10 or IEC 60825 1 SYNRAD Inc 4600 Campus Place Mukilteo WA 98275 425 349 3500 INVISIBLE LASER RADIATION AVOID EYE OR SKIN EXPOSURE TO DIRECT OR SCATTERED RADIATION CLASS 4 LASER PRODUCT EN 60825 1 2007 1400 WATTS MAX 10200 10800 nm WARNING Do n...

Page 17: ...r processing systems as specified by 21 CFR Part 1040 or EN 60825 1 SYNRAD Inc assumes no responsibility for the compliance of the system into which OEM laser products are integrated Center for Devices and Radiological Health CDRH requirements Product features incorporated into the design of Firestar i401 lasers to comply with CDRH requirements are integrated as panel controls or indicators intern...

Page 18: ...has not discovered any significant electrical interference trace able to Firestar i401 lasers System Maintenance Ensure that all exterior covers are properly fastened in position Measures to Correct Interference If you suspect that your Firestar laser interferes with other equipment take the following steps to minimize this interference 1 Use shielded cables to and from the equipment that is exper...

Page 19: ...nts of any system for subsequent sale are not subject to this Standard since the final product will itself be subject to the Standard This means that Buyers of OEM laser components are solely responsible for the assurance that the laser processing system sold to an end user complies with all laser safety requirements before the actual sale of the system Note that when an OEM laser component is inc...

Page 20: ...r Keyswitch is turned to On or remote reset start pulse is applied when Key switch is in On position Power fail Firestar circuit element Yes Yes lockout1 Disables RF driver laser output if input power is removed then later reapplied AC power failure or remote interlock actuation while Keyswitch is in On position Remote Rear panel connection Yes Yes Interlock Disables RF driver laser output when a ...

Page 21: ... Directive 2002 95 EC RoHS Directive amended 2005 618 EC EN 61010 1 2001 Safety Requirements for Electrical Equipment for Measurement Control and Laboratory Use Part 1 General Requirements EN 61000 6 4 2007 Radiated Emissions Group 1 Class A EN 61000 6 4 2007 Conducted Emissions Group 1 Class A EN 61000 6 2 2005 Electrostatic Discharge Immunity EN 61000 6 2 2005 RF Electromagnetic Field Immunity E...

Page 22: ...Standard s EN 61010 1 2001 Safety Requirements for Electrical Equipment for Measurement Control and Laboratory Use Part 1 General Requirements EN 61000 6 4 2007 Radiated Emissions Group 1 Class A EN 61000 6 4 2007 Conducted Emissions Group 1 Class A EN 61000 6 2 2005 Electrostatic Discharge Immunity EN 61000 6 2 2005 RF Electromagnetic Field Immunity EN 61000 6 2 2005 Electrical Fast Transient Bur...

Page 23: ...art at Unpack ing and work your way through Connecting This chapter contains the following information Introduction introduces the Firestar i401 laser lists important features and de scribes Firestar nomenclature Unpacking provides important information about unpacking your Firestar i401 laser Inventory displays and describes all components shipped with your i401 laser Mounting describes how to at...

Page 24: ...etting faults all Keyswitch equipped lasers incorporate a manual shutter switch to block the laser s output aperture SYNRAD s OEM lasers are primarily designed as components for integration into larger processing systems by the Original Equipment Manufacturer OEM or System Integrator who bears the responsibility for meeting the appropriate laser safety requirements for Class 4 laser systems Firest...

Page 25: ... components use care when removing packaging materi als After unpacking review the Inventory section and verify that all components are on hand Do not lift or support the laser using the cooling fittings lift the laser by the lifting handles or baseplate only Save all shipping containers and packaging materials including covers and plugs Use these special ized packing materials when shipping the l...

Page 26: ...Unpacking the i401 laser 1 Carefully cut the shipping straps wrapped around the shipping container 2 Remove the upper lid and set it aside 3 Remove the top front and top rear foam inserts To remove the center insert first slide it forward several inches to clear the notches in the lower foam insert and then lift 1 2 3 4 4 S A V E T H IS B O X F R A G IL E F R A G IL E FRAG IL E 4 ...

Page 27: ...nd paperwork packaged below the laser in the shipping container 6 Save the shipping container and foam inserts Use these specialized packaging materials when ship ping the laser to another location Removing the lifting handles Once you have placed the i401 laser in its final mounting location perform the following steps to remove the lifting attachments 1 Remove the 1 4 20 5 8 capscrews from two l...

Page 28: ...ing Kit 1 Ethernet Cable 1 Chiller Fittings Kit 1 Quick Start Plug 1 Spare Fuses not shown 4 BNC Control Cable 1 Mounting Hardware Kit 4 Cooling Tubing 1 Final Test Report not shown 1 DC Power Cables 1 SYNRAD CO2 Laser s Manual CD Cooling Tubing DC Power Cables w Sense Connector Quick Start Plug synrad co2 laser manuals P N 900 20336 01 2011 SYNRAD Inc All rights reserved BNC Control Cable Etherne...

Page 29: ... laser and back This black polyethylene tub ing is 1 2 inch O D by 30 feet and must be cut to length DC Power Cables carry DC power from the 48 V power supply to your i401 laser Standard cable length is 2 0 meters 6 5 feet while an optional 5 0 m 16 ft power cable is available The cable bundle includes voltage sense lines that connect to the recommended PS 401 DC power supply Gas Purge Kit provide...

Page 30: ...ical orientation increases the risk of damage to the laser s output optic Top down mounting To fasten your Firestar i401 laser to a mounting surface from above perform the following steps 1 Determine whether you will use metric ISO or inch SAE fasteners to mount the laser Four met ric M10 capscrews and flat split washers are included in the ship kit 2 Refer to the i401 outline and mounting drawing...

Page 31: ...and remove the factory installed mounting feet 2 Refer to the i401 outline and mounting drawing Sheet 2 of 2 for dimensions then drill four 10 6 mm close fit or 11 2 mm normal fit thru holes in your mounting surface These holes should cor respond with the fastener locations labeled C shown in Figure 1 5 Note The i401 baseplate contains two 0 252 0 500 beam alignment slots labeled D in Figure 1 5 a...

Page 32: ...it are for use with the factory installed mounting feet When fastening the i401 to your mounting surface from the bottom up use M10 1 5 mounting screws with a length of 30 mm 2 mm plus the thickness of the mounting plate and any washers between the bolt head and the mounting plate 4 Place a split washer and flat washer on each capscrew and insert the fasteners through the mounting surface into the...

Page 33: ...rom a fitting first push and hold the tubing slightly into the fitting Next push the white fitting ring evenly towards the fitting and then pull the tubing free After disconnecting tubing from a fitting trim 12 7 mm 1 2 from its end before reconnecting Trim ming the end of the tubing before reconnecting the fitting provides an undisturbed sealing surface Laser cooling fittings If your integrated l...

Page 34: ...temperature is important to the proper operation and longevity of your laser When coolant temperature is lower than the dew point the temperature at which moisture condenses out of the surrounding air condensation forms inside the laser housing leading to failure of laser electronics as well as damage to optical surfaces The greatest risk of condensation damage occurs when the laser is in a high h...

Page 35: ...4 7 10 12 14 16 18 19 21 22 23 24 26 27 28 28 90 32 44 50 54 59 62 66 69 72 74 77 79 81 83 85 87 88 7 10 12 15 17 19 21 22 23 25 26 27 28 29 31 31 95 35 48 54 59 63 67 70 73 76 79 81 84 86 88 90 92 93 9 12 15 17 19 21 23 24 26 27 29 30 31 32 33 34 100 38 52 58 63 68 71 75 78 81 84 86 88 91 93 95 97 98 11 14 17 20 22 24 26 27 29 30 31 33 34 35 36 37 To use Table 1 2 look down the Air Temp column an...

Page 36: ... chiller s Outlet port and the WATER IN port on the rear of the i401 laser 3 Cut and connect a length of cooling tubing to fit between the WATER OUT port on the rear of the laser and the chiller s Inlet port Caution possible equipment damage Inlet cooling water temperature must always be maintained above the dew point to prevent condensation and water damage to your Firestar laser 4 Turn on the ch...

Page 37: ... three phase 3Ø 30 A max per phase 50 60 Hz PS 401 DC power supply Input voltage selection The PS 401 supply is shipped with the default AC input voltage range set to 480 VAC which is used for high range 3Ø input voltages between 342 528 V with the nominal range being 380 480 VAC To operate the PS 401 DC supply on a low range 3Ø voltage between 180 264 V with the nominal range being 200 240 VAC pe...

Page 38: ...ed in accordance with applicable local state and national requirements Local state and national code requirements like NEC CSA and IEC 60364 supersede any recommendations provided in this manual Table 1 3 provides recommendations for three phase input wiring and fusing Table 1 3 AC three phase electrical recommendations Parameter Recommendation Input voltage range 3Ø 342 V 528 VAC 380 V 480 V nomi...

Page 39: ... 13 0 mm centers 1 Follow your facility s Lockout Tagout procedures and verify that input AC voltage to the DC power supply is physically locked out or disconnected 2 Connect the ground earth wire typically green to the input terminal labeled PE 3 Connect the first three phase hot wire typically black to the input terminal labeled L1 4 Connect the second three phase hot wire typically red to the i...

Page 40: ...ock on the rear of the laser 4 Attach the black negative cable to the VDC Ground Bus Bar on the PS 401 power supply using M6 or 1 4 inch fasteners 5 Connect the other end of the black negative cable to the VDC GND terminal on the rear of the i401 laser Tighten the M10 hex nut to a torque of 34 N m 25 ft lbf maximum using two wrenches While tightening the outer nut hold the inner nut the one agains...

Page 41: ...NRAD recommends the use of a UC 2000 Universal Laser Controller to generate pulse width modu lated PWM Command signals that control the laser s output power To connect a UC 2000 Controller available separately perform the steps described below Note Firestar i401 lasers can also be controlled from an alternate user supplied Command signal source Refer to Controlling laser power in the Technical Ref...

Page 42: ...and signal descriptions See Integrating Firestar safety features also in the Tech nical Reference chapter for detailed instructions on integrating Firestar s keyswitch shutter and remote interlock functions with automated control systems Other connections Gas Purge port A gas purge is highly recommended when operating the laser Purging the laser creates positive pressure inside the laser housing t...

Page 43: ...cket to the rear of the i401 laser using the 6 32 Allen capscrews and 6 flat washers provided in the kit 3 Assemble the two 90 fittings straight fitting and filter as shown in Figure 1 11B Be sure to orient the directional arrow on the filter as shown 4 Loosen the two jam nuts on the straight fitting so it will slide into the support bracket 5 Refer to Figure 1 11C and plug the filter assembly int...

Page 44: ...midity never drops below approximately 10 then increase the flow rate slightly The Gas Purge port on the Firestar i401 laser must be connected to a source of nitrogen or clean dry air only do not use any other gases for purging Purge gas specifications are listed in Table 1 4 below Table 1 4 Purge gas specifications Purge Gas Specification Nitrogen High Purity Grade 99 9500 purity or better Air Br...

Page 45: ...ate the LAN s Internet Protocol TCP IP properties 5 Select Use the following IP address and enter the following information IP Address 192 168 50 100 Subnet Mask 255 255 255 0 6 Click OK to submit the changes Connect to the Firestar i401 laser 1 Remove DC power from the laser 2 Locate the Ethernet crossover cable in the ship kit 3 Connect the crossover cable between your computer and the i401 s Et...

Page 46: ...401 s web page capability to monitor various operating parameters see the Firestar i401 web interface section in the Technical Reference chapter for additional information If you have problems connecting to the i401 web page refer to the Troubleshooting Web interface section in the Maintenance Troubleshooting chapter ...

Page 47: ...irestar i401 controls and indicators and to begin operating the laser This chapter contains the following information Controls and indicators displays and describes exterior controls and indicators on Firestar i401 lasers Initial start up explains how to start your Firestar i401 laser while verifying proper operation ...

Page 48: ...ture Seal prevents dust from damaging laser optics during shipping Remove the red self adhe sive label before applying power to the laser 4 Status Indicators LED indicators display i401 laser status From left to right INT Remote Interlock LED illuminates green to indicate the remote interlock circuit is closed and lasing may be enabled the LED is red and lasing is disabled if the interlock input i...

Page 49: ... cooling kit contains 90 tubing adaptors for both 1 2 inch and 12 mm cooling tubing 9 Lifting Handles allow you to safely lift and move the laser After laser installation all three handles can be removed if additional clearance is necessary 10 GND Terminal M10 1 5 threaded stud provides connection point for negative ground side of the 48 VDC power supply 11 48V POWER Terminal Block receives 48 VDC...

Page 50: ...sly burn human tissue the OEM or System Integrator must ensure that appropriate safeguards are in place to prevent unintended lasing Important Note For safety reasons the Firestar i401 laser contains an internal electromechanical shutter assembly that is controlled by the Shutter Open Request input signal Pin 10 on the DB 15 User I O connector The shutter opens only when a Shutter Open Request sig...

Page 51: ...ol the laser or UC 2000 externally Note When performing the initial start up sequence you must first connect the Quick Start Plug or you must provide the required Remote Interlock and Shutter Open Request signals to the User I O connector See User I O connections in the Technical Reference chapter for User I O pinouts and signal descriptions Starting auxiliary equipment 1 Ensure that all personnel...

Page 52: ...ed Important Note Each time an i401 OEM laser is powered up a five second delay occurs between the time the RDY indicator illuminates and the i401 is permitted to lase After the five second delay and while the SHT LED is off tickle is applied to maintain the laser in a ready state Once a Shutter Open Request signal is applied and the SHT LED illuminates apply PWM Command signals to begin lasing Wa...

Page 53: ...aintenance Troubleshooting chapter for troubleshooting information Without a UC 2000 Controller If you have chosen not to use a UC 2000 to control the laser follow the procedure below to verify the laser s functionality Although a tickle signal is not required you will need to provide PWM Command signals to Firestar s User I O connector Refer to User I O connections in the Technical Reference chap...

Page 54: ... 0 34 Bars 5 Ensure that your PWM controller is set to zero percent output 0 0 6 Turn on the 48 VDC power supply If the factory wired Quick Start Plug is installed the INT indicator will illuminate green the SHT indicator will illuminate blue and the RDY LED will illuminate yellow The TMP indicator will il luminate green if laser temperature is within safe operating limits Starting your Firestar i...

Page 55: ...increasing power output 3 Remove the PWM Command signal from the User I O connector The LASE indicator turns off 4 If you are connected to the i401 s Ethernet port access the i401 web page to verify operating condi tions and functionality refer back to Figure 1 12 See the Getting Started or Technical Reference chapters for details on accessing the Firestar i401 web page 5 Remove DC power from the ...

Page 56: ...operation 210 Synrad Firestar i401 operator s manual This page intentionally left blank ...

Page 57: ...specifications for the 15 pin User I O connector DC Power Cables provides information about i401 power cables Firestar i401 web interface explains details about the Firestar i401 s Ethernet inter face Integrating Firestar safety features describes how to integrate Firestar i401 safety features into your automated control system Firestar i401 general specifications provides specifications for the F...

Page 58: ...the electrodes and the gas mixture generates the laser beam Firestar i401 optical resonators are comprised of three optical elements a front mirror a rear mirror and an output window These optical elements are fastened to the tube s exterior and are exposed to its interior through holes in the end caps O rings are sandwiched between optical elements and the end cap to form a gas seal and to provid...

Page 59: ...which is then focused by a spherical focusing mirror through a water cooled aperture to remove any side lobes and then onto another spherical mirror that collimates the beam This beam then passes the shutter mechanism and through the rear folding mirror beam rotator assembly which rotates the beam 45 degrees before exiting through the output aperture Polarization Polarization is important in achie...

Page 60: ...d sensors on the control board monitor various conditions and parameters that if exceeded pose a risk of potential damage to the laser Additionally laser operation is interrupted in response to the following con ditions 1 the electromechanical shutter is closed 2 the Shutter Open Request input signal is missing 3 an over temperature or low coolant flow condition occurs 4 the Remote Reset Start Req...

Page 61: ...focused spot while providing the depth of field required for the material to be processed Optics are fragile and must be handled carefully preferably by the mounting ring only Be careful to select optics that are thick enough to withstand the maximum assist gas pressure available for the process This is especially important in metal cutting applications using high pressure assist gases Cleanliness...

Page 62: ...ers from the need to supply external tickle pulses between lasing commands Internal circuitry monitors the incoming PWM signal and determines the amount of time the laser was on lasing during the last 200 microsecond µs interval If the laser s on time was greater than the preset tickle value then no tickle pulse is generated because the PWM signal was sufficient to maintain a plasma state If no PW...

Page 63: ...y is 100 kHz The third Command signal parameter PWM duty cycle is the percentage of the period that the Com mand signal is high For example if the Command signal s amplitude at 5 kHz is high for 100 µs and low for 100 µs it has a 50 duty cycle if the amplitude is high for 190 µs and low for 10 µs it has a 95 duty cycle Figure 3 4 illustrates typical PWM Command signal parameters 0 VDC 5 VDC 100 µs...

Page 64: ...power To generate the correct analog voltage from a computer or PLC a Digital to Analog D A or DAC card capable of generating 0 V laser off to 10 V maximum laser power must be installed To generate the proper analog current install a D A card that can generate 4 mA laser off to 20 mA maximum power Software able to control your analog output card is required for either configuration Continuous wave...

Page 65: ...unctionality allows the user to easily test and verify laser operation prior to integration In an integrated system you should configure the UC 2000 s gate input logic to internal Pull Down normally off mode This prevents the beam from being enabled unless a high level 3 5 V to 5 0 VDC signal is applied to the Gate input connector In the Pull Down normally off mode an asserted logic low signal sho...

Page 66: ...emale D type subminiature connector on the i401 s rear panel Figure 3 5 below illustrates the pin arrangement of the User I O connector Caution possible equipment damage Turn off DC power before installing or removing any plug or cable from the User I O connector Ensure that user connections are made to the appropriate pins and that the appropriate signal levels are ap plied Failure to do so may d...

Page 67: ...a 0 5 A self resetting fuse The return ground path must be through Pin 12 Auxiliary DC Power Ground 5 24 VDC Auxiliary Power This connection provides 24 VDC for driving external inputs or outputs The 24 VDC Auxiliary Power output can source up to 0 5 A and is protected by a 0 5 A self resetting fuse The return ground path must be through Pin 12 Auxiliary DC Power Ground 6 Laser Active output This ...

Page 68: ...ote Reset Start Request lines 12 Auxiliary DC Power Ground This connection provides a ground earth connection for 5 and 24 VDC auxiliary power outputs This pin is the only User I O pin that is connected to chassis ground Do not use this pin for grounding if DC power to external I O circuits is supplied from an external customer supplied DC power source 13 Output Common Use this pin to complete the...

Page 69: ...ASSIS GROUND EARTH 0 5 A FUSE SELF RESETTING 0 5 A FUSE SELF RESETTING USER I O AUX DC PINS 24 VDC 5 VDC 12 4 5 48 VDC DC RETURN Figure 3 6 Auxiliary DC power diagram Pin 4 5 VDC Auxiliary Power This connection provides 5 VDC for driving external inputs or outputs The 5 VDC Auxiliary Power output can source up to 0 5 A and is protected by a 0 5 A self resetting fuse The return ground path must be ...

Page 70: ...rcuit specifications Pin 3 Remote Interlock Apply a positive or negative voltage 5 24 VDC with respect to Pin 11 Input Common to enable lasing If your system does not use a remote interlock this pin must be connected to a voltage source in the range of 5 24 VDC Refer to Figure 3 7 for a diagram showing how the Remote Interlock input is factory jumpered Because all DC power is removed from the lase...

Page 71: ...st and Remote Reset Start Request lines Refer to Table 3 4 for input circuit specifications Figure 3 7 illustrates how Remote Interlock and Shutter Open Request inputs are factory jumpered on the Quick Start Plug to enable lasing for initial testing and troubleshooting purposes Pin 1 PWM Return Pin 9 PWM Input Pin 3 Remote Interlock Pin 4 5 VDC Pin 10 Shutter Open Request Pin 11 Input Common Pin 1...

Page 72: ...Signal Name Input Device Type and Specifications PWM Input High speed optoisolator LED forward voltage drop Vf 1 5 VDC Off state Vmax 0 8 VDC On state Vmin 3 5 VDC 3 mA On state continuous Vmax 6 7 VDC 10 mA Frequency max 100 kHz Remote Reset Start Request Bi directional optoisolator LED forward voltage drop Vf 1 15 VDC Remote Interlock Off state Vmax 1 0 VDC Shutter Open Request On state Vmin 5 0...

Page 73: ...indicator Off Refer to Table 3 5 for output circuit specifications Pin 7 Fault Detected This bi directional switched output is internally connected to Pin 13 Output Common when 1 an over temperature fault TMP LED is red or 2 a No Strike condition blue SHT indica tor is flashing has occurred The output is open high impedance when laser operation is within limits TMP LED green and SHT LED blue Refer...

Page 74: ... inhibited See Table 3 5 for output circuit specifications Figure 3 9 illustrates the output circuit s equivalent internal schematic and Table 3 5 provides Firestar i401 output circuit specifications FIRESTAR i401 OUTPUT CIRCUITRY USER I O OUTPUT SIGNAL PINS SOLID STATE RELAY SOLID STATE RELAY SOLID STATE RELAY SOLID STATE RELAY SOLID STATE RELAY 0 3 A FUSE SELF RESETTING 6 LASER ACTIVE 7 FAULT DE...

Page 75: ...ding on circuit voltage requirements 12 AUX DC POWER GROUND Close switch to enable interlock USER I O PINS 5 24 VDC AUXILIARY POWER 3 REMOTE INTERLOCK 11 INPUT COMMON Close switch to enable interlock USER I O PINS 3 REMOTE INTERLOCK 11 INPUT COMMON 12 VDC 0 VDC Figure 3 10 Customer supplied interlock Figure 3 11 shows another variation for supplying a Remote Interlock signal to the laser In this c...

Page 76: ...PUT COMMON PLC DC OUTPUT MODULE V 5 24V PLC DC OUTPUT MODULE V 5 24V USER I O PINS 11 INPUT COMMON 2 REMOTE RESET START REQUEST 3 REMOTE INTERLOCK 10 SHUTTER OPEN REQUEST Figure 3 12 PLC driven interlock signal When multiple PLC outputs are used connect Firestar inputs to the PLC as shown in Figure 3 13 By supplying voltage VDC to Pin 11 Input Common and pulling individual inputs to ground each in...

Page 77: ...t the current draw does not exceed 50 mA Figure 3 15 Firestar output driving relay 5 24 VDC AUXILIARY POWER 6 LASER ACTIVE 12 AUX DC POWER GROUND 13 OUTPUT COMMON L R1 USER I O PINS 5 24 VDC AUXILIARY POWER 6 LASER ACTIVE 12 AUX DC POWER GROUND 13 OUTPUT COMMON V L USER I O PINS Figure 3 14 Firestar output driving warning lamp Figure 3 15 illustrates a method for controlling a higher voltage highe...

Page 78: ... of a Programmable Logic Controller PLC By supplying voltage VDC to Pin 13 Output Common each Firestar output is independently switched to activate individual PLC inputs Figure 3 16 Firestar output driving PLC input module USER I O PINS PLC DC INPUT MODULE 13 OUTPUT COMMON 6 LASER ACTIVE 7 FAULT DETECTED 8 LASER READY 14 SHUTTER OPEN 15 INTERLOCK OPEN V 5 24V ...

Page 79: ...sity D subminiature connec tor for use with our PS 401 DC power supply When using a power supply other than the PS 401 we recommend using remote sensing so the power supply output remains at a constant voltage over varying load conditions Choose a DC supply that can compensate for a maximum load lead loss round trip of 1 0 V Important Note If you lengthen the DC Power Cables shipped with the i401 ...

Page 80: ...Ethernet connection Web page layout Firestar i401 lasers include a web based Internet interface that allows you to access read only information including LED status RF module voltage current and temperature measurements using a standard web browser as shown in Figure 3 17 Figure 3 17 Firestar i401 Internet interface page Note On initial power up of the laser allow five seconds for the web interfac...

Page 81: ... displays operating conditions for each of the Firestar i401 s four RF modules Connected A green indicator means that the RF module is connected to the control board The indicator changes to red if there is no connection Input Voltage VDC Displays the DC voltage level measured at the input of the power board for each RF module Switch Voltage VDC Displays the DC voltage level applied to each RF mod...

Page 82: ... following sections Important Note Connection to a local network is permitted as long as the laser s fixed IP address is unique to your network otherwise a peer to peer connection is required Note The procedure described below may require the assistance of your IT Department if your facil ity s Ethernet settings are determined automatically using Dynamic Host Configuration Protocol DHCP The i401 p...

Page 83: ... IP Address page loads Figure 3 18 change IP Address Subnet Mask and Gate way addresses as required Be sure to record these address changes in a safe location Figure 3 18 Firestar i401 Change IP Address page 3 Click the Submit button 4 Remove DC power from the laser wait 30 seconds and then re apply 48 VDC power 5 Launch your web browser type the new IP address and then press Enter The i401 web pa...

Page 84: ...s from red to green and five seconds later lasing is enabled Although a Remote Reset Start Request input is not required to reset OEM faults it can be used to inhibit disable lasing Disable the laser by applying a voltage in the range of 5 24 VDC to Pin 2 the Remote Reset Start Request input Removing voltage allows power to reach the RF driver and begins a five second countdown after which lasing ...

Page 85: ...ed Lasing is disabled when the Remote Interlock signal is removed INT LED red RDY LED off DC power is applied to the RF driver only when the INT LED is green and the RDY LED is yellow Remote interlock functionality is provided by the Re mote Interlock signal via Pin 3 on the User I O connector To use Firestar s remote interlock feature to initiate lasing apply a voltage in the range of 5 24 VDC to...

Page 86: ...Input Signal Voltage 3 5 to 6 7 VDC Current max continuous 10 mA 6 7 VDC Frequency DC 100 kHz Duty Cycle 0 100 Logic Low State Vmin Vmax 0 0 to 0 8 VDC Logic High State Vmin Vmax 3 5 to 6 7 VDC Specifications subject to change without notice 1 This power level is guaranteed for 12 months regardless of operating hours 2 48 VDC input voltage to obtain guaranteed output power 3 100 Hz 10 duty cycle a...

Page 87: ...al Specifications Operating Temperature11 15 C 40 C Humidity 0 95 non condensing Physical Specifications Length 48 3 in 122 7 cm Width 8 2 in 20 8 cm Height 11 8 in 30 0 cm Weight 130 lbs 59 0 kg Specifications subject to change without notice 10 Firestar i401 lasers can be operated at coolant temperatures up to 28 C 82 F in order to reduce problems associated with condensation however this may re...

Page 88: ... 49 963 1269 05 11 375 288 93 10 000 254 00 7 185 182 50 36 200 919 48 4X 433 11 00 2X 1 050 26 67 2X 380 9 65 2X 11 250 285 75 C L 2X PIN GUIDE OPTION A DESCRIPTION FINISH MATERIAL REV ECO DATE DESCRIPTION DB TOLERANCES UNLESS NOTED 5 ANGLE 1 x 01 xx 005 xxx PROPRIETARY THIS DRAWING IS PROPRIETARY TO SYNRAD INC AND SHALL NOT BE USED OR DISCLOSED IN WHOLE OR IN PART WITHOUT WRITTEN PERMISSION OF S...

Page 89: ... DB TOLERANCES UNLESS NOTED 5 ANGLE 1 x 01 xx 005 xxx PROPRIETARY THIS DRAWING IS PROPRIETARY TO SYNRAD INC AND SHALL NOT BE USED OR DISCLOSED IN WHOLE OR IN PART WITHOUT WRITTEN PERMISSION OF SYNRAD INC PART NUMBER DWG FILE NUMBER SHEET ENG DRAWN BY DATE UNITS CATEGORY CHECKED BY DATE SIZE B FINISH CLASS APPROVED BY DATE SYNRAD INC 4600 Campus Place Mukilteo WA 98275 Phone 425 349 3500 Fax 425 34...

Page 90: ...G BOX IMPORTANT NOTE FAILURE TO PROPERLY PACKAGE LASER USING SYNRAD SHIPPING BOX AND FOAM CARDBOARD INSERTS AS SHOWN MAY VOID WARRANTY CUSTOMERS MAY INCUR ADDITIONAL REPAIR CHARGES DUE TO SHIPPING DAMAGE CAUSED BY IMPROPER PACKAGING DESCRIPTION FINISH MATERIAL REV ECO DATE DESCRIPTION DB TOLERANCES UNLESS NOTED 5 ANGLE 1 x 01 xx 005 xxx PROPRIETARY THIS DRAWING IS PROPRIETARY TO SYNRAD INC AND SHA...

Page 91: ...formation in this chapter to perform maintenance or troubleshoot your Firestar i401 laser This chapter contains the following information Maintenance describes typical Firestar i401 maintenance procedures Troubleshooting explains how to troubleshoot common Firestar i401 problems ...

Page 92: ...beam delivery optics contact SYNRAD Inc or the optics manufacturer for handling instructions Caution possible equipment damage If you operate your laser or marking head in a dirty or dusty environ ment contact SYNRAD about the risks of doing so and precautions you can take to increase the longevity of your laser marking head and associated optical components 1 Inspect all cooling tubing connection...

Page 93: ...tailed instructions on properly packaging the laser for shipment Important Note Failure to properly package the laser using SYNRAD supplied shipping boxes and foam cardboard inserts as shown in the Packaging instructions may void the war ranty Customers may incur additional repair charges for shipping damage caused by improper packaging Cleaning optical components Debris or contaminants on externa...

Page 94: ...ptics with tools always use gloved hands or fingers Hold optics by the outer edge never touch the coated surface Always place optics lens tissue for protection never place optics on hard or rough surfaces It may be necessary to use a cotton ball or fluffed cotton swab instead of a lens wipe to uniformly clean the entire surface of small diameter mounted optics Before using any cleaning agents read...

Page 95: ...tream of air at a glancing angle across the lens surface Repeat as necessary 4 Dampen a lens wipe with the selected cleaning agent Ethyl alcohol least aggressive is best for initial surface cleaning Acetone moderately aggressive is best for oily residue or minor baked on vapors and debris Important Note If acetone is used as a cleaning solvent a second follow up cleaning of the optical surface usi...

Page 96: ...to understand the sequence of events that must happen before the laser can operate Before attempting any service we advise you to read the entire troubleshoot ing guide and review both the operational flowchart and the functional block diagram Danger serious personal injury This Class 4 laser product emits invisible infrared laser radiation in the 10 6 µm CO2 wavelength band Direct or diffuse lase...

Page 97: ...r install factory supplied Quick Start Plug Check that cooling water is flowing through laser and that coolant temp is below 22 C Apply shutter open signal to Shutter Open Request input or install factory supplied Quick Start Plug Cycle DC power Apply PWM Command signal to laser Apply 48 VDC power to laser LASE indicator illuminates Red to indicate laser output Laser Start Sequence Yes Yes Yes No ...

Page 98: ...Firestar i401 functional block diagram DB 15 USER I O 48 VDC 48 VDC RF Module 1 RF Module 2 RF Module 3 RF Module 4 i401 Control Board Power Board 2 Power Board 1 Sensors RJ45 Ethernet Interface Shutter Switched 48 VDC Switched 48 VDC PWM Fault Detection PWM Fault Detection Shutter Open Command Fault Detection Over Under Voltage Fault Current Fault Over Under Voltage Fault Current Fault Humidity F...

Page 99: ... an i401 laser the RDY lamp illuminates yellow on DC power up when INT and TMP indicators illuminate green After the RDY indicator illuminates internal tickle is enabled and a five sec ond delay begins before lasing is permitted When a Shutter Open Request signal is applied the internal shutter opens the SHT LED illuminates blue and application of a PWM Command signal causes the LASE indicator to ...

Page 100: ...LED Off Off Off Blue Shutter Open output Open Open Open Closed Physical shutter position Closed Closed Closed Open DC power to RF boards Off Off On On Signal input to RF boards None None Tickle PWM Tables 4 4 through 4 9 show how the Firestar i401 s LED and output signal status changes as various oper ating and fault conditions occur Fault conditions are shown in bold Table 4 4 Normal operating co...

Page 101: ...ff Laser Active Open Table 4 6 Interlock Open condition LED Indicator LED Status Signal Name User I O Signal Status INT Red Interlock Open Closed TMP Green Fault Detected Open RDY Off Laser Ready Open SHT Off Shutter Open Open LASE Tickle only Off Laser Active Open LASE PWM applied Off Laser Active Open Table 4 7 Over Temperature fault LED Indicator LED Status Signal Name User I O Signal Status IN...

Page 102: ...osed SHT Blue Flashing Shutter Open Closed LASE Tickle only Off Laser Active Open LASE PWM applied On Laser Active Closed Laser fault indications Firestar i401 lasers have the ability to indicate five specific fault conditions In the event of certain faults the RDY LED will blink an error code pause four seconds and then repeat the error code This sequence continues until the fault is corrected an...

Page 103: ... temperatures when the laser is off In situations like this it may take 30 to 60 seconds for gas breakdown to occur and begin normal daily operation The Fault Detected output closes for a minimum of 50 ms or until the No Strike condition clears Resetting faults Remote Interlock condition A remote interlock condition occurs when the Remote Interlock input opens the INT LED changes from green to red...

Page 104: ...onditions Next cycle DC power off and then on again When the RDY LED illuminates lasing is enabled after a five second delay Over Voltage fault An over voltage fault occurs when DC input voltage rises above a preset limit of 49 5 VDC This fault is indicated by the RDY LED flashing 2 blinks To reset an over voltage fault first correct the voltage problem and ensure that 48 VDC is measured at the la...

Page 105: ...butor Common causes of No Strike gas breakdown issues are environmental conditions like cold overnight temperatures when the laser is powered down In situations like this it may take 30 to 60 seconds for gas breakdown to occur so the laser can begin normal daily operation General laser fault conditions Each Symptom listed below describes a particular fault condition For each Symptom specific cause...

Page 106: ... to disconnect the cooling tubing from the chiller inlet or the drain and run the cooling water for 30 seconds into a five gallon bucket you should have close to two gallons of water If there is much less than two gallons of coolant check the cooling path for kinked or pinched cooling tubes or check the chiller for a clogged or dirty filter On i401 lasers the over temperature fault indicated by th...

Page 107: ...I O con nections in the Technical Reference chapter for details If your system does not provide a Shutter Open Request signal connect the factory supplied Quick Start Plug to the User I O connector on the laser s rear panel or wire your male DB 15 connector so that Pin 11 Input Common is jumpered to Pin 12 Aux iliary DC Power Ground and Pin 10 Shutter Open Request is jumpered to Pin 4 5 VDC Auxili...

Page 108: ...if the i401 is connected to your network using a network router switch or hub The factory default IP address was changed Firestar i401 lasers are pre configured at the factory with a fixed IP address of 192 168 50 50 If this address was changed in the field then you must locate the new IP address it cannot be remotely reset Symptom The Firestar i401 is connected to a network however the i401 web i...

Page 109: ...appear differently To authorize the i401 web page on a local intranet Figure 4 4 click the Local intranet icon and then click the Sites button In the Local intranet dialog click Advanced In the Add this website to the zone text box type the laser s IP address and click Add Click Close and then click OK twice To add the i401 web page as a trusted web site Figure 4 4 click the Trusted sites icon and...

Page 110: ...evices like the TRENDnet TU2 ET100 USB to 10 100 Mbps Adapter allow your networked computer to access the Firestar i401 web page over the computer s USB port which isolates the laser from your computer network In this case use a crossover Ethernet cable between the i401 laser and the USB to Ethernet adapter Beam delivery optics Symptom The laser loses power over time laser output power must be inc...

Page 111: ...aminants that will damage optical surfaces it must be carefully fil tered and dried before use as a purge or assist gas Refer to Table 1 3 Purge gas specifications in the Getting Started chapter for filtering and drying specifications Warning serious personal injury A risk of exposure to toxic elements like zinc selenide may result when certain optical or beam delivery components are damaged In th...

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Page 113: ...anger 4 4 4 20 troubleshooting 4 20 4 21 warning 4 2 4 21 Beam diameter 3 2 specifications 3 30 Bend radius 3 23 Block diagram 4 8 BNC Control cable 1 6 1 7 connecting 1 19 C Caution condensation damage 1 13 2 5 2 7 2 7 2 9 coolant temperature 1 13 cooling fittings 1 11 definition 1 dirty dusty environments 4 2 4 3 dew point 1 14 2 7 2 9 National Electrical Code NEC 1 16 mounting 1 8 optics damage...

Page 114: ...16 temperature setpoint 1 13 1 14 4 16 Copyright information viii Customer Service x Customer supplied interlock 3 19 D Daily inspections 4 2 4 3 Danger definition 1 explosive atmospheres 1 eye protection 1 laser radiation 1 2 4 4 4 4 6 4 20 DB 15 connections See User I O connections DC power 3 11 24 VDC 3 11 3 13 3 19 3 21 5 VDC 3 11 3 13 3 19 4 16 4 17 Aux DC Power Ground 3 11 3 13 4 16 4 17 con...

Page 115: ...ure 1 2 optical setup 3 4 3 5 outline mounting drawings 3 32 3 33 packaging instructions 3 34 packing unpacking 1 3 1 5 safety features 3 28 3 29 specifications 3 30 3 31 storage shipping 4 3 technical overview 3 2 3 5 troubleshooting 4 6 4 21 web interface 3 24 3 27 Firestar i401 baseplate mounting 1 8 1 10 Five second delay 5 8 2 2 2 4 2 6 2 8 3 11 3 14 3 17 3 18 3 26 3 28 3 29 4 9 4 13 4 14 4 1...

Page 116: ... INT indicator See Remote Interlock INT indi cator Introduction 1 2 Firestar nomenclature 1 2 Inventory ship kit contents 1 6 1 7 IP Address 1 23 3 26 4 18 changing 3 27 K Keyswitch 5 8 1 2 Keyswitch functions integrating 3 28 L Label locations 4 Lase LASE indicator 5 8 2 2 2 6 2 8 2 9 3 6 3 11 3 17 4 9 4 10 4 11 4 12 4 15 4 16 4 17 Laser Active output 4 9 4 10 4 11 4 12 4 15 4 16 4 17 signal desc...

Page 117: ...0 4 11 4 12 4 13 4 15 4 16 4 17 Laser Active 3 11 3 17 4 9 4 10 4 11 4 12 4 15 4 16 4 17 Laser Ready 3 11 3 17 4 9 4 10 4 11 4 12 4 13 4 15 4 16 4 17 Output Common 3 12 3 17 Shutter Open 3 12 3 17 4 9 4 10 4 11 4 12 4 15 4 16 4 17 Over Temperature fault 4 11 4 16 description 4 14 Over temperature indictor See Temp TMP indicator Over temperature protection 8 Over Voltage fault 4 13 description 4 14...

Page 118: ...es Class 4 8 integrating 3 28 3 29 Safety precautions 1 3 Sales and Applications x Sample I O circuits 3 19 3 22 input circuits 3 19 3 20 output circuits 3 21 3 22 Ship kit contents 1 6 1 7 Shorting plug See Quick Start Plug Shutter See Electromechanical shutter as sembly Shutter functions 8 3 28 3 29 4 9 4 17 Shutter SHT indicator 8 2 2 2 4 2 6 2 8 3 11 3 12 3 14 3 17 3 28 3 29 4 9 4 10 4 11 4 12...

Page 119: ...put signals 3 13 3 18 sample input circuits 3 19 3 20 sample output circuits 3 21 3 22 status signals 4 9 4 12 User I O connector 1 7 1 19 1 20 2 3 2 5 2 7 2 8 2 9 3 7 3 8 3 10 3 11 3 12 3 13 3 28 3 29 4 9 4 15 4 16 4 17 W Warning aerosol dusters 2 air contaminants 2 definition 1 electrical noise 1 19 3 7 hazardous radiation exposure 2 1 20 laser output 1 19 2 4 2 6 2 8 3 6 3 7 3 9 laser radiation...

Page 120: ...index i8 Synrad Firestar i401 operator s manual ...

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