i401 operator’s manual ®

i401 operator’s manual

4600 Campus Place

Mukilteo, WA 98275

1.800.SYNRAD1

tel 1.425.349.3500

fax 1.425.349.3667

e-mail [email protected]

web www.synrad.com

®

Firestar

®

i401

Operator’s Manual

Draft version 0.4

Released September 2011

Part number 900-20150-01

4600 Campus Place

Mukilteo, WA 98275

1.800.SYNRAD1

tel 1.425.349.3500

fax 1.425.349.3667

e-mail [email protected]

web www.synrad.com

®

table of contents

Laser Safety

Hazard information ....................................................................................1

Terms ..........................................................................................................................

1

General hazards .........................................................................................................

1

Firestar i401 label locations .......................................................................4

Agency compliance ...................................................................................5

Center for Devices and Radiological Health (CDRH) requirements .......................

5

Federal Communications Commission (FCC) requirements ...................................

6

European Union (EU) requirements .........................................................................

6

Firestar i401 Declaration of Conformity ...................................................10

Getting Started

1

Introduction ...............................................................................................1-2

Firestar nomenclature ................................................................................................

1-2

Unpacking ..................................................................................................1-3

Incoming inspection ..................................................................................................

1-3

Packaging guidelines ..................................................................................................

1-3

Unpacking the i401 laser ...........................................................................................

1-4

Removing the lifting handles ....................................................................................

1-5

Inventory ....................................................................................................1-6 i401 contents description ..........................................................................................

1-7

Mounting ...................................................................................................1-8

Top down mounting ..................................................................................................

1-8

Bottom up mounting .................................................................................................

1-9

Connecting ................................................................................................1-10

Cooling connections .................................................................................................

1-10

48 V power supply connections .................................................................................

1-14

Control connections ..................................................................................................

1-18

Other connections .....................................................................................................

1-19

Operation

2

Controls and indicators .............................................................................2-2

Initial start-up ............................................................................................2-4

With a UC-2000 Controller ......................................................................................

2-5

Without a UC-2000 Controller ................................................................................

2-7

Technical Reference

3

Technical overview ....................................................................................3-2

Laser design ................................................................................................................

3-2

RF power supply .........................................................................................................

3-4

Optical setup ..............................................................................................................

3-4

Controlling laser power .............................................................................3-6

Synrad Firestar i401 operator’s manual iii

iv table of contents

Technical Reference (cont.)

Control signals ...........................................................................................................

3-6

Operating modes ........................................................................................................

3-8

User I/O connections .................................................................................3-10

User I/O connection summary ..................................................................................

3-11

Input/output signals ...................................................................................................

3-13

Sample I/O circuits ....................................................................................................

3-19

DC Power Cables .......................................................................................3-23

Firestar i401 web interface .........................................................................3-24

Web page layout ........................................................................................................

3-24

Accessing the i401 web page .....................................................................................

3-26

Changing the i401’s IP address ..................................................................................

3-27

Integrating Firestar safety features ............................................................3-28

Keyswitch functions ...................................................................................................

3-28

Shutter functions .......................................................................................................

3-28

Remote interlock functions .......................................................................................

3-29

Firestar i401 general specifications ............................................................3-30

Firestar i401 package outline & mounting drawings .................................3-32

Firestar i401 packaging instructions ..........................................................3-34

Maintenance/Troubleshooting

4

Maintenance ..............................................................................................4-2

Disabling Firestar .......................................................................................................

4-2

Daily inspections .......................................................................................................

4-2

Storage/shipping ........................................................................................................

4-3

Cleaning optical components ....................................................................................

4-3

Troubleshooting .........................................................................................4-6

Introduction ...............................................................................................................

4-6

Operational flowchart ................................................................................................

4-7

Functional block diagram ..........................................................................................

4-8

Status LEDs ................................................................................................................

4-9

Laser fault indications ................................................................................................

4-12

Resetting faults ..........................................................................................................

4-13

General laser fault conditions ...................................................................................

4-15

Web interface .............................................................................................................

4-18

Beam delivery optics ..................................................................................................

4-18

Index

Synrad Firestar i401 operator’s manual

table of contents

List of Figures

Figure 1 Firestar i401 hazard label and CE label locations ..................4

Figure 2 European compliance mark ...................................................9

Figure 1-1 Unpacking the i401 laser .......................................................1-4

Figure 1-2 Removing the i401 lifting handles ........................................1-5

Figure 1-3 Firestar i401 shipping box contents .......................................1-6

Figure 1-4 Firestar i401 top down mounting locations ...........................1-8

Figure 1-5 Firestar i401 bottom up mounting locations .........................1-9

Figure 1-6 Firestar i401 cooling connections ..........................................1-13

Figure 1-7 PS-401 voltage selection access panel ...................................1-14

Figure 1-8 PS-401 input section ..............................................................1-15

Figure 1-9 DC power connection locations – rear view .........................1-16

Figure 1-10 DC power connection locations – side view .........................1-17

Figure 1-11 Gas purge kit assembly ...........................................................1-20

Figure 2-1 Firestar i401 front panel controls and indicators ..................2-2

Figure 2-2 Firestar i401 rear panel controls and indicators ....................2-3

Figure 3-1 Hybrid waveguide/unstable resonator design ........................3-2

Figure 3-2 Firestar i401 beam ellipticity .................................................3-3

Figure 3-3 Converting 45° linear polarization to circular polarization ..3-4

Figure 3-4 PWM Command signal waveform .........................................3-7

Figure 3-5 User I/O connector pinouts ...................................................3-10

Figure 3-6 Auxiliary 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 Customer-supplied interlock, negative voltage .....................3-19

Figure 3-12 PLC driven interlock signal ...................................................3-20

Figure 3-13 Multiple PLC driven inputs ...................................................3-20

Figure 3-14 Firestar output driving warning lamp ....................................3-21

Figure 3-15 Firestar output driving relay ...................................................3-21

Figure 3-16 Firestar output driving PLC input module ............................3-22

Figure 3-17 Firestar i401 Internet interface page ......................................3-24

Figure 3-18 Firestar i401 Change IP Address page ...................................3-27

Figure 3-19 Firestar i401 outline & mounting dimensions .......................3-32

Figure 3-20 Firestar i401 outline & mounting dimensions

(mounting feet removed) .......................................................3-33

Figure 3-21 Firestar i401 packaging instructions ......................................3-34

Figure 4-1 Firestar i401 operational flowchart ........................................4-7

Figure 4-2 Firestar i401 functional block diagram ..................................4-8

Synrad Firestar i401 operator’s manual v

table of contents

List of Tables

Table 1 Class 4 safety features .............................................................8

Table 2 European Union Directives ...................................................9

Table 1-1 Firestar i401 ship kit contents ...............................................1-6

Table 1-2 Dew point temperatures .........................................................1-12

Table 1-3 AC three-phase electrical recommendations ........................1-15

Table 1-4 Purge gas specifications ..........................................................1-21

Table 3-1 Assist gas purity specifications ...............................................3-5

Table 3-2 PWM Command signal specifications ...................................3-8

Table 3-3 User I/O pin descriptions .......................................................3-11

Table 3-4 Input circuit specifications .....................................................3-16

Table 3-5 Output circuit specifications ..................................................3-18

Table 3-6 Firestar i401 general specifications ........................................3-30

Table 4-1 Required cleaning materials ..................................................4-4

Table 4-2 Status signals ..........................................................................4-9

Table 4-3 Effect of Remote Interlock input on operating parameters ...4-10

Table 4-4 Normal operating condition ..................................................4-10

Table 4-5 Quick Start Plug or interlock/shutter inputs not

connected ...............................................................................4-11

Table 4-6 Interlock Open condition ......................................................4-11

Table 4-7 Over Temperature fault ..........................................................4-11

Table 4-8 Shutter Open condition ........................................................4-12

Table 4-9 No-Strike condition ...............................................................4-12

Table 4-10 Laser fault codes .....................................................................4-13 vi Synrad Firestar i401 operator’s manual

Trademark/copyright information

SYNRAD and Firestar are registered trademarks of SYNRAD, Inc.

All other trademarks or registered trademarks are the property of their respective owners.

© 2011 by SYNRAD, Inc.

All rights reserved.

Synrad Firestar i401 operator’s manual vii

Warranty information

This is to certify that Firestar

®

i401 lasers are guaranteed by SYNRAD, Inc. to be free of all defects in materials and workmanship for a period of one year from the date of purchase. This warranty does not apply to any defect caused by negligence, misuse (including environmental factors), accident, alteration, or improper maintenance. We request that you examine each shipment within 10 days of receipt and inform

SYNRAD, Inc. of any shortage or damage. If no discrepancies are reported, SYNRAD shall assume the shipment was delivered complete and defect-free.

If, within one year from the date of purchase, any part of the Firestar i401 laser should fail to operate, contact the SYNRAD Customer Service department at 1.800.SYNRAD1 (outside the U.S. call

1.425.349.3500) and report the problem. When calling for support, please be prepared to provide the date of purchase, model number and serial number of the unit, and a brief description of the problem. When returning a unit for service, a Return Authorization (RA) number is required; this number must be clearly marked on the outside of the shipping container in order for the unit to be properly processed. If replacement parts are sent to you, then you are required to send the failed parts back to SYNRAD for evaluation unless otherwise instructed.

If your Firestar i401 laser fails within the first 45 days after purchase, SYNRAD, Inc. will pay all shipping charges to and from SYNRAD when shipped as specified by SYNRAD Customer Service. After the first 45 days, SYNRAD will continue to pay for the costs of shipping the repaired unit or replacement parts back to the customer from SYNRAD. The customer, however, will be responsible for shipping charges incurred when sending the failed unit or parts back to SYNRAD or a SYNRAD Authorized Distributor. In order to maintain your product warranty and to ensure the safe and efficient operation of your Firestar i401 laser, only authorized SYNRAD replacement parts can be used. This warranty is void if any parts other than those provided by SYNRAD, Inc. are used.

SYNRAD, Inc. and SYNRAD Authorized Distributors have the sole authority to make warranty statements regarding SYNRAD products. SYNRAD, Inc. and its Authorized Distributors neither assumes nor authorizes any representative or other person to assume for us any other warranties in connection with the sale, service, or shipment of our products. SYNRAD, Inc. reserves the right to make changes and improvements in the design of our products at any time without incurring any obligation to make equivalent changes in products previously manufactured or shipped. Buyer agrees to hold SYNRAD harmless from any and all damages, costs, and expenses relating to any claim arising from the design, manufacture, or use of the product, or arising from a claim that such product furnished Buyer by SYNRAD, or the use thereof, infringes upon any Patent, foreign or domestic.

viii Synrad Firestar i401 operator’s manual

Contact information

Worldwide headquarters

SYNRAD’s worldwide headquarters are located north of Seattle in Mukilteo, Washington, U.S.A. Our mailing address is: SYNRAD, Inc.

4600

U.S.A.

Place

Mukilteo,

Phone us at: 1.800.SYNRAD1 (1.800.796.7231)

Outside the U.S.: +1.425.349.3500

Fax: +1.425.349.3667

E-mail: [email protected]

Sales and Applications

SYNRAD’s Regional Sales Managers work with customers to identify and develop the best CO

2

laser solution for a given application. Because they are familiar with you and your laser application, use them as a first point of contact when questions arise. Regional Sales Managers also serve as the liaison between you and our Applications Lab in processing material samples per your specifications. To speak to the Regional

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 Authorization (RA) number, contact SYNRAD at 1.800.SYNRAD1 and ask to speak to a Customer Service representative.

Technical Support

SYNRAD’s Regional Sales Managers are able to answer many technical questions regarding the installation, use, troubleshooting, and maintenance of our products. In some cases, they may transfer your call to a Laser, Marking Head, or Software Support Specialist. You may also e-mail questions to the Technical

Support Group by sending your message to [email protected] or to [email protected].

Reference materials

Your Regional Sales Manager can provide reference materials including Outline & Mounting drawings,

Operator’s Manuals, Technical Bulletins, and Application Newsletters. Most of these materials are also available directly from SYNRAD’s web site at http://www.synrad.com.

European headquarters

For assistance in Europe, contact SYNRAD’s European subsidiary, Synrad Europe, at:

Synrad Europe

Münchener Straße 2A

D-82152 Planegg, Germany

Phone: +49 (0) 89 89 1462-0

Fax: +49 (0) 89 89 1462-69

E-mail: [email protected]

Synrad Firestar i401 operator’s manual ix

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x Synrad Firestar i401 operator’s manual

laser safety

Hazard information

Hazard information includes terms, symbols, and instructions used in this manual 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.

Danger:

Imminent hazards which, if not avoided, will result in death or serious injury.

Warning:

Potential hazards which, if not avoided, could result in death or serious injury.

Caution:

Potential hazards or unsafe practices which, if not avoided, may result in minor or moderate injury.

Caution:

Potential hazards or unsafe practices which, if not avoided, may result in product damage.

Note:

Points of particular interest for more efficient or convenient equipment operation; additional information or explanation concerning the subject under discussion.

General hazards

Following 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 the manual.

Danger serious personal injury

This Class 4 laser product emits invisible infrared laser radiation in the 10.6 µm CO

2

wavelength band.

Do not allow laser radiation to enter the eye by viewing direct or reflected laser energy. CO

2

laser radiation can be reflected from metallic objects even though the surface is darkened. Direct or diffuse laser radiation can inflict severe corneal injuries leading to permanent eye damage or blindness. All personnel must wear eye protection suitable for 10.6 µm CO

2

radiation when in the same area as an exposed laser beam. Eyewear protects against scattered energy but is not intended to protect against direct viewing of the beam—never look directly into the laser output aperture or view scattered laser reflections from metallic surfaces.

Enclose the beam path whenever possible. Exposure to direct or diffuse CO

2

laser radiation can seriously burn human or animal tissue, which may cause permanent damage.

This product is not intended for use in explosive, or potentially explosive, atmospheres.

Synrad Firestar i401 operator’s manual 1

laser safety

Hazard information

Warning serious personal injury

U.S. customers should refer to and follow the laser safety precautions described in the American National Standards Institute (ANSI)

Z136.1-2007 document, Safe Use of Lasers. Procedures listed in this

Standard include the appointment of a Laser Safety Officer (LSO), operation of the product in an area of limited access by trained personnel, servicing of equipment only by trained and authorized personnel, and posting of signs warning of the potential hazards.

European customers should appoint a Laser Safety Officer (LSO) who should refer to and follow the laser safety precautions described in

EN 60825-1, 2007—Safety of Laser Products.


Materials processing with a laser can generate 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 adequacy of provisions for fume extraction, filtering, and venting should be carefully considered. Review the following references for further information on exposure criteria:

ANSI Z136.1-2007, Safe Use of Lasers, section 7.3.

U.S. Government’s Code of Federal Regulations: 29 CFR 1910,

Subpart Z.

Threshold Limit Values (TLV’s) published by the American Conference of Governmental Industrial Hygienists (ACGIH).

It may be necessary to consult with local governmental agencies regarding restrictions on the venting of processing vapors.


The use of controls or adjustments or performance of procedures other than those specified herein may result in hazardous radiation exposure.

2


The use of aerosol dusters containing difloroethane causes “blooming”, a condition that significantly expands and scatters the laser beam. This beam expansion can effect mode quality and/or cause laser energy to extend beyond the confines of optical elements in the system, possibly damaging acrylic safety shielding. Do not use air dusters containing difloroethane in any area adjacent to CO

2

laser systems because difloroethane persists for long time periods over wide areas.


laser safety

Hazard information

Firestar

®

i401 lasers should be installed and operated in manufacturing or laboratory facilities by trained personnel only. Due to the considerable risks and hazards associated with the installation and operational use of any equipment incorporating a laser, the operator must follow product warning labels and instructions to the user regarding laser safety.

To prevent exposure to direct or scattered laser radiation, follow all safety precautions specified throughout this manual and exercise safe operating practices per ANSI Z136.1-2007 at all times when actively lasing.

Always wear safety glasses or protective goggles with side shields to reduce the risk of damage to the eyes when operating the laser.

A CO

2

laser is an intense heat source and will ignite most materials under the proper conditions. Never operate the laser in the presence of flammable or explosive materials, gases, liquids, or vapors.

The use of controls or adjustments or performance of procedures other than those specified herein may result in exposure to hazardous invisible laser radiation, damage to, or malfunction of the laser. Severe burns will result from exposure to the laser beam.

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 combustible object in the path of the laser beam. Use a water-cooled beam dump or power meter, or similar non-scattering, noncombustible material as the beam block. Never use organic material or metals as the beam blocker; organic materials, in general, are apt to combust or melt and metals act as specular reflectors which may create a serious hazard outside the immediate work area.

Other hazards

The following hazards are typical for this product family when incorporated for intended use: (A) risk of injury when lifting or moving the unit; (B) risk of exposure to hazardous laser energy through unauthorized removal of access panels, doors, or protective barriers; (C) risk of exposure to hazardous laser energy and injury due to failure of personnel to use proper eye protection and/or failure to adhere to applicable 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.

Disposal

This product contains components that are considered hazardous industrial waste. If a situation occurs where the laser is rendered non-functional and cannot be repaired, it may be returned to SYNRAD, Inc. who, for a fee, will ensure adequate disassembly, recycling and/or disposal of the product.

Additional laser safety information

The SYNRAD web site (http://www.synrad.com/LaserFacts/lasersafety.html) contains an online laser safety handbook that provides information on (1) Laser Safety Standards for OEM’s/System Integrators,

(2) Laser Safety Standards for End Users, (3) References and Sources, and (4) Assistance with Requirements.

In addition, the Occupational Safety and Health Administration (OSHA) provides an online Technical

Manual (located at http://www.osha.gov/dts/osta/otm/otm_iii/otm_iii_6.html). Section III, Chapter 6 and

Appendix III are good resources for laser safety information.

Another excellent laser safety resource is the Laser Institute of America (LIA). Their comprehensive web site is located at http://www.laserinstitute.org.


4 laser safety

Firestar i401 label locations

INVISIBLE LASER RADIATION

AVOID EYE OR SKIN EXPOSURE TO

DIRECT OR SCATTERED RADIATION

CLASS 4 LASER PRODUCT

CAUTION

CONDENSATION AND

WATER DAMAGE CAN

OCCUR IF COOLING WATER

IS BELOW DEW POINT.

SEE OPERATION MANUAL.

Top

WATER DAMAGE CAN

OCCUR IF COOLING WATER

IS BELOW DEW POINT.

SEE OPERATION MANUAL.

MODEL #: FSi401SB

SERIAL #: i401214110006

TESTED AT: 48V MFG: Aug 02, 2011

This laser component does not comply with standards for complete laser products as specified by 21 CFR 1040.10 or IEC 60825-1.

SYNRAD, Inc. 4600 Campus Place, Mukilteo WA 98275 425.349.3500

The RF Drive circuit in this laser is designed to sense fault conditions that could damage the laser’s electronic circuit boards. Ready (RDY) or

Shutter (SHT) LED indicator’s on the rear panel will blink a specific sequence when a fault is detected.

If a fault occurs, remove DC power from the laser, wait 30 seconds, and then re-apply DC power.

If these indicators continue to flash, note the sequence of blinks and refer to the laser’s Operator’s Manual or contact SYNRAD, Inc. as this may indicate a serious problem in the laser’s control circuit.

1400 WATTS MAX

10200-10800 nm

EN-60825-1, 2007

OEM version

MODEL #: FSi401SB

SERIAL #: i401214110006

TESTED AT: 48V MFG: Aug 02, 2011

This laser component does not comply with standards for complete laser products as specified by 21 CFR 1040.10 or IEC 60825-1.

SYNRAD, Inc. 4600 Campus Place, Mukilteo WA 98275 425.349.3500

Rear

The RF Drive circuit in this laser is designed to sense fault conditions that could damage the laser’s electronic circuit boards. Ready (RDY) or

Shutter (SHT) LED indicator’s on the rear panel will blink a specific sequence when a fault is detected.

If a fault occurs, remove DC power from the laser, wait 30 seconds, and then re-apply DC power.

If these indicators continue to flash, note the sequence of blinks and refer to the laser’s Operator’s Manual or contact SYNRAD, Inc. as this may indicate a serious problem in the laser’s control circuit.

Front

WARNING

Do not lift or pull on water fittings!

This may cause misalignment or water leaks.

If a water leak is discovered, please contact

Synrad customer service immediately.

AVOID EXPOSURE

Invisible laser radiation is emitted from this aperture.

This laser product is manufactured under one or more 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.

WARNING

Do not remove water fittings!



If a water leak is discovered, please contact


Lifting handles removed for clarity

AVOID EXPOSURE

Invisible laser radiation is emitted from this aperture.

Figure 1 Firestar i401 hazard label and CE label locations

This laser product is manufactured under one or more 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.


laser safety

Agency compliance

The Agency compliance section includes subsections:

■ Center for Devices and Radiological Health (CDRH) requirements

■ Federal Communications Commission (FCC) requirements

■ European Union (EU) requirements

SYNRAD lasers are designed, tested, and certified to comply with certain United States (U.S.) and European Union (EU) regulations. These regulations impose product performance requirements related to electromagnetic compatibility (EMC) and product safety characteristics for industrial, scientific, and medical (ISM) equipment. The specific provisions to which systems containing Firestar i401 lasers must comply are identified and described in the following paragraphs. Note that compliance to CDRH, FCC, and EU requirements depends in part on the laser version selected—Keyswitch or OEM.

In the U.S., laser safety requirements are governed by the Center for Devices and Radiological Health

(CDRH) under the auspices of the U.S. Food and Drug Administration (FDA) while radiated emission standards fall under the jurisdiction of the U.S. Federal Communications Commission (FCC). Outside the

U.S., laser safety and emissions are governed by European Union (EU) Directives and Standards.

In the matter of CE-compliant laser products, SYNRAD, Inc. assumes no responsibility for the compliance of the system into which the product is integrated, other than to supply and/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 processing system, they 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 OEM laser products are integrated.

Center for Devices and Radiological

Health (CDRH) requirements

Product features incorporated into the design of Firestar i401 lasers to comply with CDRH requirements are integrated as panel controls or indicators, internal circuit elements, or input/output signal interfaces.

Specifically, these features include a Keyswitch (Keyswitch versions), lase and laser ready indicators, remote interlock for power on/off, a laser aperture shutter switch, and a five-second delay between power on and lasing. Incorporation of certain features is dependent on the laser version (Keyswitch or OEM). Table 1,

Class 4

safety features, indicates which features are available on i401 lasers, the type and description of the feature, and if the feature is required by CDRH regulations.

OEM models

Firestar i401 OEM lasers are OEM products intended for incorporation as components in laser processing systems. As supplied by SYNRAD, these lasers do not meet the requirements of 21 CFR, Subchapter J without additional safeguards. In the U.S., the Buyer of these OEM laser components is 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. Under CDRH regulations, the Buyer must submit a report to the CDRH prior to shipping the system. In jurisdictions outside the U.S., it is the sole responsibility of the

Buyer of these OEM components to ensure that they meet all applicable local laser safety requirements. In cases where the Buyer is also the end-user of the OEM laser product, the Buyer/end-user must integrate the laser so that it complies with all applicable laser safety standards as set forth above.


laser safety

Agency compliance

Federal Communications Commission (FCC) requirements

The United States Communication Act of 1934 vested the Federal Communications Commission (FCC) with the authority to regulate equipment that emits electromagnetic radiation in the radio frequency spectrum. The purpose of the Communication Act is to prevent harmful electromagnetic 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, Part 18, Subpart C.

SYNRAD’s Firestar i401 lasers have been tested and found to comply by demonstrating performance characteristics that have met or exceeded the requirements of 47 CFR, Part 18, Radiated and Conducted

Emissions.

FCC information to the user

NOTE: The following FCC information to the user is provided to comply with the requirements of 47

CFR, Part 18, Section 213.

Interference Potential

In our testing, SYNRAD, Inc. has not discovered any significant electrical interference traceable to Firestar i401 lasers.

System Maintenance

Ensure that all exterior covers are properly fastened in position.

Measures to Correct Interference

If you suspect that your Firestar laser interferes with other equipment, take the following steps to minimize this interference:

1 Use shielded cables to and from the equipment that is experiencing interference problems.

2 Ensure that the Firestar laser is properly grounded to the same electrical potential as the equipment or system it is connected to.

FCC caution to the user

The Federal Communications Commission warns the user that changes or modifications of the unit not expressly approved by the party responsible for compliance could void the user’s authority to operate the equipment.

European Union (EU) requirements

RoHS compliance

SYNRAD Firestar i401 lasers meet the requirements of the European Parliament and Council Directive

2002/95/EC on the Restriction of the Use of Certain Hazardous Substances in Electrical and Electronic

Equipment, as amended by Decision 2005/618/EC establishing maximum concentration values for certain hazardous substances in electrical and electronic equipment.

6 Synrad Firestar i401 operator’s manual

laser safety

Agency compliance

Laser safety standards

Under the Low Voltage Directive, 2006/95/EC, the European Norm (EN) document EN 60825-1 was developed to protect persons from laser radiation by imposing requirements upon manufacturers of laser products to provide an indication of laser radiation; to classify laser products according to the degree of hazard; to require both user and manufacturer to establish procedures so that proper precautions are adopted; to ensure adequate warning of the hazards associated with accessible radiation through signs, labels, and instructions; to improve control of laser radiation through protective features; and to provide safe usage of laser products by specifying user control measures. Table 1, Class 4 safety features, summarizes Firestar i401 product features, indicating the type and description of features and whether those features are required by

European Union regulations.

OEM models

Firestar i401 OEM lasers are OEM products intended for incorporation as components in laser processing systems. As supplied by SYNRAD, these lasers do not meet the requirements of EN 60825-1 without additional safeguards. European Union Directives state that “OEM laser products which are sold to other manufacturers for use 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 component is incorporated into another device or system, the entire machinery installation may be required to conform to EN 60825-1; EN 60204-1:2006, Safety of Machinery; the Machinery Directive,

2006/42/EC; and/or any other applicable Standards. In cases where the Buyer is also the enduser of the OEM laser product, the Buyer/end-user must integrate the laser so that it complies with all applicable laser safety standards as set forth above.

Electromagnetic interference standards

The European Union’s Electromagnetic Compatibility (EMC) Directive, 2004/108/EC, is the sole Directive developed to address electromagnetic interference (EMI) issues in electronic equipment. In particular, the Directive calls out European Norm (EN) documents that define the emission and immunity standards for specific product categories. For Firestar i401 lasers, EN 61000-6-4 defines radiated and conducted RF emission limits while EN 61000-6-2 defines immunity requirements for industrial environments.

SYNRAD’s Firestar i401 lasers have demonstrated performance characteristics that have met or exceeded the requirements of EMC Directive 2004/108/EC.


8 laser safety

Agency compliance

Table 1

Class 4 safety features

Feature

Keyswitch

1

Shutter function

Location / Description

Rear panel control

On/Off/Reset Keyswitch controls power to laser electronics.

Key cannot be removed from switch in the “On” position.

Laser control

Functions as a beam attenuator to disable RF driver/laser output when closed.

Shutter indicator

Ready indicator

Rear panel indicator (Blue)

Illuminates blue to indicate shutter is open.

Rear panel indicator (Yellow)

Indicates that laser has power applied and is capable of lasing.

Lase indicator

Rear panel indicator (Red)

Indicates that Firestar is actively lasing. Lase LED illuminates when the duty cycle of the Command signal is long enough to produce laser output.

Five second Firestar circuit element delay

Disables RF driver/laser output for five seconds after Keyswitch is turned to “On” or remote reset/start pulse is applied when Key- switch is in “On” position.

Required by:

CDRH EN60825-1

Yes Yes

Yes

No

Yes

Yes

Yes

Yes

No

Yes

Yes

No

Yes Yes Power fail lockout

1

Remote

Interlock

Firestar circuit element

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.

Rear panel connection

Disables RF driver/laser output when a remote interlock switch on an equipment door or panel is opened.

Yes Yes

Remote

Interlock indicator

Temp indicator

Rear panel indicator (Green/Red)

Illuminates green when Remote Interlock circuitry is closed.

Illuminates red when interlock circuitry is open.

Over Firestar circuit element temperature

Temperature shutdown occurs if temperature of the laser tube protection rises above safe operating limits.

Rear panel indicator (Green/Red)

Illuminates green when laser temperature is within operating limits, changing to red when thermal limits are exceeded.

Warning labels

Firestar exterior

Labels attached to various external housing locations to warn personnel of potential laser hazards.

No

No

No

Yes

No

No

No

Yes

1 Not available on i401 OEM lasers


laser safety

Agency compliance

When integrating SYNRAD’s Firestar i401 OEM lasers, the Buyer and/or integrator of the end system is responsible for meeting all applicable Standards to obtain the CE mark. To aid this compliance process,

SYNRAD’s testing program has demonstrated that Firestar i401 lasers comply with the relevant requirements of 2004/108/EC, the Electromagnetic Compatibility Directive, as summarized in Table 2 below.

Table 2 European Union Directives

Applicable Standards / Norms

2004/108/EC

2006/95/EC

2002/95/EC

EN 61010-1:2001

EN 61000-6-4:2007

EN 61000-6-4:2007

EN 61000-6-2:2005

EN 61000-6-2:2005

EN 61000-6-2:2005

EN 61000-6-2:2005

Electromagnetic Compatibility Directive

Low Voltage Directive

RoHS Directive (amended 2005/618/EC)

Safety Requirements for Electrical Equipment for Measurement,

Control, and Laboratory Use - Part 1: General Requirements

Radiated Emissions Group 1, Class A

Conducted Emissions Group 1, Class A

Electrostatic Discharge Immunity

RF Electromagnetic Field Immunity

Electrical Fast Transient/Burst Immunity

Conducted RF Disturbances Immunity

After a laser or laser processing system has met the requirements of all applicable EU Directives, the product can bear the official compliance mark of the European Union as shown in Figure 2 and a Declaration of Conformity is provided for the compliant component.

Figure 2 European compliance mark


laser safety

Firestar i401 Declaration of Conformity

Declaration of Conformity

in accordance with ISO / IEC 17050-2:2004

We,

Manufacturer’s Name:

SYNRAD, Inc.

Manufacturer’s Address: 4600 Campus Place

Mukilteo, WA 98275

U.S.A.

hereby declare under our sole responsibility that the following equipment:

Product Name: Firestar i401 Laser

Model Number: FSi401SB (OEM * ) conforms to the following Directive(s) and Standard(s):

Applicable Directive(s): 2004/108/EC Electromagnetic Compatibility Directive

2006/95/EC

2002/95/EC

Low Voltage Directive

RoHS Directive (amended by 2005/618/EC)

Applicable Standard(s): EN 61010-1:2001 Safety Requirements for Electrical Equipment

EN 61000-6-4:2007 Radiated Emissions, Group 1, Class A

EN 61000-6-4:2007 Conducted Emissions, Group 1, Class A

EN 61000-6-2:2005 Electrostatic Discharge Immunity

EN 61000-6-2:2005 RF Electromagnetic Field Immunity

EN 61000-6-2:2005 Electrical Fast Transient/Burst Immunity

EN 61000-6-2:2005 Conducted RF Disturbances Immunity

*

OEM lasers do not comply with EN 60825-1:2007, Safety of Laser Products. Buyers of OEM laser products are solely responsible for meeting applicable Directives and Standards for CE compliance and marking.

Corporate Officer:

Dave Clarke, President of SYNRAD, Inc.

Dated 03 August 2011

European Contact:

Synrad Europe

Münchener Straße 2A

D-82152 Planegg

Germany


Use information in this chapter to prepare your Firestar i401 laser for operation. The order of information presented in this chapter is the same as the order of tasks that you will need to perform. The best way to get your laser ready for operation is to start at Unpack-

ing and work your way through Connecting.

This chapter contains the following information:

1

■

Introduction – introduces the Firestar i401 laser, lists important features, and describes Firestar nomenclature.

■

Unpacking – provides important information about unpacking your Firestar i401 laser.

■

Inventory – displays and describes all components shipped with your i401 laser.

■

Mounting – describes how to attach your i401 laser to a mounting surface.

■

Connecting – explains how to connect cooling tubing, power, and control cabling.


1

1

getting started

Introduction

The Firestar

®

i401 laser is a new addition to SYNRAD’s Firestar series of high power lasers. This single tube

400 W laser features an integrated RF power supply with no external RF cables. The compact, single-tube design mounts easily to flatbed cutters, robotic arms, or gantry systems making integration into your production line simple and fast.

Firestar i401 features include:

■

Built-in electromechanical shutter

■ TCP/IP web-based Internet interface

■ Field-replaceable integrated RF modules

■

Duty cycles from < 10% to 100% (CW)

■

Built-in gas purge port

■ Color-coded LEDs mirror user output status

■ “Industrial-strength” ±5 V to 24 VDC I/O

■

Low 6.5 kW heat load

Firestar nomenclature

Firestar lasers are divided into two distinct functional categories: Keyswitch and OEM models. In addition to a manual Keyswitch for resetting faults, all Keyswitch-equipped lasers incorporate a manual shutter switch to block the laser’s output aperture.

SYNRAD’s OEM lasers are primarily designed as components for integration into larger processing systems by the Original Equipment Manufacturer (OEM) or System Integrator who bears the responsibility for meeting the appropriate laser safety requirements for Class 4 laser systems.

Firestar i401 lasers are currently available only as OEM lasers; however, they do include an electromechanical shutter assembly.

Model numbers

The last three characters in the Firestar model number serve to designate the functional category, cooling method, and model version. The functional category is indicated by either a “K” for Keyswitch or “S”

(Switch-less) for OEM models. The next letter indicates the cooling method: “W” for water-cooled units,

“F” for fan-cooled units, and “A” for air-cooled lasers (the cooling method, the “W”, is omitted on all i401 lasers since they are all water-cooled lasers). The last letter in the model number indicates the current model version beginning with “B”.

1


getting started

Unpacking

The Unpacking section includes subsections:

■ Incoming inspection

■ Packaging guidelines

■ Unpacking the i401

■ Removing the lifting handles

Incoming inspection

Upon arrival, inspect all shipping containers for signs of damage. If you discover shipping damage, document the damage (photographically if possible), then immediately notify the shipping carrier and

SYNRAD, Inc.

The shipping carrier is responsible for any damage occurring during transportation from SYNRAD, Inc. to your receiving dock.

Packaging guidelines

Warning possible personal injury

Lifting or moving the Firestar i401 laser poses a potential for injury.

Use appropriate lifting techniques and/or equipment to prevent a risk of injury. In some cases, you may require assistance from additional personnel to safely unpack and move this equipment.

■

To prevent equipment damage or loss of small components, use care when removing packaging materials.

■ After unpacking, review the Inventory section and verify that all components are on hand.

■ Do not lift or support the laser using the cooling fittings; lift the laser by the lifting handles or baseplate only.

■ Save all shipping containers and packaging materials, including covers and plugs. Use these specialized packing materials when shipping the laser to another location.

■ 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, etc.

■ Refer to Packaging instructions drawings in the Technical Reference chapter for details on packaging i401 lasers using SYNRAD-supplied shipping materials.

■ When storing or shipping water-cooled lasers, remember to drain all cooling water from the laser and then cap the open fittings to prevent debris from entering the coolant path.

■ Firestar i401 lasers are heavy and awkward to move. Use appropriate lifting techniques, additional personnel, and/or hoisting equipment to prevent a risk of injury when rigging this equipment.


1

3

getting started

Unpacking

Unpacking the i401 laser

To unbox the i401 laser, refer to Figure 1-1 and perform the following steps:

Figure 1-1 Unpacking the i401 laser

1


getting started

Unpacking

Removing the lifting handles

Once you have placed the i401 laser in its final mounting location, perform the following steps to remove the lifting attachments.

1 Remove the 1/4–20 × 5/8" capscrews from two locations on each of the three handles as shown in

Figure 1-2.

2 Save the lifting handles and capscrews so the handles can be reinstalled if the i401 is moved to another location.

i401 Front View i401 Rear View

Figure 1-2

Removing the i401 lifting handles


1

5

getting started

Inventory

SYNRAD CO

2

Laser's Manual CD

Ethernet Cable

Quick Start Plug

BNC Control Cable

Cooling Tubing

synrad manuals

P/N

90020336

-01 © 20 11 SYNRAD, Inc. All rights reserved

Gas Purge Kit

Cooling Kit

+48V Bus Cover

Mounting Hardware

DC Power Cables w/ Sense Connectors

Firestar i401 Laser

Figure 1-3 Firestar i401 shipping box contents

Table 1-1 Firestar i401 ship kit contents

Shipping Box Contents Qty

Firestar i401 400 W Laser ...................... 1

SYNRAD CO

2

Lasers Manual CD ........ 1

Ethernet cable ........................................ 1

Quick Start Plug ................................... 1

BNC Control Cable .............................. 1

Cooling Tubing ...................................... 1

DC Power Cables .................................. 1

Shipping Box Contents Qty

Gas Purge Kit ..........................................1

Cooling Kit ............................................1

+48V Bus Cover .....................................1

Spare Fuses (not shown) ........................4

Mounting Hardware ..............................4

Final Test Report (not shown) ..............1

1


getting started

Inventory

i401 contents description

Each item listed in Table 1-1 is described below:

Firestar i401 400 W Laser –

The Firestar i401 laser is a compact, single tube 400 W laser producing nearperfect beam quality with < 100 µs rise/fall times and a PWM duty cycle range from < 10% up to 100% (full

CW) .

SYNRAD CO

2

Lasers Manual CD – contains a Firestar i401 manual that provides setup, operation, and maintenance information for your i401 laser.

Ethernet cable – provides the communications link between a host and the laser for accessing operating parameters via a TCP/IP web-based interface.

Quick Start Plug – connects to Firestar’s User I/O connector. Jumpers are built into the plug to enable Firestar’s interlock circuits for initial start-up and testing.

BNC Control Cable – Coaxial cable carries the PWM Command signal from the UC-2000 Controller to the laser’s Quick Start Plug.

Cooling Tubing – carries cooling water from the chiller to the laser and back. This black polyethylene tubing is 1/2-inch O.D. by 30 feet and must be cut to length.

DC Power Cables – carry DC power from the 48 V power supply to your i401 laser. Standard cable length is 2.0 meters (6.5 feet) while an optional 5.0 m (16 ft) power cable is available. The cable bundle includes sense lines that connect to the recommended PS-401 DC power supply.

Gas Purge Kit – provides a filtering and connection point to the laser from your facility’s purge gas system.

Cooling Kit – adapts the laser’s straight 1/2-inch coolant fittings to 90° adaptor fittings for either 1/2-inch standard or 12-mm metric cooling tubing.

+48V Bus Cover – provides a protective barrier to the i401’s 48 VDC, 135 A input bus.

Spare Fuses (not shown) – 40 ampere fast-blow fuses protects Firestar’s internal RF circuitry.

Mounting Hardware – fasten Firestar to your mounting surface. Four each M10 × 1.5 × 35 mm capscrews,

M10 washers, and M10 split washers are provided for mounting Firestar i401 lasers.

Final Test Report (not shown) – contains data collected during the laser’s final pre-shipment test.

1


getting started

Mounting

The Mounting section includes subsections:

■ Top down mounting

■ Bottom up mounting

The Firestar i401 baseplate is designed so that the laser is easily mounted using four fasteners as described in the subsections below. Refer to the Firestar i401 package outline drawing in the Technical Reference chapter for mounting locations and dimensions.

Caution possible equipment damage

SYNRAD does not recommend mounting lasers in a vertical “headdown” or “tail-down” orientation. If you must mount your laser in this manner, please contact the factory for limitations as a vertical orientation increases the risk of damage to the laser’s output optic.

Top down mounting

To fasten your Firestar i401 laser to a mounting surface from above, perform the following steps:

1 Determine whether you will use metric (ISO) or inch (SAE) fasteners to mount the laser. Four metric (M10) capscrews and flat/split washers are included in the ship kit.

2 Refer to the i401 outline and mounting drawing (Sheet 1 of 2) for dimensions, then drill and tap four M10 × 1.5 or four 3/8" (UNC or UNF) holes into your mounting surface. These holes should correspond with the holes labeled “A” shown in Figure 1-4.

Each mounting foot also contains a 0.380" dowel pin guide (labeled “B” in Figure 1-3) for applications that require precision positioning for alignment purposes.

A

B

A

B

i401 Top View

A

Figure 1-4 Firestar i401 top down mounting locations

A

1


getting started

Mounting

3 Carefully place the i401 laser on the mounting surface so the holes in the mounting feet line up over the threaded holes in the mounting surface.

4 Place a split washer and flat washer on each capscrew and insert the fasteners through the feet into the mounting surface. Turn the screws by hand until the threads fully engage.

5 Evenly tighten all four fasteners to a torque of 40 N m (29 ft lb f

).

Note: After the laser is fastened into position, you may remove the lifting handles if necessary.

Bottom up mounting

To fasten your Firestar i401 laser to a mounting surface from below, perform the following steps:

1 Unscrew the four M10 capscrews fastening the feet to the bottom of the i401 laser and remove the factory-installed mounting feet.

2 Refer to the i401 outline and mounting drawing (Sheet 2 of 2) for dimensions, then drill four 10.6 mm (close fit) or 11.2 mm (normal fit) thru holes in your mounting surface. These holes should correspond with the fastener locations labeled “C” shown in Figure 1-5.

The i401 baseplate also contains two 0.375" × 0.500" beam alignment slots (labeled “D” in Figure

1-5) for applications that require precision positioning for alignment purposes.

C

i401 Bottom View

C

D

D

C

Figure 1-5 Firestar i401 bottom up mounting locations

C

3 Carefully place the i401 laser on the mounting surface so the M10 threaded holes in the baseplate line up over the thru holes in the mounting surface.

Important Note:

Verify the correct fastener length for your mounting application. The M10 × 1.5

× 35 mm capscrin the ship kit are for use with the factory-installed mounting feet.

When fastening the i401 to your mounting surface from the bottom up, use M10 ×

1.5 mounting screws with a

length of 30 mm +/- 2 mm plus the thickness of the

mounting plate and any washers between the bolt head and the mounting plate.

4 Place a split washer and flat washer on each capscrew and insert the fasteners through the mounting surface into the laser baseplate. Turn the screws by hand until the threads fully engage.

5 Evenly tighten all four fasteners to a torque of 40 N m (29 ft lb f

).


1

9

getting started

Connecting

The Connecting section includes subsections:

■ Cooling connections

■ 48 V power supply connections

■ Control connections

■ Other connections

Cooling connections

Read Guidelines for cutting and installing tubing before installing any cooling tubing and then make sure to connect the cooling system exactly as described for your particular laser.

Guidelines for cutting and installing tubing

■ Cut tubing lengths generously to allow for trimming.

■ Cut tubing squarely; diagonal cuts may not seal properly. Trim away burrs if the cut is “ragged”.

■ Avoid excessive stress on fittings; create gentle bends when routing tubing close to connectors. Excessive stress from sharp bends will compromise the sealing properties of the fitting.

■ Never allow the tubing to kink, since kinking severely restricts coolant flow.

■ Push tubing completely into the fitting, then pull the tubing to verify that it is locked into place. Tubing extends into the fitting approximately 22 mm (0.875").

■ 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 12.7 mm (1/2") from its end before reconnecting. Trimming the end of the tubing before reconnecting the fitting provides an undisturbed sealing surface.

Laser cooling fittings

If your integrated laser application uses metric cooling tubing, we recommend the installation of tubing adaptors to convert the laser’s existing WATER IN/WATER OUT fittings from 1/2-inch standard to

12-mm metric tubing. The ship kit sent with your Firestar i401 laser includes a cooling kit containing two each 1/2-inch male to 1/2-inch female 90° adaptors and two each 1/2-inch male to 12-mm female 90° adaptors. If required, many tubing and fitting manufacturers can supply 1/2-inch to 12-mm straight fittings.


Firestar i401 lasers incorporate special coolant fittings that accept only standard 1/2" O.D. cooling tubing.

DO NOT REMOVE OR ADJUST THESE FITTINGS!

Each laser is shipped with a cooling kit that includes 90° push-on tubing connectors to adapt the coolant fittings to your choice of standard (1/2-inch) or metric (12-mm) cooling tubing.

1


getting started

Connecting

Chiller preparation guidelines

■ You must provide fittings that will adapt the laser’s 1/2-inch O.D. polyethylene cooling tubing to your chiller’s Inlet and Outlet ports. These fittings can be either “quick disconnect” or compression type fittings.

■

Because Firestar’s cooling tubing is supplied in inch sizes, do not use metric tubing fittings unless you have installed the appropriate inch-to-metric tubing adaptors. The use of metric fittings on inch size tubing will lead to coolant leaks or may allow the pressurized tubing to blow off the fitting.

Coolants

SYNRAD recommends that the laser’s cooling fluid contain at least 90% water (distilled or tap) by volume. In closed-loop systems, use a corrosion inhibitor/algaecide such as Optishield

®

Plus or equivalent as required. Avoid glycol-based additives because they reduce the coolant’s heat capacity and high concentrations may affect power stability. For SYNRAD lasers, the minimum coolant setpoint is 18 °C (64

°F) so glycol is not necessary unless the chiller is subjected to freezing temperatures. In applications where biocides containing chlorides are used, concentrations should not exceed 25 parts per million (PPM).

Maintain a coolant pH level above 7.0. We recommend the installation of a filter on the chiller’s return line, especially in areas where water hardness is a problem. Firestar i401 lasers incorporate the following wetted materials in the coolant path—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 inside the laser housing leading to failure of laser electronics as well as damage to optical surfaces.

The greatest risk of condensation damage occurs when the laser is in a high heat/high humidity environment and the chiller’s coolant temperature is colder than the dew point of the surrounding air or when the system is shut down, but coolant continues to flow through the laser for extended periods of time.

The chiller’s temperature setpoint must always be set above the dew point temperature. In cases where this is not possible within the specified coolant temperature range of 18 °C to 22 °C (64 °F to 72 °F), then the following steps MUST be taken to reduce the risk of condensation damage.

■ Use the Gas Purge port to introduce nitrogen or dry, filtered air into the laser housing.

■ Air-condition the room or the enclosure containing the laser.

■ Install a dehumidifier to reduce the humidity of the enclosure containing the laser.

■ Stop coolant flow when the laser is shut down.

■ Increase coolant flow by an additional 1.0 GPM. Do not exceed a coolant pressure of 60 PSI.

■ Refer to Table 1-2 and gradually increase coolant temperature until it is above the dew point temperature and condensation disappears. Do not exceed a coolant temperature of 28 °C (82 °F).

Table 1-2 on the following page provides dew point temperatures for a range of air temperature and relative humidity values. Remember that the laser’s coolant temperature must be set above the dew point temperatures given in the chart;

however, for best results and performance, use a coolant temperature in

the range of 18 –22 °C (64–72 °F).


1

11

getting started

Connecting


Operating the laser at coolant temperatures above 22 °C (72 °F) may result in decreased performance and/or premature failure of electronic components.

Table 1-2 Dew point temperatures

Dew Point Temperature Chart °F (°C)

Relative Humidity (%)

Air Temp

°F (°C)

20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95

60 (16)

— — — 32 36 39 41 44 46 48 52

(0) (2) (4) (5) (7) (8) (9) (10) (11) (12) (13) (14) (15)

65 (18)

— — 33 37 40 43 46 48 51 53 55 57 59 60 62 64

(1) (3) (4) (6) (8) (9) (11) (12) (13) (14) (15) (16) (17) (18)

70 (21)

— 33 37 41 45 48 51 53 56 58 60 62 64 65 67 69

(1) (3) (5) (7) (9) (11) (12) (13) (14) (16) (17) (18) (18) (19) (21)

75 (24)

— 37 42 46 49 52 55 58 60 62 65 67 68 70 72 73

(3) (6) (8) (9) (11) (13) (14) (16) (17) (18) (19) (20) (21) (22) (23)

80 (27)

35 41 46 50 54 57 60 62 65 67 69 71 73 75 77 78

(2) (5) (8) (10) (12) (14) (16) (17) (18) (19) (21) (22) (23) (24) (25) (26)

85 (29)

40 45 50 54 58 61 64 67 70 72 74 76 78 80 82 83

(4) (7) (10) (12) (14) (16) (18) (19) (21) (22) (23) (24) (26) (27) (28) (28)

90 (32)

44 50 54 59 62 66 69 72 74 77 79 81 83 85 87 88

(7) (10) (12) (15) (17) (19) (21) (22) (23) (25) (26) (27) (28) (29) (31) (31)

95 (35)

48 54 59 63 67 70 73 76 79 81 84 86 88 90 92 93

(9) (12) (15) (17) (19) (21) (23) (24) (26) (27) (29) (30) (31) (32) (33) (34)

100 (38)

52 58 63 68 71 75 78 81 84 86 88 91 93 95 97 98

(11) (14) (17) (20) (22) (24) (26) (27) (29) (30) (31) (33) (34) (35) (36) (37)

To use Table 1-2, look down the Air Temp column and locate an air temperature in Fahrenheit or Celsius (°C values are shown in parentheses) that corresponds to the air temperature in the area where your laser is operating. Follow this row across until you reach a column matching the relative humidity in your location. The value at the intersection of the Air Temp and Relative Humidity columns is the Dew Point temperature in °F (or °C). The chiller’s temperature setpoint must be set above the dew point temperature. For example, if the air temperature is 85 °F (29 °C) and the relative humidity is 60%, then the dew point temperature is 70 °F (21 °C). Adjust the chiller’s temperature setpoint to 72 °F (22 °C) to prevent condensation from forming inside the laser.

1


getting started

Connecting

Cooling tubing connections

To connect cooling tubing to your i401 laser, refer to Figure 1-6 and perform the following steps. The numbered items in Figure 1-6 correspond to the step numbers in the following procedure.

1

Chiller

INLET

OUTLET

Water Inlet

Water Outlet

WATER

OUT

WATER

IN

3

2

Figure 1-6 Firestar i401 cooling connections

1 Locate the 1/2-inch O.D. polyethylene cooling tubing in the i401 ship kit.

2 Cut and connect a length of cooling tubing to fit between the chiller’s Outlet port and the

WATER IN port on the rear of the i401 laser.

3 Cut and connect a length of cooling tubing to fit between the WATER OUT port on the rear of the laser and the chiller’s Inlet port.


Inlet cooling water temperature must always be maintained above the dew point to prevent condensation and water damage to your Firestar laser.

4 Turn on the chiller and adjust the temperature setpoint to 18 °C to 22 °C. Regulate coolant flow to

4.0 GPM at less than 60 PSI of pressure.

5 Closely examine all cooling connections and verify that there are no leaks.


1

13

getting started

Connecting

48 V power supply connections

Note: The negative (–) side of the DC input to the laser is internally connected so that the laser chassis 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 insulating pad or film in order to electrically isolate the laser when other equipment is grounded to the laser’s DC power supply.

The following procedures describe how to connect a 48 VDC power supply to the i401 laser. Firestar i401 lasers require a DC power source capable of supplying a minimum of 135 A at 48 VDC.

We recommend the SYNRAD PS-401 DC power supply, which can provide a maximum of 145 A at 48

VDC. AC input requirements for the PS-401 supply are 180–264/342–528 VAC, three-phase (3Ø), 30 A max per phase, 50–60 Hz.

PS-401 DC power supply

Input voltage selection

The PS-401 supply is shipped with the default AC input voltage range set to 480 VAC, which is used for high-range 3Ø input voltages between 342–528 V with the nominal range being

380–480 VAC.

To operate the PS-401 DC supply on a low-range 3Ø voltage between 180–264 V with the nominal range being 200–240 VAC, perform the following steps to reconfigure the unit:

1 Verify that input AC voltage to the DC power supply is physically locked out or disconnected.

2 Refer to Figure 1-7 for the location of the voltage selection assembly on the front of the supply.

Access Panel for

Input Voltage Selection

240VAC

480VAC

Nominal 380–480 VAC; 3Ø

Min/Max Range 342–528 VAC; 3Ø

Nominal 200–240 VAC; 3Ø

Min/Max Range 180–264 VAC; 3Ø

Figure 1-7 PS-401 voltage selection access panel

1

14

3 Unscrew the knurled thumbscrews fastening the voltage selection assembly to the PS-

401 chassis.

4 Pull the voltage selection assembly out of the chassis and rotate it 180° so the notch is now facing upwards.


getting started

Connecting

5 Carefully insert the voltage selection assembly back in to the power supply chassis. The words “240VAC” should appear in the cutout area as seen in Figure 1-7.

6 Tighten the knurled thumbscrews fastening the voltage selection assembly to the PS-401 chassis.

AC three-phase connections


All AC input wiring and fusing to the DC power supply must be sized and connected in accordance with applicable local, state, and national requirements.

Local, state, and national code requirements (like NEC, CSA, and

IEC 60364) supersede any recommendations provided in this manual.

Table 1-3 provides recommendations for three-phase input wiring and fusing.

Table 1-3

AC three-phase electrical recommendations

Parameter Recommendation

Input voltage range (3Ø) 342 V–528 VAC; 380 V–480 V nominal

180 V–264 VAC; 200 V–240 V nominal

Input current, max.

Wire gauge

Fuse/circuit breaker

25 Amperes per phase

10 AWG

30 Amps

To connect three-phase AC input power, refer to Figure 1-7 and perform the following steps:

PE

AC INPUT

L1

L2

L3

Figure 1-8 PS-401 input section


1

15

getting started

Connecting

Note: Because AC input connections and requirements vary from facility to facility, customers must provide the AC power cable or wiring. AC input connections to the PS-401

DC power supply are made using a four-position terminal strip with M4 screw terminals on 13.0 mm centers.

1 Follow your facility’s Lockout/Tagout procedures and verify that input AC voltage to the

DC power supply is physically locked out or disconnected.

2 Connect the ground (earth) wire, typically green, to the input terminal labeled PE.

3 Connect the first three-phase hot wire, typically black, to the input terminal labeled L1.

4 Connect the second three-phase hot wire, typically red, to the input terminal labeled L2.

5 Connect the third hot wire, typically blue, to the input terminal labeled L3.

DC Power Cables

To connect DC power to your i401, refer to Figure 1-9 and Figure 1-10 and perform the following steps:


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 below to ensure that DC Power Cables are properly connected to the correct

DC output terminals.

+48 VDC OUTPUT

BUS BAR

DC OUTPUT

POS

NEG

– VDC GROUND

BUS BAR

AC

DC

Vadj

T

SIGNAL

REMOTE SENSE

SIGNAL CONNECTOR

PS-401 DC Power Supply Firestar i401 Laser

Figure 1-9 DC power connection locations – rear view

+48 VDC POWER

– VDC GROUND

1


getting started

Connecting

DO NOT ADJUST

OR TIGHTEN!

Fasten Red (Positive)

DC Cable Here …

Fasten Black (Negative)

DC Cable Here …

Firestar i401 Laser

Figure 1-10 DC power connection locations – side view

1 Verify that input AC voltage to the DC power supply is physically locked out or disconnected.

2 Locate the DC Power Cables in the i401 ship kit. The power supply end of the DC Power Cables includes a 26-pin High Density (HD) D-subminiature connector wired for remote sensing and jumpers to enable the PS-401’s Output Inhibit and Output Interlock inputs.

Important Note: If you are not using a PS-401 DC supply, we highly recommend installing a DC power supply that includes remote sense capability and can compensate for a maximum load lead loss (round trip) of 1.0 V.

3 Attach the black (negative) cable to the –VDC Ground Bus Bar on the PS-401 power supply using

M6 (or 1/4 inch) fasteners.

4 Connect the other end of the black (negative) cable to the –VDC GND terminal on the rear of the i401 laser. Tighten the M10 hex nut to a torque of 34 N m (25 ft lb es—one on each hex nut.

f

) maximum using two wrench-

5 Attach the red (positive) cable to the +48 VDC Output Bus Bar on the PS-401 power supply using

M6 (or 1/4 inch) fasteners.

Important Note: Do not overtighten the fastener into +48 VDC POWER terminal on the laser because this may damage the threads.

6 Connect the other end of the red (positive) cable to the +48 VDC POWER terminal on the rear of the laser.

Carefully tighten the M10 bolt to a torque of 7.4 N m (5.5 ft lb f

) maximum.

7 Connect the 26-pin HD D-subminiature connector into the Remote Sense Signal Connector on the rear of the PS-401 power supply.

8 Locate the +48V Bus Cover and mounting hardware in the ship kit. Use the 6–32 capscrews and #6 washers to mount the acrylic cover to the bus bar block on the rear of the laser.


1

17

getting started

Connecting

Control connections

All control connections to Firestar i401 lasers are made through the 15-pin User I/O connector on the rear panel. The User I/O port receives power commands from SYNRAD’s UC-2000 Universal Laser

Controller, or FH Flyer marking head, and also serves as the connection point for auxiliary signals between the laser and any parts handling, automation, or monitoring equipment.


Always use shielded cable when connecting your PWM Command signal source to PWM Input / PWM Return inputs. In electricallynoisy environments, long lengths of unshielded wire act like an antenna and may generate enough voltage to trigger uncommanded lasing.

UC-2000 Universal Laser Controller

SYNRAD recommends the use of a UC-2000 Universal Laser Controller to generate pulse width modulated (PWM) Command signals that control the laser’s output power. To connect a UC-2000 Controller

(available separately), perform the steps described below:

Note: Firestar i401 lasers can also be controlled from an alternate user-supplied Command signal source.

Refer to Controlling laser power in the Technical Reference chapter for control signal descriptions and refer to User I/O connections, also in the Technical Reference chapter, for signal specifications and connection details.

1 Disconnect 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 connector on the rear of the i401 laser.

4 Attach the BNC connector on the end of the UC-2000’s Power/Control cable to the BNC connector on the rear of the Quick Start Plug.

5 Connect the miniature DC power plug on the UC-2000’s Power/Control cable to the miniature connector on the cable from the UC-2000’s wall plug transformer.

6 Connect the mini-DIN connector on the other end of the UC-2000’s Power/Control cable to the

Laser connector on the UC-2000’s rear panel.

7 Plug the UC-2000’s compact transformer into any 100–240 VAC, 50–60 Hz outlet.

1


getting started

Connecting

Quick Start Plug


The use of the Quick Start Plug bypasses the laser’s safety interlock function, potentially exposing personnel in the area to invisible infrared laser radiation.

Because this plug jumpers Remote Interlock and Shutter Open

Request signals, the laser will fire immediately on application of a PWM Command signal. Your integrated control system should provide interlock and shutter signals directly to the DB-15 User I/O connector only after safe operating conditions are established.

The Quick Start Plug is intended only for initial testing and troubleshooting by qualified personnel. In normal operation, the laser’s

Remote Interlock input should be connected to the machine’s safety interlock circuitry.


Turn off DC power before installing or removing any plug or cable from the User I/O connector. Ensure that user connections are made to the appropriate pins and that the appropriate signal levels are applied. Failure to do so may damage the laser.

In order for your Firestar i401 laser to properly operate, several input signals must be applied to the DB-15

User I/O connector before lasing is enabled. Voltage must be applied to Remote Interlock (Pin 3) and

Shutter Open Request (Pin 10) inputs before the laser becomes ready to fire. In applications where

Firestar lasers are integrated into automated systems and safety interlocks are required, these input signals must be provided by the customer’s control system. The Quick Start Plug included in the ship kit has factory-installed shorting jumpers wired into it to enable these inputs. Connect the Quick Start Plug to the

User I/O connector when performing initial start-up and testing of your Firestar laser.

For further information about the User I/O connector, see User I/O connections in the Technical Reference chapter for User I/O pinouts and signal descriptions. See Integrating Firestar safety features, also in the Technical Reference chapter, for detailed instructions on integrating Firestar’s keyswitch, shutter, and remote interlock functions with automated control systems.

Other connections

Gas Purge port

A gas purge is highly recommended when operating the laser. Purging the laser creates positive pressure inside the laser housing that prevents dirt and debris from accumulating on optical surfaces inside the laser housing. In condensing atmospheres, a gas purge helps to reduce the potential for condensation damage.

To connect the Firestar i401 gas purge port, refer to Figure 1-11 and perform the following steps:


1

19

getting started

Connecting

A B

2

FLO

W

1

3

C

FLO

W

Figure 1-11 Gas purge kit assembly

1 Locate the Gas Purge Kit in the i401 ship kit. The kit consists of two each male/female 90° quickdisconnect fittings, a straight fitting, a low-flow gas filter, and a support bracket with fasteners.

2 Refer to Figure 1-11A and fasten the filter support bracket to the rear of the i401 laser using the

6–32 Allen capscrews and # 6 flat washers provided in the kit.

3 Assemble the two 90° fittings, straight fitting, and filter as shown in Figure 1-11B. Be sure to orient the directional arrow on the filter as shown.

4 Loosen the two jam nuts on the straight fitting so it will slide into the support bracket.

5 Refer to Figure 1-11C and plug the filter assembly into the Gas Purge port connector.

6 Adjust the jam nuts on the on either side of the support bracket to hold the filter assembly in position.

1


getting started

Connecting

7 Connect nitrogen or breathing-grade air to the straight connector using 1/4-inch plastic 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.


Do not exceed a gas purge pressure of 5 PSI (0.34 Bars). Excessive pressure may damage the purge assembly or other internal laser components.

Do not use argon as a purge gas. Use only nitrogen or clean, dry air as described in Table 1-3, Purge gas specifications.

8 Set a purge pressure between 2–5 PSI (0.14–0.34 Bars). This provides just enough positive airflow to prevent dust and debris from entering the laser. If a flowmeter is available, set a flow rate of 30–60

Standard Cubic Feet per Hour (SCFH) at a pressure not to exceed 5 PSI (0.34 Bars).

The Gas Purge port on the Firestar i401 laser must be connected to a source of nitrogen or clean, dry air only; do not use any other gases for purging. Purge gas specifications are listed in Table 1-4 below.

Table 1-4 Purge gas specifications

Purge Gas

Nitrogen

Air

Air

Specification

High Purity Grade 99.9500% purity or better

Breathing Grade 99.9996% purity or better

Compressed 99.9950% purity or better, water-free; oil filtered to 5 mg/m

3 or better; particulate filtered to < 1.0 micron; and dried to lower dew point below coolant temperature setpoint

Ethernet port

A connection to the Firestar i401 Ethernet port is not required for normal operation. To use the i401’s web page capability to monitor various operating parameters, see the Firestar i401 web interface section in the

Technical Reference chapter for details and connection instructions.

Important Note: The Ethernet cable included in the laser’s ship kit is a shielded crossover cable. If your network application requires a straight-thru (patch) cable or you supply your own crossover cable, be sure the Ethernet cable is an industrially-shielded CAT 5e or CAT 6 cable.

1


getting started


1


Use information in this chapter to familiarize yourself with Firestar i401 controls and indicators and to begin operating the laser.


Firestar i401 lasers.

2

■

Controls and indicators – displays and describes exterior controls and indicators on

■

Initial start-up – explains how to start your Firestar i401 laser while verifying proper operation.


2

1

operation

Controls and indicators

3

1

2

Figure 2-1

Firestar i401 front panel controls and indicators

1 Laser Aperture – provides an opening in Firestar’s front panel from which the beam exits. The opening is threaded to accept beam delivery components with M29× 1.0 threads.

2 Optical Accessories Mounting – provides six threaded holes (8–32) for mounting optional beam delivery components available from SYNRAD. Because excessive weight may damage the laser, consult

SYNRAD before mounting components not specifically designed as Firestar options. Refer to Firestar

i401 package outline drawings in the Technical Reference chapter for mounting dimensions.

Note: When mounting optical components to i401 lasers, the 8–32 UNC fasteners must extend no further than 0.25" (6.35 mm) into the laser’s faceplate.

3 Aperture Seal – prevents dust from damaging laser optics during shipping. Remove the red self-adhesive label before applying power to the laser.

4 Status Indicators – LED indicators display i401 laser status. From left to right:

INT (Remote Interlock) LED illuminates green to indicate the remote interlock circuit is closed and lasing may be enabled; the LED is red and lasing is disabled if the interlock input is open.

TMP (Temperature) LED illuminates green to indicate laser temperature is within limits and lasing may be enabled; the LED is red and lasing is disabled if coolant temperature or flow rate is outside operating limits.

RDY (Ready) LED illuminates yellow when the laser is enabled, indicating that, after a five-second delay, lasing will begin when a PWM Command signal is applied.

SHT (Shutter) LED illuminates blue to indicate that the electromechanical shutter is Open and lasing is enabled. The SHT LED is off and lasing is disabled if the shutter is Closed.

2

2

LASE LED illuminates red to indicate the Firestar i401 is actively lasing.


5

6

7

8

9 operation

Controls and indicators

4

12

INT TMP RDY SHT LASE

GAS PURGE

Clean and

N

2

only

WARNING

Do not remove water fittings!




WATER

OUT

USER I/O ETHERNET

DC POWER

48 VDC

WATER

IN

11

10

9

0 VDC

Figure 2-2 Firestar i401 rear panel controls and indicators

5 User I/O Connector – provides a connection point for auxiliary output power, as well as input and output signals. Refer to the Technical Reference chapter for pinouts and signal descriptions.

6 Gas Purge Assembly – provides a low pressure nitrogen (or pure air) connection to prevent dust and debris from damaging electronic or optical components inside the housing.

7 WATER IN Port – provides inlet connection for Firestar’s cooling system using straight 1/2-inch fittings. The cooling kit contains 90° tubing adaptors for both 1/2-inch and 12-mm cooling tubing.

8 WATER OUT Port – provides outlet connection for Firestar’s cooling system using straight 1/2-inch fittings. The cooling kit contains 90° tubing adaptors for both 1/2-inch and 12-mm cooling tubing.

9 Lifting Handles – allow you to safely lift and move the laser. After laser installation, all three handles can be removed if additional clearance is necessary.

10 GND (–) Terminal – M10 × 1.5 threaded stud provides connection point for negative (ground) side of the 48 VDC power supply.

11 48V POWER Terminal – receives +48 VDC from the 48 VDC power supply. Fasten the positive DC

Power Cable using the supplied M10 × 1.5 bolt at the indicated connection point.

12 Ethernet Port – provides the connection point for a TCP/IP web-based interface between your computer or network and the i401 laser.

2


operation

Initial start-up

The Initial start-up section includes subsections:

■ With a UC-2000 Controller

■

Without a UC-2000 Controller


This Class 4 laser product emits invisible infrared laser radiation in the 10.6 µm CO

2

wavelength band. Since direct or diffuse laser radiation can inflict severe corneal injuries, always wear eye protection when in the same area as an exposed laser beam. Do not allow the laser beam to contact a person. This product emits an invisible laser beam that is capable of seriously burning human tissue.

Always be aware of the beam’s path and always use a beam block while testing.


Remote interlock faults are not latched on Firestar i401 OEM lasers.

Clearing the fault condition re-enables the RDY indicator and the laser will fire after the five-second delay provided the SHT indicator is lit and a PWM Command signal is applied. Because exposure to 10.6

µm CO

2

laser radiation can inflict severe corneal injuries and seriously burn human tissue, the OEM or System Integrator must ensure that appropriate safeguards are in place to prevent unintended lasing.





Important Note: For safety reasons, the Firestar i401 laser contains an internal electromechanical shutter assembly that is controlled by the Shutter Open Request input signal (Pin

10 on the DB-15 User I/O connector). The shutter opens only when a Shutter

Open Request signal is applied and the RDY LED is on (Remote Interlock input active and no over-temperature fault exists).

Use the interlock input to provide maximum operator safety. When the Remote

Interlock input is opened (voltage source removed), the internal shutter automatically closes to block the beam path, the RDY LED turns Off, the SHT LED turns Off

(regardless of the state of the Shutter Open Request input), and all DC power is removed from the RF boards.

2


operation

Initial start-up

Important Note:

To initiate lasing, apply a voltage in the range of ±5–24 VDC to the Remote Inter-

(continued)

lock input. This causes the INT LED to turn green, the RDY indicator to turn yellow, and sends DC power to the laser’s RF boards, allowing internal tickle pulses to reach the tube. Apply a Shutter Open Request signal (a voltage in the range of

±5–24 VDC) to open the physical shutter assembly and then apply a PWM Command signal to begin lasing.

Removing the Shutter Open Request signal causes the shutter to close and block the beam path while simultaneously disabling the PWM input signal, leaving the internal tickle generator enabled to supply tickle signals as required to maintain tube readiness.

With a UC-2000 Controller

Before your Firestar

®

i401 laser is put into service for the first time, its functionality should be verified. Follow this procedure to verify the laser system is operating at optimum performance. For this procedure, use the UC-2000 as a stand-alone controller; do not attempt to control the laser or UC-2000 externally.

Note: When performing the initial start-up sequence, you must first connect the Quick Start Plug or you must provide the required Remote Interlock and Shutter Open Request signals to the User I/O connector. See User I/O connections in the Technical Reference chapter for User I/O pinouts and signal descriptions.

Starting auxiliary equipment

1 Ensure that all personnel in the area are wearing protective eyewear.

2 Place a beam block 24 inches from the laser aperture to prevent the beam from traveling beyond the work area.



3 Turn on the chiller and set the temperature setpoint between 18 °C–22 °C. Verify that the chiller is delivering a flow rate of 4 GPM at less than 60 PSI of pressure. Examine all cooling connections carefully and ensure that they do not leak.





2

5

operation

Initial start-up

4 Start purge gas flow at a rate of 30–60 Standard Cubic Feet per Hour (SCFH) at a pressure not to exceed 5 PSI (0.34 Bars) If a flowmeter is not available, set a purge pressure between 2–5 PSI

(0.14–0.34 Bars).

Note: If you have not yet operated your UC-2000 Universal 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 provide zero percent output (0.0%). The UC-2000’s Lase indicator should be Off.

6 Turn on the +48 VDC power supply.

If the factory-wired Quick Start Plug is installed, the INT indicator will illuminate green, the SHT indicator will illuminate blue, and the RDY LED will illuminate yellow. The TMP indicator will illuminate green if laser temperature is within safe operating limits.

Starting your Firestar i401 laser

Important Note:

Unlike other Firestar lasers, the SHT LED on i401 lasers is dependent on the state of the RDY indicator. Although a Shutter Open Request signal is applied, the SHT

LED will not light while the RDY LED is Off. Therefore, no power is applied to the

RF boards until the RDY indicator is illuminated.

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


Because of phase differences, external tickle pulses may combine 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.

1 Press the UC-2000’s Lase On/Off button. The Lase indicator on the UC-2000 should illuminate.

2 Use the PWM Adj Knob on the UC-2000 Controller to slowly increase power. The LASE LED turns red when PWM Command signal pulses are long enough to produce laser output (typically 7–10 µs at 5 kHz). The spot where the beam hits the beam block increases in brightness to indicate increased power output.

3 Press the UC-2000’s Lase On/Off button to stop lasing. Lase indicators on the UC-2000 and the laser should both turn off.

4 Shut off the chiller or otherwise stop coolant flow through the laser.

2


operation

Initial start-up


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.

5 Shut off gas purge flow to the laser. In dirty or dusty environments; however, it may be necessary to purge the laser continuously to prevent contamination of internal optics.

If your Firestar i401 laser fails to lase, refer to Troubleshooting in the Maintenance/Troubleshooting chapter for troubleshooting information.

Without a UC-2000 Controller

If you have chosen not to use a UC-2000 to control the laser, follow the procedure below to verify the laser’s functionality. Although a tickle signal is not required, you will need to provide PWM Command signals to Firestar’s User I/O connector. Refer to User I/O connections in the Technical Reference chapter for connector pinouts and refer to Controlling laser power in the Technical Reference chapter for Command signal descriptions.

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 wearing protective eyewear.

2 Place a beam block 24 inches from the laser aperture to prevent the beam from traveling beyond the work area.



3 Turn on the chiller and set the temperature setpoint between 18 °C–22 °C. Verify that the chiller is delivering a flow rate of 4 GPM at less than 60 PSI of pressure. Examine all cooling connections carefully and ensure that they do not leak.

2


operation

Initial start-up




4 Start purge gas flow at a rate of 30–60 Standard Cubic Feet per Hour (SCFH) at a pressure not to exceed 5 PSI (0.34 Bars) If a flowmeter is not available, set a purge pressure between 2–5 PSI

(0.14–0.34 Bars).

5 Ensure that your PWM controller is set to zero percent output (0.0%).

6 Turn on the +48 VDC power supply.

If the factory-wired Quick Start Plug is installed, the INT indicator will illuminate green, the SHT indicator will illuminate blue, and the RDY LED will illuminate yellow. The TMP indicator will illuminate green if laser temperature is within safe operating limits.

Starting your Firestar i401 laser

Important Note:

Unlike other Firestar lasers, the SHT LED on i401 lasers is dependent on the state of the RDY indicator. Although a Shutter Open Request signal is applied, the SHT

LED will not light while the RDY LED is Off. Therefore, no power is applied to the

RF boards until the RDY indicator is illuminated.

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



1 Apply a PWM Command signal (+5 VDC, 5 kHz square wave of 4 µs duration) between PWM Input

(Pin 9) and PWM Return (Pin 1) on Firestar’s User I/O connector.

2 Slowly increase the duty cycle of the square wave. The LASE indicator illuminates red when PWM signal pulses are long enough to produce laser output (typically 7–10 µs at 5 kHz). The spot where the beam hits the beam block increases in brightness, indicating an increasing power output.

2


operation

Initial start-up

3 Remove the PWM Command signal from the User I/O connector. The LASE indicator turns off.

4 Shut off the chiller or otherwise stop coolant flow through the laser.


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.

5 Shut off gas purge flow to the laser. In dirty or dusty environments; however, it may be necessary to purge the laser continuously to prevent contamination of internal optics.

If your Firestar i401 laser fails to lase, refer to Troubleshooting in the Maintenance/Troubleshooting chapter for troubleshooting information.


2

9

operation


2



3

■

Technical overview – briefly describes Firestar’s technology and basic optical setup.

■

Controlling laser power – explains various aspects of Firestar control signals.

■

User I/O connections – describes input/output signals and specifications for the 15pin User I/O connector.

■

DC Power Cables – provides information about i401 power cables.

■

Firestar i401 web interface – explains details about the Firestar i401’s Ethernet interface.

■

Integrating Firestar safety features – describes how to integrate Firestar i401 safety features into your automated control system.

■

Firestar i401 general specifications – provides specifications for the Firestar i401 laser.

■

Firestar i401 package outline drawing – illustrates laser package outline and mounting dimensions for i401 lasers.

■

Packaging instructions – illustrates how to package Firestar i401 lasers for shipment.


3

1

technical reference

Technical overview

The Technical overview section includes subsections:

■ Laser design

■ RF power supply

■ Optical setup

Laser design

Optical resonator

Firestar

®

i401 lasers were developed using new technology developed by SYNRAD, Inc. This new technology, based on an hybrid waveguide/unstable resonator design (Figure 3-1), enables SYNRAD to economically produce a symmetrical laser beam from a small but powerful laser capable of operating for many years with virtually no maintenance. Firestar’s unique extruded aluminum envelope offers excellent heat transfer, long gas life, and low operating costs in contrast to other laser tube technologies. Besides being the vessel that maintains the lasing environment, the aluminum tube is also the structural platform that integrates the laser’s optical, electrical, and cooling components.

RF Generator

RF Generator

RF Generator

Laser Output

RF Generator

Figure 3-1 Hybrid waveguide/unstable resonator design

The optical resonator, in conjunction with the electrodes and the gas mixture, generates the laser beam.

Firestar i401 optical resonators are comprised of three optical elements: a front mirror, a rear mirror, and an output window. These optical elements are fastened to the tube’s exterior and are exposed to its interior through holes in the end caps. O-rings are sandwiched between optical elements and the end cap to form a gas seal and to 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.

The structure of the resonator and internal beam conditioning optics combine to produce a near Gaussian mode quality (M

2

factor) of < 1.2. Beam waist diameter is 6.0 mm at the output aperture and full-angle divergence due to diffraction is approximately 2.3 milliradians (a 2.3 mrad divergence means that beam diameter increases 2.3 mm over every one meter distance traveled). Beam ellipticity measures approximately

< 1.2 as it exits the resonator, but becomes closer to 1.0 in the far field (or at the point of focus) as shown in Figure 3.2.

3


technical reference

Technical overview

2

2

1.8

1.6

1

1.4

1.2

1

0.8

0.6

0

0.4

0.2

0

0

0

1

Ellipticity

2 3 4 5 6 7 z 2.6

Distance From Front Plate in Meters

8 9 10

10

Figure 3-2 Firestar i401 beam ellipticity

2

2

1.8

1.6

1

1.4

1.2

1

0.8

0.6

0

0.4

0.2

0

0

0

Ellipticity

10 20 30 40 50 60 70 z 2.6

Distance From Front Plate in Meters

80 90 100

100

Heat removal

Heat generated by excited CO

2

molecules is transferred to the bore walls by diffusion. Collected heat is transferred to the water in the cooling tubes by conduction of the electrodes and aluminum envelope. The coolant path is directed through corrosion-resistant copper alloy tubing to regulate laser temperature for maximum stability.

Beam conditioning

The i401 laser incorporates a novel beam conditioning system that first converts the beam to a circular profile, cleans up the beam to remove side lobes and improve beam quality, and then rotates the polarization through 45 degrees as an aid in applications where a circular polarizer is used. To do this, the laser beam exits the resonator and is turned back on itself through a front folding block that directs the beam into a cylindrical lens located about 25 inches (0.63 m) away from the resonator output. The cylindrical lens converts the beam into a round beam which is then focused by a spherical focusing mirror through a water-cooled aperture (to remove any side lobes) and then onto another spherical mirror that collimates the beam. This beam then passes the shutter mechanism and through the rear folding mirror/beam rotator assembly which rotates the beam 45 degrees before exiting through the output aperture.

Polarization

Polarization is important in achieving the best cut quality from a laser and this is usually achieved with linear polarization aligned with the cut direction; however, in most applications where two axes of cut are required, linearly polarized light can lead to differences in cut quality depending on the orientation of the polarization with respect to the cutting direction.

Converting the laser polarization from linear to circularly polarized light gives uniform cut quality in both axes. Circularly polarized light can be generated without significant power loss by using a circular polarizer (also known as a cut quality enhancer or CQE) or a simple phase retarding mirror.

For the simplest and most cost-effective solution, a reflective phase retarder, laser polarization must be rotated by 45°. Because most lasers have horizontally or vertically polarized outputs with the cutting or welding substrate placed horizontally, this rotation of the polarization is usually done by mounting the laser at 45° to the horizontal or by using two or more mirrors.

Mounting the laser at 45° is often not practical while the addition of extra mirrors in the beam path adds cost and complexity and can reduce reliability.

3


technical reference

Technical overview

To reduce the complexity and cost of beam delivery components, the Firestar i401 laser was designed with the beam polarized at 45° to the base plate. This design allows the use of a simple reflective phase retarder and eliminates the need for additional mirrors or complex mounting schemes. To use a reflective phase retarder with an i401 laser, the linearly polarized beam must make a 45° angle with the plane of incidence as shown in Figure 3-3.

Reflective Phase Retarder Mirror

45°

Electric Vector Polarization

45° i401 Output Beam Linearly Polarized at 45° with Respect to the Baseplate

Reflected Beam is

Circularly Polarized

Figure 3-3 Converting 45° linear polarization to circular polarization

(illustration courtesy of II-VI, Inc.)

RF power supply

Firestar i401 lasers are driven by four compact RF modules mounted internally in the laser chassis. Each

RF module converts 48 VDC input power into a radio frequency (RF) signal that is then amplified and routed to its corresponding electrode structure in the laser tube where it excites the gas mixture in the tube to produce lasing.

Control circuity built into the laser interrupts operation if any critical parameter is violated. Switches and sensors on the control board monitor various conditions and parameters that, if exceeded, pose a risk of potential damage to the laser. Additionally, laser operation is interrupted in response to the following conditions: (1) the electromechanical shutter is closed; (2) the Shutter Open Request input signal is missing;

(3) an over temperature or low coolant flow condition occurs; (4) the Remote Reset/Start Request input signal is enabled; (5) the Remote Interlock input signal is missing; or (6) any fault is present.

Optical setup

After selecting a laser for a CO

2

laser processing system, the two most important elements to consider are:

(1) beam delivery optics to transmit the beam to the work area; and (2) focusing optics to focus the beam onto the part or material to be processed. Each element is crucial in the development of a reliable laserbased material processing system 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 in materials processing since a larger beam entering the focusing optic produces a smaller focused spot.

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Technical overview

Note: Optical components in the beam path must always be aligned to the actual beam path, not the laser faceplate. Because of slight variations in laser construction, the beam path may not always be centered in, or perpendicular to, the aperture in the faceplate.

Expander/collimators are optical devices that reduce beam divergence while at the same time increasing beam diameter by a selectable magnification factor. Adding an expander/collimator substantially 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 is positioned only one meter away from the focusing optic and a small spot size is required, an expander/collimator is again the best solution to provide the required beam expansion before reaching the focusing optic.

Focusing optics

When selecting a focusing optic, the primary consideration should be material thickness and any vertical tolerances that occur during final part positioning rather than making a selection based only on minimum spot size. The chosen focal length should create the smallest possible focused spot while providing the depth of field required for the material to be processed.

Optics are fragile and must be handled carefully, preferably by the mounting ring only. Be careful to select optics that are thick enough to withstand the maximum assist gas pressure available for the process. This is especially important in metal cutting applications using high-pressure assist gases.

Cleanliness is another important issue affecting performance; a dirty or scratched lens will under perform and exhibit a vastly 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 particles of oil and other contaminants that will damage optical surfaces. If compressed shop air is the only choice available, it must be filtered to the specifications shown in Table 3-1.

Table 3-1 Assist gas purity specifications

Assist Gas

Air

Air

Argon

Helium

Nitrogen

Oxygen

Typical Purpose

Cutting/Drilling

Cutting/Drilling

Welding

Welding

Cutting/Drilling

Cutting/Drilling

Specification

Breathing Grade

Compressed

99.9996% purity or better

99.9950% purity or better, water-free; oil filtered to 5 mg/m

3

or better; particulate filtered to less than 1.0 micron




Ultra Pure Grade 99.9998% purity or better

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technical reference

Controlling laser power

The Controlling laser power section includes subsections:

■ Control signals

■

Operating modes

Control signals

Much of the information provided in this section describes the use of a SYNRAD UC-2000 Universal

Laser Controller to provide PWM Command signals to the i401 laser. If using an alternate method of laser control, thoroughly review this section, Controlling laser power, as well as the following section, User I/O

connections, for an understanding of the signal requirements necessary to control Firestar lasers. For more information about the UC-2000, please consult the UC-2000 Laser Controller Operator’s Manual.

Tickle pulse

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 almost instantaneously to PWM Command signals, even when there is considerable delay

(laser off time) between applied Command signals. All Firestar i401 lasers incorporate a built-in tickle generator, freeing customers from the need to supply external tickle pulses between lasing commands.

Internal circuitry monitors the incoming PWM signal and determines the amount of time the laser was on (lasing) during the last 200 microsecond (µs) interval. If the laser’s on time was greater than the preset tickle value, then no tickle pulse is generated because the PWM signal was sufficient to maintain a plasma state. If no PWM signal was applied during the 200-µs measurement period (or was shorter than the preset tickle value), internal circuitry generates a tickle pulse such that the laser always receives a pre-set amount of RF drive averaged over any 200-µs interval.



Pulse Width Modulation (PWM)

Pulse Width Modulation, or PWM, controls laser power by varying the duty cycle of Firestar’s RF amplifiers, which in turn control the time-averaged RF power applied to the laser. The percentage of optical output increases as duty cycle increases (at a constant PWM frequency) or as PWM frequency decreases

(at a constant duty cycle).

Firestar i401 lasers are designed to operate at Command signal base frequencies up to 100 kHz; however, the choice of PWM frequency depends on the user’s specific application. In the majority of laser applications, the UC-2000’s default Command signal frequency of 5 kHz has proven to work well. When considering Command frequencies at 5 kHz or below, please review Marking/engraving operation later in this section. For high-speed motion applications that cannot tolerate any ripple in the optical beam response but still need adjustable power levels, we recommend the use of higher PWM frequencies, up to 100 kHz maximum.

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Command signal

The modulated Command signal applied between Pin 9, PWM Input, and Pin 1, PWM Return, of the User

I/O connector on the Firestar i401 laser has three parameters: signal amplitude, base frequency, and PWM duty cycle. By changing these parameters, you can command the beam to perform a variety of marking, cutting, welding, or drilling operations.


Always use shielded cable when connecting your PWM Command signal source to PWM Input/PWM Return inputs. In electricallynoisy environments, long lengths of unshielded wire act like an antenna and may generate enough voltage to trigger uncommanded lasing.

The first Command signal parameter, signal amplitude, is either logic low—corresponding to laser beam off, or logic high—corresponding to beam on. The laser off voltage, typically 0 V, can range from 0.0 V to

+0.8 VDC while the laser on voltage, typically 5 V, can range from +3.5 V to +6.7 VDC.

Base frequency, the second parameter, is the repetition rate of the PWM input signal. The standard base frequency is 5 kHz, which has a period of 200 µs. Maximum PWM frequency is 100 kHz.

The third Command signal parameter, PWM duty cycle, is the percentage of the period that the Command signal is high. For example, if the Command signal’s amplitude (at 5 kHz) is high for 100 µs and low for 100 µs, it has a 50% duty cycle; if the amplitude is high for 190 µs and low for 10 µs, it has a 95% duty cycle. Figure 3-4 illustrates typical PWM Command signal parameters.

100 µs

5 VDC

200 µs 200 µs

190 µs

0 VDC

5 kHz Command Signal at 50% Duty Cycle

Figure 3-4 PWM Command signal waveform

5 kHz Command Signal at 95% Duty Cycle

Firestar’s User I/O PWM input consists of a high-speed optoisolator LED with a forward voltage drop (Vf) of 1.5 VDC. The PWM input frequency can range from DC (0 Hz) to 100 kHz. Table 3-2 on the following page provides minimum, maximum, and nominal PWM signal specifications.

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Table 3-2 PWM Command signal specifications

Laser State

Laser Off

Minimum

0.0 VDC

Laser On +3.5 VDC (3 mA)

Frequency Range 0 Hz (DC)

Duty Cycle 0%

Nominal

0.0 VDC

+5.0 VDC

5 kHz

— —

Maximum

+0.8 VDC

+6.7 VDC (10 mA), continuous

100 kHz

100%

Operating modes

External control

In addition to controlling the Firestar i401 laser using a UC-2000 Controller, control of the i401 externally, without a UC-2000, is also possible. The two primary elements of laser control are gating, the ability to turn the laser on and off at the appropriate times, and power, the ability to control the laser’s output energy. Both gating and power can be handled by a device such as a personal computer, Programmable

Logic Controller (PLC), or function generator capable of sending PWM pulses at the proper time (gating) and with the proper duty cycle (power).

Analog voltage or current control

Although Firestar i401 lasers cannot be controlled directly by analog voltage or current signals, this type of control is possible when using the UC-2000 Controller. The Controller is connected normally to the laser and analog voltage or current signals sent to the UC-2000’s ANV/C connector then control both laser gating and power.

To generate the correct analog voltage from a computer or PLC, a Digital-to-Analog (D/A or DAC) card capable of generating 0 V (laser off) to 10 V (maximum laser power) must be installed. To generate the proper analog current, install a D/A card that can generate 4 mA (laser off) to 20 mA (maximum power).

Software able to control your analog output card is required for either configuration.

Continuous wave (CW)

In some applications, such as high speed marking or cutting, the time constant of the laser and the PWM modulation causes a series of dots that may be visible on the marking surface instead of a “clean” line.

Operating the laser in CW mode will prevent this behavior from occurring.

To operate the laser in CW mode, apply a constant +5 VDC signal to Pin 9, PWM Input, and Pin 1, PWM

Return, on the User I/O connector. This constant voltage source forces the internal switching electronics to remain on, providing continuous and uninterrupted laser output power. During CW operation, output power cannot be changed. To adjust output power, refer back to the Pulse Width Modulation (PWM) section for information regarding high frequency operation.

Note: SYNRAD lasers are designed for maximum performance using a 95% duty cycle. Increasing the maximum PWM percentage beyond 95% greatly increases the laser’s heat load with little or no corresponding increase in laser output power. Continuous operation at 99% duty cycle may lead to thermal instability and optical degradation.

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Gated operation

In many marking and cutting applications, the laser is required to pulse, or gate, on and off in synchronization 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.

Users who intend to use a gating signal should set the UC-2000’s gate input logic to internal Pull-Down

(normally off) mode. This prevents the beam from being enabled unless a high level (+3.5 V to +5.0

VDC) signal is applied to the Gate input connector. In the pull-down (normally off) mode an asserted logic low state, short circuit to ground, or an open or disconnected Gate input locks the beam off.

Many CO

2

lasers operating in applications requiring short gating pulses at repetition rates below 500 Hz will exhibit some leading edge overshoot regardless of the PWM frequency. This occurs because a cooler lasing medium (the CO

2

gas) is more efficient than a hotter one. This overshoot effect is more pronounced at lower gating frequencies since the gas has a longer time to cool down between Command signal pulses.


The UC-2000’s default gate logic is factory set to internal Pull-Up

(normally on) mode so that an open (disconnected) Gate input causes the laser to turn on. This functionality allows the user to easily test and verify laser operation prior to integration.

In an integrated system, you should configure the UC-2000’s gate input logic to internal Pull-Down (normally off) mode. This prevents the beam from being enabled unless a high level (+3.5 V to +5.0

VDC) signal is applied to the Gate input connector. In the Pull-

Down (normally off) mode an asserted logic low signal, short circuit to ground, or an open or disconnected Gate input locks the beam off.

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 important 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.

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User I/O connections

The User I/O connections section includes subsections:

■ User I/O connection summary

■

Input/output signals

■ Sample I/O circuits

The PWM Command signal and all input/output (I/O) control signals are connected to the User I/O port, a 15 pin female D-type subminiature connector, on the i401’s rear panel. Figure 3-5 below illustrates the pin arrangement of the User I/O connector.


Turn off DC power before installing or removing any plug or cable from the User I/O connector. Ensure that user connections are made to the appropriate pins and that the appropriate signal levels are applied. Failure to do so may damage the laser.

Pin 8

INT TMP RDY SHT LASE

Pin 1

Pin 15

USER I/O

Pin 9

Figure 3-5 User I/O connector pinouts

ETHERNET

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User I/O connection summary

Table 3-3 below provides a quick reference summary to Firestar i401 User I/O connections.

Table 3-3 User I/O pin descriptions

Pin Function

1 PWM Return

Description

Use this input pin as the return side of the PWM Command signal.

2 Remote Reset/Start Request input

Apply a positive or negative voltage (±5–24 VDC) with respect to Pin 11, Input Common, to reset or remote keyswitch the laser. The laser remains disabled while voltage is applied.

Removing voltage from the Remote Reset/Start Request input causes the laser’s RDY indicator to illuminate and begins a five-second countdown after which lasing is enabled.

3

Remote Interlock input

Apply a positive or negative voltage (±5–24 VDC) with respect to Pin 11, Input Common, to enable lasing. If your system does not use a remote interlock, this pin must be connected to a voltage source in the range of ±5–24 VDC. Refer to Figure 3-7 for a diagram showing how the Remote Interlock input is factory-jumpered.

4

5

+ 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 Power Ground.

+ 24 VDC Auxiliary Power

This connection provides +24 VDC for driving external inputs or outputs. The +24 VDC

Auxiliary Power output can source up to 0.5 A and is protected by a 0.5 A self-resetting fuse. The return (ground) path must be through Pin 12, Auxiliary DC Power Ground.

6

7

8

Laser Active output

This bi-directional switched output is internally connected to Pin 13, Output Common, when the laser is actively lasing (LASE indicator illuminated red). This output is open

(high impedance) when no beam is being emitted (LASE indicator Off).

Fault Detected output

This bi-directional switched output is internally connected to Pin 13, Output Common, when (1) laser temperature is above safe operating limits (TMP LED illuminated red) or

(2) a No-Strike condition has occurred (blue SHT indicator is flashing). The output is open

(high impedance) when laser operation is within limits (TMP LED green and SHT LED blue).

Laser Ready output

This bi-directional switched output is internally connected to Pin 13, Output Common, when the laser is enabled (RDY LED illuminated yellow), indicating that lasing will occur when a PWM Command signal is applied to Pin 9 and Pin 1. When this output is initially switched closed, there is a five-second delay during which lasing is inhibited. This output is open (high impedance) when the laser is disabled (RDY indicator Off).


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technical reference


Pin Function

9 PWM Input

Description

Connect your PWM Command signal (+5 VDC, 5 kHz nominal, 100 kHz max, pulse width modulated) to this input pin to control laser output power. Refer back to Controlling laser

power for further information on laser control signals.

10

11

12

13

14

15

Shutter Open Request input

Apply a positive or negative voltage (±5–24 VDC) with respect to Pin 11, Input Common, to open the internal electromechanical shutter assembly. If your system does not supply a

Shutter Open Request signal, this pin must be connected to a voltage source in the range of ±5–24 VDC. Refer to Figure 3-7 for a diagram showing how the Shutter Open Request input is factory-jumpered. The shutter will not activate until a voltage is also applied to the

Remote Interlock input (INT LED illuminated green and RDY LED On).

Input Common

Use this input pin to connect return lines for Remote Interlock, Shutter Open Request, and Remote Reset/Start Request lines.

Auxiliary DC Power Ground

This connection provides a ground (earth) connection for +5 and +24 VDC auxiliary power outputs. This pin is the only User I/O pin that is connected to chassis ground. Do not use this pin for grounding if DC power to external I/O circuits is supplied from an external customer-supplied DC power source.

Output Common

Use this pin to complete the return path for output connections (Pin 6, 7, 8, 14, or 15).

The Output Common line is protected by a 0.3 A self-resetting fuse.

Shutter Open output

This bi-directional switched output is internally connected to Pin 13, Output Common, when Remote Interlock and Shutter Open Request signals are present (RDY indicator illuminated yellow and SHT indicator blue) to indicate that the shutter is open and lasing is enabled This output is open (high impedance) when the laser is disabled (SHT indicator

Off).

Interlock Open output

This bi-directional switched output is internally connected to Pin 13, Output Common, when remote interlock circuitry is open (INT indicator illuminated red), indicating that lasing is disabled. The output is open (high impedance) when lasing is enabled (INT indicator green).

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Input/output signals

The Firestar i401’s input/output signals are divided into three categories: auxiliary DC power, input signals, and output signals. Signals in each category are fully described in the following sections.

Auxiliary DC power

Firestar’s User I/O connector provides auxiliary DC power for driving external inputs or outputs connected to the User I/O port. Pin 4, +5 VDC Auxiliary Power, and Pin 5, +24 VDC Auxiliary Power, are protected by self-resetting fuses rated at 0.5 A. Pin 12, Auxiliary DC Power Ground, is connected to chassis ground while all other User I/O pins are floating with respect to chassis ground. Figure 3-6 illustrates Firestar’s internal DC supply wiring.

DC POWER INPUT

+48 VDC (+)

DC RETURN (–)

+48 V TO DC POWER BOARDS

VOLTAGE REGULATORS

AND

48 V SWITCH

+24 VDC

+5 VDC

0.5 A FUSE

SELF-RESETTING

0.5 A FUSE

SELF-RESETTING

CHASSIS GROUND (EARTH)

(12) (4) (5)

USER I/O AUX DC PINS

Figure 3-6 Auxiliary power supply wiring

Pin 4 + 5 VDC Auxiliary Power

This connection provides +5 VDC for driving external inputs or outputs. The +5 VDC Auxiliary

Power output can source up to 0.5 A and is protected by a 0.5 A self-resetting fuse. The return

(ground) path must be 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 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 the laser’s chassis ground. Do not use this pin for grounding if I/O circuits are powered from an external customer-supplied DC power source.

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Input signals

A total of four user inputs allow control of Firestar lasers. Remote Interlock, Shutter Open Request, and

Remote Reset/Start Request inputs are optoisolated and bi-directional, allowing for positive or negative polarity signal inputs. These three signals also share a common return connection, Input Common, which is separate from chassis ground to completely isolate control signals for optimal EMI performance. The fourth input, PWM Input, is optoisolated and has a separate return, PWM Return, to fully isolate PWM signals from the other three user inputs. Note that throughout this manual, input voltage levels are specified with respect to their corresponding return line.

Pin 1 PWM Return

Connect the return side of your PWM Command signal to this pin. Refer to Table 3-4 for input circuit specifications.

Pin 2 Remote Reset/Start Request

Apply a positive or negative voltage (±5–24 VDC) with respect to Pin 11, Input Common, to disable the laser. The laser remains disabled while voltage is applied to this pin. Removing voltage from the Remote Reset/Start Request pin causes the laser’s RDY lamp to illuminate and begins a five-second countdown after which lasing is enabled. Because all DC power is removed from the laser’s RF modules when this input is active, no lasing can occur until voltage is removed from

Pin 2. Refer to Table 3-4 for input circuit specifications.

Pin 3 Remote Interlock

Apply a positive or negative voltage (±5–24 VDC) with respect to Pin 11, Input Common, to enable lasing. If your system does not use a remote interlock, this pin must be connected to a voltage source in the range of ±5–24 VDC. Refer to Figure 3-7 for a diagram showing how the

Remote Interlock input is factory-jumpered. Because all DC power is removed from the laser’s RF modules when this input is inactive, no lasing can occur until voltage is applied to Pin 3. Refer to

Table 3-4 for input circuit specifications.

Remote Interlock faults (INT LED illuminates red) are not latched. Re-applying a voltage to Pin

3 enables the RDY indicator and lasing is possible after the five-second delay, provided that the

SHT indicator is also lit.

Use the interlock function to provide maximum operator safety. When the Remote Interlock input is opened (voltage source removed), the internal shutter automatically closes to block the beam path, the RDY LED turns Off, the SHT LED turns Off (regardless of the state of the Shutter

Open Request input), and all DC power is removed from the RF boards.

Pin 9 PWM Input

Connect your PWM Command signal (+5 VDC, 5 kHz nominal, 100 kHz max) to Pin 9. This pulse width modulated Command signal controls laser output so that a duty cycle of 50% corresponds to a laser output of approximately one-half rated output power and a duty cycle of 95% corresponds to approximately full output power. Refer to Controlling laser power in this chapter for further information on laser control signals. Connect the PWM signal source return to Pin 1,

PWM Return. See Table 3-4 for input circuit specifications.

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technical reference


Pin 10 Shutter Open Request

Apply a positive or negative voltage (±5–24 VDC) with respect to Pin 11, Input Common, to open the internal electromechanical shutter assembly (when the Remote Interlock input is active). If your system does not supply a Shutter Open Request signal, then this pin must be connected to a voltage source in the range of ±5–24 VDC. Refer to Figure 3-7 for a diagram showing how the Shutter Open Request input is factory-jumpered. See Table 3-4 for input circuit specifications.

Note: Shutter Open Request and Remote Interlock inputs are dependent control functions.

The internal shutter mechanism will not activate (open) until a voltage is also applied to the Remote Interlock input (causing INT LED to illuminate green and RDY LED to turn On).

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 Table 3-4 for input circuit specifications.

Figure 3-7 illustrates how Remote Interlock and Shutter Open Request inputs are factory-jumpered on the Quick Start Plug to enable lasing for initial testing and troubleshooting purposes.





Pin 1

Pin 9

PWM Return

PWM Input

Pin 3

Pin 4

Remote Interlock

+5 VDC

Pin 10 Shutter Open Request

Pin 11 Input Common

Pin 12 Aux. DC Power Ground

Pin 8

Pin 15

Figure 3-7 Quick Start Plug wiring diagram

Rear (Solder Side) of Male DB15

"Quick Start"

Shorting Plug

Pin 1

Pin 9

PWM Input BNC

Figure 3-8 on the following page illustrates the input circuit’s equivalent internal schematic while Table

3-4 provides Firestar i401 input circuit specifications.


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technical reference


USER I/O INPUT SIGNAL PINS

220 Ohm, 1/8W

PWM INPUT (+)

(9)

430 Ohm, 1/10W

PWM RETURN (–)

(1)

REMOTE RESET/START REQUEST

(2)

600 Ohm, 2W

FIRESTAR i401

INPUT CIRCUITRY

REMOTE INTERLOCK

(3)

600 Ohm, 2W

SHUTTER OPEN REQUEST

(10)

600 Ohm, 2W

INPUT COMMON

(11)

Figure 3-8 Input equivalent schematic

Table 3-4 Input circuit specifications

Input Signal Name

PWM Input

Input Device Type and Specifications

High-speed optoisolator LED, forward voltage drop (Vf) 1.5 VDC

Off state Vmax +0.8 VDC

On state Vmin +3.5 VDC @ 3 mA

On state (continuous) Vmax +6.7 VDC @ 10 mA

Frequency, max. 100 kHz

Remote Reset/Start Request Bi-directional optoisolator LED, forward voltage drop (Vf) 1.15 VDC

Remote Interlock

Shutter Open Request

Off state Vmax < 1.0 VDC

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).

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Output signals

Firestar’s five user outputs correspond to the status functions described below. These outputs are optoisolated solid-state relays that allow for high-side or low-side switching. The shared connection, Output Common, is separate from the laser’s chassis ground to allow high-side or low-side switching and to isolate control signals for optimum EMI performance.

Firestar’s optically-isolated outputs are useful for sending laser status to a Programmable Logic Controller

(PLC) or computerized control system. Each of the five outputs can source 50 mA at ±24 VDC maximum for a total load of 250 mA. For controlling larger loads, use these outputs to drive a control relay.

Note: Interlock Open and Shutter Open output signals are dependent control functions. The Shutter

Open output will not close (SHT LED On) until a Shutter Open Request signal is applied and the Interlock Open output opens (causing INT LED to illuminate green and RDY LED to turn

On).

Pin 6 Laser Active

This bi-directional switched output is internally connected to Pin 13, Output Common, when the laser is actively lasing (LASE indicator red). This output is open (high impedance) when no beam is being emitted (LASE indicator Off). Refer to Table 3-5 for output circuit specifications.

Pin 7 Fault Detected

This bi-directional switched output is internally connected to Pin 13, Output Common, when

(1) an over-temperature fault (TMP LED is red) or (2) a No-Strike condition (blue SHT indicator is flashing) has occurred. The output is open (high impedance) when laser operation is within limits (TMP LED green and SHT LED blue). 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 enabled (RDY indicator On), indicating that lasing will occur when a PWM Command signal is applied to Pin 9 and Pin 1. When this output is initially switched closed, there is a five-second delay during which lasing is inhibited. This output is open (high impedance) when the laser is disabled (RDY LED Off). Refer to Table 3-5 for output circuit specifications.

Pin 13 Output Common

Use this pin to complete the return (ground) path for any output connection (Pin 6, 7, 8, 14, or

15). The Output Common line is protected by a 0.3 A self-resetting fuse.

Pin 14 Shutter Open

This bi-directional switched output is internally connected to Pin 13, Output Common, when

Remote Interlock and Shutter Open Request signals are present (SHT LED blue and RDY LED yellow), indicating that lasing is enabled. This output is open (high impedance) when the laser is disabled (SHT LED Off). Refer to Table 3-5 for output circuit specifications.

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Pin 15 Interlock Open

This bi-directional switched output is internally connected to Pin 13, Output Common, when remote interlock input circuitry is open (INT red), indicating that lasing is disabled. This output is open (high impedance) when the laser is enabled (INT indicator green). When this output is initially switched open, there is a five-second delay during which lasing is inhibited. See Table 3-5 for output circuit specifications.

Figure 3-9 illustrates the output circuit’s equivalent internal schematic and Table 3-5 provides Firestar i401 output circuit specifications.

USER I/O OUTPUT SIGNAL PINS

(6) LASER ACTIVE

FIRESTAR i401

OUTPUT CIRCUITRY

SOLID

STATE

RELAY

SOLID

STATE

RELAY

SOLID

STATE

RELAY

SOLID

STATE

RELAY

SOLID

STATE

RELAY

(7) FAULT DETECTED

(8) LASER READY

(14) SHUTTER OPEN

(15) INTERLOCK OPEN

0.3 A FUSE,

SELF-RESETTING

(13) OUTPUT COMMON

Figure 3-9 Output equivalent schematic

Table 3-5 Output circuit specifications

Output Device

Bi-directional MOSFET

Specifications

2.5 Ohms Rdson

10 MOhms Off

Voltage ±24 VDC, max.

Current 50 mA, max.

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Sample I/O circuits

Sample inputs

Figure 3-10 illustrates one method of supplying a Remote Interlock signal using a customer-supplied limit switch. Firestar’s +24 VDC Auxiliary Power output powers the circuit. Note that Pin 4, +5 VDC Auxiliary

Power, could have been used instead, depending on circuit voltage requirements.

Close switch to enable interlock

USER I/O PINS

(5) +24 VDC AUXILIARY

POWER

(3) REMOTE INTERLOCK

(11) INPUT COMMON

(12) AUX. DC POWER

GROUND

Figure 3-10 Customer-supplied interlock

Figure 3-11 shows another variation for supplying a Remote Interlock 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.

Close switch to enable interlock

USER I/O PINS


–12 VDC

0 VDC


Figure 3-11 Customer-supplied interlock, negative voltage


3

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technical reference


A Programmable Logic Controller (PLC) can also drive Firestar inputs. Figure 3-12 shows a typical method for connecting to a PLC output module when only one Firestar input is used.

PLC

DC

OUTPUT

MODULE

+V

(+5–24V)

USER I/O PINS



Figure 3-12 PLC driven interlock signal

When multiple PLC outputs are used, connect Firestar inputs to the PLC as shown in Figure 3-13. By supplying voltage (+VDC) to Pin 11, Input Common, and pulling individual inputs to ground, each input can be independently activated by the PLC’s output module.

PLC

DC

OUTPUT

MODULE

+V

(+5–24V)

USER I/O PINS


(2) REMOTE RESET/START REQUEST


(10) SHUTTER OPEN REQUEST

Figure 3-13 Multiple PLC driven inputs

3


technical reference


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 3-14 illustrates one method of controlling a remote warning lamp using power supplied by Firestar’s +24 VDC Auxiliary Power output. Remember to size current-limiting resistor, R1, so that the current draw does not exceed 50 mA.

USER I/O PINS


POWER


R1

L

(12) AUX. DC POWER

GROUND


Figure 3-14 Firestar output driving warning lamp

Figure 3-15 illustrates a method for controlling a higher voltage, higher current load by using a 24V control relay. Ensure that the relay coil’s pull-in current does not exceed 50 mA. A diode or surge suppressor must be installed across the relay coil to prevent voltage spikes from damaging Firestar outputs.

USER I/O PINS


POWER

+V


(12) AUX.DC POWER

GROUND


Figure 3-15 Firestar output driving relay

L

3


technical reference


Figure 3-16 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 independently switched to activate individual PLC inputs.

USER I/O PINS



PLC

DC

INPUT

MODULE

V+

(+5–24V)

(7) FAULT DETECTED

(8) LASER READY

(14) SHUTTER OPEN

(15) INTERLOCK OPEN

Figure 3-16 Firestar output driving PLC input module

3


technical reference

DC Power Cables

The DC Power Cables shipped with Firestar i401 lasers are manufactured with 1/0 AWG wire to a standard length of 6.5 feet (2.0 m) or an optional length of 16 feet (5.0 m). Nominal finished O.D. is 0.586" (14.9 mm) so the minimum bend radius must be greater than 4.7 inches (12 cm). The cable assembly also includes 22 AWG remote voltage sense wiring connected to a 26-pin high-density D-subminiature connector for use with our PS-401 DC power supply.

When using a power supply other than the PS-401, we recommend using remote sensing so the power supply output remains at a constant voltage over varying load conditions.

Important Note: If you lengthen the DC Power Cables shipped with the i401 laser, you must calculate and measure the additional voltage drop to ensure that 48.0 VDC is available at the laser’s +48V POWER terminal under full-load conditions. Depending on the additional length required, you may need to use larger gauge (2/0) wire.


3

23

technical reference

Firestar i401 web interface

The Firestar i401 web interface section includes subsections:

■ Web page layout

■

Accessing the i401 web page

■ Changing the i401’s IP address

Web page layout

Firestar i401 lasers include a web-based Internet interface that allows you to access read-only information including LED status, RF module voltage, current, and temperature measurements using a standard web browser as shown in Figure 3-17.

Figure 3-17 Firestar i401 Internet interface page

Note: On initial power-up of the laser, allow five seconds for the web interface to load before accessing the web page.

3


technical reference


When the web page opens, the Firestar i401 laser begins sending status data based on the laser’s current condition. Once the initial data is loaded, the Get Data button becomes active. Click this button to begin updating the static web page once a second. Click the Pause button to halt updating. If a fault should occur while the web page is active, the updating process will automatically halt and an error message is displayed.

Displayed data values are accurate to within ±0.25 units.

Get Data button

Click to begin refreshing web page data once a second.

Pause button

Click to halt web page updates.

Laser Status

Displays the current state of laser Status indicators.

Note: Because the i401 web page is a static web page, the RDY indicator display will not flash an error code; however, the Error messages section will display the fault.

RF module data

This section displays operating conditions for each of the Firestar i401’s RF modules.

Connected

A green indicator means that the RF module is connected to the control board. The indicator changes to red if there is no connection.

Input Voltage (VDC)

Displays the DC voltage level measured at the input to the power board for each RF module.

Switch Voltage (VDC)

Displays the DC voltage level applied to each RF module.

Current (A)

Displays DC current (Amperage) being drawn by each RF module.

Temperature (°C)

Displays the heat sink temperature of each RF module.

Relative Humidity:

Displays the measured relative humidity (R.H.) within the i401 laser housing.

Flow Sensor Temp*:

Displays cooling system temperature measured after the RF amplifier modules. This value is not a mea-

surement of coolant temperature.

Internal Tickle Setting:

Indicates that tickle is active and displays the actual tickle setting.

5 Seconds Delay Setting:

Indicates that the five-second delay is active.


3

25

technical reference


Error message area

If a fault occurs, the gray error message area displays the fault condition. If a fault occurs before the web interface is activated, the error message is displayed; however, no other operating data is archived or displayed.

i401 diagram

Illustrates various subsections and their location inside the laser housing.

Configure IP Address link

Click this link to change the laser’s factory-default IP Address. See the Changing the i401’s IP address section for details.

Accessing the i401 web page

Firestar i401 lasers are pre-configured with a fixed IP address that allows a simple Ethernet connection between the i401 laser and a host. To connect your host computer to the i401 laser using a peer-to-peer

Ethernet connection, perform the steps in the following sections:

Important Note: Connection to a local network is permitted as long as the laser’s fixed IP address is unique to your network, otherwise a peer-to-peer connection is required.

Note: The procedure described below may require the assistance of your IT Department if your facility’s Ethernet settings are determined automatically using Dynamic Host Configuration Protocol

(DHCP). The i401 peer-to-peer Ethernet connection must be connected to a computer with a static IP address that is not connected to a local network.

Set your computer’s static IP address

1 Disconnect the computer from your local network by removing any networking cables.

2 From the Start menu, go to Settings and choose Network Connections.

3 Double-click on the appropriate Local Area Network (LAN).

4 Locate the LAN’s Internet Protocol (TCP/IP) properties.

5 Select “Use the following IP address:” and enter the following information:

IP Address: 192.168.90.100

Subnet Mask: 255.255.255.0

Connect to the Firestar i401 laser

1 Remove DC power from the laser.

2 Locate the Ethernet crossover cable in the ship kit.

3 Connect the crossover cable between your computer and the i401’s Ethernet port.

3


technical reference


Note: When connecting to a local network, use a straight-thru Ethernet cable between the i401 laser and your Ethernet router or hub.

4 Apply 48 VDC power to the laser.

5 Launch your web browser, type “http://192.168.90.29” (without the quotes,) and then press Enter.

Changing the i401’s IP address

To change the i401’s factory-default IP address, perform the following steps:

Important Note: You must carefully record and store the new IP address for future reference. After the factory-default IP address is changed, it cannot be remotely reset.

1 From the Firestar i401 web page, click the Configure IP Address link.

2 When the Change IP Address page loads (Figure 3-18), change IP Address, Subnet Mask and Gateway addresses as required. Be sure to record these address changes in a safe location.

Figure 3-18 Firestar i401 Change IP Address page

3 Click the Submit button.

4 Remove DC power from the laser, wait 30 seconds, and then re-apply 48 VDC power.

5 Launch your web browser, type the new IP address, and then press Enter. The i401 web page will appear as shown back in Figure 3-17.

3


technical reference

Integrating Firestar safety features

The Integrating Firestar safety features section includes subsections:

■ Keyswitch functions

■

Shutter functions

■ Remote interlock functions

Firestar’s DB-15 User I/O connector allows system integrators or end-users to integrate Firestar safety features into their control system. Firestar’s keyswitch, shutter, and remote interlock functions serve to enable or disable DC power to Firestar’s RF drive. Without DC power, the RF driver cannot supply RF energy to the resonator, causing the CO

2

gas to remain in a zero-energy state. Firestar status indicators provide users with a quick visual indication of the laser’s operational status. All power to the laser’s RF board is removed when the RDY indicator is Off (Laser Ready output open).

Keyswitch functions

OEM lasers

On OEM lasers, the RDY LED illuminates on DC power-up (when the Remote Interlock input is enabled) and five seconds later, DC power is applied to the RF driver. When the Shutter Open Request input is inactive (SHT indicator Off) only tickle pulses are applied to the laser. PWM Command signals are enabled only when voltage is applied to both Shutter Open Request and Remote Interlock inputs (INT

LED green, RDY LED On, and SHT LED On). Over temperature faults are reset by removing and then re-applying DC power after the laser has cooled. Remote interlock faults are not latched; the RDY LED illuminates yellow as soon as the interlock circuit is closed (when the INT LED turns from red to green) and five seconds later lasing is enabled.

Although a Remote Reset/Start Request input is not required to reset OEM faults, it can be used to inhibit (disable) lasing. Disable the laser by applying a voltage in the range of ±5–24 VDC to Pin 2, the

Remote Reset/Start Request input. Removing voltage allows power to reach the RF driver and begins a five-second countdown after which lasing is enabled (RDY LED illuminates yellow). The RF driver is disabled as long as voltage 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 between Pin 8, Laser Ready, and Pin 13, Output Common (see Figure 3-16).

The Laser Ready output closes when the laser is enabled (RDY LED illuminated yellow), indicating that lasing is possible. The output is open (RDY LED off) when lasing is disabled.

Note: After the Laser Ready output closes, a five-second delay occurs before lasing is enabled.

Shutter functions

An internal electromechanical shutter is installed on all i401 lasers. Lasing is enabled when the shutter is open (SHT LED illuminated blue) and disabled when the shutter is Closed (SHT LED off).

For i401 OEM lasers in automated systems, shutter actuation is provided by the Shutter Open Request signal via Pin 10 on the User I/O connector. To use this feature, apply a voltage in the range of ±5–24

VDC to Pin 10, Shutter Open Request. This input signal causes the SHT LED to illuminate (provided the RDY indicator is On) and opens the physical shutter to allow lasing. Removing voltage from the Shutter Open Request input, causes the physical shutter to close and block the beam path, extinguishing the

SHT lamp and allowing only tickle signals to reach the tube.

3


technical reference

Integrating Firestar safety features

Your control system can monitor the laser’s shutter status on the User I/O connector by connecting your system’s input to Pin 14, Shutter Open, and Pin 13, Output Common (see Figure 3-16). The Shutter

Open output closes when a Shutter Open Request signal is present (SHT LED illuminated blue) and the

Laser Ready output is closed (RDY LED is On). The output is open (SHT LED Off) when the Shutter

Open Request signal is removed or the Laser Ready output is open (RDY LED is Off).

Remote interlock functions

Interlock circuits are often used to disable machinery when a shield, panel, or door is opened. Firestar’s remote interlock function allows you to connect into an external remote interlock circuit and prevent lasing by removing DC power from the laser’s RF driver boards when the circuit is electrically “open”.

Lasing is enabled when a Remote Interlock signal is present (INT LED illuminated green), if the RDY

LED is illuminated and a Shutter Open Request signal is applied. Lasing is disabled when the Remote

Interlock signal is removed (INT LED red, RDY LED off). DC power is applied to the RF driver only when the INT LED is green and the RDY LED is yellow. Remote interlock functionality is provided by the Remote Interlock signal via Pin 3 on the User I/O connector.

To use Firestar’s remote interlock feature to initiate lasing, apply a voltage in the range of ±5–24 VDC to

Pin 3, Remote Interlock. Applying a Remote Interlock signal causes the INT LED to turn green, the RDY indicator to turn yellow, and sends DC power to the laser’s RF boards. After a five-second delay, a tickle signal is applied to the tube. When a Shutter Open Request signal is present, PWM Command signals are enabled to begin lasing. Removing voltage stops DC power from reaching the RF driver, causing the

INT LED to turn red and the RDY LED to turn Off. Lasing remains disabled until a voltage is reapplied to

Pin 3.

Your control system can monitor the laser’s remote interlock status on the User I/O connector by connecting your system’s input to Pin 15, Interlock Open, and Pin 13, Output Common (see Figure 3-16). This output is closed when remote interlock circuitry is open (INT LED illuminated red). The output is open

(INT LED green) when interlock circuitry is closed.


3

29

technical reference

Firestar i401 general specifications

Table 3-6


Parameter

Output Specifications

Wavelength ...................................................10.2–10.7 microns

Power Output

1, 2

Pulsed

3

....................................................440 Watts

Power Stability

4

.............................................± 7%

Power Stability

5

.............................................± 5%

Mode Quality

6

...............................................M

2

< 1.2

Beam Waist Diameter (at 1/e

2

)

7

....................6.0 ± 0.6 mm

Beam Divergence, full angle, (at 1/e

2

)

7

.........2.5 ± 0.3 mrad

Ellipticity .......................................................< 1.2

Polarization ...................................................linear, rotated 45°

Extinction Ratio ............................................> 100:1

Rise Time

8

.....................................................< 100 µs

Modulation (Optical response) ....................up to 100 kHz

Input Specifications

Power Supply

Maximum Current

9

................................125 A

Inrush Current (max.) ...........................170 A for < 10 ms

Command Input Signal

Voltage ..........................................................+3.5 to +6.7 VDC

Current (max., continuous) ..........................10 mA @ +6.7 VDC

Frequency ......................................................DC–100 kHz

Duty Cycle ....................................................0–100%

Logic Low State (Vmin–Vmax.) ..................0.0 to +0.8 VDC

Logic High State (Vmin–Vmax.) .................+3.5 to +6.7 VDC

* Specifications subject to change without notice.

1 This power level is guaranteed for 12 months regardless of operating hours.

2 48 VDC input voltage to obtain guaranteed output power.

3 100 Hz, 10% duty cycle, average power as read by laser power meter, then multiplied by 10.

4 From cold start (tube at 20 °C for 30 minutes before start) at 99% duty cycle with 4 GPM flow and 20 °C coolant temperature.

5 After two minutes (typical) at 99% duty cycle, 4 GPM flow, and 20 °C coolant temperature.

6 Measured at 99% duty cycle, 5 kHz, and 20 °C coolant temperature after 30 minute warm-up.

7 Measured at beam waist. See the laser’s Final Test Report for beam waist location.

8 Measured at 100 Hz, 10% duty cycle.

9 Measured at 48 VDC input, 100% duty cycle.

3


technical reference


Parameter

Cooling Specifications

Maximum Heat Load ....................................6000 Watts (20.5 kBtu/hr)

Flow Rate (minimum) ..................................4 GPM at < 60 PSI (15 lpm at < 4.1 bar)

Pressure Drop .................................................10 PSI at 4 GPM (0.6 bar at 15 lpm)

Coolant Temperature

10

.................................18 °C to 22 °C

Environmental Specifications

Operating Temperature

11

..............................15 °C – 40 °C

Humidity .......................................................0–95%, non-condensing

Physical Specifications

Length ...........................................................48.3 in (122.7 cm)

Width ............................................................ 8.2 in (20.8 cm)

Height ...........................................................11.8 in (30.0 cm)

Weight ...........................................................130 lbs (59.0 kg)

* Specifications subject to change without notice.

10 Firestar i401 lasers can be operated at coolant temperatures up to 28 °C (82 °F) in order to reduce problems associated with condensation; however, this may result in decreased laser performance and/or reduced laser lifetime.

11 Published specifications guaranteed at a cooling temperature of 20 °C.


3

31

technical reference

Firestar i401 outline & mounting drawings

LASE (RED

8.200 208.2

1.450 36.83

.865 21.97

1.875 47.63

5.600 142.2

2.600 66.04

3.375 85.73

C L

4.767 121.0

5.450 138.4

3.400 86.36

2X 11.250 [285.75]

10.000 254.0

C L

Mukilteo, WA 98275 Phone: (425)349-3500 Fax: (425)349-366

SYNRAD INC. AND SHALL NOT BE USED OR DISCLOSED IN WHOL

48.275 1226.19

49.963 1269.05

36.200 919.48

.433 11.0

6.359 161.52

7.185 182.50

11.850 300.99

12.450 316.23

11.375 288.93

C L

2X .800 [20.32

2X .800 [20.32

2X 2.300 [58.42

10.791 274.09

Figure 3-19 Firestar i401 outline & mounting dimensions

3


technical reference

Firestar i401 outline & mounting drawings

Mukilteo, WA 98275 Phone: (425)349-3500 Fax: (425)349-366

C L

SYNRAD INC. AND SHALL NOT BE USED OR DISCLOSED IN WHOL

36.200 919.48

1.500 38.1

.252 6.40

7.185 182.50

2.010 51.0

2.010 51.0

Figure 3-20 Firestar i401 outline & mounting dimensions (mounting feet removed)


3

33

technical reference

Firestar i401 packaging instructions

Figure 3-21 Firestar i401 packaging instructions

3


maintenance/ troubleshooting

Use information in this chapter to perform maintenance or troubleshoot your Firestar i401 laser.


4

■

Maintenance – describes typical Firestar i401 maintenance procedures.

■

Troubleshooting – explains how to troubleshoot common Firestar i401 problems.


4

1


Maintenance

The Maintenance section includes subsections:

■ Disabling Firestar

■

Daily inspections

■ Storage/shipping

■ Cleaning optical components

Disabling Firestar

Before performing any maintenance on your Firestar

®

i401 laser, be sure to completely disable the laser by disconnecting the DC Power Cables from the DC power supply.

Daily inspections

Perform the following steps daily to keep your Firestar i401 laser in optimum operating condition. Except for the procedures described below, no other service is required or should be attempted.


If you operate your laser or marking head in a dirty or dusty environment, contact SYNRAD about the risks of doing so and precautions you can take to increase the longevity of your laser, marking head, and associated optical components.


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.

1 Inspect all cooling tubing connections for signs of leakage. Check for signs of condensation that may indicate the cooling water temperature has been set below the dew point temperature. Condensation will damage electrical and optical components inside the laser. See Setting coolant temperature in the

Getting Started chapter for details on preventing condensation.

2 When using compressed air as a purge gas on your i401 laser, empty water traps and oil separators on each filter and/or dryer between the laser and your compressed air source. Compressed air purity must meet the purge gas specifications shown in Table 1-3 in the Getting Started chapter.

4



Maintenance

3 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 manufacturer’s instructions.

4 Visually inspect the exterior housing of the laser to ensure that all warning labels are present. Refer to the Laser Safety chapter for i401 label types and locations.

Storage/shipping

When preparing the laser for storage or shipping, remember to drain cooling water from the laser. In cold climates, any water left in the cooling system may freeze, which could damage internal components. After draining thoroughly, use compressed shop air at no more than 29 PSI (wear safety glasses!) to remove any residual water. When finished, cap all connectors to prevent debris from entering the cooling system.

When shipping SYNRAD lasers to another facility, we highly recommend that you ship the unit in its original SYNRAD shipping container. If you no longer have the original shipping box and inserts, contact

SYNRAD Customer Service about 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 properly package the laser using SYNRAD-supplied shipping boxes and foam/cardboard inserts as shown in the Packaging instructions may void the warranty. Customers may incur additional repair charges for shipping damage caused by improper packaging.

Cleaning optical components

Debris or contaminants on external beam delivery components may affect laser processing and lead to damage or failure of the optics and/or the laser. Carefully follow the steps below to inspect and clean the optical components in the beam path. Before beginning the cleaning process, read this entire section thoroughly to ensure that all cleaning materials are available and that each step is completely understood.


Even small amounts of contamination on optics in the beam path can absorb enough energy to damage the optic. Inspect beam delivery optics periodically for signs of contaminants and carefully clean as required. In dirty environments, purge laser optics using filtered air or nitrogen to prevent vapor and debris from accumulating on optical surfaces.

Important – Firestar i401 lasers have several beam conditioning optics between the output aperture and the faceplate. To prevent dust and debris from damaging these optical surfaces, always connect nitrogen or filtered air to the laser’s Gas Purge port.

4



Maintenance


Ensure that DC power to the laser is turned off and locked out before inspecting optical components in the beam path. Invisible CO

2

laser radiation is emitted through the aperture. Corneal damage or blindness may result from exposure to laser radiation.

Important Note: Exercise great care when handling infrared optics; they are much more fragile than common glass materials. Optical surfaces and coatings are easily damaged by rough handling and improper cleaning methods.

Cleaning guidelines

■

Wear rubber or latex finger cots or rubber gloves (powder-free) 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.

■ Always place optics lens tissue for protection; never place optics on hard or rough surfaces.

■ It may be necessary to use a cotton ball or fluffed cotton swab instead of a lens wipe to uniformly clean the entire surface of small-diameter mounted optics.

■

Before using any cleaning agents, read Material Safety Data Sheets (MSDS) and observe all necessary safety precautions.

Required cleaning materials

Table 4-1 lists the type and grade of materials required to properly clean optical surfaces.

Table 4-1 Required cleaning materials

Cleaning Material

Finger cots or rubber gloves

Air bulb

Ethyl alcohol

Acetone

Lens wipe (preferred)

Cotton balls or cotton swabs

Requirements

Powder-free

Clean air bulb

Spectroscopic or reagent grade

Spectroscopic or reagent grade

Optical (cleanroom) quality

High-quality surgical cotton/high-quality paper-bodied

4



Maintenance

Cleaning optics

1 Shut off and lock out all power to the laser. You must verify that the laser is OFF (in a zero-energy state) before continuing with the optical inspection!

2 Visually inspect all optical surfaces in the beam path for contaminants.

Caution possible lens damage

Do not allow the nozzle of the air bulb to touch the optical surface.

Any contact may damage the optic by scratching coatings on the optical surface.

Do not use compressed shop air to blow contamination from the optic. Compressed air contains significant amounts of water and oil that form adsorbing films on the optical surface.

Do not exert pressure on the surface of the optic during cleaning.

Optical surfaces and coatings are easily scratched by dislodged contaminants.

Use a new lens wipe on each pass as contaminants picked up by the wipe may scratch the optical surface.

3 Remove loose contaminants from the optic by holding a clean air bulb at an angle to the optic and blow 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. Ethyl alcohol (least aggressive) is best for initial surface cleaning. Acetone (moderately aggressive) is best for oily residue or minor baked-on vapors and debris.

Important Note: If acetone is used as a cleaning solvent, a second follow-up cleaning of the optical surface using ethyl alcohol is required.

5 Gently, and without applying pressure, drag the damp lens wipe across the optical surface in a single pass. Do not rub or apply any pressure, 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 optical surfaces or coatings.

To prevent streaking during the final ethyl alcohol cleaning, drag the lens wipe slowly across the surface so that the cleaning liquid evaporates right behind the wipe

6 Carefully examine the optic under a good light. Certain contaminants or damage such as pitting cannot be removed. In these cases the optic must be replaced to prevent catastrophic failure.

7 Repeat Steps 4 through 6 as required, removing all traces of contaminants and deposits.

4



Troubleshooting

The Troubleshooting section includes subsections:

■ Introduction

■

Operational flowchart

■ Functional block diagram

■ Status LEDs

■ Laser fault indications

■ Resetting faults

■

General laser fault conditions

■ Web interface

■ Beam delivery optics

Introduction

This section is designed to help isolate problems to the module level only. Problems on circuit boards or the laser tube are outside the scope of this guide because they are not user-serviceable assemblies; do not attempt to repair them. Contact SYNRAD or a SYNRAD Authorized Distributor for repair or replacement information.

To troubleshoot Firestar i401 lasers, it is necessary to understand the sequence of events that must happen before the laser can operate. Before attempting any service, we advise you to read the entire troubleshooting guide and review both the operational flowchart and the functional block diagram.


This Class 4 laser product emits invisible infrared laser radiation in the 10.6 µm CO animal tissue.

2

wavelength band. Direct or diffuse laser radiation can inflict severe corneal injuries and can seriously burn human or

Service personnel troubleshooting Firestar lasers must be thoroughly trained in laser safety practices and electronic service techniques before attempting repairs.


4

6

Attempting repair of a SYNRAD Firestar laser without the express authorization of SYNRAD, Inc. will void the product warranty.

If troubleshooting or service assistance is required, please contact

SYNRAD Customer Service.



Troubleshooting

Operational flowchart

The flowchart in Figure 4-1 illustrates Firestar’s start-up sequence.

Laser Start Sequence

Apply 48 VDC power to laser

INT indicator

Green?

No

Yes

TMP indicator

Green?

No

Yes

RDY indicator

Yellow?

No

Yes

SHT indicator

Blue?

No

Yes

Apply PWM Command signal to laser

Apply interlock signal to Remote Interlock input or install factory-supplied

Quick Start Plug

Check that cooling water is flowing through laser and that coolant temp is below 22° C

Cycle DC power

Apply shutter open signal to Shutter Open

Request input or install factory-supplied Quick

Start Plug

Cycle DC power

(remove DC power, wait 15 seconds, reapply DC power)

RDY indicator

Yellow?

Yes

No

SHT indicator

Flashing?

Yes

Apply tickle pulses or a

PWM Command signal

(< 5% duty cycle) for

30 to 60 seconds

No

LASE indicator illuminates Red to indicate laser output

Figure 4-1 Firestar i401 operational flowchart


4

7


Troubleshooting

Functional block diagram

Figure 4-2 is a functional block diagram illustrating the i401’s control architecture.

Humidity/ Flow Sense

Figure 4-2 Firestar i401 functional block diagram

4



Troubleshooting

Status LEDs

Firestar i401 LED indicators, also mirrored as output signals on the User I/O connector, provide status information to the user. Table 4-2 shows Firestar output signal and LED indicator states during normal and fault conditions. User I/O outputs are Closed when the state indicated by the signal name is logically True.

Table 4-2

Status signals

LED

INT

LED Status

Normal Fault

Green

– –

– –

Red

TMP

RDY

SHT

LASE

Green

– –

Yellow

– –

Blue

– –

– –

Red

– –

– –

Red

– –

Off/Flashing

– –

Off

Flashing

– –

Off

Output Signal Name

Interlock Open

Interlock Open

Fault Detected

Fault Detected

Laser Ready

Laser Ready

Shutter Open

Shutter Open

Fault Detected

Laser Active

Laser Active

User I/O Output Status

Normal Fault

Open

– –

– –

Closed

Open

– –

Closed

– –

– –

Closed

– –

Open

Closed

– –

– –

Closed

– –

– –

Open

Closed

– –

Open

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

LASE indicator to illuminate red as lasing begins.

For safety reasons, the shutter function on i401 lasers is dependent on the state of the Remote Interlock input, which is reflected by the state of INT and RDY indicators. Although a Shutter Open Request signal may be applied, the SHT LED will not illuminate while the INT LED is red (RDY LED Off). Therefore, no power is applied to the RF boards until the INT indictor is green (and the RDY LED is yellow).

Table 4-3 (on the following page) illustrates the dependencies of various operating parameters based on the state of the Remote Interlock input. The conditions shown in bold are those required for lasing to be enabled.

4



Troubleshooting

Table 4-3 Effect of Remote Interlock input on operating parameters

Parameter

INT LED

Interlock Open output

Remote Interlock Input

Inactive (No V+)

Red

Closed

Remote Interlock input

Active (V+ Applied)

Green

Open

RDY LED (if TMP LED Green) Off

Laser Ready output (if FD output Open) Open

Shutter Open Request input

SHT LED

Shutter Open output

Inactive

Off

Open

Physical shutter position

DC power to RF boards

Signal input to RF boards

Closed

Off

None

Off

Open

Off

Open

Closed

Off

None

Yellow Yellow

Closed Closed

Off

Open

Closed

On

Tickle

Blue

Closed

Open

On

PWM

Tables 4-4 through 4-9 show how the Firestar i401’s LED and output signal status changes as various operating and fault conditions occur. Fault conditions are shown in bold.

Table 4-4 Normal operating condition

LED Indicator LED Status Signal Name User I/O Signal Status

INT

Interlock Open Open

TMP

Fault Detected Open

RDY

SHT

Yellow

Blue

Laser Ready Closed

Shutter Open Closed

LASE (Tickle only) Off

LASE (PWM applied) Red

Laser Active Open

Laser Active Closed

4



Troubleshooting

Table 4-5

Quick Start Plug or interlock/shutter inputs not connected

LED Indicator

INT

LED Status

Red

Signal Name

Interlock Open

User I/O Signal Status

Closed

TMP Green Fault Detected Open

RDY Off Laser Ready

Open

SHT Off


LASE (PWM applied) Off

Shutter Open

Open

Laser Active Open

Laser Active Open

Table 4-6 Interlock Open condition

LED Indicator

INT

LED Status

Red

Signal Name

Interlock Open


Closed

TMP

Fault Detected Open

RDY

SHT

Off

Off

Laser Ready

Shutter Open

Open

Open



Laser Active Open

Laser Active Open

Table 4-7 Over Temperature fault

LED Indicator

INT

LED Status

Green

TMP

RDY

Red

Off

SHT

Off




Signal Name User I/O Signal Status

Interlock Open Open

Fault Detected

Laser Ready

Closed

Open

Shutter Open Open

Laser Active Open

Laser Active Open

4

11


Troubleshooting

Table 4-8

Shutter Open condition

Signal Name

INT

LED Indicator

Green

TMP

RDY

Green

Yellow

SHT

Off



LED Status

Interlock Open

Fault Detected

Laser Ready


Open

Open

Closed

Shutter Open

Open

Laser Active Open

Laser Active Open

Table 4-9 No-Strike condition

Signal Name

INT

TMP

RDY

LED Indicator

Green

Green

Yellow

SHT

Blue (Flashing)


LASE (PWM applied) On

LED Status

Interlock Open

Fault Detected

Laser Ready

Shutter Open


Open

Closed

Closed

Closed

Laser Active Open

Laser Active Closed

Laser fault indications

Firestar i401 lasers have the ability to indicate five specific fault conditions. In the event of certain faults, the RDY LED will blink an error code, pause four seconds, and then repeat the error code. This sequence continues until the fault is corrected and the laser is reset by cycling DC power to the laser. If a No-Strike condition occurs, the SHT LED flashes continuously until the gas breaks down into a plasma state.

Table 4-10 on the following page lists error codes, the corresponding fault, and describes basic corrective action. See the following section, Resetting faults, for detailed corrective actions.

4



Troubleshooting

Table 4-10

Laser fault codes

LED # of Blinks

RDY

1 blink

RDY

2 blinks

RDY

3 blinks

RDY

4 blinks

SHT

Continuous

Fault Condition

Under Voltage fault

1

Over Voltage fault

1

RF Drive Switch fault

1

PWM Drive fault

1

No-Strike condition

2

Corrective Action in Field

Verify 48.0 VDC (measured at laser under load)

Verify 48.0 VDC (measured at laser under load)

Remove DC power to laser, wait 30 seconds, and then reapply DC power

Remove DC power to laser, wait 30 seconds, and then reapply DC power

Apply tickle or PWM signal (<5% duty cycle) for 30 to 60 seconds

2 A continuously flashing SHT LED indicates a No-Strike condition and the laser is limited to a 5% duty cycle (at 5 kHz). If the

No-Strike condition clears, the laser will recover without cycling power. Common causes of No-Strike condition (gas breakdown) issues are environmental conditions—like cold overnight temperatures when the laser is off. In situations like this, it may take 30 to 60 seconds for gas breakdown to occur and begin normal daily operation. The Fault Detected output closes for a minimum of

50 ms or until the No-Strike condition clears.

Resetting faults


On Firestar i401 OEM lasers, remote interlock faults are not latched.


µm CO

2


Remote Interlock condition

A remote interlock condition occurs when the Remote Interlock input opens (the INT LED changes from green to red and the Interlock Open output Closes). The internal shutter mechanism closes (even when the Shutter Open Request input is active) and lasing is halted immediately.

On i401 lasers, a remote interlock condition is not latched. Re-establish the Remote Interlock signal input (INT LED changes from red to green and the Interlock Open output Opens) to enable the RDY indicator and begin lasing after the five-second delay.

4



Troubleshooting

Over Temperature fault

Over-temperature faults occur when coolant temperature or flow limits in the laser are exceeded (the TMP

LED changes from green to red and the Fault Detected output Closes).

To reset an over-temperature fault, lower coolant temperature below 28 °C to cool the laser and then cycle

DC power to the laser. Once the TMP indicator turns green (Fault Detected output Opens) and the RDY lamp is illuminated, lasing is possible after the five-second delay.

Note: Because of the over-temperature latch circuit, the TMP indicator remains red (and the Fault Detected output remains Closed) prior to cycling power even after the laser has cooled sufficiently to begin operation. If the TMP indicator remains red after cycling power, the laser is not sufficiently cooled or the flow rate is too low—cool the laser for several more minutes and/or verify the flow rate and then cycle power.

Under Voltage fault

An under voltage fault occurs when DC input voltage falls below a preset limit of 46.5 VDC. This fault is indicated by the RDY LED flashing 1 blink. To reset an under voltage fault, first correct the voltage problem and ensure that 48 VDC is measured at the laser’s DC power terminals under full-load conditions.

Next, cycle DC power off and then on again. When the RDY LED illuminates, lasing is enabled after a five-second delay.

Over Voltage fault

An over voltage fault occurs when DC input voltage rises above a preset limit of 49.5 VDC. This fault is indicated by the RDY LED flashing 2 blinks. To reset an over voltage fault, first correct the voltage problem and ensure that 48 VDC is measured at the laser’s DC power terminals under full-load conditions.

Next, cycle DC power off and then on again. When the RDY LED illuminates, lasing is enabled after a five-second delay.

RF Drive Switch fault

An RF Drive Switch fault occurs on power-up when the tube fails to breakdown or a fault occurs in the RF

Driver’s 48-volt switching circuitry. In this case, the RDY LED flashes 3 blinks. If an RF Drive Switch fault occurs, reset the laser by removing DC power to the laser, wait 30 seconds, and then reapply power. When the RDY LED illuminates, lasing is enabled after a five-second delay. If the RF Drive Switch fault reappears, the laser requires service—contact SYNRAD or a SYNRAD Authorized Distributor.

PWM Drive fault

A PWM Drive fault indicates a problem in the laser’s internal RF circuitry and causes the RDY LED to flash 4 blinks. Reset the laser by removing DC power to the laser, wait 30 seconds, and then reapply power.

When the RDY LED illuminates, lasing is enabled after a five-second delay. If the RF Drive DC fault reappears, the laser requires service—contact SYNRAD or a SYNRAD Authorized Distributor.

4



Troubleshooting

DC Pre-Charge fault

A DC Pre-Charge fault indicates that 48 VDC is not available on the input of one or more RF modules and causes the RDY LED to flash 5 blinks. Reset the laser by removing DC power to the laser, wait 30 seconds, and then reapply power. When the RDY LED illuminates, lasing is enabled after a five-second delay. If the DC Pre-Charge fault 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 Command frequency of 5 kHz). This fault is annunciated by the SHT indicator flashing continuously and an error message appears on the i401’s web page. To clear the No-Strike condition, apply tickle pulses or a PWM

Command signal (< 5% duty cycle) for 30 to 60 seconds. When the gas breaks down into a plasma state, the laser will recover and begin lasing at the commanded power level without cycling DC power. If the

No-Strike condition persists, contact SYNRAD or a SYNRAD Authorized Distributor.

Common causes of No-Strike (gas breakdown) issues are environmental conditions–like cold overnight temperatures when the laser is powered down. In situations like this, it may take 30 to 60 seconds for gas breakdown to occur so the laser can begin normal daily operation.

General laser fault conditions

Each Symptom listed below describes a particular fault condition. For each Symptom, specific causes and solutions are described in the Possible Causes section.


On Firestar i401 OEM lasers, remote interlock faults are not latched.


µm CO

2


Symptom:

■ A remote interlock condition is indicated by the following status LEDs and I/O states:

TMP LED

RDY LED

SHT LED

LASE LED

Red

– Green

– Off

– Off

– Off

Interlock Open

Fault Detected

Laser Ready

Shutter Open

Laser Active

– Closed

– Open

– Open

– Open

– Open

Possible Causes:

■ No voltage is applied to Pin 3 (Remote Interlock) of the User I/O connector.


4

15


Troubleshooting

On systems using remote interlocks, check to see that a positive or negative voltage in the range of ±5–24

VDC is applied to Pin 3, Remote Interlock, with respect to Pin 11, Input Common, on the User I/O connector (refer to User I/O connections in the Technical Reference chapter for details). For systems not using interlocks, connect the factory-supplied Quick Start Plug to the User I/O connector on the laser’s rear panel or wire your male DB-15 connector so that Pin 11 (Input Common) is jumpered to Pin 12 (Auxiliary DC

Power Ground) and Pin 3 (Remote Interlock) is jumpered to Pin 4 (+5 VDC Auxiliary Power).

Symptom:

■ An over-temperature fault is indicated by the following status LEDs and I/O states:

INT LED

TMP LED

RDY LED

SHT LED

LASE LED

– Green

– Red

– Off

– Off

– Off

Interlock Open

Fault Detected

Laser Ready

Shutter Open

Laser Active

– Open

– Closed

– Open

– Open

– Open


■

Coolant temperature is above 28 °C (82 °F) or there is inadequate coolant flow through the laser.

Check that your chiller is maintaining a water temperature between 18 °C–28 °C (64 °F–82 °F) at a flow rate of four gallons per minute (GPM).

If water temperature is OK, check the flow rate. The simplest way to do this, if a flow meter is not available, is to disconnect the cooling tubing from the chiller inlet (or the drain) and run the cooling water for 30 seconds into a five-gallon bucket; you should have close to two gallons of water. If there is much less than two gallons of coolant, check the cooling path for kinked or pinched cooling tubes or check the chiller for a clogged or dirty filter.

On i401 lasers, the over-temperature fault (indicated by the TMP indicator turning red) is latched. This means that if an over-temperature condition occurs the TMP indicator will turn red, the Fault Detected output will Close, the RDY light goes out, and lasing is disabled. Because of its latched condition, the TMP indicator will remain red even after the laser has cooled sufficiently to begin operation.

To reset an over-temperature fault, lower coolant temperature below 28 °C and then cycle DC power

(remove DC power, wait 30 seconds, reapply DC power). When the RDY indicator illuminates, lasing is enabled after the five-second delay. If the TMP indicator remains red after cycling power, continue to flow cooling water through the laser for a few more minutes and/or verify the coolant flow rate and then cycle

DC power again.

Symptom:

■ The SHT LED is flashing continuously because of a No-Strike condition as indicated by the following status LEDs and I/O states:

INT LED

TMP LED

RDY LED

SHT LED

LASE LED

– Green

– Green

Interlock Open

Fault Detected

– Yellow Laser Ready

– Blue (Flashing) Shutter Open

– Off or Red Laser Active

– Open

– Closed

– Closed

– Closed

– Open or Closed

4



Troubleshooting


■

A No-Strike condition has occurred, possibly due to cold environmental conditions that may prevent the gas from breaking down into a plasma state. When this occurs while a PWM signal is applied, laser output is limited to a PWM duty cycle of approximately 5%.

Apply tickle pulses or a PWM Command signal (< 5% duty cycle) for 30 to 60 seconds. When the gas breaks down into a plasma state, the laser will recover and begin lasing at the commanded duty cycle without cycling DC power.

Symptom:

■ A shutter closed condition is indicated by the following status LEDs and I/O states:.

INT LED

TMP LED

RDY LED

SHT LED

LASE LED

– Green

– Green

– Yellow

– Off

– Off

Interlock Open

Fault Detected

Laser Ready

Shutter Open

Laser Active


■ No Shutter Open Request signal on Pin 10 of the User I/O connector.

– Open

– Open

– Closed

– Open

– Open

Check to see that a positive or negative voltage in the range of ±5–24 VDC is applied to Pin 10, Shutter

Open Request, with respect to Pin 11, Input Common, on the User I/O connector (refer to User I/O con-

nections in the Technical Reference chapter for details). If your system does not provide a Shutter Open

Request signal, connect the factory-supplied Quick Start Plug to the User I/O connector on the laser’s rear panel or wire your male DB-15 connector so that Pin 11 (Input Common) is jumpered to Pin 12 (Auxiliary DC Power Ground) and Pin 10 (Shutter Open Request) is jumpered to Pin 4 (+5 VDC Auxiliary

Power).

When a Shutter Open Request signal is applied to the laser, it takes approximately 30 ms for the electromechanical shutter to fully open. Although tickle signals are applied to RF circuitry during this interval,

PWM Command signals are inhibited until the shutter is open. When the Shutter Open Request signal is removed from Pin 10, PWM Command signals are inhibited immediately when though the electromechanical shutter takes approximately 120 ms to fully close.

Symptom:

■

Your OEM laser has quit lasing or lasing halted and then restarted. The LASE LED may be Off or On depending on whether PWM Command signals are being applied, but no fault is indicated.

INT LED

TMP LED

RDY LED

SHT LED

LASE LED

– Green

– Green

– Yellow

– Blue

– Off or On

Interlock Open

Fault Detected

Laser Ready

Shutter Open

Laser Active


■ The remote interlock circuit momentarily opened.

– Open

– Open

– Closed

– Closed

– Open or Closed


4

17


Troubleshooting

Remote interlock faults are not latched on OEM lasers. This means that if an interlock open fault occurs, the INT indicator will turn red, the Interlock Open output will Close, the internal shutter automatically closes to block the beam path, the RDY LED turns Off, the SHT LED turns Off (regardless of the state of the Shutter Open Request input), and all DC power is removed from the RF boards.

However, if the interlock circuit closes again, the INT indicator changes from red to green, the Interlock

Open output Opens, the RDY light illuminates, the SHT LED turns On, the internal shutter opens, and five seconds later lasing is enabled.

Web interface

Symptom:

■ DC power is applied, but the Firestar i401 web interface cannot be accessed.


■ The peer-to-peer connection was made using a straight-thru Ethernet cable.

Use an Ethernet crossover cable for a peer-to-peer connection between the Firestar i401 laser and the computer. A straight-thru cable is required if the i401 is connected to your network using a network router or hub.

■ The factory-default IP address was changed.

Firestar i401 lasers are pre-configured at the factory with a fixed IP address of 192.168.90.29. If this address was changed in the field, then you must locate the new IP address, it cannot be remotely reset.

Beam delivery optics

Symptom:

■ The laser loses power over time; laser output power must be increased to maintain performance.


■ Beam delivery optics are coated by vapor residue or debris.


Ensure that DC power to the laser is turned off and locked out before inspecting optical components in the beam path. Invisible CO

2

laser radiation is emitted through the aperture. Corneal damage or blindness may result from exposure to laser radiation.

4



Troubleshooting

Shut down the laser and carefully inspect each optic in the beam delivery path. If the optic requires cleaning, refer back to Maintenance for cleaning instructions. Use only recommended cleaning materials (see

Table 4-1) to prevent scratching delicate optical surfaces. If the focusing optic is pitted, it must be replaced immediately. Because of the extremely high power density of Firestar lasers, pits or debris on the lens surface may absorb enough energy from the focused beam to crack the lens. If this happens, other optics in the beam path may be contaminated or damaged as well.


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 breathing quality air available in cylinders from a welding supply company. Because compressed shop air contains minute particles of oil and other contaminants that will damage optical surfaces, it must be carefully filtered and dried before use as a purge or assist gas. Refer to Table 1-3, Purge gas specifications, in the Getting

Started chapter for filtering and drying specifications.


4

19



4


i401 operator’s manual ®

i401 operator’s manual

®

®

Technical Reference (cont.)

Maintenance/Troubleshooting

Index

List of Figures

List of Tables

Worldwide headquarters

European headquarters

Terms

General hazards

WARNING

Figure 1 Firestar i401 hazard label and CE label locations

Center for Devices and Radiological

Health (CDRH) requirements

Federal Communications Commission (FCC) requirements

European Union (EU) requirements

Table 1

Class 4 safety features

Table 2 European Union Directives

Figure 2 European compliance mark

Declaration of Conformity

ing and work your way through Connecting.

Firestar nomenclature

Model numbers

Incoming inspection

Packaging guidelines

Unpacking the i401 laser

Figure 1-1 Unpacking the i401 laser

Removing the lifting handles

Figure 1-2

Removing the i401 lifting handles

Figure 1-3 Firestar i401 shipping box contents

Table 1-1 Firestar i401 ship kit contents

i401 contents description

Top down mounting

Figure 1-4 Firestar i401 top down mounting locations

Bottom up mounting

Figure 1-5 Firestar i401 bottom up mounting locations

Cooling connections

Table 1-2 Dew point temperatures

Figure 1-6 Firestar i401 cooling connections

48 V power supply connections

Access Panel for

Input Voltage Selection

Figure 1-7 PS-401 voltage selection access panel

Table 1-3

AC three-phase electrical recommendations

Figure 1-8 PS-401 input section

Figure 1-9 DC power connection locations – rear view

Figure 1-10 DC power connection locations – side view

Control connections

Other connections

Figure 1-11 Gas purge kit assembly

Table 1-4 Purge gas specifications

Figure 2-1

Firestar i401 front panel controls and indicators

Figure 2-2 Firestar i401 rear panel controls and indicators

With a UC-2000 Controller

Without a UC-2000 Controller

Laser design

Figure 3-1 Hybrid waveguide/unstable resonator design

Figure 3-2 Firestar i401 beam ellipticity

Figure 3-3 Converting 45° linear polarization to circular polarization

RF power supply

Optical setup

Table 3-1 Assist gas purity specifications

Control signals

Figure 3-4 PWM Command signal waveform

Table 3-2 PWM Command signal specifications

Operating modes

USER I/O

Figure 3-5 User I/O connector pinouts

ETHERNET

User I/O connection summary

Table 3-3 User I/O pin descriptions

Input/output signals

Figure 3-6 Auxiliary power supply wiring