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maintenance/

troubleshooting

4

17

Synrad

Firestar ti-Series

operator’s manual

Troubleshooting

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
the event of damage to laser, marking head, or beam delivery optics,
contact SYNRAD, Inc. or the optics manufacturer for handling
instructions.

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 gas or welding supply company, Because compressed shop air
contains minute particles of oil and other contaminants that will damage optical surfaces, it must be care-
fully filtered and dried before use as a purge or assist gas. Refer to Table 3-1,

Assist gas purity specifications

, in

the Technical Reference chapter for filtering and drying specifications.

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Содержание Firestar TI Series

Страница 1: ...ti Series 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 www synrad com An Excel Technology Company...

Страница 2: ......

Страница 3: ...0 version C ti100 version B Version 1 2 Released March 2010 Part number 900 19846 02 4600 Campus Place Mukilteo WA 98275 1 800 SYNRAD1 tel 1 425 349 3500 fax 1 425 349 3667 e mail synrad synrad com ww...

Страница 4: ......

Страница 5: ...irements 8 Declaration of Conformity 11 Introduction 1 2 Firestar nomenclature 1 2 Unpacking 1 3 Incoming inspection 1 3 Packaging guidelines 1 3 Inventory 1 4 Contents description 1 5 Mounting 1 6 Fa...

Страница 6: ...estar safety features 3 26 Keyswitch functions 3 26 Shutter functions 3 27 Remote interlock functions 3 27 Firestar ti60 general specifications 3 28 Firestar ti100 general specifications 3 30 Firestar...

Страница 7: ...ative Firestar ti Series waveforms 3 6 Figure 3 4 PWM Command signal waveform 3 7 Figure 3 5 Representative ti Series optical output pulse 3 9 Figure 3 6 User I O connector pinouts 3 12 Figure 3 7 Aux...

Страница 8: ...oled Firestar ti60 SA model package outline and mounting dimensions sheet 1 of 2 3 34 Figure 3 25 OEM air cooled Firestar ti60 SA model package outline and mounting dimensions sheet 2 of 2 3 35 Figure...

Страница 9: ...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 23 Table 3 7 Firestar...

Страница 10: ...nual Trademark copyright information SYNRAD Firestar and Power Wizard are registered trademarks of SYNRAD Inc All other trademarks or registered trademarks are the property of their respective owners...

Страница 11: ...YNRAD 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 fro...

Страница 12: ...vice 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...

Страница 13: ...g are descriptions 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...

Страница 14: ...ate air contaminants such as vapors fumes and or particles that may be noxious toxic or even fatal Material Safety Data Sheets MSDS for materials being processed should be thoroughly evaluated and the...

Страница 15: ...nic 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 typi...

Страница 16: ...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 CAUTION CONDENSATION AND WATER DAMAGE CAN OCCUR IF COOLING WATER IS BELOW DEW POINT SEE...

Страница 17: ...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 CAUTION CONDENSATION AND WATER DAMAGE CAN OCCUR IF COOLING WATER IS BELOW DEW POINT SEE OPERATI...

Страница 18: ...do not meet all of the Standards for complete laser 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 O...

Страница 19: ...sted the Federal Communications Commission FCC with the authority to regulate equipment that emits electromagnetic radiation in the radio frequency spec trum The purpose of the Communication Act was t...

Страница 20: ...ontrol measures Keyswitch models Firestar ti Series Keyswitch models are designed to comply with the requirements imposed by EN 60825 1 for Class IV laser products Table 1 Class IV safety features sum...

Страница 21: ...after 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...

Страница 22: ...ing all applicable Standards to obtain the CE mark To aid this compliance process SYNRAD s testing program has demonstrated that Firestar ti Series lasers comply with the relevant re quirements of 200...

Страница 23: ...Measurement Control and Laboratory Use Part 1 General Requirements EN 60825 1 2007 Safety of Laser Products Keyswitch only CISPR 11 2003 03 Conducted and Radiated Emissions Group 1 Class A EN 61000 4...

Страница 24: ...laser safety 12 Synrad Firestar ti Series operator s manual This page intentionally left blank...

Страница 25: ...is to start at Unpacking and work your way through Connecting This chapter contains the following information Introduction introduces Firestar ti Series lasers lists important features and de scribes...

Страница 26: ...categories Keyswitch and OEM models In addition to a manual Keyswitch all Keyswitch equipped lasers include a manual shutter switch that allows the laser output aperture to be blocked OEM lasers do no...

Страница 27: ...he 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 mounting feet or base plate only Save all shipping con...

Страница 28: ...s Qty Shipping Box Contents Qty SYNRAD Firestar ti Series Laser 1 Mounting Bolts 3 Firestar ti Series Operator s Manual 1 Spare Fuse 2 Quick Start Plug except SA models 1 Final Test Report not shown 1...

Страница 29: ...A models connects to Firestar s User I O connector Jumpers are built into the plug to enable Firestar s shutter and remote interlock circuits for initial start up and testing Cooling Tubing water cool...

Страница 30: ...for your application When mounting Firestar ti Series lasers you can choose to fasten from above into your mounting surface or from below into the laser s base plate Note For proper airflow air or fa...

Страница 31: ...to the threaded holes labeled C shown in Figure 1 3 Figure 1 3 Fasten 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 w...

Страница 32: ...everely restricts coolant flow Push tubing completely into the fitting then pull the tubing to verify that it is locked into place Tub ing extends into the fitting approximately 7 8 of an inch If tubi...

Страница 33: ...ongevity 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 t...

Страница 34: ...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 9...

Страница 35: ...Series 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 Caution possible equipment damage Inlet cooling water te...

Страница 36: ...ovide proper airflow cooling fans should have a diameter of approximately 4 5 5 inches 114 127 mm and have at least 2 25 57 2 mm of unobstructed clearance between the outside edge of the fan housing a...

Страница 37: ...oard circuitry Carefully follow the direc tions below to ensure that DC cable leads are properly connected to the correct DC output terminals Firestar ti60 lasers require a DC power supply capable of...

Страница 38: ...source to PWM Input PWM Return inputs In electrically noisy environments long lengths of unshielded wire act like an antenna and may generate enough voltage to trigger uncommanded lasing UC 2000 Univ...

Страница 39: ...rlock and shutter signals directly to the DB 15 User I O connector only after safe operating conditions are established In order for your Firestar ti Series laser to properly operate several input sig...

Страница 40: ...getting started 116 Synrad Firestar ti Series operator s manual This page intentionally left blank...

Страница 41: ...star s controls and indica tors and to begin operating the laser This chapter contains the following information Controls and indicators displays and describes exterior controls and indicators on Fire...

Страница 42: ...hutter Switch Keyswitch models only activates a mechanical shutter that opens or closes the laser aperture Closing the shutter also interrupts RF power to the laser There is a five second delay impose...

Страница 43: ...te that a Shutter Open Request signal is con nected 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 recog...

Страница 44: ...xiliary 5 V power source as well as 48 VDC for powering 48 V cooling fans The 5 VDC output is protected by a 0 5 A self resetting fuse while both 48 VDC outputs are sourced directly from the user s 48...

Страница 45: ...ys use a beam block while testing Warning serious personal injury On Firestar ti Series OEM lasers remote interlock INT faults are not latched Clearing the fault condition re enables the RDY indica to...

Страница 46: ...Laser Controller refer to the UC 2000 Laser Controller Operator s Manual for setup and operation instructions before continuing 5 Set the UC 2000 to MANUAL mode and then set the PWM Adj Knob to provid...

Страница 47: ...e to internal optics and electronic circuits Note For remote keyswitch operation keyswitch versions you can set the Keyswitch to the ON posi tion and use the Remote Reset Start Request input on the Us...

Страница 48: ...st 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 c...

Страница 49: ...osition Verify that the RDY Ready indicator on the laser s rear panel is illuminated Note Each time an OEM laser is powered up or a keyswitch version is cycled OFF ON a five second delay occurs betwee...

Страница 50: ...uipment 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 that may result in catastrophic damage...

Страница 51: ...SA models only describes pin configuration and specifications for the SA model s side mounted DB 9 connector Integrating Firestar safety features describes how to integrate Firestar ti Series safety f...

Страница 52: ...h 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 necessary for alignment All...

Страница 53: ...and each element should be approached with the same careful attention to detail Beam delivery optics Divergence or expansion of the laser beam is important for materials processing since a larger bea...

Страница 54: ...ge laser optics using filtered air or nitrogen to prevent vapor and debris from accumulating on optical surfaces Optics are fragile and must be handled carefully preferably by the mounting ring only C...

Страница 55: ...rease in pulse width adds enough energy to the plasma to cause laser emission Tickle pulses cause the laser to respond predictably and almost instantaneously to PWM Command signals even when there is...

Страница 56: ...ncies 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 continuous wave CW value with just a small amount of ripple present Comm...

Страница 57: ...tate 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 mA 6 7 VDC 10 mA continuous Frequency Range 0 Hz DC 5 kHz 25 kHz Duty Cycle 0 100 Operating modes Externa...

Страница 58: ...ons the laser is required 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 pul...

Страница 59: ...ceeds 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 ant...

Страница 60: ...onnected to a voltage source in the range of 5 24 VDC Refer to Figure 3 8 for a diagram showing how the Remote Interlock input is factory jumpered 4 5 VDC Auxiliary Power This connection provides 5 VD...

Страница 61: ...ng 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...

Страница 62: ...D type subminiature connector on the laser s rear panel Note See DB 9 connections later in this section for signal descriptions and pinouts of the SA model s side mounted DB 9 connector Caution possi...

Страница 63: ...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 outp...

Страница 64: ...irst place the Keyswitch in the ON position Then after each DC power up cycle or to reset a fault condition apply a momentary voltage pulse in the range of 5 24 VDC to Pin 2 This reset action initiate...

Страница 65: ...n position Las ing is inhibited when voltage is removed from Pin 10 or the Shutter Switch is Closed Note To ensure optimum laser performance there is a five second delay imposed from the time a Shutte...

Страница 66: ...emote 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 VDC 7 mA On state continuous V...

Страница 67: ...mperature 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 specific...

Страница 68: ...equivalent schematic Table 3 5 Output circuit specifications Output Device Specifications Bi directional MOSFET 20 Ohm Rdson 10 MOhms Off Voltage 24 VDC max Current 50 mA max FIRESTAR ti SERIES OUTPU...

Страница 69: ...t instead depending on circuit voltage requirements Figure 3 11 Customer supplied interlock Figure 3 12 shows another variation for supplying a Remote Interlock signal to the laser In this case the cu...

Страница 70: ...l When multiple PLC inputs are required connect Firestar inputs to the PLC as shown in Figure 3 14 By supplying voltage VDC to Pin 11 Input Common and pulling individual inputs to ground each input ca...

Страница 71: ...at the current draw does not exceed 50 mA Figure 3 15 Firestar output driving warning lamp Figure 3 16 illustrates a method for controlling a higher voltage higher current load by using a 24 V con tro...

Страница 72: ...e 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 17 Firestar output d...

Страница 73: ...ion 1 No Connection 2 Shutter Switch In Keyswitch models this input connects to the physical Shutter Switch Leave this input open to enable lasing Grounding this pin indicates that the shutter is Clos...

Страница 74: ...he user s 48 VDC power supply and is protected by a 1 1 A self resetting fuse Pin 4 and Pin 8 can only source a combined current of 1 0 A total 9 Fan Power Return This connection provides a return gro...

Страница 75: ...s of cooling fans are not designed for PWM control and will stall at low speeds SYNRAD has tested Delta EFB1248SHE cooling fans with good results Isolated cooling fan connections To connect cooling fa...

Страница 76: ...oltage allows DC power to reach the RF driver and begins a five second delay after which lasing is enabled RDY LED illuminates yellow The RF driver is disabled as long as voltage is applied to Pin 2 Y...

Страница 77: ...or the Shutter Open Request signal is removed Note After the Shutter Open output closes a five second delay occurs before lasing is enabled Remote interlock functions Interlock circuits are often used...

Страница 78: ...0 8 VDC Logic High State Vmin Vmax 3 5 to 6 7 VDC Cooling Specifications Air cooled Water cooled Maximum Heat Load 900 Watts 900 Watts Minimum Flow Rate 150 CFM per fan 2 1 0 2 0 GPM 60 PSI Coolant T...

Страница 79: ...oled KFC SFC models Length 22 46 in 57 1 cm Width 7 72 in 19 6 cm Height 5 90 in 15 0 cm Weight 29 1 lbs 13 2 kg ti60 air cooled SAC models Length 22 46 in 57 1 cm Width 6 22 in 15 8 cm Height 5 83 in...

Страница 80: ...equency6 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 Water cooled Maximum Heat Load 1700 Watts Minimum Flow Rat...

Страница 81: ...Humidity 0 95 non condensing Physical Specifications ti100 water cooled KWB SWB models Length 22 98 in 58 4 cm Width 5 62 in 14 3 cm Height 5 90 in 15 0 cm Weight 26 2 lbs 11 9 kg Specifications subje...

Страница 82: ...ING POINT 250 STEEL BALL BEAM PATH MAY NOT BE CENTERED OR PERPENDICULAR TO FACEPLATE APERTURE C DESCRIPTION FINISH MATERIAL REV ECO DATE DESCRIPTION DB TOLERANCES UNLESS NOTED ANGLE x xx xxx PROPRIETA...

Страница 83: ...NITS CATEGORY CHECKED BY DATE SIZE B FINISH CLASS APPROVED BY DATE SYNRAD INC 4600 Campus Place Mukilteo WA 98275 Phone 425 349 3500 Fax 425 349 3667 OUTLINE MOUNTING FAN COOLED Ti60 10 Mar 09 300 198...

Страница 84: ...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 CLA...

Страница 85: ...Y 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 CA...

Страница 86: ...technical reference 336 Synrad Firestar ti Series operator s manual Firestar ti Series packaging instructions Figure 3 26 Firestar ti Series packaging instructions...

Страница 87: ...Use information in this chapter to perform maintenance or troubleshoot your Firestar ti Series laser This chapter contains the following information Maintenance describes typical ti Series maintenanc...

Страница 88: ...the dew point tempera ture Condensation will damage electrical and optical components inside the laser See Setting coolant temperature in the Getting Started chapter for details on preventing condensa...

Страница 89: ...to Firestar ti Series label locations in the Laser Safety chapter for label types and locations Storage shipping When preparing a water cooled laser for storage or shipping remember to drain cooling...

Страница 90: ...e to prevent contamination of optical surfaces by dirt and skin oils Never handle optics with tools always use gloved hands or fingers Hold optics by the outer edge never touch the coated surface Alwa...

Страница 91: ...especially when using a cotton swab Drag the wipe without applying any downward pressure Note Use a clean lens wipe on each pass The wipe will pick up and carry surface contaminants that may scratch...

Страница 92: ...re troubleshooting 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...

Страница 93: ...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 supp...

Страница 94: ...ETECTOR 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 IS...

Страница 95: ...utter Switch is set to Open 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...

Страница 96: ...LASE Off Laser Active Open Table 4 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 Re...

Страница 97: ...te interlock fault re establish the Remote Inter lock signal input INT indicator changes from red to green and cycle the Keyswitch from OFF to ON or apply a Remote Reset Start Request pulse with the K...

Страница 98: ...y DC power and then toggle the Keyswitch from OFF to ON or apply a Remote Reset Start Request pulse with the Keyswitch set to ON If the PWM Drive fault reappears contact SYNRAD or a SYNRAD Authorized...

Страница 99: ...ed by the RDY indicator flashing 3 blinks Reset the laser by removing DC power to the laser wait 30 seconds and then reapply DC power If the RF Drive DC fault reappears contact SYNRAD or a SYNRAD Auth...

Страница 100: ...LASE LED Off Laser Active output Open Possible Causes Water cooled lasers Cooling water temperature is above 30 C 86 F or there is inadequate water flow through the laser Check that the chiller is mai...

Страница 101: ...ear panel or wire your male DB 15 connector so that Pin 11 Input Common is jumpered to Pin 12 Auxiliary DC Power Ground and Pin 10 Shutter Open Request is jumpered to Pin 4 5 VDC Auxiliary Power Sympt...

Страница 102: ...inspecting optical components in the beam path Invisible CO2 laser radiation is emitted through the aperture Corneal damage or blind ness may result from exposure to laser radiation Symptom The laser...

Страница 103: ...optics manufacturer for handling instructions 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 gas o...

Страница 104: ...maintenance troubleshooting 418 Synrad Firestar ti Series operator s manual This page intentionally left blank...

Страница 105: ...4 16 troubleshooting 4 16 4 17 warning 4 2 4 17 Beam diameter 3 2 3 3 specifications 3 28 3 30 Block diagram 4 8 C Caution condensation damage 1 11 2 6 2 7 2 8 2 10 coolant temperature 1 10 1 11 defi...

Страница 106: ...Customer supplied interlock 3 19 D Daily inspections 4 2 4 3 Danger definition 1 explosive atmospheres 2 eye protection 1 laser radiation 1 2 5 2 8 4 3 4 6 4 16 DB 15 connections See User I O connecti...

Страница 107: ...unting 1 6 1 7 Firestar ti Series laser 1 4 1 5 Five second delay 9 2 2 2 3 2 5 2 7 2 9 3 10 3 11 3 14 3 15 3 17 3 23 3 26 3 27 4 9 4 11 4 12 4 13 4 15 Flowchart laser start up 4 7 Focusing optics 3 4...

Страница 108: ...ing 3 26 3 27 L Label locations 4 5 Lase LASE indicator 6 9 2 3 2 7 2 9 3 10 3 17 4 9 4 10 4 14 4 15 Laser Active output 4 9 4 10 4 14 4 15 signal description 3 10 3 17 Laser aperture 2 2 2 6 2 8 4 16...

Страница 109: ...Package outline drawings 3 32 3 35 Packaging guidelines 1 3 Packaging instruction drawing 3 36 PLC driven interlock 3 20 Power fail lockout 9 Power supply connections 1 13 1 14 Pulse Width Modulation...

Страница 110: ...3 4 RF power supply 3 3 Technical support x Temp TMP indicator 9 2 3 2 6 2 9 3 10 3 17 4 9 4 10 4 11 4 12 4 14 4 15 Tickle pulse 3 5 Trademark information viii Troubleshooting 4 6 4 17 beam delivery...

Страница 111: ...ti Series operator s manual coolants 1 9 coolant temperature 1 9 1 10 1 11 2 6 2 8 3 28 3 29 3 30 4 11 4 12 4 14 fittings 1 8 guidelines 1 8 tubing connections 1 11 Water In Water Out ports 1 11 2 3...

Страница 112: ...index i8 Synrad Firestar ti Series operator s manual This page intentionally left blank...

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