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technical reference

62

SYNRAD OEM v40 Operator’s Manual Version 4

Controlling laser power

Marking/engraving operation

When the delay between the end of one PWM Command signal pulse and the beginning of the next 

PWM pulse exceeds 200 microseconds (less than or equal to 5 kHz), Firestar’s on-board tickle generator 

sends a tickle pulse to maintain plasma ionization in the tube. Because the on-board tickle generator can 

not anticipate when the next PWM Command pulse will arrive, the tickle pulse (which typically lasts for 

2–6 µs depending on the laser) can effectively merge with a PWM signal that follows closely afterwards. 

When the PWM pulse that follows is short, causing the tickle pulse to become a significant fraction of the 

PWM pulse duration, then the tickle pulse effectively substantially increases the length of the PWM pulse 

it has merged with. For subtle marking applications on sensitive, low threshold materials this lengthened 

PWM pulse may affect mark quality. 

While this situation can occur when using PWM Command signal frequencies of 5 kHz and less, it is im-

portant to note that it isn’t the Command signal frequency itself that is the determining factor but rather 

this behavior happens only when the off time between PWM pulses exceeds 200 microseconds.

Summary of Contents for Firestar V Series

Page 1: ...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 ...

Page 2: ...OEM v40 Operator s Manual Version 4 SYNRAD is a registered trademark of Novanta Corporation Novanta Corporation 2019 All Rights Reserved No reproduction without written authorization DATE March 2019 ...

Page 3: ...e 1 2 Unpacking 1 3 Incoming inspection 1 3 Packaging guidelines 1 3 Inventory 1 4 Contents description 1 5 Mounting 1 6 Fastening from above 1 6 Fastening from below 1 7 Connecting 1 8 Water cooled connections 1 8 OEM air cooled connections SAB models 1 12 Electrical connections 1 14 Control connections 1 16 Keyswitch controls and indicators 2 2 v40 front panel 2 2 v40 rear panel 2 3 OEM controls...

Page 4: ...its 3 19 DB 9 connections SAB models only 3 22 Integrating Firestar safety features 3 24 Keyswitch functions 3 24 Shutter functions 3 25 Remote interlock functions 3 25 v40 general specifications 3 26 Firestar v40 package outline drawings 3 28 Packaging instructions drawing 3 31 Maintenance 4 2 Disabling Firestar 4 2 Daily inspections 4 2 Storage shipping 4 3 Cleaning optical components 4 3 Troubl...

Page 5: ...cs beam path 3 4 Figure 3 3 Representative Firestar v40 waveforms 3 6 Figure 3 4 PWM Command signal waveform 3 7 Figure 3 5 User I O connector pinouts 3 12 Figure 3 6 Auxiliary power supply wiring 3 13 Figure 3 7 Quick Start Plug wiring diagram 3 15 Figure 3 8 Input equivalent schematic 3 16 Figure 3 9 Output equivalent schematic 3 18 Figure 3 10 Customer supplied interlock 3 19 Figure 3 11 Custom...

Page 6: ... contents vi SYNRAD OEM v40 Operator s Manual Version 4 List of Figures cont Figure 3 21 Firestar v40 packaging instructions 3 31 Figure 4 1 Operational flowchart 4 7 Figure 4 2 v40 functional block diagram 4 8 ...

Page 7: ... levels 3 7 Table 3 3 User I O pin descriptions 3 10 Table 3 4 Input circuit specifications 3 16 Table 3 5 Output circuit specifications 3 18 Table 3 6 Side mounted DB 9 pin descriptions 3 22 Table 3 7 Firestar v40 general specifications 3 26 Table 4 1 Required cleaning materials 4 4 Table 4 2 Status signals 4 9 Table 4 3 Interlock Open condition 4 10 Table 4 4 Over Temperature condition 4 10 Tabl...

Page 8: ...erator s manual Trademark copyright information SYNRAD and Firestar are registered trademarks of SYNRAD All other trademarks or registered trademarks are the property of their respective owners 2019 by SYNRAD All rights reserved ...

Page 9: ...within the first 45 days after purchase SYNRAD 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 cus tomer from SYNRAD The customer however will be responsible for shipping charges incurred when sending the failed unit ...

Page 10: ...al Sales Manager in your area call SYNRAD at 1 800 SYNRAD1 Customer Service For assistance with order or delivery status service status or to obtain a Return Au thorization RA number contact SYNRAD at 1 800 SYNRAD1 and ask to speak to a Customer Service representative or you can email us by sending a message to customer care synrad com Technical Support SYNRAD Regional Sales Managers are able to a...

Page 11: ...EU headquarters For assistance in Europe contact SYNRAD European subsidiary Synrad Europe at Novanta Distribution USD GmbH Parkring 57 59 85748 Garching bei München Germany Phone 49 89 31707 0 web www synrad com e mail EMEA service novanta com ...

Page 12: ...ry and work your way through Connecting This chapter contains the following information Introduction introduces the Firestar v40 laser lists important features and describes Firestar nomenclature Unpacking provides important information about shipping your v40 laser Inventory displays and describes all components shipped with your laser Mounting describes how to attach laser components to a mounti...

Page 13: ...toamanual Keyswitch allKeyswitch equippedlasersincludeamanualshutterswitchthatallowsthe laser output aperture to be blocked OEM lasers do not incorporate either a manual keyswitch or shutter assembly since they are primarily designed as components to be integrated into a larger processing system by the Original Equipment Manufacturer OEM or System Integrator who bears the responsibility for meetin...

Page 14: ...and packaging materials including covers and plugs Use these special ized packing materials when shipping the laser to another location After unpacking review the Inventory section and verify that all components are on hand When packing a laser for shipment be sure to remove all accessory items not originally attached to the laser including beam delivery components cooling tubing fittings etc Refe...

Page 15: ...Start Plug except SAB models 1 Spare Fuse not shown 2 Cooling Tubing water cooled only 1 Final Test Report not shown 1 Mounting Bolts 3 Firestar v40 Operator s Manual Mounting Bolts and Fuses Cooling Tubing water cooled only Quick Start Plug Firestar v Series Laser v40 fan cooled laser shown AVOID EXPOSURE Invisible laser radiation is emitted from this apertu re INVISIBLE LASER RADIATION AVOID EYE...

Page 16: ... remote interlock circuits for initial start up and testing Cooling Tubing water cooled only carries cooling water from the chiller to the laser and back This black polyethylene tubing is 1 2 O D by 30 feet and must be cut to length Mounting Bolts 1 4 20 5 8 bolts fasten Firestar to your mounting surface Firestar v40 Operator s Manual provides setup operation and maintenance information for your F...

Page 17: ...urface Caution possible equipment damage SYNRAD does not recommend mounting lasers in a vertical head down or tail down orientation If you must mount your laser in this manner please contact the factory for limitations as vertical orientation increases the risk of damage to the laser s output optic Fastening from above To fasten Firestar to a mounting surface from above perform the following steps...

Page 18: ...Figure 1 3 Fastening from below 2 Place Firestar on the mounting surface so that the threaded holes on the base plate labeled C in Figure 1 3 line up with the holes drilled through the mounting surface 3 Insert 1 4 20 5 8 UNC capscrews through the mounting surface into the threaded holes of Fire star s base plate Turn the screws by hand until the threads engage 4 Tighten all three capscrews to a t...

Page 19: ...ush tubing completely into the fitting then pull the tubing to verify that it is locked into place Tubing extends into the fitting approximately 7 8 of an inch If tubing must be disconnected from 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 ...

Page 20: ...following wetted materials in the coolant path aluminum brass copper Delrin PBT polyethylene stainless steel and Viton Setting coolant temperature Choosing the correct coolant 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 insi...

Page 21: ...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 and locate an air temperature in Fahrenheit or Cel sius C values shown in parentheses that corresponds to the air temperature in the area where your laser is operating Follow t...

Page 22: ...2 F may resultindecreasedperformanceand orprematurefailureofelectronic components Figure 1 4 Firestar cooling connections 1 Cut and connect a length of tubing to fit between the chiller s Outlet port and the upper WATER IN port on the rear of the Firestar v40 laser 2 Cut and connect a length of tubing to fit between the lower WATER OUT port on the rear of the laser and the chiller s Inlet port 3 T...

Page 23: ...ow evenly over the entire surface area of the combined laser RF chassis is vitally important to the performance and longevity of the laser Figure 1 5 Recommended v40 cooling fan locations Note The air cooled OEM laser s front plate is not compatible with the fan kit used on fan cooled v40 lasers Because a different front plate is required the factory supplied fan kit cannot be retro fitted to air ...

Page 24: ...area of the combined laser RF chassis is vitally important to the performance and longevity of the laser Figure 1 6 Rear mounted cooling Guidelines for rear cooling The cooling shroud must be designed so that it encloses the full length of both the laser and the cooling fan The shroud must fit snugly against the laser s cooling fins so that cooling air is ducted between the fins and not around the...

Page 25: ...teps listed in the 240 VAC input operation section Figure 1 7 DC 5 power supply Note The negative side of the DC input to the laser is internally connected so that the laser chas sis serves as DC power ground You should isolate the laser s DC power supply so that the only grounded connection is at the laser Alternatively you can mount the laser chassis on an insulat ing pad or film in order to ele...

Page 26: ...rce to the terminal labeled L AC Line 8 Connect the ground earth wire typically green from your AC voltage source to the terminal labeled with the ground symbol 240 VAC input operation 1 Verify that input AC power to the DC power supply is physically locked out or disconnected 2 Locate the 30 VDC output terminals on the power supply s output section and connect the black DC power cable from the la...

Page 27: ...roller SYNRAD 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 not included with the Firestar v40 laser perform the following steps 1 Remove DC power from the laser 2 Locate the Quick Start Plug in the ship kit 3 Connect the Quick Start Plug to the User I O connect...

Page 28: ...ar laser For further information about the User I O connector see User I O connections in theTechnical Reference chapterforUserI Opinoutsandsignaldescriptions See IntegratingFirestarsafetyfeatures alsointheTech nical Reference chapter for detailed instructions on integrating Firestar s keyswitch shutter and remote interlock functions with automated control systems Figure 3 7 Quick Start Plug wirin...

Page 29: ...getting started 29 SYNRAD OEM v40 Operator s Manual Version 4 This page intentionally left blank ...

Page 30: ...t your laser Compliance explains in the subsections therein applicable and appropriate regula tion information Note Read the entire safety section This will ensure you are familiar with the hazards and warnings prior to starting Serious personal injury This Class 4 CO2 laser product emits invisible infrared laser radiation in the 9 3 10 6 µm wavelength band Because direct or diffuse laser radiatio...

Page 31: ... or on the equipment to alert both operating and service personnel to the recommended precautions in the care use and handling of Class 4 laser equipment Terms Certain terms are used throughout this manual or on the equipment labels Please familiarize yourself with their definitions and significance Figure 2 1 Labeling terms and definitions Two Person Lift Important Note Tip Note Serious personal ...

Page 32: ...anent damage This product is not intended for use in explosive or potentially explosive atmospheres Materials processing with a laser can generate air contaminants such as vapors fumes and or particles that may be noxious toxic or even fatal Safety Data Sheets SDS for materials being processed should be thoroughly evaluated and the adequacy of provisions for fume extraction filtering and venting s...

Page 33: ...and will ignite most materials under the proper con ditions Never operate the laser in the presence of flammable or explosive materials gases liquids or vapors Safe operation of the laser requires the use of an external beam block to safely block the beam from traveling beyond the desired work area Do not place your body or any combusti ble object in the path of the laser beam Use a water cooled b...

Page 34: ...pplicable laser safety procedures D risk of exposure to hazardous or lethal voltages through unauthorized removal of covers doors or access panels E generation of hazardous air contaminants that may be noxious toxic or even fatal Additional laser safety information The SYNRAD web site https www synrad com resources general_information lasersafetyre sources contains an online laser safety handbook ...

Page 35: ...for deviations pursuant to Laser Notice No 50 dated June 24 2007 SYNRAD Inc 4600 Campus Place Mukilteo WA 98275 425 349 3500 DANGER INVISIBLELASER RADIATION AVOIDEYEORSKIN EXPOSURETODIRECTOR SCATTEREDRADIATION CLASS4LASERPRODUCT EN 60825 1 2014 This laser product is manufactured under one or more of the following U S Patents 6 195 379 6 198 758 6 198 759 6 603 794 6 614 826 7 480 323 9 031 110 9 1...

Page 36: ...d or recommend laser components that are CE marked for compliance with applicable European Union Directives Because OEM laser products are intended for incorporation as components in a laser process ing system they do not meet all of the Standards for complete laser processing systems as specified by 21 CFR 1040 or EN 60825 1 SYNRAD assumes no responsibility for the compli ance of the system into ...

Page 37: ...magnetic interference EMI from affecting authorized radio communication services The FCC regulations that govern industrial scientific and medical ISM equipment are fully described in 47 CFR 18 C SYNRAD laser lasers have been tested and found to comply by demonstrating performance characteristics that have met or exceeded the requirements of 47 CFR 18 Radiated and Conducted Emissions FCC informati...

Page 38: ...as components 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 compon...

Page 39: ...s applied when Keyswitch is in On position Power fail circuit element Yes Yes No 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 Yes Interlock Disables RF driver laser output when a remote interlock switch on an equipment door or panel is ope...

Page 40: ...etic Compatibility Directive 2014 35 EU Low Voltage Directive 2011 65 EU RoHS Directive EN 61010 1 2010 Safety Requirements for Electrical Equipment for Measure ment 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 ...

Page 41: ...cal Equipment for Measurement Control and Laboratory Use Part 1 General Requirements EN 60825 1 4 2014 Safety of Laser Products Keyswitch only 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 Electronic Fields Immunity EN 61000 6 2 2005 Electrical Fast Transient Burst I...

Page 42: ... the laser This chapter contains the following information Keyswitch controls and indicators displays and describes exterior controls and indicators on Keyswitch equipped v40 lasers OEMcontrolsandindicators displaysanddescribesexteriorcontrolsandindicators on the OEM v40 lasers Initial start up explains how to start your Firestar v40 laser while verifying proper operation 3 ...

Page 43: ...Closing the shutter also interrupts RF power to the laser There is a five second delay imposed from the time the shutter is opened to the time that PWM Command signals are accepted 4 Optical Accessories Mounting provides six threaded holes 8 32 UNC for mounting optional beam delivery components available from SYNRAD Because excessive weight may damage the laser consult SYNRAD before mounting compo...

Page 44: ... indicate that the shutter is Open and that lasing may be enabled The SHT indicator is off and lasing is disabled if the shutter is Closed When the shutter is switched Open there is a five second delay until PWM inputs are recognized 6 LASE Indicator illuminates red to indicate that Firestar is actively lasing The LASE indicator is off when tickle pulses are being generated and illuminates red whe...

Page 45: ...rom SYNRAD Because excessive weight may damage the laser consult SYNRAD before mounting components not specifically designed as Firestar options Refer to Firestar package outline drawings in the Technical Reference chapter for mounting hole dimensions 3 DP Power Connector not shown standard except on OEM air cooled SAB models Provides a convenient 5 VDC 50 mA receptacle to power a visible red diod...

Page 46: ...al is applied 5 SHT Shutter Indicator illuminates blue to indicate that the Quick Start Plug or a Shutter Open Request signal is connected to the User I O port and lasing may be enabled When a Shutter Open Request signal is applied there is a five second delay until PWM inputs are recognized 6 LASE Indicator illuminates red to indicate that the laser is actively lasing The LASE indicator is off wh...

Page 47: ...rs OEM v40 side panel SAB models Figure 3 5 OEM v40 side panel controls and indicators 1 DB 9 connector provides a Shutter Switch input as well as auxiliary 5 and 24 VDC outputs See DB 9 connections in the Technical Reference chapter for connection details Air Cooled v40 OEM Shown 1 ...

Page 48: ...s a stand alone controller do not attempt to control the laser or UC 2000 externally Warning serious personal injury On Firestar v40 OEM lasers remote interlock INT faults are not latched Clearing the fault condition re enables the RDY indicator and the laser will fire after the five second delay provided that the SHT indicator is lit and a PWM Command signal is applied Because exposure to 10 6 µm...

Page 49: ...the PWM Adj Knob to provide zero percent output 0 0 The UC 2000 s Lase indicator should be Off 5 Verify that the laser s Keyswitch if equipped is in the OFF position 6 Turn on the DC power supply If the Quick Start Plug is installed the INT Remote Interlock indicator will illuminate green and the SHT Shutter indicator will illuminate blue if the manual Shutter Switch is Open The TMP Temperature in...

Page 50: ...se indicator on the UC 2000 should illuminate 5 Use the PWM Adj Knob on the UC 2000 to slowly increase power The LASE LED turns red when PWM signal pulses are long enough to produce laser output typically 5 10 µs at 5 kHz The spot where the beam hits the beam block increases in brightness to indicate increased power output 6 Press the UC 2000 s Lase On Off button to stop lasing Lase indicators on ...

Page 51: ...ock while testing 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 in the area are ...

Page 52: ...uminate 3 Rotate the Keyswitch if equipped to the ON position Verify that the yellow RDY Ready indicator on the laser illuminates Note Each time an OEM laser is powered up or a Keyswitch version is cycled OFF ON a five second delay occurs between the time that RDY and or SHT indicators illuminate and Firestar is permit ted to lase Note For remote operation Keyswitch lasers it is possible to set th...

Page 53: ...ers shut off the chiller or otherwise stop coolant flow through the laser Caution possible equipment damage Do not flow coolant through the laser for an extended period of time when the laser is shutdown This causes condensation to form inside the laser which may result in catastrophic damage to internal optics and electronic circuits If your Firestar v40 laser fails to lase refer toTroubleshootin...

Page 54: ...scribes signals and specifications for the 15 pin User I O connector DB 9 connections describes signals and specifications for the SAB model s side mounted DB 9 connector IntegratingFirestarsafetyfeatures describeshowtointegrateFirestarsafetyfeatures into your automated control system v40 general specifications provides specifications for the Firestar v40 laser Firestar v40 package outline drawing...

Page 55: ...or through holes in the end caps O rings sandwiched between optical elements and each end cap form a gas seal and provide a flexible cushion that allows the slight movement necessary for alignment All optical elements are aligned and locked into place by factory technicians before the laser is shipped Caution possible equipment damage Because of their smaller beam diameter Firestar lasers have sig...

Page 56: ...focus the beam onto the part or material to be processed Each element is crucial in the development of a reliable laser based material processing system and each element should be approached with the same careful attention to detail Delivery optics Divergence or expansion of the laser beam is important for materials processing since a larger beam entering the focusing optic produces a smaller focu...

Page 57: ...air available in cylinders from a welding supply company Compressed shop air contains minute particles of oil and other contaminants that will damage optical surfaces If compressed shop air is the only choice available it must be filtered and dried to the specifications shown in Table 3 1 Table 4 1 Assist gas purity specifications Purge Gas Specification Nitrogen High Purity Grade 99 9500 purity o...

Page 58: ...ne with the internally generated tickle signal causing the LASE LED to flicker during the transition from tickle to lasing Laser output may occur if the LASE LED flickers Tickle pulses pre ionize the laser gas to just below the lasing threshold so that a further increase in pulse width adds enough energy to the plasma to cause laser emission Tickle pulses cause the laser to respond predictably and...

Page 59: ... PWM frequencies up to 25 kHz maximum At 25 kHz the laser s optical beam response no longer follows the Command input and is very nearly a DC value with just a small amount of ripple present Command signal 1 5 00 V M 50 0µs Ch1 1 24 V Ch1 Typical optical output pulse 50 duty cycle at 5 kHz T 2 1 5 00 V M 50 0µs Ch1 1 24 V Ch1 Typical optical output pulse 50 duty cycle at 3 kHz T 2 The modulated Co...

Page 60: ...l levels Laser State Minimum Nominal Maximum Laser Off 0 0 VDC 0 0 VDC 0 8 VDC Laser On 3 5 VDC 3 mA 5 0 VDC 6 7 VDC 10 mA continuous Frequency Range 0 Hz DC 5 kHz 25 kHz Duty Cycle 0 100 Operating modes External control In addition to controlling your Firestar laser using a UC 2000 Controller control of Firestar externally without a UC 2000 is also possible The two primary elements of laser contr...

Page 61: ...red to pulse or gate on and off in synchroni zation with an external control signal typically from a computer or function generator operating in the range from DC to 1 kHz To pulse or gate the laser connect a signal providing 5 0 VDC pulses to the Gate connector on the rear panel of the UC 2000 Universal Laser Controller Users who intend to use a gating signal should set the UC 2000 s gate input l...

Page 62: ...ng on the laser can effectively merge with a PWM signal that follows closely afterwards When the PWM pulse that follows is short causing the tickle pulse to become a significant fraction of the PWM pulse duration then the tickle pulse effectively substantially increases the length of the PWM pulse it has merged with For subtle marking applications on sensitive low threshold materials this lengthen...

Page 63: ...ted 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 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 through Pin 12 Auxiliary DC P...

Page 64: ...econd delay during which lasing is inhibited 11 Input Common Use this input pin to connect return lines for Remote Interlock Shutter Open Request and Remote 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 gr...

Page 65: ...15 pin female D type subminiature connector on Firestar s rear panel Note See DB 9 connections later in this section for signal descriptions and pinouts of the SAB model s side mounted DB 9 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 t...

Page 66: ...protected by a 0 5 A self resetting fuse The return ground path must be through Pin 12 Auxiliary DC Power Ground Pin 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 Pin 12 Aux...

Page 67: ... 3 4 for input circuit specifications Note To prevent operator injury when using Keyswitch equipped lasers the Remote Re set Start Request signal is ignored when the Keyswitch is set to the OFF position The manually operated Keyswitch mustbesettotheONpositionbeforethelasercanbereset or started from a remote location Pin 3 Remote Interlock Apply a positive or negative voltage 5 24 VDC with respect ...

Page 68: ...optimumlaserperformance thereisafive seconddelayimposedfromthetime a Shutter Open Request occurs to the time that PWM Command signals are accepted Pin 11 Input Common Use this pin to connect return lines for Remote Interlock Shutter Open Request and Remote Reset Start Request lines Refer to the following table for input circuit specifications Figure below illustrates how Remote Interlock and Shutt...

Page 69: ...ax 25 kHz Remote Reset Start Request Bi directional optoisolator LED Vf 1 15 VDC Remote Interlock Off state Vmax 1 0 VDC Shutter Open Request On state Vmin 5 0 VDC 7 mA On state continuous Vmax 24 0 VDC 40 mA Note The Remote Reset Start Request input must not be sent until Firestar s 5 VDC power supply has stabilized approximately 200 ms after DC power up USER I O INPUT SIGNAL PINS PWM INPUT 9 PWM...

Page 70: ...imits TMP indicator red The output is open high impedance when laser temperature is within operating limits TMP indicator green After an over temperature fault occurs cool the laser and then cycle DC power to reset the laser Refer to Table 3 5 for output circuit specifications Pin 8 Laser Ready This bi directional switched output is internally connected to Pin 13 Output Common when the laser is en...

Page 71: ... s equivalent internal schematic and the following table pro vides Firestar v40 output circuit specifications Figure 4 9 Output equivalent schematic Table 4 5 Output circuit specifications Output Device Specifications Bi directional CMOS 20 Ohms Rdson 10 MOhms Off Voltage 24 VDC max Current 50 mA max FIRESTAR v40 OUTPUT CIRCUITRY ...

Page 72: ... signal to the laser In this case the customer is using a limit switch and supplying a negative voltage to drive Firestar s input circuit 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 4 11 Customer supplied interlo...

Page 73: ...UEST 3 REMOTE INTERLOCK 10 SHUTTER OPEN REQUEST Figure 4 13 Multiple PLC driven inputs Sample outputs Firestar s optoisolated bi directional switched outputs can drive small loads 50 mA max PLC inputs or relays that can control higher current loads Figure below illustrates one method of controlling a remote warning lamp using power supplied by Firestar s 24 VDC Auxiliary Power output Remember to s...

Page 74: ... outputs 5 24 VDC AUXILIARY POWER 6 LASER ACTIVE 12 AUX DC POWER GROUND 13 OUTPUT COMMON V L USER I O PINS Figure 4 15 Firestar output driving relay Figure below illustrates how Firestar s outputs can drive the DC Input Module of a Programmable Logic Controller PLC By supplying voltage VDC to Pin 13 Output Common each Firestar output is inde pendently switched to activate individual PLC inputs USE...

Page 75: ... each pin on the DB 9 connector Table 4 6 Side mounted DB 9 pin descriptions Pin Function Description 1 No Connection 2 No Connection 3 DC Power Ground This connection provides a return ground connection for Pin 4 and Pin 5 24 VDC Fan Power and Pin 9 5 VDC Auxiliary Power This pin is the only DB 9 pin connected to chassis ground Do not use this pin if DC power is supplied from an external customer...

Page 76: ...put connects to the physical Shutter Switch Leave this input open to enable lasing Grounding this pin indicates that the shutter is Closed which disables lasing If connecting an external shutter switch to Pin 8 the circuit path must be grounded to Pin 3 DC Power Ground There is a five second delay imposed from the time the shutter input is opened to the time that PWM Command signals are accepted 9...

Page 77: ...lamp to illuminate and begins a five second countdown after which lasing is enabled The RF driver is disabled as long as a 5 24 VDC signal is applied to Pin 2 Your control system can monitor the laser s ready status on the User I O connector by connecting your system s input to Pin 8 Laser Ready and Pin 13 Output Common see output driving PLC input module Figure 4 16 The Laser Ready output closes ...

Page 78: ... SHT LED off when the Shutter Switch is Closed or the Shutter Open Request signal is removed Note A five second delay occurs between the time the Shutter Open output closes and lasing is enabled Remote interlock functions Interlock circuits are often used to disable machinery when a shield panel or door is opened Firestar s re mote interlock function allows you to connect into an external remote i...

Page 79: ...mum Current 24 A Typical 18 A Command Input Signal Voltage 3 5 to 6 7 VDC Current 10 mA 6 7 VDC Frequency 6 DC 25 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 Cooling Specifications Air cooled Water cooled Maximum Heat Load laser 700 Watts 700 Watts Minimum Flow Rate 140 CFM per fan 1 0 GPM 60 PSI Rear air cooled 300 CFM N A Coolant Temper...

Page 80: ... v40 fan cooled Length 24 45 in 62 1 cm Width incl fans 8 25 in 20 9 cm Height 6 21 in 15 8 cm Weight 26 0 lbs 11 8 kg v40 air cooled Length 24 45 in 62 1 cm Width 6 22 in 15 8 cm Height 5 76 in 14 6 cm Weight 23 0 lbs 10 4 kg Specifications subject to change without notice 7 Published specifications guaranteed at a cooling temperature of 22 C For air cooled lasers some performance degradation may...

Page 81: ...CKED BY CATEGORY I UNITS INCHES DATE 12 Sep 01 DRAWN BY DB pdmdb SHEET 1 OF 1 DWG FILE NUMBER 300 18565 03 PART NUMBER SEE TABLE OUTLINE MOUNTING WATER COOLED V40 PART NUMBER MODEL FSV40KW KEY FSV40SW OEM NOTES THIS MOUNTING HOLE PATTERN USED WHEN TOP ACCESS FASTENING DESIRED THIS MOUNTING HOLE PATTERN USED WHEN BOTTOM ACCESS FASTENING DESIRED HARDENED BALL MOUNTING POINT 3X Ø 1875 BALL BEARING KE...

Page 82: ...TE CHECKED BY CATEGORY I UNITS INCHES DATE 13 Jul 01 DRAWN BY DB pdmdb SHEET 1 OF 1 DWG FILE NUMBER 300 18565 02 PART NUMBER SEE TABLE OUTLINE MOUNTING FAN COOLED V40 PART NUMBER MODEL FSV40KF KEY FSV40SF OEM NOTES THIS MOUNTING HOLE PATTERN USED WHEN TOP ACCESS FASTENING DESIRED THIS MOUNTING PATTERN USED WHEN BOTTOM ACCESS FASTENING DESIRED HARDENED BALL MOUNTING POINT 3X Ø 1875 BALL BEARING KEY...

Page 83: ...CES UNLESS NOTED DB DESCRIPTION DATE ECO REV REVISED NOTE ON FRONT VIEW 1 Mar 06 3169 B DATE APPROVED BY FINISH CLASS A SIZE B DATE CHECKED BY CATEGORY I UNITS INCHES DATE 10 Apr 01 DRAWN BY DB pdmdb SHEET 1 OF 1 DWG FILE NUMBER 300 18565 01 PART NUMBER FSV40A OEM OUTLINE MOUNTING AIR COOLED V40 OEM NOTES THIS MOUNTING HOLE PATTERN USED WHEN TOP ACCESS FASTENING DESIRED THIS MOUNTING PATTERN USED ...

Page 84: ...technical reference 84 SYNRAD OEM v40 Operator s Manual Version 4 Packaging instructions drawing Figure 4 21 Firestar v40 packaging instructions ...

Page 85: ...technical reference 85 SYNRAD OEM v40 Operator s Manual Version 4 This page intentionally left blank ...

Page 86: ...on 4 Use information in this chapter to perform maintenance or troubleshoot your Firestar v40 laser This chapter contains the following information Maintenance describes typical v40 maintenance procedures Troubleshooting explains how to troubleshoot common v40 problems 5 ...

Page 87: ...temperature is set below the dew point tempera ture Condensationwilldamageelectricalandopticalcomponentsinsidethelaser See Settingcoolant temperature in the Getting Started chapter for details on preventing condensation 2 Inspect beam delivery components for signs of dust or debris and clean as required When cleaning the optical surfaces of beam delivery components carefully follow the manufacture...

Page 88: ...te www synrad com manuals packaging htm for detailed instructions on properly packaging the laser for shipment Important Note Failure to properly package the laser using a SYNRAD supplied shipping box and foam cardboard inserts as shown in the Packaging Instructions may void the war ranty Customersmayincuradditionalrepairchargesforshippingdamagecausedby improper packaging Cleaning optical componen...

Page 89: ...l components on lens tissue for protection never place optics on hard or rough surfaces It may be necessary to use fluffed cotton swabs instead of cotton balls to uniformly clean the entire surface of small diameter mounted optics Before using any cleaning agents read their Material Safety Data Sheets MSDS and observe all necessary safety precautions Required cleaning materials Table below lists t...

Page 90: ...econd follow up cleaning of the optical surface using ethyl alcohol is required 5 Gently wipe the optical surface with the damp cotton beginning in the center of the optic and work ing outward Do not rub or apply any pressure especially when using a cotton swab Lightly drag the cotton ball or swab without applying any downward pressure Note Use a clean cotton ball or fluffed swab on each pass The ...

Page 91: ...leshooting guide and review both the operational flowchart and the functional block diagram Symptoms and possible causes are highlighted by dark print and bullet points throughout this section Information about each symptom and cause can be found in the paragraphs fol lowing each heading Caution possible equipment damage Attempting repair of a SYNRAD Firestar laser without the express authorizatio...

Page 92: ...art Plug Water Cooled Check that cooling water is flowing through laser and that coolant temp is within specified limits Apply shutter open signal to Shutter Open Request input or install factory supplied Quick Start Plug Cycle Keyswitch from ON to OFF and then back to ON on OEM lasers cycle DC power Ensure that manual Shutter Switch if equipped is set to Open Apply PWM Command signal to laser Tur...

Page 93: ...RE DETECTOR REMOTE INTERLOCK DETECTOR STATUS INDICATORS INT TMP RDY SHT LASE SHUTTER CONTROL CATGEN DELAY TIMER 30 VDC INPUT DB15 USER I O CONNECTOR POWER ON AND FAULT DETECT OUTPUT ISOLATION INPUT ISOLATION TO RF DRIVER BOARDS TO CONTROL BOARD PWM OUT OVER TEMPERATURE LASER ACTIVE LASE INDICATOR INTERLOCK OPEN REMOTE INTERLOCK SHUTTER OPEN REQUEST SHUTTER OPEN VOLTAGE REGULATOR DC POWER SWITCH FA...

Page 94: ...e manual Shutter Switch is set to ON If the RDY indicator is lit and the shutter is switched from Closed to Open there is a five second delay until PWM inputs are recognized When PWM Command pulses are applied and are long enough to produce laser output the LASE LED illuminates red On OEM lasers the RDY lamp illuminates on DC power up when INT and TMP indicators illuminate green After the RDY indi...

Page 95: ...ASE Off Laser Active Open Table 5 4 Over Temperature condition LED Indicator LED Status Signal Name Output Signal Status INT Green Interlock Open Open TMP Red Over Temperature Closed RDY Off Laser Ready Open SHT Blue Shutter Open Closed LASE Off Laser Active Open Table 5 5 Shutter Open condition LED Indicator LED Status Signal Name User I O Output Status INT Green Interlock Open Open TMP Green Ove...

Page 96: ...wait 30 seconds and then reapply DC power 4 blinks PWM Drive Fault Remove DC power to the laser wait 30 seconds and then reapply DC power Resetting faults Keyswitch lasers Remote interlock fault A remote interlock fault occurs when the Remote Interlock input opens the INT indicator changes from green to red To reset a remote interlock fault close the interlock input INT indicator changes from red ...

Page 97: ...ds and then reapply DC power If the RF Drive DC fault reappears contact SYNRAD or a SYNRAD Authorized Distributor PWM Drive fault A PWM Drive fault is indicated by the RDY indicator flashing 4 blinks Reset the laser by removing DC power to the laser wait 30 seconds and then reapply DC power If the PWM Drive fault reappears contact SYNRAD or a SYNRAD Authorized Distributor OEM lasers Warning seriou...

Page 98: ...led after a five second delay provided that the RDY indicator is illumi nated yellow Under over voltage fault An under voltage or over voltage fault occurs when the DC input voltage is below or above preset limits This fault is indicated by the RDY indicator flashing 1 blink under voltage or 2 blinks over voltage To reset an under voltage or over voltage fault ensure that 30 VDC is applied to the ...

Page 99: ...ded lasing Symptom A remote interlock fault is indicated INT LED Red Interlock Open Closed TMP LED Green Over Temperature Open RDY LED Off Laser Ready Open SHT LED Blue Shutter Open Closed LASE LED Off Laser Active Open Possible Causes No voltage applied to Pin 3 Remote Interlock on the User I O connector On systems using remote interlocks check to see that a positive or negative voltage 5 24 VDC ...

Page 100: ...oper airflow cooling fans must have at least 2 25 57 2 mm of unobstructed clearance between the outside edge of the cooling fan housing and any mounting surface or enclosure Symptom A shutter closed condition is indicated INT LED Green Interlock Open Open TMP LED Green Over Temperature Open RDY LED Yellow Laser Ready Closed SHT LED Off Shutter Open Open LASE LED Off Laser Active Open Possible Caus...

Page 101: ... clear the over temp fault the TMP indicator will change from red to green the RDY light illuminates and five seconds later lasing is enabled The remote interlock circuit momentarily opened Remote interlock faults are not latched on OEM lasers This means if an interlock open fault occurs the INT indicator will turn red the Interlock Open output will Close the RDY light goes out and lasing is disab...

Page 102: ...2 laser radiation is emitted through the aperture Corneal damage or blind ness may result from exposure to laser radiation Symptom The laser loses power over time laser output power must be increased to maintain performance Possible Causes Beam delivery optics are coated by vapor residue or debris Shut down the laser and carefully inspect each optic in the beam delivery path including the laser s ...

Page 103: ...maintenance troubleshooting 103 SYNRAD OEM v40 Operator s Manual Version 4 This page intentionally left blank ...

Page 104: ...everse polarity 1 14 toxic exposure 4 2 4 17 User I O connector 1 16 3 12 voiding warranty 4 6 CDRH 5 6 safety features 8 Chiller connection 1 11 coolants 1 9 fittings 1 8 flow rate 1 11 2 8 2 10 3 26 4 15 preparation 1 9 temperature setpoint 1 9 1 10 1 11 2 8 2 10 4 15 Chiller fittings 1 8 Class IV safety requirements 8 Cleaning optic components 4 3 4 5 Collimators 3 3 Command signal 3 6 3 7 base...

Page 105: ...r 2 6 3 12 3 22 3 23 DC 5 DC power supply 1 14 1 15 AC input requirements 1 14 connecting 1 14 1 15 DC power 24 VDC 3 10 3 13 3 19 3 20 5 VDC 3 10 3 13 3 19 4 14 4 15 Aux DC Power Ground 3 11 3 13 4 14 4 15 DC Power cable 1 15 2 3 2 5 connecting 1 15 DC Power Ground 3 22 3 23 Delivery optics 3 3 3 4 Dew point 1 9 1 10 1 11 cautions 1 11 2 8 2 9 2 10 2 12 chart 1 10 Diode Pointer aperture dust cove...

Page 106: ...scriptions 3 14 3 15 sample diagrams 3 19 3 20 specifications 3 16 Input Common 3 11 3 14 3 15 3 20 3 24 3 25 4 14 4 15 description 3 15 Input Output signals 3 12 3 21 Input signals 3 14 3 16 customer supplied interlock 3 19 customer supplied interlock negative volt age 3 19 Input Common 3 11 3 14 3 15 3 20 3 24 3 25 4 14 4 15 multiple PLC driven inputs 3 20 PLC driven interlock signal 3 19 PWM In...

Page 107: ...flowchart 4 7 Operator s manual 1 4 1 5 Optical accessories mounting 2 2 2 4 Optical components cleaning 4 3 4 5 cleaning materials 4 4 guidelines 4 4 Optical output pulse waveforms 3 6 Optical resonator 3 2 Optical setup delivery optics 3 3 3 4 focusing optics 3 4 troubleshooting 4 17 Other laser faults 4 14 4 16 Outline and Mounting drawings 3 28 3 30 Output circuit equivalent schematic 3 18 pin...

Page 108: ...ns 3 16 Remote Reset Start Request input 2 8 2 11 3 3 3 10 3 14 3 16 3 24 4 11 description 3 10 3 14 specifications 3 16 Resetting faults 4 11 4 13 Keyswitch lasers 4 11 4 12 OEM lasers 4 12 4 13 RF driver board 3 24 3 25 RF power supply 3 3 S Safety features 8 integrating 3 24 3 25 Safety precautions 1 2 laser 1 3 Sales and Applications xii Sample I O circuits 3 19 3 21 Shorting plug See Quick St...

Page 109: ...gnals 3 12 3 18 sample input circuits 3 19 3 20 sample output circuits 3 20 3 21 status signals 4 9 4 10 User I O connector 1 16 2 3 2 5 2 8 2 10 3 6 3 12 3 24 3 25 4 9 4 11 4 15 V v40 label locations 4 W Warning air contaminants 2 definition 1 electrical noise 1 16 3 6 hazardous radiation exposure 2 laser output 2 9 2 11 3 5 laser safety precautions 2 OEM faults 2 7 4 12 4 14 UC 2000 Gate logic 3...

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