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Synrad

Pulstar p100

operator’s manual

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Summary of Contents for Pulstar P100 Series

Page 1: ...OEM p100 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: ...p100 Operator s Manual Version 1 0 Released April 2012 Part number 900 20388 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...

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Page 5: ...tion of Conformity 10 Introduction 1 2 Pulstar nomenclature 1 2 Model numbers 1 2 Unpacking 1 3 Incoming inspection 1 3 Packaging guidelines 1 3 Inventory 1 4 Contents description 1 5 Mounting 1 6 Mou...

Page 6: ...res 3 23 Keyswitch functions 3 23 Shutter functions 3 23 Remote interlock functions 3 24 Pulstar p100 general specifications 3 25 Pulstar p100 outline mounting drawings 3 27 Pulstar p100 packaging ins...

Page 7: ...00 pulse profile 37 5 duty cycle at 10 kHz 3 4 Figure 3 5 Pulstar p100 pulse profile 37 5 duty cycle at 20 kHz 3 5 Figure 3 6 PWM Command signal waveform 3 8 Figure 3 7 User I O connector pinouts 3 10...

Page 8: ...signal specifications 3 9 Table 3 4 User I O pin descriptions 3 11 Table 3 5 Input circuit specifications 3 16 Table 3 6 Output circuit specifications 3 18 Table 3 7 Pulstar p100 general specification...

Page 9: ...perator s manual Trademark copyright information SYNRAD is a registered trademark of SYNRAD Inc All other trademarks or registered trademarks are the property of their respective owners 2012 by SYNRAD...

Page 10: ...r 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 con...

Page 11: ...h 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...

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Page 13: ...ions 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 Dan...

Page 14: ...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...

Page 15: ...terials 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 fo...

Page 16: ...e of the following U S Patents 4 805 182 5 065 405 6 195 379 6 603 794 4 837 772 5 215 864 6 198 758 6 614 826 5 008 894 5 602 865 6 198 759 Other U S and International Patents pending MODEL PSP100SWB...

Page 17: ...ocessing 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 an...

Page 18: ...sting SYNRAD Inc has not discovered any significant electrical interference trace able to Pulstar p100 lasers System Maintenance Ensure that all exterior covers are properly fastened in position Measu...

Page 19: ...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...

Page 20: ...r Keyswitch is turned to On or remote reset start pulse is applied when Key switch is in On position Power fail Pulstar circuit element Yes Yes lockout1 Disables RF driver laser output if input power...

Page 21: ...Voltage Directive 2011 65 EU RoHS Directive EN 61010 1 2001 Safety Requirements for Electrical Equipment for Measurement Control and Laboratory Use Part 1 General Requirements EN 61000 6 4 2007 Radiat...

Page 22: ...r products are solely responsible for meeting applicable Directives and Standards for CE compliance and marking Corporate Officer European Contact Dave Clarke President of SYNRAD Inc Dated 6 April 201...

Page 23: ...art at Unpack ing and work your way through Connecting This chapter contains the following information Introduction introduces the Pulstar p100 laser lists important features and de scribes Pulstar no...

Page 24: ...as purge port Peak pulse energy 190 millijoules mJ Color coded LEDs mirror user output status Rise times 40 microseconds s Industrial strength 5 V to 24 VDC I O Pulse widths up to 600 s Weighs only 30...

Page 25: ...w 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 base plate only Save all shippin...

Page 26: ...0 Pulsed Laser 1 Mounting Bolts 3 SYNRAD CO2 Lasers Manual CD 1 Gas Purge Kit 1 Quick Start Plug 1 Cooling Kit 1 Cooling Tubing 1 Spare Fuses not shown 2 DC Power Cable Set not shown 1 Final Test Repo...

Page 27: ...cts 48 VDC from the DC power supply to the Pulstar p100 laser Standard cable length is 1 8 meters 6 0 ft Cooling Tubing carries cooling water from the chiller not included to the laser and back This b...

Page 28: ...YNRAD 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 a vertical orientati...

Page 29: ...install the optional p100 mounting kit SYNRAD P N 250 20440 01 available separately from the factory Attach the optional mounting feet To attach the optional mounting feet to the OEM p100 laser perfor...

Page 30: ...e rear holes in each mounting foot while the 1 4 20 fasteners black oxide finish fit the front holes Please review the drawings carefully because the threads in the p100 base plate can be damaged if t...

Page 31: ...o 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 0 5 from its end before reconnecting Trim...

Page 32: ...al cooling systems 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...

Page 33: ...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...

Page 34: ...connect a length of cooling tubing to fit between the chiller s Outlet port and the WATER IN port on the rear of the p100 laser 3 Cut and connect a length of cooling tubing to fit between the WATER OU...

Page 35: ...ipment damage Do not reverse polarity when connecting the DC power cables to your DC power source Reversed DC polarity may damage the laser s internal RF power supply Carefully follow the directions b...

Page 36: ...iliary signals between the laser and any parts handling automation or monitoring equipment Warning serious personal injury Always use shielded cable when connecting your pulse signal source to PWM Inp...

Page 37: ...I O connector on the rear of the p100 laser UC 2000 Universal Laser Controller Important Note Except for bench testing we do not recommend using a UC 2000 Controller with the Pulstar p100 laser The t...

Page 38: ...tubing Note To disconnect gas purge tubing 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 Caution p...

Page 39: ...cators and to begin operating the laser This chapter contains the following information Controls and indicators displays and describes exterior controls and indicators on Pulstar p100 lasers Start up...

Page 40: ...amination and is field replaceable if it becomes damaged See Output window replacement in the Maintenance Troubleshooting chapter for details 4 Optical Accessories Mounting provides four threaded hole...

Page 41: ...is illuminated 10 SHT Shutter LED illuminates blue to indicate that a Shutter Open Request signal is connected to the User I O port and lasing may be enabled 11 LASE LED illuminates red to indicate t...

Page 42: ...is lit and a PWM Command signal is applied Because exposure to 10 6 m CO2 laser radiation can inflict severe corneal injuries and seriously burn human tissue the OEM or System Integrator must ensure...

Page 43: ...all personnel in the area are wearing protective eyewear 2 Remove the red self adhesive aperture seal covering the laser aperture 3 Place a power meter or appropriate beam block 61 cm 24 in from the...

Page 44: ...led 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 o...

Page 45: ...d signal pulses as well as Remote Interlock and Shutter Open Request input signals to the p100 s User I O connector Refer to User I O connections in the Techni cal Reference chapter for interface deta...

Page 46: ...g limits Starting your Pulstar OEM p100 laser Important Note Because the Pulstar p100 is a pulsed laser it will not operate when a constant 5V 100 duty cycle PWM signal is applied If this occurs lasin...

Page 47: ...nues lasing The laser will recover immediately and begin following the actual commanded duty cycle percentage when it is lowered below the limits shown in Table 2 1 Table 2 1 Pulse frequency duty cycl...

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Page 49: ...tar control signals User I O connections describes input output signals and specifications for the 15 pin User I O connector Integrating Pulstar safety features describes how to integrate Pulstar p100...

Page 50: ...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 provide a flexible cushion that allows the slight movement necessar...

Page 51: ...er beam diameter reduces the power density incident on the laser s output window thereby reducing the likelihood of damaged optics OEM p100 pulse performance Figures 3 1 through 3 5 illustrate represe...

Page 52: ...ofile 37 5 duty cycle at 5 kHz Figure 3 4 Pulstar p100 pulse profile 37 5 duty cycle at 10 kHz 100 200 300 400 500 600 700 Typical Power Pulse PWM 37 5 PRF 5 kHz Time s Power Output Arbitrary Units 0...

Page 53: ...ntially reduces beam divergence and any variance in beam diameter caused by the changing optical path length in an XY flying optics table application In fixed length delivery systems where the laser i...

Page 54: ...y shortened lifetime When the laser application requires air as an assist gas use only breathing quality air available in cylinders from a welding supply company Compressed shop air contains minute pa...

Page 55: ...laser off time between applied Command signals Internal circuitry monitors the incoming PWM signal and determines the amount of time the laser was on lasing during the last 200 microsecond s interval...

Page 56: ...3 6 illustrates typical PWM Command signal parameters Important Note Because the Pulstar p100 is a pulsed laser it will not operate when a constant 5V 100 duty cycle PWM signal is applied If this occ...

Page 57: ...r LED with a forward voltage drop Vf of 1 5 VDC The PWM input frequency can range from a single shot up to 100 kHz Table 3 3 provides minimum maximum and nominal PWM signal specifications Table 3 3 PW...

Page 58: ...p100 s User I O port a 15 pin female D type subminiature connector on the rear panel Figure 3 7 illustrates the pin arrangement of the User I O connector Caution possible equipment damage Turn off DC...

Page 59: ...is 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...

Page 60: ...on 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 connec...

Page 61: ...ction 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 throu...

Page 62: ...ge 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...

Page 63: ...in 9 PWM Input Pin 3 Remote Interlock Pin 4 5 VDC Pin 10 Shutter Open Request Pin 11 Input Common Pin 12 Aux DC Power Ground Pin 15 Pin 9 Pin 8 Pin 1 PWM Input BNC Rear Solder Side of Male DB15 Quick...

Page 64: ...put equivalent schematic Table 3 5 Input circuit specifications Input Signal Name Input Device Type and Specifications PWM Input High speed optoisolator LED forward voltage drop Vf 1 5 VDC Off state V...

Page 65: ...ications Important Note Because of the output circuit response time the Laser Active output s turn on turn off time may lag the PWM input pulse by up to 205 s Pin 7 Fault Detected output This bi direc...

Page 66: ...ifications Figure 3 11 illustrates the output circuit s equivalent internal schematic and Table 3 6 provides Pulstar p100 output circuit specifications Figure 3 11 Output equivalent schematic Table 3...

Page 67: ...circuit voltage requirements Figure 3 12 Customer supplied interlock Figure 3 13 shows another variation for supplying a Remote Interlock signal to the laser In this case the customer is using a limi...

Page 68: ...e PLC outputs are used connect Pulstar inputs to the PLC as shown in Figure 3 15 By sup plying voltage VDC to Pin 11 Input Common and pulling individual inputs to ground each input can be independentl...

Page 69: ...rrent draw does not exceed 50 mA Figure 3 16 Pulstar output driving warning lamp Figure 3 17 illustrates a method for controlling a higher voltage higher current load by using a 24V con trol relay Ens...

Page 70: ...Logic Controller PLC By supplying voltage VDC to Pin 13 Output Common each Pulstar output is inde pendently switched to activate individual PLC inputs USER I O PINS PLC DC INPUT MODULE 13 OUTPUT COMMO...

Page 71: ...eset 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 R...

Page 72: ...functionality is provided by the Remote Interlock input signal via Pin 3 on the User I O connector To use Pulstar s remote interlock feature apply a voltage in the range of 5 24 VDC to Pin 3 Remote I...

Page 73: ...mrad Ellipticity 1 2 Polarization Linear vertical Rise Time3 40 s Input Specifications Power Supply Voltage 48 1 0 VDC Current max 40 A Command Input Signal Voltage 3 5 to 6 7 VDC 5V nominal Current 1...

Page 74: ...m 1 This power level is guaranteed for 12 months regardless of operating hours 2 Specification applies over recommended coolant flow rate and temperature range 3 Measured at 625 Hz 4 From cold start...

Page 75: ...150 3 81 197 5 00 2X DETAIL B ALIGNMENT SLOT MILLIMETERS IN BRACKETS NOTES 1 FOR FULL DETAIL SEE THE USER GUIDE MANUAL SUPPLIED WITH THE UNIT HARDENED BALL MOUNTING POINT 3X 250 BALL BEARING BEAM PATH...

Page 76: ...TION 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...

Page 77: ...ZATION NUMBER 5 ON OUTSIDE OF SHIPPING BOX IMPORTANT NOTE FAILURE TO PROPERLY PACKAGE LASER USING SYNRAD SHIPPING BOX AND FOAM CARDBOARD INSERTS AS SHOWN MAY VOID WARRANTY CUSTOMERS MAY INCUR ADDITION...

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Page 79: ...rmation in this chapter to perform maintenance or troubleshoot your Pulstar OEM p100 laser This chapter contains the following information Maintenance describes typical Pulstar p100 maintenance proced...

Page 80: ...marking head or 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 d...

Page 81: ...out purchasing replacement packaging Refer to Packaging instructions in the Technical Reference chapter for detailed instructions on properly packaging the laser for shipment Important Note Failure to...

Page 82: ...to uniformly clean the entire surface of small diameter mounted optics Before using any cleaning agents read Material Safety Data Sheets MSDS and observe all necessary safety precautions Required clea...

Page 83: ...low a stream of air at a glancing angle across the lens surface Repeat as necessary 4 Dampen a lens wipe with the selected cleaning agent Alcohol least aggressive is best for initial surface cleaning...

Page 84: ...l surfaces in the laser or the external beam path may become contaminated or damaged Important Note If the output window has broken do not attempt to replace the optic A broken op tic may have contami...

Page 85: ...using If the optic was damaged place used lens wipes inside a re sealable plastic bag and discard appropriately as hazardous waste 2 Locate the replacement O ring and insert it into the corresponding...

Page 86: ...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 Caution p...

Page 87: ...tall factory supplied Quick Start Plug 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 ins...

Page 88: ...OR REMOTE INTERLOCK DETECTOR STATUS INDICATORS REMOTE INTERLOCK TEMP READY SHUTTER LASE SHUTTER CONTROL CATGEN DELAY TIMER 48 VDC INPUT DB15 USER I O CONNECTOR POWER ON AND FAULT DETECT OUTPUT ISOLATI...

Page 89: ...ser Ready Closed Off Flashing Laser Ready Open SHT Blue Shutter Open Closed Off Shutter Open Open Flashing Fault Detected Closed LASE Red Laser Active Closed Off Laser Active Open On DC power up of an...

Page 90: ...active Off Laser Active Open LASE if PWM applied Red Laser Active Closed Table 4 4 Quick Start Plug or interlock shutter inputs not connected LED Indicator LED Status Signal Name User I O Signal Statu...

Page 91: ...Signal Status INT Green Interlock Open Open TMP Green Fault Detected Open RDY Yellow Laser Ready Closed SHT Off Shutter Open Open LASE tickle inactive Off Laser Active Open LASE if PWM applied Off Las...

Page 92: ...for 30 to 60 seconds SHT 2 blinks Frequency Limit condition3 Lower PWM frequency below 100 kHz SHT 3 blinks 100 D C condition4 Lower PWM duty cycle below 100 1 The Laser Ready output opens switches to...

Page 93: ...e SHT indicator is illuminated blue Note Because of the over temperature latch circuit the TMP indicator remains red and the Fault De tected output remains Closed prior to cycling power even after the...

Page 94: ...lt reappears the laser requires service contact SYNRAD or a SYNRAD Authorized Distributor No Strike condition When a No Strike condition occurs lasing is limited to a maximum 5 duty cycle at a PWM Com...

Page 95: ...SHT LED Blue Shutter Open Closed LASE LED Off Laser Active Open Possible Causes No voltage is applied to Pin 3 the Remote Interlock input on the User I O connector On systems using remote interlocks c...

Page 96: ...ently to begin operation To reset an over temperature fault lower coolant temperature below 30 C and then cycle DC power remove DC power wait 30 seconds reapply DC power When the RDY indicator illumin...

Page 97: ...0 or full continuous wave CW operation When the PWM duty cycle drops below 100 the laser will recover and begin lasing immediately at the commanded power level without cycling DC power Symptom A shutt...

Page 98: ...ght illuminates the Laser Ready output Closes and lasing is enabled Symptom The following status indications and output states appear on power up INT LED Red Interlock Open Closed TMP LED Green Fault...

Page 99: ...load 99 duty cycle conditions A fuse inside the laser may have blown Contact SYNRAD Customer Service for information about accessing and replacing the fast blow 25 A mini automotive type blade fuses L...

Page 100: ...ible equipment damage Contamination on the laser s output window or on any beam deliv ery optic can absorb enough energy to damage optical components in the beam path Periodically inspect the p100 s o...

Page 101: ...nufacturer for handling instructions Troubleshooting When the application requires air instead of nitrogen as an assist gas we recommend the use of breath ing quality air available in cylinders from a...

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Page 103: ...limator 3 5 focusing optics 3 5 3 6 inspection 4 3 radiation danger 4 4 4 22 troubleshooting 4 21 4 23 warning 4 2 4 21 4 23 Beam diameter 3 2 specifications 3 25 Block diagram 4 10 C Caution condensa...

Page 104: ...18 temperature setpoint 1 10 1 11 1 12 2 5 2 7 4 15 4 17 4 18 Copyright information vii Customer Service ix Customer supplied interlock 3 19 Customer supplied interlock negative voltage 3 19 D Daily i...

Page 105: ...cription 4 16 Functional block diagram 4 10 Fuses 1 4 1 5 replacement 4 21 G Gas purge kit 1 4 1 5 1 16 Gas Purge port 1 18 1 16 2 3 4 3 connecting 1 16 Gas purge flow rate 1 16 2 5 2 8 maintenance 4...

Page 106: ...aults resetting 4 15 4 21 Laser Institute of America LIA 3 Laser Manual CD 1 4 1 5 Laser Ready output 3 23 4 11 4 12 4 13 4 14 4 15 4 16 4 17 4 18 4 19 4 20 signal description 3 12 3 17 signal specifi...

Page 107: ...ple inputs 3 20 multiple outputs 3 22 Remote Interlock input 3 20 Power cable See DC power cables Power fail lockout 8 Power supply connections 1 13 1 14 Protective eyewear See Eye protection PS 48 DC...

Page 108: ...S Safety features Class 4 8 integrating 3 23 3 24 Safety precautions 1 3 Sales and Applications ix Sample I O circuits 3 19 3 22 input circuits 3 19 3 20 output circuits 3 21 3 22 Ship kit contents 1...

Page 109: ...ging guidelines 1 3 User I O connections 3 10 3 22 connection summary 3 11 3 12 Input Output signals 3 13 3 18 sample I O circuits 3 19 3 22 status signals 4 11 4 13 User I O connector 1 14 1 15 2 3 2...

Page 110: ...index i8 Synrad Pulstar p100 operator s manual This page intentionally left blank...

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