p400 operator`s manual
400
400
p400
operator’s
manual
®
4600 Campus Place
Mukilteo, WA 98275
1.800.SYNRAD1
tel 1.425.349.3500
fax1.425.349.3667
e-mail synrad@synrad.com
web www.synrad.com
Pulstar® p400
Operator’s Manual
Version 1.0
Released June 2015
Part number 900-20966-01
®
4600 Campus Place
Mukilteo, WA 98275
1.800.SYNRAD1
tel 1.425.349.3500
fax1.425.349.3667
e-mail synrad@synrad.com
web www.synrad.com
Table of contents
Introduction
Warranty Information........................................................................................8-9
Worldwide Headquarters...................................................................................10
Laser Safety
1
Hazard information............................................................................................13
Terms..............................................................................................................14
General hazards............................................................................................14
Other hazards................................................................................................15
Disposal..........................................................................................................15
Additional laser safety information............................................................15
Pulstar p400 label locations...............................................................................16
Agency compliance.............................................................................................17
Center for Devices and Radiological Health (CDRH) requirements....18
Federal Communications Commission (FCC) requirements................18
European Union (EU) requirements..........................................................18-21
Pulstar p400 Declaration of Conformity..........................................................22
Getting Started 2
Introduction.........................................................................................................23
Pulstar nomenclature...................................................................................24
Model numbers.............................................................................................24
Unpacking............................................................................................................25
Incoming inspection.....................................................................................25
Packaging guidelines....................................................................................31
Unpacking the p400 laser............................................................................31
Removing the lifting handles......................................................................27
Inventory..............................................................................................................28
p400 contents description............................................................................29
Mounting..............................................................................................................30
Four-point mount with feet.........................................................................30
Four-point mount without feet...................................................................31
Three-point mount without feet.................................................................32
Connecting...........................................................................................................35
Cooling connections....................................................................................37
48 V power supply connections..................................................................38
Control connections.....................................................................................40
Other connections........................................................................................42
Synrad Pulstar p400 operator’s manual ver 1.0
iii
Table of contents
Operation 3
Controls and indicators.......................................................................................... 46
Initial start-up.......................................................................................................... 49
With a UC-2000 Controller............................................................................. 49
Without a UC-2000 Controller....................................................................... 49
Technical Reference 4
Technical overview.................................................................................................. 56
Laser design................................................................................................................................ 56
RF power supply........................................................................................................................ 58
Optical setup.............................................................................................................................. 58
Controlling laser power.......................................................................................... 60
Control signals............................................................................................................................ 60
User I/O connections....................................................................................... 68
User I/O connection summary................................................................................................. 69
Input/output signals................................................................................................................... 71
Sample I/O circuits..................................................................................................................... 77
DC power/DC sense cables.................................................................................... 81
DC power cables......................................................................................................................... 81
DC voltage sense cable............................................................................................................... 81
Pulstar p400 web interface..................................................................................... 82
Accessing the p400 web page.................................................................................................... 82
Home page layout....................................................................................................................... 84
Event log page layout................................................................................................................. 86
Changing the p400’s IP address................................................................................................ 86
Alternate Ethernet connection................................................................................................. 87
Pulstar p400 firmware upgrade............................................................................. 88
Required materials/equipment................................................................................................. 88
Firmware upgrade procedure................................................................................................... 88
Integrating Pulstar safety features ........................................................................ 94
Keyswitch functions................................................................................................................... 94
Shutter functions........................................................................................................................ 94
Remote interlock functions....................................................................................................... 95
Pulstar p400 general specifications....................................................................... 96
Pulstar p400 outline and mounting drawings..................................................... 98
Pulstar p400 packaging instructions..................................................................... 100
Synrad Pulstar p400 operator’s manual ver 1.0
iv
Table of contents
Maintenance/Troubleshooting 5
Maintenance............................................................................................................. 101
Disabling the p400 laser................................................................................... 101
Daily inspections............................................................................................... 101
Storage/shipping............................................................................................... 103
Cleaning optical components.......................................................................... 103
Troubleshooting....................................................................................................... 106
Operational flowchart...................................................................................... 107
Functional block diagram................................................................................ 108
Status LEDs........................................................................................................ 109
Laser fault indications...................................................................................... 112
Web page fault annunciation........................................................................... 117
Web interface..................................................................................................... 117
Beam delivery optics........................................................................................ 120
Index
(List of Figures)
Figure 1-1 Pulstar p400 hazard label and CE label locations......................... 16
Figure 1-2 European compliance mark............................................................. 22
Figure 2-1 Unpacking the p400 laser................................................................. 26
Figure 2-2 Removing the p400 lifting handles................................................. 27
Figure 2-3 Pulstar p400 shipping box contents................................................ 28
Figure 2-4 Mounting locations for four-point mount with feet..................... 31
Figure 2-5 Mounting locations for four-point mount without feet............... 32
Figure 2-6 Mounting locations for three-point mount without feet............. 33
Figure 2-7 Pulstar p400 cooling connections................................................... 37
Figure 2-8 DC power connection locations – rear view.................................. 39
Figure 2-9 DC power connection locations – rear view.................................. 42
Figure 2-10 Gas Purge Assembly– rear view...................................................... 45
Figure 3-1 Pulstar p400 front panel controls and indicators.......................... 47
Figure 3-2 Pulstar p400 rear panel controls and indicators............................ 48
Figure 4-1 Hybrid waveguide/unstable resonator design............................... 56
Figure 4-2 Pulstar p400 beam ellipticity............................................................ 57
Figure 4-3 Converting 45° linear polarization to circular polarization........ 58
Figure 4-4 PWM command signal wave form................................................. 61
Figure 4-5 Representative output energy profile-10% DS-100Hz.................. 62
Figure 4-6 Representative output energy profile-10% DS-1kHz.................... 62
Figure 4-7 Representative output energy profile-20% DS-1kHz....................63
Synrad Pulstar p400 operator’s manual ver 1.0
v
Table of contents
Index
(List of Figures continued)
Figure 4-8 Representative output energy profile-45% DS-1kHz.................... 63
Figure 4-9 Representative output energy profile-45% DS-5kHz.................... 64
Figure 4-10 Representative output energy profile-45% DS-5kHz-50 µs......... 64
Figure 4-11 Representative output energy profile-45% DS-10kHz-500 µs..... 65
Figure 4-12 Representative output energy profile-45% DS-10kHz-50 µs....... 65
Figure 4-13 Representative output energy profile-45% DS-20kHz-500 µs..... 66
Figure 4-14 Representative output energy profile-45% DS-20kHz-50 µs....... 66
Figure 4-15 User I/O connector pinouts............................................................. 68
Figure 4-16 Quick Start Plug wiring diagram..................................................... 71
Figure 4-17 Quick Start Plug wiring diagram..................................................... 73
Figure 4-18 Input equivalent schematic.............................................................. 74
Figure 4-19 Output equivalent schematic........................................................... 76
Figure 4-20 Customer-supplied interlock........................................................... 77
Figure 4-21 Customer-supplied interlock, negative voltage....................................77
Figure 4-22 PLC driven interlock signal.............................................................. 78
Figure 4-23 Multiple PLC driven inputs.............................................................. 78
Figure 4-24 Pulstar output driving warning lamp............................................. 79
Figure 4-25 Pulstar output driving relay............................................................. 79
Figure 4-26 Pulstar output driving PLC input module..................................... 80
Figure 4-27 Pulstar p400 home page.................................................................... 84
Figure 4-28 Pulstar p400 event log page ............................................................. 86
Figure 4-29 Pulstar p400 Change IP Address page............................................ 87
Figure 4-30 Windows Control Panel.................................................................... 89
Figure 4-31 Programs and Features dialog.......................................................... 89
Figure 4-32 Windows Features dialog................................................................. 89
Figure 4-33 Local Area Connection Properties dialog...................................... 90
Figure 4-34 Internet Protocol (TCP/IP) Properties dialog............................... 91
Figure 4-35 Configure IP Address link on Pulstar p400 home page............... 92
Figure 4-36 Pulstar p400 change IP address page.............................................. 92
Figure 4-37 Pulstar p400 web browser display................................................... 93
Figure 4-38 Pulstar p400 outline & mounting dimensions............................... 98
Synrad Pulstar p400 operator’s manual ver 1.0
vi
Table of contents
Index
(List of Figures continued)
Figure 4-39 Pulstar p400 outline & mounting dimensions (no feet)............... 99
Figure 4-40 Pulstar p400 packaging instructions............................................... 100
Figure 5-1 Pulstar p400 operational flowchart................................................. 107
Figure 5-2 Pulstar p400 functional block diagram.......................................... 108
Figure 5-3 Status signals for Normal Operation Idle....................................... 110
Figure 5-4 Status signals for Normal Operation Lasing.................................. 110
Figure 5-5 Status signals for a Remote Interlock Fault.................................... 110
Figure 5-6 Status signals for a shutter closed condition.................................. 111
Figure 5-7 Status signals for a disconnected I/O fault..................................... 111
Figure 5-8 Status signal for a temperature Fault............................................... 112
Figure 5-9 Blinking Ready LED Fault................................................................ 113
Figure 5-10 Blinking Shutter LED Fault.................................................................. 115
Figure 5-11 Java script enabling............................................................................ 115
Figure 5-12 Adding IP address............................................................................. 119
Index
(List of Tables)
Table 1-1
Table 1-2
Table 2-1
Table 2-2
Table 2-3
Class 4 safety features........................................................................ 20
European Union Directives.............................................................. 21
Pulstar p400 ship kit contents.......................................................... 28
Dew point temperature..................................................................... 36
Gas Purge Specifications................................................................... 42
Table 4-1
Table 4-2
Table 4-3
Table 4-4
Table 4-5
Table 4-6
Assist gas purity specifications........................................................ 59
PWM Command signal specifications........................................... 67
User I/O pin descriptions................................................................. 69
Input circuit specifications............................................................... 74
Output circuit specifications............................................................ 76
Pulstar p400 general specifications................................................. 96
Table 5-1
Table 5-2
Table 5-3
Required cleaning materials............................................................. 104
Pulstar Output & LED Status Signals............................................. 109
Pulstar p400 laser fault codes........................................................... 113-115
Synrad Pulstar p400 operator’s manual ver 1.0
vii
Warranty section
Trademark/copyright information
SYNRAD and Pulstar are registered trademarks of SYNRAD, Inc.
All other trademarks or registered trademarks are the property of their respective owners.
© 2013 by SYNRAD, Inc.
All rights reserved.
Synrad p400 operator’s manual ver 1.0
8
Warranty section
This is to certify that Pulstar® p400 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. This includes, but is not limited to, damage due to corrosion, condensation, or failing to supply properly conditioned purge
gas.
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 Pulstar p400 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 Pulstar p400 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 Pulstar p400 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.
Synrad p400 operator’s manual ver 1.0
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Warranty section
Worldwide headquarters
SYNRAD’s worldwide headquarters are located north of Seattle in Mukilteo, Washington, U.S.A. Our mailing address is:
SYNRAD, Inc.
4600 Campus Place
Mukilteo, WA 98275
U.S.A.
Phone us at:
Outside the U.S.:
Fax:
E-mail:
1.800.SYNRAD1 (1.800.796.7231)
+1.425.349.3500
+1.425.349.3667
synrad@synrad.com
Sales and Applications
SYNRAD’s Regional Sales Managers work with customers to identify and develop the best CO2 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 support@synrad.com or to support@winmark.com.
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 GSI Europe
Münchener Straße 2A
82152 Planegg, Deutchland
Phone:
+49 (0) 89 31 707-0
Fax:
+49 (0) 89 31 707-222
E-mail:info.gsig-europe@gsig.com
Synrad p400 operator’s manual ver 1.0
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Warranty section
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Synrad p400 operator’s manual ver 1.0
11
Laser Safety
1
Information presented in this chapter is the safety information that you will need to know prior to
getting started.
This chapter contains the following information:
Hazard Information – includes equipment label terms and hazards, please familiarize yourself
with all definitions and their significance.
General & Other Hazards – provides important information about the hazards and unsafe
practices that could result in death, severe injury, or product damage.
Disposal – contains information on your p400 laser parts and/or components as they pertain
to disposal.
Additional Safety Information – describes how to find additional information about your
p400 laser.
Compliance – explains in the subsections therein applicable and appropriate regulation information.
Synrad p400 operator’s manual version 1.0
12
Laser Safety
Hazard Information
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.
Imminent hazards which, if not avoided, will result in death or serious injury.
Potential hazards which, if not avoided, could result in death or serious injury.
Alerts the operator of
Alerts the operator of
hazardous radiation.
serious dangers.
Alerts the operator of
Alerts the operator of
vapor dangers.
dangerous voltages.
Potential hazards or unsafe practices which, if not avoided, may result in minor or mod-
erate injury.
Alerts the operator of
Two
Person Lift
lifting dangers.
Potential hazards or unsafe practices which, if not avoided, may result in product dam
age.
Alerts the operator of
equipment dangers.
Important information or recommendations concerning the subject under discussion.
Note
Note: Points of particular interest are for more efficient or convenient equipment operation; additional information or explanation concerning the subject can be found under the discussion that follows.
Warning
Serious
personal
injury
For laser systems being used or sold within the U.S.A., customers should
refer to and follow the laser safety precautions described in the American
National Standards Institute (ANSI) document Z136.1-2007, Safe Use of
Lasers.
For laser systems being used or sold outside the U.S.A., customers should
refer to and follow the laser safety precautions described in
European Normative and International Electrotechnical Commission
documents EN 60825-1:2007, Safety of Laser Products – Part 1: Equipment Classification and Requirements and IEC/TR 60825-14:2004, Safety
of Laser Products – Part 14: A User’s Guide.
Synrad p400 operator’s manual version 1.0
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Laser Safety
Hazard Information
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 CO2 wavelength band.
Do not allow laser radiation to enter the eye by viewing direct or reflected laser energy. CO2 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 CO2 radiation when in the same area as an exposed laser beam.
Eye wear 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
CO2 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.
Warning
Serious
personal
injury
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.
Warning
Serious
personal
injury
The use of aerosol dusters containing difluoroethane 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
difluoroethane in any area adjacent to CO2 laser systems because difluoroethane persists for long time periods over wide areas.
Another excellent laser safety resource is the Laser Institute of America (LIA). Their comprehensive web site is located at http://www.laserinstitute.org.
Synrad p400 operator’s manual version 1.0
14
Laser Safety
Hazard Information
Pulstar® p400 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 or IEC/TR 60825-14:2004 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 CO2 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.
Synrad p400 operator’s manual version 1.0
15
Laser Safety
Agency Compliance
Pulstar p400 label locations
CAUTION
INVISIBLE LASER RADIATION
AVOID EYE OR SKIN EXPOSURE TO
DIRECT OR SCATTERED RADIATION
CLASS 4 LASER PRODUCT
CONDENSATION AND
WATER DAMAGE CAN
OCCUR IF COOLING WATER
IS BELOW DEW POINT.
SEE OPERATION MANUAL.
CAUTION
CONDENSATION AND
WATER DAMAGE CAN
OCCUR IF COOLING WATER
IS BELOW DEW POINT.
SEE OPERATION MANUAL.
EN-60825-1, 2007
1400 WATTS MAX
10200-10800 nm
INVISIBLE LASER RADIATION
AVOID EYE OR SKIN EXPOSURE TO
DIRECT OR SCATTERED RADIATION
CLASS 4 LASER PRODUCT
Top
MODEL #: FSi401SB
SERIAL #: i40121411000
TESTED AT: 48V
MFG: Aug 02, 2011
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.
This laser component does not comply with standards for complete
laser products as specified by 21 CFR 1040.10 or IEC 60825-1.
If a fault occurs, remove DC power from the laser,
wait 30 seconds, and then re-apply DC power.
SYNRAD, Inc. 4600 Campus Place, Mukilteo WA 98275 425.349.3500
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.
OEM version
MODEL #: PSP400SH
SERIAL #: p4007551234
TESTED AT: 48V
MFG: 2015
1400 WATTS MAX
10200-10800 nm
This laser component does not comply with standards for complete
laser products as specified by 21 CFR 1040.10 or IEC 60825-1.
EN-60825-1, 2007
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.
Front
Rear
WARNING
Do not remove water fittings!
Do not lift or pull on water fittings!
AVOID EXPOSURE
Invisible laser radiation
is emitted from
this aperture.
This may cause misalignment or water leaks.
If a water leak is discovered, please contact
Synrad customer service immediately.
WARNING
This laser product is manufactured under
one or more of the following U.S. Patents:
5,602,865 6,195,379 6,198,758 6,198,759
6,603,794 6,614,826 7,480,323
Other U.S. and International Patents pending.
Lifting handles removed for clarity
AVOID EXPOSURE
Invisible laser radiation
is emitted from
this aperture.
Figure 1-1 Pulstar p400 hazard label locations.
Synrad p400 operator’s manual version 1.0
16
Do not remove water fittings!
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.
This laser product is manufactured under
one or more of the following U.S. Patents:
5,602,865 6,195,379 6,198,758 6,198,759
6,603,794 6,614,826 7,480,323
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 Pulstar p400 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 Pulstar p400 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 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 p400 lasers, the
type and description of the feature, and if the feature is required by CDRH regulations.
OEM models
Pulstar p400 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
Synrad p400 operator’s manual version 1.0
17
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 Pulstar p400 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 Pulstar p400 lasers.
System Maintenance
Ensure that all exterior covers are properly fastened in position.
Measures to Correct Interference
If you suspect that your Pulstar 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 Pulstar 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 Pulstar p400 lasers meet the requirements of the European Parliament and Council
Directive 2011/65/EU on the Restriction of the Use of Certain Hazardous Substances in Electrical
and Electronic Equipment that establishes maximum concentration values for certain hazardous
substances in electrical and electronic equipment.
Synrad p400 operator’s manual version 1.0
18
Laser Safety
Agency Compliance
Laser safety standards
Under the Low Voltage Directive, 2006/95/EC, the European Norm (EN) document EN 608251:2007 was developed to provide laser safety guidance and includes clauses on Engineering Specifications, Labeling, Other Informational Requirements, Additional Requirements for Specific
Laser Products, Classification, and Determination of the Accessible Emission Level. To develop
a risk assessment plan/laser safety program for users, see IEC/TR 60825-14:2004 that includes
clauses on Administrative Policies, Laser Radiation Hazards, Determining the MPE, Associated
Hazards, Evaluating Risk, Control Measures, Maintenance of Safe Operation, Incident Reporting
and Accident Investigation, and Medical Surveillance.
OEM models
Pulstar p400 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, EN 2006/42/
EC; and/or any other applicable Standards and in cases where the system is being imported into the U.S., it must also comply with CDRH regulations.
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. Table 1, Class 4 safety features, summarizes Pulstar p400 product features, indicating the type and description of features and whether those features
are required by European Union regulations.
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 Pulstar p400 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 Pulstar p400 lasers have demonstrated performance characteristics that have met or
exceeded the requirements of EMC Directive 2004/108/EC.
Synrad p400 operator’s manual version 1.0
19
Laser Safety
Agency Compliance
Table 1-1 Class 4 safety features.
Required by:
Available on:
Feature
Location / Description
CDRH
EN60825-1 OEM p400
Keyswitch1
Rear panel control Yes Yes No
Shutter function
Laser control Yes Yes Yes
Shutter
indicator
Ready
indicator
Rear panel indicator (Blue) No No Yes
Lase
indicator
Rear panel indicator (Red) No No Yes
Five second
delay
Pulstar circuit element Yes No Yes
Power fail
lockout1 Pulstar circuit element Yes Yes No
Remote
Interlock Rear panel connection Yes Yes Yes
On/Off/Reset Keyswitch controls power to laser electronics.
Key cannot be removed from switch in the “On” position.
Functions as a beam attenuator to disable RF driver/
laser output when closed.
Illuminates blue to indicate shutter is open.
Rear panel indicator (Yellow) Yes Yes Yes
Indicates that laser has power applied and is capable
of lasing.
Indicates that Pulstar is actively lasing. Lase LED
illuminates when the duty cycle of the Command signal
is long enough to produce laser output.
Disables RF driver/laser output for five seconds after
Keyswitch is turned to “On” or remote reset/start pulse is
applied when Keyswitch is in “On” position.
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.
Disables RF driver/laser output when a remote interlock
switch on an equipment door or panel is opened.
Remote
Rear panel indicator (Green/Red) No No Yes
Interlock Illuminates green when Remote Interlock circuitry is closed.
indicator
Illuminates red when interlock circuitry is open.
Over Pulstar circuit element No No Yes
temperature Temperature shutdown occurs if temperature of the laser
protection
tube rises above safe operating limits.
Temp Rear panel indicator (Green/Red) No No Yes
indicator
Illuminates green when laser temperature is within
operating limits, changing to red when thermal limits
are exceeded.
Warning
labels Pulstar exteriorYes Yes Yes
Labels attached to various external housing locations to
warn personnel of potential laser hazards.
1 Not available on p400 OEM lasers
Synrad p400 operator’s manual version 1.0
20
Laser Safety
Agency Compliance
When integrating SYNRAD’s Pulstar p400 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 Pulstar p400 lasers comply
with the relevant requirements of 2004/108/EC, the Electromagnetic Compatibility Directive, as
summarized in Table 2 below.
Table 1-2 European Union Directives.
Applicable Standards / Norms
2004/108/EC
Electromagnetic Compatibility Directive
2006/95/EC Low Voltage Directive
2011/65/EU
RoHS Directive
EN 61010-1:2001
Safety Requirements for Electrical Equipment for Measurement, Control, and Laboratory Use - Part 1: General Requirements
EN 61000-6-4:2007
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
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 a Declaration of
Conformity.
Synrad p400 operator’s manual version 1.0
21
Laser Safety
Agency Compliance
Declaration of Conformity
in accordance with ISO / IEC 17050-2:2004
900-20976-05 Rev A (ECO 5210)
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:
Pulstar p400 Laser
Model Number:
PSp400SH
(OEM*)
conforms to the following Directive(s) and Standard(s):
Applicable Directive(s):
2004/108/EC
2006/95/EC
2011/65/EU
Electromagnetic Compatibility Directive
Low Voltage Directive
RoHS Directive
Applicable Standard(s):
EN 61010-1:2001
Safety Requirements for Electrical Equipment
for Measurement, Control, and Laboratory
Use - Part 1: General Requirements
EN 61000-6-4:2007
Radiated Emissions, Group 1, Class A
EN 61000-6-4:2007
Conducted Emissions, Group 1, Class A
EN 61000-6-2:2005
Electrostatic Discharge Immunity
EN 61000-6-2:2005
RF Electromagnetic Field Immunity
EN 61000-6-2:2005
Electrical Fast Transient/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:
European Contact:
Pedro Landers, R & D Manager of SYNRAD, Inc.
Synrad Europe
Münchener Straße 2A
D-82152 Planegg
Germany
Dated 25 June 2015
Figure 1-2 EU Compliance mark.
Synrad p400 operator’s manual version 1.0
22
Getting Started
2
Use information in this chapter to prepare your Pulstar p400 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 Unpacking and work your
way through Connecting.
This chapter contains the following information:
Introduction – introduces the Pulstar p400 laser, lists important features, and describes Pulstar nomenclature.
Unpacking – provides important information about unpacking your Pulstar p400 laser.
Inventory – displays and describes all components shipped with your p400 laser.
Mounting – describes how to attach your p400 laser to a mounting surface.
Connecting – explains how to connect cooling tubing, power, and control cabling.
Synrad p400 operator’s manual ver 1.0
23
Getting Started
Introduction
The Introduction section includes subsections:
Pulstar nomenclature.
Model numbers.
The Pulstar® p400 laser is a new addition to SYNRAD’s Pulstar 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.
Pulstar p400 features include:
Optional Built-in electromechanical (EM)shutter.
Built-in gas purge port.
TCP/IP web-based Internet interface.
Color-coded LEDs mirror user out
put status.
Field-replaceable integrated RF modules. “Industrial-strength” ±5 V to 24 VDC I/O.
Built-in internal humidity sensor. Beam output pre-aligned to within ±1.0 mm.
Duty cycles from < 1% to 50% (CW). Low 6 kW heat load.
Pulstar nomenclature
Pulstar 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.
Pulstar p400 lasers are currently available only as OEM lasers; however, they do include an EM shutter assembly.
Model numbers
The last three characters in the Pulstar 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 p400 lasers since they are all water-cooled lasers).
The last letter in the model number indicates the current model version beginning with “B”.
Synrad p400 operator’s manual ver 1.0
24
Getting Started
Unpacking
The Unpacking section includes subsections:
Incoming inspection.
Packaging guidelines.
Unpacking the p400.
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
Two
Person Lift
Possible
personal
Lifting or moving the Pulstar p400 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.
injury
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 p400
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.
Pulstar p400 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.
Synrad p400operator’s manual ver 1.0
25
Getting Started
Unpacking
Unpacking the p400 laser
To unbox the p400 laser, refer to Figure 2-1 and perform the following steps:
Note: The numbered items in Figure 2-1 correspond to the step numbers in the following procedure.
1
2
E
IL
G
A
FR
IS
VE
SA
X
BO
TH
E
IL
AG
FR
FR
A
G
IL
E
3
4
4
4
Figure 2-1 Unpacking the p400 laser.
1
Carefully cut the shipping straps wrapped around the shipping container.
2
Remove the upper lid and set it aside.
3
Remove the top front and top rear foam inserts. To remove the center insert, first slide it forward several inches, to clear the notches in the lower foam insert, and then lift.
Synrad p400 operator’s manual ver 1.0
26
Getting Started
Unpacking
4
Carefully lift or hoist the p400 laser out of the container using the three lifting handles. To prevent injury to
personnel or damage to the laser, always use a minimum of two people to handle the p400 laser.
Note: Do not lift or support the p400 laser using the cooling fittings. Lift the laser by the lifting handles or baseplate only.
5
After removing the laser, pull out all accessory items and paperwork packaged below the laser in the shipping
container.
6
Save the shipping container and foam inserts. Use these specialized packaging materials when shipping and/or
moving the laser to another location.
Removing the lifting handles
Once you have placed the p400 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 two handles as shown in Figure 2-2.
Don’t forget to repeat the process for the handle in the back.
2
+ 48 VDCcapscrews
Power
Save the lifting handles and
so the handles can be reinstalled if the p400 is moved to another location.
- VDC Ground
Capscrew location 3 of 3 is located on the back of the laser.
Capscrew location 2 of 3.
Capscrew location 1 of 3.
Figure 2-2 Removing the p400 lifting handles.
Synrad p400operator’s manual ver 1.0
27
Getting Started
Inventory
SYNRAD CO2
Laser's Manual CD
Quick Start Plug
synrad
co 2 laser
manuals
P/N
90
0-2
0
33 6
-
01
© 20
11
, In c. A ll righ ts reserved
SYNR AD
Ethernet Crossover
Cable
1/2” Tubing Fittings
BNC Control Cable
Mounting Hardware
Kit
Gas Purge Kit
12 mm Cooling Tubing
DC Power Cables
Pulstar p400 Laser
Figure 2-3 Pulstar p400 shipping box contents.
Table 2-1 Pulstar p400 ship kit contents.
Shipping Box Contents
Qty
Qty
Pulstar p400 400 W Laser..........................1
Quick Start Plug ......................................... 1
SYNRAD CO2 Lasers Manual CD............1
Mounting Hardware Kit ........................... 4
Ethernet Crossover Cable...........................1
Gas Purge Kit.............................................. 1
BNC Control Cable ....................................1
Spare Fuses (not shown)............................ 4
12 mm Cooling Tubing...............................1
Final Test Report (not shown).................. 1
DC Power Cables ........................................1
Synrad p400 operator’s manual ver 1.0
28
Shipping Box Contents
Getting Started
Inventory
p400 contents description
Each item listed in Table 2-1 is described below:
Pulstar p400 400 W Laser – The Pulstar p400 laser is a compact, single tube 400 W laser producing near-perfect beam
quality with rise times < 50 µs and fall times < 100 µs and a PWM duty cycle range from 1% up to 50% (full power
operation).
SYNRAD CO2 Lasers Manual CD – contains a Pulstar p400 manual that provides setup, operation, and maintenance
information for your p400 laser.
Ethernet Crossover Cable – provides the communications link between a host and the laser for accessing operating
parameters via a TCP/IP web-based interface.
BNC Control Cable – Coaxial cable carries the PWM Command signal from the UC-2000 Controller to the laser’s
Quick Start Plug.
12 mm Cooling Tubing – carries cooling water from the chiller to the laser and back. This clear polyethylene tubing is
12 mm 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 p400 laser. Standard cable length is 2.0
meters (6.5 feet) while optional 5.0 m (16 ft) power cables are available.
Quick Start Plug – connects to Pulstar’s User I/O connector. Jumpers are built into the plug to enable Pulstar’s interlock circuits for initial start-up and testing.
Mounting Hardware Kit – fasten Pulstar to your mounting surface. Four each M10 × 1.5 × 35 mm capscrews and
M10 washers are provided for mounting the Pulstar p400 laser.
Gas Purge Kit – provides a filtering and connection point to the laser from your facility’s purge gas system.
Spare Fuses (not shown) – 50 ampere fast-blow fuses protects Pulstar’s internal RF circuitry.
Final Test Report (not shown) – contains data collected during the laser’s final pre-shipment test.
Synrad p400operator’s manual ver 1.0
29
Getting Started
Mounting
The Mounting section includes subsections:
Four-point mount with feet.
Four-point mount without feet.
Three-point mount without feet.
The Pulstar p400 baseplate is designed so that the laser is easily mounted in various configurations as described in the
subsections below. Refer to the Pulstar p400 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 “head-down” 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.
Four-point mount with feet
Use this scheme to mount the laser to a horizontal or vertical surface (or to a surface that will move dynamically in
multiple axes) using the factory-installed mounting feet. To use a four-point mount, the variation in mounting surface flatness must not exceed 1.02 mm (0.040").
To install a Pulstar p400 (with feet) using the four-point mounting method, perform the following steps:
1
Determine whether you will use metric (ISO) or inch (SAE) fasteners to mount the laser. Four M10 (metric)
capscrews and M10 flat/split washers are included in the ship kit.
2
Refer to the p400 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 2-4.
Note: Each mounting foot also contains a 9.65 mm (0.380") dowel pin guide (labeled “B” in Figure 2-4) for applications that require precision positioning for alignment purposes.
Synrad p400 operator’s manual ver 1.0
30
Getting Started
Mounting
A
B
p400 Top View
A
A
B
A
Figure 2-4 Mounting locations for four-point mount with feet.
3
Carefully place the p400 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).
Note: After the laser is fastened into position, remove the lifting handles if necessary.
Four-point mount without feet
Use this scheme to mount the laser to a horizontal or vertical surface (or to a surface that will move dynamically in
multiple axes) by fastening directly into the laser’s baseplate. To use a four-point mount, the variation in mounting
surface flatness must not exceed 1.02 mm (0.040").
To install a Pulstar p400 (without feet) using the four-point mounting method, perform the following steps:
Caution
Possible
equipment
damage
When removing the mounting feet, raise the laser by placing support blocks
under the baseplate. Do not lay or place the p400 laser on its side or top,
even temporarily, because the sheet-metal covers are not designed to support the weight of the laser. Always support and mount the laser using the
mounting feet or baseplate to avoid damaging the laser.
1
Raise the p400 laser and place support blocks under the baseplate.
2
Unscrew the four M10 capscrews fastening the feet to the bottom of the p400 laser and remove the factory-installed mounting feet.
Synrad p400operator’s manual ver 1.0
31
Getting Started
Mounting
3
Refer to the p400 outline and mounting drawing (Sheet 2 of 2) for dimensions, then drill four 10.6 mm (close
fit) or 11.2 mm (normal fit) through holes in your mounting surface. These holes should correspond with the
fastener locations labeled “C” shown in Figure 2-5.
Note: The p400 baseplate contains two 6.40 mm × 12.70 mm (0.252" × 0.500") dowel pin slots (labeled “D” in
Figure 2-5) and a 6.40 mm (0.252") dowel pin hole for applications that require precision positioning of the
laser.
p400 Bottom View
C
C
C
C
Figure 2-5 Mounting locations for four-point mount without feet.
4
Carefully place the p400 laser on the mounting surface so the M10 threaded holes in the baseplate line up over
the through holes in the mounting surface.
Important Note:
Verify the correct fastener length for your mounting application. The M10 × 1.5 × 35 mm
capscrews the ship kit are for use with the factory-installed mounting feet. When fastening
the p400 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.
5
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.
6
Evenly tighten all four fasteners to a torque of 40 N m (29 ft lb).
Three-point mount without feet
Use this scheme to mount the laser to a static horizontal surface only by fastening directly into the laser’s baseplate. A
three-point mount is required when the variation in mounting surface flatness exceeds 1.02 mm (0.040").
To install an p400 (without feet) using the three-point mounting method, perform the following steps:
1
Raise the p400 laser and place support blocks under the baseplate.
2
Unscrew the four M10 capscrews fastening the feet to the bottom of the p400 laser and remove the factory-installed mounting feet.
Synrad p400 operator’s manual ver 1.0
32
Getting Started
Mounting
Important Note:
3
The single rear fastener must be located at position “E” shown in the bottom view illustration
in Figure 1-6. This mounting point is designed to accommodate the full load of the laser without distorting the chassis.
Refer to the p400 outline and mounting drawing (Sheet 2 of 2) for dimensions, then drill three 10.6 mm (close
fit) or 11.2 mm (normal fit) through holes in your mounting surface. These holes should correspond with the
fastener locations labeled “E” shown in Figure 2-6.
Caution
Possible
equipment
damage
When removing the mounting feet, raise the laser by placing support blocks
under the baseplate. Do not lay or place the p400 laser on its side or top,
even temporarily, because the sheet-metal covers are not designed to support the weight of the laser. Always support and mount the laser using the
mounting feet or baseplate to avoid damaging the laser.
Note: The p400 baseplate contains two 6.40 mm × 12.70 mm (0.252" × 0.500") dowel pin slots (labeled “F” in
Figure 2-6) and a 6.40 mm (0.252") dowel pin hole for applications that require precision positioning of the
laser.
4
Carefully place the p400 laser on the mounting surface so the M10 threaded holes in the baseplate line up over
the through holes in the mounting surface.
Important Note:
Verify the correct fastener length for your mounting application. The M10 × 1.5 × 35 mm
capscrews the ship kit are for use with the factory-installed mounting feet. When fastening
the p400 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.
E
F
F
E
Figure 2-6 Mounting locations for three-point mount without feet.
5
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.
6
Evenly tighten all three fasteners to a torque of 40 N m (29 ft lb).
Synrad p400operator’s manual ver 1.0
33
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 (0.50") from its end before reconnecting. Trimming the
end of the tubing provides an undisturbed sealing surface inside the fitting.
Cooling fitting adapters
Pulstar p400 cooling fittings are designed to accept 12 mm polyethylene tubing. If your integrated system uses 1/2
inch cooling tubing, we recommend installing tubing adapters to convert the laser’s 12-mm tubing to 1/2-inch
tubing. This type of adaptor is available from McMaster-Carr (P/N 51495K416). Alternatively, you can purchase TRI
THREAD fittings from Pneuforce.com and replace the factory-installed 12 mm fittings with 1/2 inch tubing fittings.
Pneuforce P/N PC1/2-U03 is a suitable straight 1/2 inch tubing connector while P/N PL12-U03 is a 1/2 inch 90°
swivel elbow connector.
Chiller preparation guidelines
You must provide fittings to adapt the laser’s 12 mm O.D. polyethylene cooling tubing to the chiller’s Inlet and
Outlet ports. These fittings can be either “quick disconnect” or compression type fittings.
Because Pulstar’s cooling fittings and tubing are metric (12 mm), do not use 1/2 inch size tubing or fittings unless
you have installed the appropriate adapters. Mixing inch and metric tubing/fittings will lead to coolant leaks or
may allow the pressurized tubing to blow off the fitting.
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Coolants
SYNRAD recommends the laser’s cooling fluid contain at least 90% distilled water 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 set point is 18 °C (64 °F) so glycol is not necessary unless the chiller is subjected to
freezing temperatures. If tap water is used, chloride levels should not exceed a concentration of 25 parts per million
(PPM) and total hardness should be below 100 PPM. Install a filter on the chiller’s return line and inspect frequently.
Pulstar p400 lasers incorporate the following wetted materials in the coolant path—brass, copper, Delrin®, PBT, polyethylene, stainless steel, and Viton®.
Note: DO NOT use de-ionized (DI) water as a coolant. DI water is unusually corrosive and is not recommended
for mixed material cooling systems.
Setting coolant temperature
Choosing the correct coolant temperature is important to the proper operation and longevity of your laser. When
coolant temperature is lower than the dew 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 set point 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.
Increase coolant flow by an additional 3.8 liters per minute (1.0 GPM). Do not exceed a coolant pressure of 414
kPa (60 PSI).
Refer to Table 2-2 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).
Caution
Possible
equipment
damage
The Pneuforce.com TRI THREAD fittings used on p400 lasers are designed
to seal on the face of the O-ring, which allows them to seal properly even
when re-used. When replacing TRI THREAD fittings, turn the fitting by
hand until the O-ring touches the face of the cooling manifold and then use
a wrench to tighten the fitting an additional 1/4 turn clockwise.
DO NOT over-tighten TRI THREAD fittings and DO NOT install any other
type of fitting into the p400 cooling manifold.
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Getting Started
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Table 2-2 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).
Table 2-2 Dew point temperatures.
Dew Point Temperature Chart °F (°C)
Relative Humidity (%)
20253035404550556065707580859095
Air Temp
°F (°C)
60 (16)
———32363941444648 505254555759
(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
(1) (3) (4) (6) (8) (9) (11)(12)(13)(14)(15)(16)(17)(18)
64
70 (21)
—
33 37 41 45 48
51 53 56 58 60 62 64 65 67
(1) (3) (5) (7) (9) (11)(12)(13)(14)(16)(17)(18)(18)(19)(21)
69
75 (24)
—
37 42 46 49
52 55 58 60 62 65 67 68 70 72
(3) (6) (8) (9) (11)(13)(14)(16)(17)(18)(19)(20)(21)(22)(23)
73
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)
—
Caution
Possible
equipment
damage
Operating the laser at coolant temperatures above 22 °C (72 °F) may result
in decreased performance and/or premature failure of electronic components.
Synrad p400 operator’s manual ver 1.0
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Getting Started
Connecting
To use Table 2-2, 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 set point 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
set point to 72 °F (22 °C) to prevent condensation from forming inside the laser.
Cooling tubing connections
To connect cooling tubing to your p400 laser, refer to Figure 2-7 and perform the following steps.
To Chiller
3
From Chiller
2
Figure 2-7 Pulstar p400 cooling connections.
1
Locate the 12 mm clear polyethylene cooling tubing in the p400 ship kit.
Note: The Pulstar p400 laser is equipped with fittings for 12 mm tubing. If other equipment in your system uses
1/2 inch O.D. cooling tubing, you must install 12 mm to 1/2 inch tubing adaptors between the laser and
other equipment in your processing system.
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 p400 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.
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Getting Started
Connecting
Caution
Possible
equipment
damage
Inlet cooling water temperature must always be maintained above the dew
point to prevent condensation and water damage to your Pulstar laser.
4
Turn on the chiller and adjust the temperature set point to 18 °C to 22 °C. Regulate coolant flow to 15.1 liters
per minute (4.0 GPM) at less than 414 kPa (60 PSI) of pressure.
5
Closely examine all cooling connections and verify that there are no leaks.
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 DC return from the machinery’s chassis ground.
Pulstar p400 lasers require a DC power source capable of supplying a minimum of 150A and 1 rms at 48 VDC. A
supply with remote sense capability that can compensate for a minimum load lead loss (round trip) of 1.0 V is highly
recommended. We recommend the SYNRAD PS-p400 DC power supply, which can provide a pulsed current at 48
VDC and a default AC range. Please refer to the PS-p400 supply manual.
DC power supply cable
To connect the DC power cable to your p400, refer to Figure 2-8 and perform the following steps.
Laser connections
Important Note: If using a power supply other than the recommended PS-p400, and you have a
manufactured DC voltage sense cable to match the power supply’s DC voltage
sense connections, attach the sense cable to the laser as described in the following
steps.
1
Locate the DC power cable in the p400 PS-p400 ship kit. If using, also locate the DC voltage sense
cable.
2
Remove the two 6–32 capscrews and acrylic shield covering the +48 VDC POWER terminal block
on the rear of the laser.
3
Remove the M10 bolt, flat washer, and external star washer from the +48 VDC POWER terminal
block.
4
Remove the M4 capscrew from the end of the –VDC GND terminal on the rear of the laser and
then remove the M10 hex nut, flat washer, and external star washer.
Synrad p400 operator’s manual ver 1.0
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Getting Started
Connecting
Place the DC power sense
cables here if using your
own power source.
+ 48 VDC Power
- VDC Ground
Place the DC
sense cables here if
using.
Figure 2-8 DC power connection locations – rear view.
Caution
Possible
equipment
damage
Do not reverse polarity when connecting the DC power cable to your DC
power source. Reversed DC polarity may damage the laser’s internal RF
power supply. Carefully follow the directions below to ensure the DC power
cable is properly connected to the correct DC output terminals.
5
Slide the black (negative) DC power cable over the –VDC GND terminal followed by the M10
external star washer, flat washer, and hex nut (see Figure 2-9).
6
Tighten the M10 hex nut to a torque of 34 N m (15 ft lb) maximum using two wrenches. While
tightening the outer nut, hold the inner nut, the one against the laser’s rear plate, so that it does not
move.
7
Place the black (negative) DC sense lead to the end of the –VDC GND terminal with the M4 capscrew and flat washer. Carefully tighten the capscrew to a torque value of 1.8 N m (16 in lb).
Note: Do not overtighten the M10 fastener into +48 VDC POWER terminal on the laser because this
may damage the threads.
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Getting Started
Connecting
8
Fasten the red (positive) DC power cable and red DC sense lead to the +48 VDC POWER terminal
on the rear of the laser using the M10 bolt, flat washer, and star washer as shown in Figure 2-9.
Carefully tighten the M10 bolt to a torque of 7.4 N m (65 ft lb) maximum.
9
Replace the acrylic cover on the +48 VDC POWER terminal block and fasten it in place using two
6–32 capscrews.
DC power supply connections
Note: If you are not using a PS-p400 DC supply, we highly recommend installing a DC power supply
with remote sense capability that can compensate for a minimum load lead loss (round trip) of
1.0 V.
1
Verify that input AC voltage to the DC power supply is physically locked out or disconnected.
2
Attach the black (negative) DC power cable to the –VDC Ground Bus Bar on the PS-p400 power
supply using M6 (or 1/4 inch) fasteners (Figure 2-8).
3
Attach the red (positive) DC power cable to the +48 VDC Output Bus Bar on the PS-p400 power
supply using M6 (or 1/4 inch) fasteners.
If using a DC power supply other than the recommended PS-p400, connect the DC power cables
per the manufacturer’s recommendations.
Control connections
All control connections to Pulstar p400 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.
Warning
Serious
personal
injury
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.
Synrad p400 operator’s manual ver 1.0
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Getting Started
Connecting
Quick Start Plug
In order for your Pulstar p400 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 Pulstar 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 Pulstar laser.
Caution
Possible
equipment
damage
Turn off DC power before installing or removing any plug or cable from the
User I/O connector. Ensure that user connections are made to the appropriate pins and that the appropriate signal levels are applied. Failure to do so
may damage the laser.
For further information about using 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 Pulstar safety features, also in the Technical
Reference chapter, for detailed instructions on integrating Pulstar’s keyswitch, shutter, and remote interlock functions
with automated control systems.
Synrad p400operator’s manual ver 1.0
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Getting Started
Connecting
UC-2000 Universal Laser Controller
Note: Except for bench testing, we do not recommend using a UC-2000 Controller with the Pulstar p400 laser.
The tickle signal from the UC-2000 may interfere with pulsing performance of the laser.
Warning
Serious
personal
injury
Always use shielded cable when connecting your PWM Command signal
source to PWM Input/PWM Return inputs. In electrically-noisy environments, long lengths of unshielded wire act like an antenna and may generate
enough voltage to trigger uncommanded lasing.
PWM or pulse signal source
To connect your PWM or pulse signal source to the p400 laser, perform the following steps:
1 Attach the BNC control cable between your PWM or pulse signal source and the BNC connector o the rear of
the Quick Start Plug.
Alternately, you can wire your PWM or pulse signal source (and inputs/outputs from your automation controller) to
the DB-15 User I/O connector on the rear of the laser.
Note: Because the p400 is a pulse laser, it will not operate when a constant 5V (100% duty cycle) PWM signal is
applied. If the occurs, lasing will halt and status LED’s/outputs will indicate a fault condition (see Troubleshooting in the Maintenance/troubleshooting section for further information). When the PWM duty cycle
drops below 100%, the laser begins lasing immediately at its 50% PWM limit. The p400 laser begins following the actual PWM command signal when the PWM duty cycle percentage drops to 50% or below.
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 Pulstar p400 gas purge port, refer to Figure 2-9 and perform the following steps:
Gas Purge Kit
Figure 2-9 Gas purge kit assembly.
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Getting Started
Connecting
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.
1 Locate the gas purge kit in the p400 ship kit. Refer to figure 2-9. Assemble the two 90o fittings as shown.
2
Set a purge pressure between 13.8–34.5 kPa (2–5 PSI). This provides just enough positive airflow to prevent
dust from entering the laser. If a flow-meter is available, set a flow rate of 0.85–1.7 m3/hr (30–60 SCFH, Standard Cubic Feet per Hour) at a pressure not to exceed 34.5 kPa (5 PSI).
3 When purge gas is flowing, access the p400’s web page and monitor the Relative Humidity value. The measured
value should drop to 0% (± 10%) within 10–15 minutes. If the relative humidity never drops below approximately 10%, then increase the flow rate slightly.
The Gas Purge port on the Pulstar p400 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 2-3 below.
Table 2-3 Purge gas specifications.
Purge Gas
Specification
Nitrogen
High Purity Grade
> 99.9500% purity; filtered to ISO Class 1 particulate level
Air
Breathing Grade
> 99.9996% purity; filtered to ISO Class 1 particulate level
Air
Compressed
Instrument-grade air filtered and dried to ISO 8573-1:2010 Class 1, 2, 1 (< 10 1.0–5.0 µm particles/m3; < –40 °F dew
point; < 0.01 mg/m3 oil vapor)
Ethernet port
A connection to the Pulstar p400 Ethernet port is not required for normal operation; however, we strongly recommend that you setup the p400 web page and verify its functionality as part of the initial start-up procedure. This will
ensure the p400 web page is available for troubleshooting purposes if necessary during preliminary testing of the
Pulstar p400 laser.
Set-up the p400 web page
Pulstar p400 lasers are pre-configured with a fixed IP address that allows a simple Ethernet connection between the
p400 laser and a host. To connect your host computer to the p400 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. When connecting to a local network, use a straight-through Ethernet cable between the
p400 laser and the Ethernet router or hub.
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 p400 peer-to-peer Ethernet connection must be connected to a com-
puter with a static IP address that is not connected to a local network.
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Getting Started
Connecting
Set your computer’s static IP address
Note:
The exact steps may vary depending on your operating system.
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: 192.168.50.100
Subnet Mask:
255.255.255.0
6 Click OK to submit the changes.
Connect to the Pulstar p400 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 p400’s Ethernet port.
Important Note: The Ethernet cable included in the laser’s ship kit is a shielded crossover cable. If your network application requires a straight-through (patch) cable or you supply your
own crossover cable, be sure the Ethernet cable is an industrially-shielded CAT 5e or CAT
Note: When connecting to a local network, use a straight-through Ethernet cable between the p400 laser
and your Ethernet router or hub.
4 Follow the initial start-up procedure in the Operation chapter and proceed with Step 5 below when DC power
is applied to the laser.
Note:
5
The p400 web page is not compatible with the Google Chrome browser.
Launch your web browser, type “http://192.168.50.50” (without the quotes,) and then press Enter. The p400
web page should appear as shown in Figure 2-10 on the next page.
Synrad p400 operator’s manual ver 1.0
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Getting Started
Connecting
Figure 2-10 Pulstar p400 web page.
To use the p400’s web page capability to monitor various operating parameters, see the Pulstar p400 web interface section in the Technical Reference chapter for additional information. If you have problems connecting to
the p400 web page, refer to the Troubleshooting – Web interface section in the Maintenance/Troubleshooting
chapter.
Caution
Possible
equipment
damage
Do not exceed a gas purge pressure of 34.5 kPa (5 PSI). 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 2-4, Purge gas specifications.
Synrad p400operator’s manual ver 1.0
45
Operation
3
Use information in this chapter to familiarize yourself with Pulstar p400 controls and
indicators and to begin operating the laser.
This chapter contains the following information:
Controls and indicators – displays and describes exterior controls and indicators on
Pulstar p400 lasers.
Initial start-up – explains how to start your Pulstar p400 laser while verifying proper
operation.
Synrad p400 operator’s manual ver1.0
46
Operation
Controls and Indicators
3
1
2
Figure 3-1 Pulstar p400 front panel controls and indicators.
1
Laser Aperture – provides an opening in Pulstar’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 Pulstar options. Refer to Pulstar p400 package outline drawings in the Technical Reference chapter for mounting dimensions.
Note: When mounting optical components to p400 lasers, the 8–32 UNC fasteners must extend no further than
6.35 mm (0.25") 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 p400 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 Feature) LED illuminates blue to indicate that the EM shutter is Open and lasing is enabled. The
SHT LED is off and lasing is disabled if the shutter is Closed.
LASE LED illuminates red to indicate the Pulstar p400 is actively lasing.
Synrad p400 operator’s manual ver1.0
47
Operation
Controls and Indicators
4
5
12
6
INT
TMP
RDY
SHT
LASE
USER I/O
ETHERNET
GAS PURGE
7
Clean and
Dry Air or
N2 only
WARNING
8
9
Do not remove water fittings!
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.
DC POWER
48 VDC
11
WATER
OUT
WATER
IN
10
0 VDC
9
Figure 3-2 Pulstar p400 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 Port/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 a 12 mm inlet connection to Pulstar’s cooling system for 12 mm O.D. cooling tubing.
8
WATER OUT Port – provides a 12 mm outlet connection from Pulstar’s cooling system for 12 mm O.D. cooling tubing.
9
Lifting Handles – allow you to safely lift and move the laser. After laser installation, all three handles can be
removed if additional clearance is necessary.
10 GND (–) Terminal – M10 × 1.5 threaded stud provides connection point for negative (ground) side of the 48
VDC power supply.
11 48V POWER Terminal Block – receives +48 VDC 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 p400 laser.
Synrad p400 operator’s manual ver1.0
48
Operation
Initial Start-up
Start-up with and without a controller
The Start-up and pulsed operation section includes the following subsections:
Initial start-up with a UC-2000 Controller
Without a UC-2000 Controller
Danger
Serious
personal
injury
This Class 4 laser product emits invisible infrared laser radiation in the 10.6
µm CO2 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.
Warning
Serious
personal
injury
Warning
Serious
personal
injury
Important Note:
Remote interlock faults are not latched on Pulstar p400 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 CO2 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.
The use of the optional Quick Start Plug bypasses the laser’s safety interlock
function, potentially exposing personnel in the area to invisible infrared
laser radiation.
The Quick Start Plug feature 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.
As an additional safety feature, the Pulstar p400 laser may contain an (optional) internal EM
shutter assembly that is controlled by the Shutter Open Request input signal (Pin 10 on the
DB-15 User I/O connector). The (EM) 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), (EM) 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.
Synrad p400 operator’s manual ver1.0
49
Operation
Initial Start-up
Important Note:
(continued)
To initiate lasing, apply a voltage in the range of ±5–24 VDC to the Remote Interlock 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. If
a shutter option is available, apply a Shutter Open Request signal (a voltage in the range of
±5–24 VDC) to open the physical shutter assembly (it takes approximately 30 ms for the EM
shutter to fully open) and then apply a PWM Command signal to begin lasing. Your laser may
not be equipped with the shutter option.
Removing the Shutter Open Request signal causes the shutter to close and block the beam
path while simultaneously disabling the PWM signal, leaving internal tickle enabled to supply
tickle signals as required to maintain tube readiness.
With a UC-2000 Controller
Before your Pulstar® p400 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.
Important Note: Except for bench testing, we don’t recommend using a UC-2000 controller with the Pulstar OEM p400 laser. The automatically-generated tickle signal from the UC-2000 may inter-
fere with the laser’s pulsing performance.
Note:
When performing the initial start-up, you must first connect the (optional) Quick Start Plug or 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 pinouts and signal descriptions.
Starting auxiliary equipment
1
Ensure that all personnel in the area are wearing protective eye-wear.
2
Remove the red self-adhesive aperture seal from the laser faceplate.
3
Place a beam block 0.5 meters (20 in) from the laser aperture to prevent the beam from traveling beyond the
work area.
4
Turn on the chiller and set the temperature setpoint between 18 °C–22 °C. Verify that the chiller is delivering a
flow rate of 15.1 liters per minute (4 GPM) at less than 414 kPa (60 PSI) of pressure. Examine all cooling connections carefully and ensure that they do not leak.
Caution
Possible
equipment
damage
Synrad p400 operator’s manual ver1.0
50
Do not exceed a gas purge pressure of 34.5 kPa (5 PSI). 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 2-4, Purge gas specifications.
Operation
Initial Start-up
Caution
Possible
equipment
damage
5
Inlet cooling water temperature must always be maintained above the dew
point to prevent condensation and water damage to your Pulstar laser.
Start purge gas flow at a rate of 0.85–1.7 m3/hr (30–60 SCFH, Standard Cubic Feet per Hour) at a pressure not
to exceed 34.5 kPa (5 PSI) If a flow-meter is not available, set a purge pressure between 13.8–34.5 kPa (2–5
PSI).
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.
6
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.
7
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 Pulstar p400 laser
Important Note:
Unlike other Pulstar lasers, the SHT LED on p400 lasers is dependent on the state of the RDY
indicator. Although the Shutter Open Request signal may be 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 p400 OEM laser is powered up, a five-second delay occurs between the time the
RDY indicator illuminates and the p400 is permitted to lase. After the five-second delay (and
while the SHT LED is off), tickle is applied to maintain the laser in a ready state. Once a Shutter Open Request signal is applied (if your laser is equipped with this feature), and the SHT
LED illuminates, apply PWM Command signals to begin lasing.
Warning
Serious
personal
injury
Caution
Possible
equipment
damage
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.
Remove the aperture seal before firing the laser. The self-adhesive seal is installed to prevent dust from entering the laser housing during shipment and
installation and must be removed before operation. During laser operation,
use a gas purge to keep dust and vapor out of the beam path.
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Operation
Initial Start-up
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 2-5 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
If you are connected to the p400’s Ethernet port, access the p400 web page to verify operating conditions and
functionality (refer back to Figure 2-10). See the Getting Started connecting and/or Technical Reference web
interface chapters for details on accessing the Pulstar p400 web page.
While purge gas is flowing, check the Relative Humidity value. The measured value should drop to 0% (± 10%)
within 10–15 minutes. If the relative humidity never drops below approximately 10%, then increase the flow
rate slightly.
5
Remove DC power from the laser.
Caution
Possible
equipment
damage
Do not flow coolant through the laser 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.
6
Shut off the chiller or otherwise stop coolant flow through the laser.
7
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 Pulstar p400 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 Pulstar’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, you must first connect the Quick Start Plug (optional) or 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 pinouts and signal descriptions.
Starting auxiliary equipment
1
Ensure that all personnel in the area are wearing protective eye-wear.
Synrad p400 operator’s manual ver1.0
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Operation
Initial Start-up
Caution
Possible
equipment
damage
Remove the aperture seal before firing the laser. The self-adhesive seal is installed to prevent dust from entering the laser housing during shipment and
installation and must be removed before operation. During laser operation,
use a gas purge to keep dust and vapor out of the beam path.
2
Remove the red self-adhesive aperture seal from the laser faceplate.
3
Place a beam block 0.5 meters (20 in) from the laser aperture to prevent the beam from traveling beyond the
work area.
Caution
Possible
equipment
damage
4
Inlet cooling water temperature must always be maintained above the dew
point to prevent condensation and water damage to your Pulstar laser.
Turn on the chiller and set the temperature setpoint between 18 °C–22 °C. Verify that the chiller is delivering a
flow rate of 15.1 liters per minute (4 GPM) at less than 414 kPa (60 PSI) of pressure. Examine all cooling connections carefully and ensure that they do not leak.
Caution
Possible
equipment
damage
Do not exceed a gas purge pressure of 34.5 kPa (5 PSI). 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 2-4, Purge gas specifications.
5
Start purge gas flow at a rate of 0.85–1.7 m3/hr (30–60 SCFH, Standard Cubic Feet per Hour) at a pressure not
to exceed 34.5 kPa (5 PSI) If a flow-meter is not available, set a purge pressure between 13.8–34.5 kPa (2–5
PSI).
6
Ensure that your PWM controller is set to zero percent output (0.0%).
7
Turn on the +48 VDC power supply.
If the factory-wired (optional) 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 Pulstar p400 laser
Important Note:
Unlike other Pulstar lasers, the SHT LED on p400 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. Your laser may or may not have this particular shutter feature.
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Operation
Initial Start-up
Important Note:
Each time an p400 OEM laser is powered up, a five-second delay occurs between the time the
RDY indicator illuminates and the p400 is permitted to lase. After the five-second delay (and
while the SHT LED is off), tickle is applied to maintain the laser in a ready state. Once the
Shutter Open Request signal is applied, and the SHT LED illuminates, apply PWM Command
signals to begin lasing.
Warning
Serious
personal
injury
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
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 Pulstar’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 2–5 µs at 5 kHz). The spot where the beam hits the beam
block increases in brightness, indicating an increasing power output.
3
Remove the PWM Command signal from the User I/O connector. The LASE indicator turns off.
4
If you are connected to the p400’s Ethernet port, access the p400 web page to verify operating conditions and
functionality (refer back to Figure 2-10). See the Getting Started or Technical Reference chapters for details on
accessing the Pulstar p400 web page.
While purge gas is flowing, check the Relative Humidity value. The measured value should drop to 0% (± 10%)
within 10–15 minutes. If the relative humidity never drops below approximately 10%, then increase the flow
rate slightly.
Caution
Possible
equipment
damage
Do not flow coolant through the laser 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
Remove DC power from the laser.
6
Shut off the chiller or otherwise stop coolant flow through the laser.
7
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 Pulstar p400 laser fails to lase, refer to Troubleshooting in the Maintenance/Troubleshooting chapter for troubleshooting information.
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Technical Reference
4
Use information in this chapter as a technical reference for your Pulstar p400 laser.
This chapter contains the following information:
Technical overview – briefly describes Pulstar’s technology and basic optical setup.
Controlling laser power – explains various aspects of Pulstar control signals.
User I/O connections – describes input/output signals and specifications for the 15-pin User
I/O connector.
DC power/DC sense cables – provides information about p400 DC power and voltage sense
cables.
Pulstar p400 web interface – explains details about the Pulstar p400’s Ethernet interface.
Pulstar p400 firmware upgrade – describes how to perform an upgrade to the p400’s operating firmware.
Integrating Pulstar safety features – describes how to integrate Pulstar p400 safety features
into your automated control system.
Pulstar p400 general specifications – provides specifications for the Pulstar p400 laser.
Pulstar p400 outline and mounting drawings – illustrates laser package outline and mounting
dimensions for p400 lasers.
Pulstar p400 packaging instructions – illustrates how to package Pulstar p400 lasers for shipment.
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Technical Reference
Technical Overview
The Technical overview section includes subsections:
Laser design
RF power supply
Optical setup
Laser design
Optical resonator
Pulstar® p400 lasers were developed using new technology developed by SYNRAD, Inc. This new technology, based
on an hybrid waveguide/unstable resonator design (Figure 4-1), 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. Pulstar’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
RF Generator
Laser Output
Figure 4-1 Hybrid waveguide/unstable resonator design.
The optical resonator, in conjunction with the electrodes and the gas mixture, generates the laser beam. Pulstar p400
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 (M2 factor) of < 1.2. Beam waist diameter is typically 6.7 mm at the output aperture and full-angle divergence
due to diffraction is approximately 2.5 milliradians (a 2.5 mrad divergence means that beam diameter increases 2.5
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 4.2.
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Technical Reference
Technical Overview
2
Ellipticity
2
2
widthY( z)
ωx( z)
1.6
1.6
1.4
1 1.2
1.4
1 1.2
1
0.8
0.6
widthY( z)
ωx( z)
1
0.8
0.6
0.4
0.4
0 0.2
0 0.2
0
Ellipticity
2
1.8
Ellipticity
Ellipticity
1.8
0
0
1
2
3
4
5
z
6
7
8
2.6
Distance From Front Plate in Meters
9
10
10
0
0
0
10
20
30
40
50
z
60
70
80
90
2.6
Distance From Front Plate in Meters
100
100
Figure 4-2 Pulstar p400 beam ellipticity.
Heat removal
Heat generated by excited CO2 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 p400 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 0.63 m (25 in)
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.
To reduce the complexity and cost of beam delivery components, the Pulstar p400 laser was designed
with the beam polarized at 45° to the base plate (see Figure 3-19 for details). 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 retarding mirror, the linearly polarized beam must make a 45° angle
with the plane of incidence as shown in Figure 4-3.
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Technical Reference
Technical Overview
Reflective Phase Retarding Mirror
45°
Electric Vector Polarization
45°
p400 Output Beam Linearly Polarized
at 45° with Respect to the Baseplate
Reflected Beam is
Circularly Polarized
Figure 4-3 Converting 45° linear polarization to circular polarization
(illustration courtesy of II-VI, Inc.).
RF power supply
Pulstar p400 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 EM 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 CO2 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 laser-based 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.
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
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Technical Reference
Technical Overview
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 4-1.
Table 4-1 Assist gas purity specifications.
Assist Gas
Typical Purpose
Air
Cutting/Drilling
Specification
Breathing Grade
particulate level
> 99.9996% purity; filtered to ISO Class 1 Air
Cutting/Drilling
Compressed
Instrument-grade air filtered and dried to ISO 8573-1:2010 Class 1, 2, 1 (< 10 1.0–
5.0 µm particles/m3; < –40 °F (–40 °C) dew 3
point; < 0.01 mg/m oil vapor)
Argon
Welding
High Purity Grade
particulate level
> 99.998% purity; filtered to ISO Class 1 Helium
Welding
High Purity Grade
particulate level
> 99.997% purity; filtered to ISO Class 1 Nitrogen
Cutting/Drilling
High Purity Grade
particulate level
> 99.9500% purity; filtered to ISO Class 1 Oxygen
Cutting/Drilling
Ultra Pure Grade
particulate level
> 99.9998% purity; filtered to ISO Class 1 Synrad Pulstar p400 operator’s manual ver 1.0
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Technical Reference
Controlling Laser Power
The Controlling laser power section includes subsections:
Control signals
Operating modes
Important Note:
Except for bench testing, we do not recommend using a UC-2000 Controller with the Pulstar OEM p400 laser. The automatically-generated tickle signal from the UC-2000 may interfere with the lasers pulsing performance.
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 p400 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 Pulstar lasers. For more information about the UC-2000,
please consult the UC-2000 Laser Controller Operator’s Manual.
Tickle pulse
Note: Because all Pulstar OEM p400 lasers incorporate a built-in tickle generator (1 µs pulses at 5kHz), there is no
need to supply external tickle pulses. The application of external tickle pulses may affect the p400’s pulsing
performance
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 Pulstar p400 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.
Warning
Serious
personal
injury
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.
Pulse Width Modulation (PWM)
Pulse Width Modulation, or PWM, controls laser power by varying the duty cycle of Pulstar’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).
Pulstar p400 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
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Technical Reference
Controlling Laser Power
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.
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 Pulstar p400 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.
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.
Warning
Serious
personal
injury
Always us shielded cable when connecting to your PWM Command signal
source to PWM Input/PWM Return inputs. In electrically-noisy environments, long lengths of unshielded wire act like an antenna and may generate
enough voltage to trigger un-commanded lasing.
Pulse frequency, the second parameter, is the repetition rate of the PWM input signal. The p400’s pulse frequency can
range from a single-shot up to a maximum frequency of 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 4-4 illustrates typical
PWM Command signal parameters.
Important Note: Because the Pulstar p400 is a pulsed laser, it will not operate when a constant 5V (100% duty cycle) PWM signal is applied. If this occurs, lasing will halt and status LEDs/outputs will indicate a fault condition (see Troubleshooting in the Maintenance/Troubleshooting chapter for further information). The laser will begin lasing immediately when the PWM duty cycle drops below 100%.
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 Pulstar p400 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.
Figure 4-4 PWM command signal wave form.
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Technical Reference
Controlling Laser Power
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. Figures 4-5 through 4-14 illustrate representative output energy profiles of the p400 laser at various PWM duty cycles and pulse repetition frequencies (PRF). As
shown in Figures 4-5 – 4-7, at low frequencies (approximately 1 kHz or less) and low duty cycles (approximately
20%), the p400 delivers maximum peak output power and energy while providing full depth of modulation (where
the output rises from zero power to peak power on each pulse).
Figure 4-5 Representative output energy profile-10% duty cycle, 100Hz, 500 µs timebase.
As PWM frequency and/or duty cycle increases above a certain point, the p400 transitions from operating in peak
pulsed mode to a quasi-CW mode where output power is less than peak pulse power and depth of modulation begins
to decrease around the point of average power output. Figure 4-5 illustrates the p400 laser delivering full peak power
(approximately 800 W) and peak pulse energy (at the maximum 1000 µs pulse width) with 100% depth of modulation. The leading edge of the output energy pulse reaches full peak power and then drops off slightly as the tube gain
diminishes due to plasma heating.
Figure 4-6 Representative output energy profile-10% duty cycle, 1kHz, 500 µs timebase.
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Technical Reference
Controlling Laser Power
Figure 4-6 shows the p400 laser delivering near peak output power. At a 10% duty cycle (at 1 kHz), the rise and fall
time of the p400 limits depth of modulation to approximately 85% of peak power. At 20% duty cycle (at 1 kHz), p400
laser delivers peak output power at full depth of modulation as shown in the following figure.
Figure 4-7 Representative output energy profile-20% duty cycle, 1kHz, 500 µs timebase.
As the duty cycle is increased from 20% (Figure 4-7) to 50% (as seen in the figure below), p400 output still reaches
full depth of modulation; however, maximum power is lower than peak power because of the loss of tube gain due
to plasma heating. As PWM frequency increases beyond 1 kHz (at maximum duty cycle), peak power begins to decrease and average power output becomes a larger factor in materials processing than peak power output.
Figure 4-8 Representative output energy profile-50% duty cycle, 1 kHz, 500 µs timebase.
Figure 4-9 Shows pulsed output behavior with a 50% duty cycle at a frequency of 5kHz. Here the depth of modulation
is approximately 80% compared to the prior figure. Note that the output does not rise to the maximum peak value or
fall to the ground (off) state.
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Controlling Laser Power
Figure 4-9 Representative output energy profile-50% duty cycle, 5 kHz, 500 µs timebase.
Figure 4-10 Shows details of the output energy waveform from the prior figure using a 50 µs timebase.
Figure 4-10 Representative output energy profile-50% duty cycle, 5 kHz, 50 µs timebase.
Figure 4-11 Shows output details with a 50% duty cycle at a frequency of 10kHz. The depth of modulation is approximately 50%. Note that at a constant duty cycle percentage, the depth of modulation (and laser output power) decreases as frequency increases.
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Figure 4-11 Representative output energy profile-50% duty cycle, 10 kHkz, 500 µs timebase.
Figure 4-12 Shows details of the 50%, 10kHz waveform using a 50 µs timebase.
Figure 4-12 Representative output energy profile-50% duty cycle, 10 kHkz, 50 µs timebase.
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Figure 4-13 Below illustrates laser output driven by a 50% duty cycle a frequency of 20kHz. At this frequency, the
depth of modulation is approximately 25% and is nearly a continuous wave (CW) type output.
Figure 4-13 Representative output energy profile-50% duty cycle, 20 kHz, 500 µs timebase.
Figure 4-14 Shows an expanded view of the 50%, 20kHz waveform using a 50 µs timebase.
Figure 4-14 Representative output energy profile-50% duty cycle, 20 kHz, 50 µs timebase.
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Table 4-2 PWM Command signal specifications.
Laser State
Minimum
Nominal
Maximum
Laser Off 0.0 VDC
0.0 VDC
+0.8 VDC
Laser On +3.5 VDC (3 mA)
+5.0 VDC
+6.7 VDC (10 mA), continuous
Frequency Range
0 Hz (DC)
5 kHz
100 kHz
Duty Cycle
1%
— —
50%
Warning
Serious
personal
injury
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), Pulstar’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. Please
refer to the figure below for the 15 pin female D-type sub-miniature connector on the p400’s rear panel. The figure
below illustrates the pin arrangement of the User I/O connector.
Caution
Possible
equipment
damage
Turn off DC power before installing or removing any plug or cable from the
User I/O connector. Ensure that user connections are made to the appropriate
pins and that the appropriate signal levels are applied. Failure to do so may
damage the laser.
Pin 8
Pin 1
INT
TMP
RDY
SHT
LASE
ETHERNET
USER I/O
Pin 15
Figure 4-15 User I/O connector pinouts.
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User I/O Connections
User I/O connection summary
Table 4-3 below provides a quick reference summary to Pulstar p400 User I/O connections.
Table 4-3 User I/O pin descriptions.
PinFunction
1
Description
PWM Return
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.
Note:
3
When connecting field wiring to the Remote Reset/Start Request input, use twisted pair and/or
shielded cabling. Refer to SYNRAD Technical Bulletin #021 for details.
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 on the Quick Start Plug.
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.
5
+ 24 VDC Auxiliary Power
This connection provides +24 VDC for driving external inputs or outputs. The +24 VDC Auxiliary Power output can source up to 0.5 A and is protected by a 0.5 A self-resetting fuse. The return
(ground) path must be through Pin 12, Auxiliary DC Power Ground.
6
Laser Active output
This 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).
7
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).
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Table 4-3 User I/O pin descriptions (continued).
PinFunction
8
Description
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).
9
PWM Input
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
Shutter Open Request input
Apply a positive or negative voltage (±5–24 VDC) with respect to Pin 11, Input Common, to enable
the laser. This input is also used to actuate the optional EM shutter if your laser is so equipped. 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 4-17 for a diagram showing how the Shutter Open
Request input is factory-jumpered on the Quick Start Plug. The shutter will not activate until a voltage
is also applied to the Remote Interlock input (INT LED illuminated green and RDY LED On).
11
Input Common
Use this input pin to connect return lines for Remote Interlock, Shutter Open Request, and Remote
Reset/Start Request lines.
12
Auxiliary DC Power Ground
This connection provides a ground (earth) connection for +5 and +24 VDC auxiliary power outputs.
This pin is the only User I/O pin that is connected to chassis ground. Do not use this pin for grounding if DC power to external I/O circuits is supplied from an external customer-supplied DC power
source.
13
Output Common
Use this pin to complete the 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.
14
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).
15
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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User I/O Connections
Input/output signals
The Pulstar p400’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
Pulstar’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. The figure below illustrates Pulstar’s internal DC supply wiring.
DC POWER INPUT
+48 V TO DC POWER BOARDS
+48 VDC (+)
VOLTAGE REGULATORS
AND
48 V SWITCH
DC RETURN (–)
+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 4-16 Auxiliary DC power diagram.
Pin 4 + 5 VDC Auxiliary Power
This connection provides +5 VDC for driving external inputs or outputs. The +5 VDC Auxiliary Power
output can source up to 0.5 A and is protected by a 0.5 A self-resetting fuse. The return (ground) path must
be 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 Pulstar 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 4-4 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 4-4 for input circuit specifications.
Note:
Pin 3
When connecting field wiring to the Remote Reset/Start Request input, use twisted pair and/or
shielded cabling. Refer to SYNRAD Technical Bulletin #021 for details.
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 4-17 for a diagram showing how the Remote Interlock input is factory-jumpered on the Quick Start Plug to enable lasing and for troubleshooting purposes. 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 4-4 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 22.5% corresponds to a laser output
of approximately one-half rated output power and a duty cycle of 50% 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 4-4 for input circuit specifications.
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User I/O Connections
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 EM 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 4-17 for a diagram showing how the Shutter Open Request input is factory-jumpered
on the Quick Start Plug. See Table 4-4 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 4-4 for input circuit specifications.
Figure 4-17 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.
Warning
Serious
personal
injury
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.
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.
Pin 1
Pin 9
PWM Return
PWM Input
Pin 3
Pin 4
Pin 10
Remote Interlock
+5 VDC
Shutter Open Request
Pin 11
Pin 12
Input Common
Aux. DC Power Ground
Rear (Solder Side)
of Male DB15
"Quick Start"
Shorting Plug
Pin 8
Pin 1
PWM Input BNC
Pin 15
Pin 9
Figure 4-17 Quick Start Plug wiring diagram.
Figure 4-18 on the following page illustrates the input circuit’s equivalent internal schematic while Table 4-4 provides
Pulstar p400 input circuit specifications.
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USER I/O INPUT SIGNAL PINS
PWM INPUT (+) (9)
220 Ohm, 1/8W
430 Ohm, 1/10W
PWM RETURN (–) (1)
REMOTE RESET/START REQUEST (2)
REMOTE INTERLOCK (3)
600 Ohm, 2W
600 Ohm, 2W
PULSTAR p400
INPUT CIRCUITRY
600 Ohm, 2W
SHUTTER OPEN REQUEST (10)
INPUT COMMON (11)
Figure 4-18 Input equivalent schematic.
Table 4-4 Input circuit specifications.
Input Signal Name
Input Device Type and Specifications
PWM Input High-speed optoisolator LED, forward voltage drop (Vf) 1.5 VDC
Off state 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
Max PWM = 45%
Max Pulse Length = 1 millisecond
Remote Reset/Start Request
Remote Interlock
Shutter Open Request
Bi-directional optoisolator LED, forward voltage drop (Vf) 1.15 VDC
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 Pulstar’s +5 VDC power supply has stabilized
(approximately 200 ms after DC power-up).
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User I/O Connections
Output signals
Pulstar’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.
Pulstar’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 4-5 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 4-5 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
4-5 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 4-5 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 indicator 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 4-5 for output circuit specifications.
Figure 4-19 illustrates the output circuit’s equivalent internal schematic and Table 4-5 provides Pulstar
p400 output circuit specifications.
USER I/O OUTPUT SIGNAL PINS
(6) LASER ACTIVE
SOLID
STATE
RELAY
(7) FAULT DETECTED
SOLID
STATE
RELAY
(8) LASER READY
PULSTAR p400
OUTPUT CIRCUITRY
SOLID
STATE
RELAY
(14) SHUTTER OPEN
SOLID
STATE
RELAY
(15) INTERLOCK OPEN
SOLID
STATE
RELAY
(13) OUTPUT COMMON
0.3 A FUSE,
SELF-RESETTING
Figure 4-19 Output equivalent schematic.
Table 4-5 Output circuit specifications.
Output Device Specifications
Bi-directional MOSFET
2.5 Ohms Rdson
10 MOhms Off
Voltage ±24 VDC, max.
Current 50 mA, max.
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User I/O Connections
Sample I/O circuits
Sample inputs
Figure 4-20 illustrates one method of supplying a Remote Interlock signal using a customer-supplied limit switch.
Pulstar’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.
USER I/O PINS
(5) +24 VDC AUXILIARY
POWER
Close switch to
enable interlock
(3) REMOTE INTERLOCK
(11) INPUT COMMON
(12) AUX. DC POWER
GROUND
Figure 4-20 Customer-supplied interlock.
Figure 4-21 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 Pulstar’s input circuit.
Close switch to
enable interlock
USER I/O PINS
(3) REMOTE INTERLOCK
–12 VDC
(11) INPUT COMMON
0 VDC
Figure 4-21 Customer-supplied interlock, negative voltage.
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Controlling Laser Power
A Programmable Logic Controller (PLC) can also drive Pulstar inputs. Figure 4-22 shows a typical method for connecting to a PLC output module when only one Pulstar input is used.
PLC
DC
OUTPUT
MODULE
+V
(+5–24V)
USER I/O PINS
(3) REMOTE INTERLOCK
(11) INPUT COMMON
Figure 4-22 PLC driven interlock signal.
When multiple PLC outputs are used, connect Pulstar inputs to the PLC as shown in Figure 4-23. 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
(11) INPUT COMMON
(2) REMOTE RESET/START REQUEST
(3) REMOTE INTERLOCK
(10) SHUTTER OPEN REQUEST
Figure 4-23 Multiple PLC driven inputs.
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User I/O Connections
Sample outputs
Pulstar’s optoisolated, bi-directional switched outputs can drive small loads (50 mA max), PLC inputs, or relays that
can control higher current loads. The following figure illustrates one method of controlling a remote warning lamp
using power supplied by Pulstar’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
(5) +24 VDC AUXILIARY
POWER
R1
L
(6) LASER ACTIVE
(12) AUX. DC POWER
GROUND
(13) OUTPUT COMMON
Figure 4-24 Pulstar output driving warning lamp.
Figure 4-25 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 Pulstar outputs.
USER I/O PINS
+V
(5) +24 VDC AUXILIARY
POWER
(6) LASER ACTIVE
L
(12) AUX.DC POWER
GROUND
(13) OUTPUT COMMON
Figure 4-25 Pulstar output driving relay.
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Controlling Laser Power
Figure 4-26 illustrates how Pulstar’s outputs can drive the DC Input Module of a Programmable Logic Controller
(PLC). By supplying voltage (+VDC) to Pin 13, Output Common, each Pulstar output is independently switched to
activate individual PLC inputs.
USER I/O PINS
(13) OUTPUT COMMON
(6) LASER ACTIVE
(7) FAULT DETECTED
(8) LASER READY
(14) SHUTTER OPEN
(15) INTERLOCK OPEN
Figure 4-26 Pulstar output driving PLC input module.
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PLC
DC
INPUT
MODULE
V+
(+5–24V)
Technical Reference
User I/O connections
The DC power/DC sense cables section includes subsections:
DC power cables
DC voltage sense cable
DC power cables
The DC power cables shipped with Pulstar p400 lasers are manufactured with 1/0 AWG wire to a standard length of
2.0 m (6.5 ft) or an optional length of 5.0 m (16 ft). Nominal finished O.D. is 14.9 mm (0.586") so the minimum bend
radius must be greater than 12 cm (4.7 in). Terminals on the laser end of the cables fit the laser’s M10 studs while
terminals on the power supply ends are sized to fit M6 (0.25") bolts.
When using a power supply other than the PS-p400, we recommend using remote sensing so the power supply
output remains at a constant voltage over varying load conditions. Choose a DC supply that can compensate for a
minimum load lead loss (round trip) of 1.0 V.
Important Note:
If you lengthen the DC Power Cables shipped with the p400 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.
DC voltage sense cable
The DC voltage sense cable shipped with the p400 laser is matched to the length of the DC power cable—either the
standard length of 2.0 m (6.5 ft) or an optional length of 5.0 m (16 ft). The laser end of the voltage sense cable is finished with an M10 ring terminal to fit the +48 VDC POWER terminal and an M4 spade terminal to fit the end of the
–VDC GND terminal. The power supply end of the sense cable is terminated with a 26-pin high-density D-subminiature connector that connects to the PS-p400 DC power supply. In addition to remote sensing connections, the 26-pin
HD connector includes jumpers to enable the PS-p400’s Output Inhibit and Output Interlock inputs.
When using a power supply other than the PS-p400, you can fabricate your own DC voltage sense cable or you can
remove the 26-pin HD D-subminiature connector and terminate the sense cable to match your power supply’s DC
voltage sense connections.
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Pulstar p400 web Interface
The Pulstar p400 web interface section includes subsections:
Accessing the p400 web page
Home page layout
Event log page layout
Changing the p400’s IP address
Alternate Ethernet connection
Accessing the p400 web page
Important Note:
The p400 web interface is not compatible with the Google Chrome browser.
Pulstar p400 lasers are pre-configured with a fixed IP address that allows a simple Ethernet connection between the
p400 laser and a host. To connect your host computer to the p400 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. When connecting to a local network, use a straight-through Ethernet cable between the p400 laser and your Ethernet router or hub.
Note:
The procedure described below may require the assistance of your IT Department if your facil
ity’s Ethernet settings are determined automatically using Dynamic Host Configuration Protocol (DHCP). The p400 peer-to-peer Ethernet connection must be connected to a computer with a static IP address that is not connected to a local network.
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Pulstar p400 web Interface
Set your computer’s static IP address
Note:
The exact steps may vary depending on your operating system.
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. When done, click OK to submit the
changes:
IP Address:
Subnet Mask:
192.168.50.100
255.255.255.0
Connect to the Pulstar p400 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 p400’s Ethernet port.
Note: The Ethernet cable included in the laser’s ship kit is a shielded crossover cable. If your network application
requires a straight-through (patch) cable or you supply your own crossover cable, be sure the Ethernet cable
is an industrially-shielded CAT 5e or CAT 6 cable.
4
Apply 48 VDC power to the laser.
5
Launch your web browser, type “http://192.168.50.50” (without the quotes,) and then press Enter.
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Pulstar p400 home page
Home page layout
Pulstar p400 lasers feature a web-based Internet interface that allows you to access read-only information about LED
and RF module status–including voltage, current, and temperature measurements—using a standard web browser as
shown in Figure 4-27.
Figure 4-27 Pulstar p400 home page.
Note: On initial power-up of the laser, allow five seconds for the web interface to load before accessing the web
page.
When the home page opens, the Pulstar p400 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
home page once a second. Click the Pause button to halt updating. If a fault should occur while the home 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.
Status LEDs
Interlock, Temp, Ready, and Shutter icons display the current state of the laser’s Status LEDs.
Note:
Because the p400 home page is a static web page, Ready and Shutter icons will not flash fault codes; however,
the gray Error messages section will display the fault.
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Pulstar p400 home page
RF module data
This section displays operating conditions for each of the p400’s four RF modules.
Connected
‘OK’ means that the RF module is connected to the Control module. ‘NC’ means the Control module
does not sense a connection to the RF module.
Input Voltage (VDC)
Displays the DC voltage level measured at the input of the Power module.
Switch Voltage (VDC)
Displays the DC voltage level measured at the input of the 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 (RH) within the p400 laser housing. When purge gas is flowing, the RH value should drop to 0% (± 10%) within 10–15 minutes. If the relative humidity never drops below approximately 10%,
then slightly increase the purge gas flow rate.
Flow Sensor Temp*:
Displays cooling system temperature measured after the RF amplifier modules.
Important Note:
The Flow Sensor Temp value is not a measurement of coolant temperature and should not be
used to adjust the chiller’s setpoint!
Internal Tickle Setting:
Indicates that tickle is active (ON) and displays the actual tickle setting.
5 Seconds Delay Setting:
Indicates that the five-second delay is active (Enabled).
Error message area
Hard faults (those that require a power cycle), are annunciated in the upper (red) error message area while warnings
are described in the lower (yellow) message area. If a fault occurs before the web interface is active, the fault or warning message is displayed; however, no other operating data is archived or displayed.
Reference: p400 Diagram
Hyperlink to an illustration showing various p400 modules and their location inside the laser housing.
Configure IP Address link
Click this link to change the laser’s factory-default IP address (192.168.50.50). See the Changing the p400’s IP address
section for details.
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Pulstar p400 web interface
Event log page layout
Figure 4-28 Pulstar p400 event log page.
To access the p400’s event log page (Figure 4-28), open your web browser, type “http://192.168.50.50/service.html”
(without the quotes,) and then press Enter. The event log page opens and displays information recorded over the life
of the laser. This information includes power-on cycles as well as total on-time/total lase time; maximum values for
voltage, current, temperature, and humidity; and the number of times that various fault conditions have occurred.
Refer to the home page for a display of currently active faults, if any exist.
Changing the p400’s IP address
To change the p400’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 Pulstar p400 web page, click the Configure IP Address link.
2
The Change IP Address page loads (Figure 4-29), displaying the factory default IP Address, Subnet Mask and
Gateway addresses.
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Figure 4-29 Pulstar p400 Change IP Address page.
3
Change IP Address, Subnet Mask and Gateway addresses as required. Be sure to record these address changes
in a safe location and then click the Submit button.
To revert back to the factory default IP settings, simply click Submit when the Change IP Address page opens.
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 (http://xxx.xxx.xxx.xxx), and then press Enter. The p400
home page will appear as shown back in Figure 4-27. To reach the event log page, enter “http://xxx.xxx.xxx.xxx/
service.html” (without the quotes); where xxx.xxx.xxx.xxx is the new IP address.
Alternate Ethernet connection
In situations where it is necessary to isolate the Pulstar p400 laser from your internal IT network, but still access
the p400 web page from a networked control computer, you can connect the p400 laser to the networked computer
using a USB to Ethernet adapter. Devices like the TRENDnet TU2-ET100 USB to 10/100 Mbps Adapter allow your
networked computer to access the Pulstar p400 web page over the computer’s USB port, which isolates the laser from
your computer network. In this case, use a crossover Ethernet cable between the p400 laser and the USB to Ethernet
adapter.
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Pulstar p400 Web Interface
The Pulstar p400 firmware upgrade section includes subsections:
Required materials/equipment
Firmware upgrade procedure
Required materials/equipment
The following materials and equipment is required to upgrade the firmware in an p400 laser:
Firmware upgrade file (p400_Firmware_Upgrade.zip) from SYNRAD
Ethernet crossover cable
Windows®-based personal computer
Firmware upgrade procedure
Important Note:
The firmware upgrade must be performed using a peer-to-peer connection between the p400 laser and host computer as described below.
Note:
The Pulstar p400 web interface is not compatible with Google Chrome browsers.
Disable your computer’s firewall
1
If your computer’s firewall is enabled, notify your IT Administrator and disable the firewall before continuing
with this procedure.
Enable your computer’s TFTP Client
Note: 1
By default, the TFTP Client is disabled on Windows® 7 and Vista operating systems. Follow the steps in this subsection to enable the TFTP Client feature.
In the Windows Control Panel (Figure 4-30), double-click Programs and Features.
2 Once in the Programs and features dialog, click the ‘Term Windows Features On or Off ’ Option as shown in
figure 4-31.
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Figure 4-30 Windows Control Panel.
Figure 4-31 Programs and Features dialog.
3
In the Windows Features dialog (Figure 4-32), check “TFTP Client” and then click OK.
Figure 4-32 Windows Features dialog.
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Pulstar p400 Firmware Upgrade
4
A progress bar window will appear while the TFTP Client feature is being activated. When the window closes,
continue with the next section.
5
Restart this computer.
Set your computer’s static IP address
Note: The exact steps may vary depending on your operating system.
1
Disconnect the computer from your local network by removing any networking cables.
2
In the Windows Control Panel, double-click Network and Sharing Center.
3
In the Network and Sharing Center dialog, click the Local Area Connection option.
4
In the Local Area Connection Status dialog, click the Properties button.
5
In the Local Area Connection Properties dialog (Figure 4-33), select Internet Protocol Version 4 (TCP/IPv4)
and click the Properties button.
Figure 4-33 Local Area Connection Properties dialog.
6
In the Internet Protocol Version 4 (TCP/IPv4) Properties dialog (Figure 4-34), select “Use the following IP
address:” and enter the following information:
IP Address:
Subnet Mask: 192.168.50.100
255.255.255.0
Note: The Default Gateway field can be left blank.
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Figure 4-34 Internet Protocol (TCP/IP) Properties dialog.
7
Click OK to submit the changes.
Prepare the upgrade files
1
Double-click the p400_Firmware_Upgrade.zip file and extract the enclosed firmware upgrade folder to the
computer’s desktop.
2
Double-click the firmware upgrade folder to open it.
Connect to the Pulstar p400 laser
1
Remove DC power from the laser.
2
Locate the Ethernet crossover cable in the ship kit and connect it between your computer and the p400’s Ethernet port.
3
Remove the Quick Start Plug from the p400’s User I/O connector.
4
Apply 48 VDC power to the laser and wait 15 seconds for the firmware to initialize.
5
If you have changed the p400’s IP address (the factory default is 192.168.50.50), you must change it back. If not,
proceed to the next section, Perform the firmware upgrade.
a
Launch your web browser, type the laser’s IP address, and then press Enter.
b
When the home page appears as shown in Figure 4-35, click the Configure IP Address link at the bottom
of the page.
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Figure 4-35 Configure IP Address link on Pulstar p400 home page.
c
When the Change IP Address page loads showing the default IP address (Figure 4-36), click the Submit
button. This resets the laser’s IP address to 192.168.50.50.
Figure 4-36 Pulstar p400 Change IP Address page.
Perform the firmware upgrade
1
In the firmware upgrade folder, double-click the Update.bat file.
2
Wait until the batch file dialog displays the “Done! Press any key to continue...” message.
3
Press any key to exit the batch file.
4
Remove DC power from the laser, wait 15 seconds, and then re-apply 48 VDC power.
5
Launch your web browser, type: “http://192.168.50.50” (without the quote symbols) and then press Enter.
6
When the p400 Home page appears (Figure 4-37), check the label on the web browser’s tab. It should read:
Pulstar p400: CONFIG 2 – X.X to indicate the laser is running upgraded firmware.
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Figure 4-37 Pulstar p400 web browser display.
7
If necessary, click the Configure IP Address link at the bottom of the p400 web page and reset the default IP
address to the specific address required for your application.
Re-enable your computer’s firewall
1
If your computer’s firewall was disabled for this procedure, notify your IT Administrator and re-enable the
firewall.
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Integrating Pulstar Safety Features
The Integrating Pulstar safety features section includes subsections:
Keyswitch functions
Shutter functions
Remote interlock functions
Pulstar’s DB-15 User I/O connector allows system integrators or end-users to integrate Pulstar safety features into
their control system. Pulstar’s keyswitch, shutter, and remote interlock functions serve to enable or disable DC power
to Pulstar’s RF drive. Without DC power, the RF driver cannot supply RF energy to the resonator, causing the CO2
gas to remain in a zero-energy state. Pulstar 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.
Note:
When connecting field wiring to the Remote Reset/Start Request input, use twisted pair and/or shielded
cabling. Refer to SYNRAD Technical Bulletin #021 for details.
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 4-36).
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 EM shutter is optional for p400 lasers, but the electronic shutter is available on all lasers. Lasing is enabled when the shutter is open (SHT LED illuminated blue) and disabled when the shutter is Closed (SHT LED off).
For p400 OEM lasers in automated systems, shutter actuation is provided by the (EM) 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, Shut
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Integrating Pulstar Safety Features
ter 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.
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. Pulstar’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 Pulstar’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 4-26). 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.
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Pulstar p400 General Specifications
Table 4-6 Pulstar p400 general specifications.
ParameterPulstar p400
Output Specifications
Wavelength† ................................................................ 10.5–10.7 microns
Power output, continuous1, 2 .................................... >440 Watts
Peak Power.................................................................. >1.0kW
Max Pulse Length ...................................................... 1.0 milliseconds
Power Stability3 .......................................................... ± 7%
Power Stability4 .......................................................... ± 5%
Mode Quality5 ............................................................ M2 < 1.2
Option 1: Beam Waist Diameter (at 1/e2)6...............6.0 ± 1.0 mm
At faceplate (at 1/e2)6 typical....................6.5 ± 1.0 mm
Beam Divergence, ‘full angle’..................typ=2.4mrad
Option 2: Beam Waist Diameter (at 1/e2)6..............8.0 ± 1.0 mm
At faceplate (at 1/e2)6 typical....................9.0 ± 1.0 mm
Beam Divergence, ‘full angle’...................typ =1.8 mrad
Ellipticity ................................................................... < 1.2
Polarization ............................................................... Linear 45 degrees
Extinction Ratio......................................................... > 100:1
Rise Time7 /Fall Time7.............................................. typ < 50µs/< 100µs
Input Specifications
Power Supply
Voltage ................................................................ 48 V ±0.5 VDC
Maximum Current8 .......................................... 175 A
Peak Current (max.) ......................................... 300 A for > 1 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 ................................................................. 1%–50%
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. †Typical. Actual wavelength range may vary from 10.2–10.8 µm.
1 This power level is guaranteed for 12 months regardless of operating hours.
2 48 VDC input voltage to obtain guaranteed output power.
3 From cold start (tube at 20 °C for 30 minutes before start) at 50% duty cycle with 4 GPM flow and 20 °C coolant temperature.
4 After two minutes (typical) at 50% duty cycle, 4 GPM flow, and 20 °C coolant temperature.
5 Measured at 50% duty cycle, at 1 kHz , 5 kHz, and 20 °C coolant temperature after 30 minute warm-up.
6 Measured at beam waist. See the laser’s Final Test Report for beam waist location.
7 Measured at 1 kHz, 5 kHz, at 50% duty cycle.
8 At 48 V, 50% duty cycle.
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Pulstar p400 General Specifications
Table 4-6 Pulstar p400 general specifications continued.
ParameterPulstar p400
Cooling Specifications
Maximum Heat Load ..............................................8.5 kW
Flow Rate (minimum) ............................................4 GPM at < 60 PSI (15.1 liters per minute at < 414 kPa)
Coolant Temperature9 .............................................18 °C to 22 °C
Coolant Temperature Stability................................± 1.0 °C
Environmental Specifications
Operating Temperature10 ........................................15 °C – 40 °C
Humidity...................................................................0-95%, non-condensing
Coolant Temperature Stability ...............................± 1.0 °C
Random Vibration Specifications
Operating ..................................................................0.75 Grms, 20-2kHz
Non operating ........................................................ 1.0 Grms, 20-2kHz
Shock Maximum Specifications
Operating /Non-Operating ....................................20.0 G, 9ms, half sine
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)
*
9
Specifications subject to change without notice.
Pulstar p400 lasers can be operated at coolant temperatures up to 28 °C (82 °F) in order to reduce problems associated with condensa-
tion; however, this may result in decreased laser performance and/or reduced laser lifetime.
10
Published specifications guaranteed at a cooling temperature of 20 °C.
Synrad Pulstar p400 operator’s manual ver 1.0
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98
2X .800
[20.32]
Synrad Pulstar p400 operator’s manual ver 1.0
Figure 4-38 Pulstar p400 outline & mounting dimensions.
.788
20.00
2X .600
15.24
12.450
316.23
.609
15.47
11.850
300.99
THIS MOUNTING HOLE PATTERN USED FOR BOTTOM ACCESS FASTENING.
2
2X 1.050
[26.67]
7.185
182.50
6.359
161.52
BEAM CENTERED IN APERTURE WITHIN ±1.0mm
OPTION 'A'
MOUNTING
11.375
288.93
6X 8-32 UNC-2B .20
ACCESSORY MOUNTING HOLES
45° PLANE OF
POLARIZATION
CL
C
3X .225
5.72
3X 1.125
28.58
1
NOTES:
10.791
274.09
DETAIL C
2X .800
[20.32]
M29 X 1.0
BEAM EXIT
2X 2.300
[58.42]
1
4X
36.200
919.48
2X PIN GUIDE
2X .380
9.65
.433
11.00
49.963
1269.05
48.275
1226.19
.xx = ± .01
MATERIAL:
10.000
254.00
5.450
138.43
2X 11.250
[285.75]
3.400
86.36
4.767
121.08
UNITS: Inches
SIZE: B
.
SHEET 1 of 2
TEMP
(GRN/RED)
CL
CONTROL I/O
INTERLOCK
(GRN/RED)
A
8.200
208.28
FINISH CLASS: .
1/4" PURGE FITTING
APPROVED BY:
CHECKED BY:
LASE
(RED)
SHUTTER
(BLUE)
READY(YEL)
2.600
66.04
5.600
142.24
DATE:
DATE:
DATE: 6-Jan-11
SYNRAD INC.
4600 Campus Place
Mukilteo, WA 98275
Phone: (425)349-3500
Fax: (425)349-3667
DETAIL A
3.375
85.73
GND TERM.
(M10X1.5)
WATER INLET E
(12mm TUBE FITTING)
48V POWER TERM.
(M10X1.5)
DWG/FILE NUMBER: 300-20151-01
DRAWN BY: D. DUVALL
DB
DMD
DMD
DMD
ETHERNET PORT
.865
21.97
OUTLINE & MOUNTING, p400
CATEGORY: .
ENG: .
PART NUMBER: 300-20151-01
DESCRIPTION:
PROPRIETARY
THIS DRAWING IS PROPRIETARY TO
SYNRAD INC. AND SHALL NOT BE
USED OR DISCLOSED IN WHOLE
OR IN PART WITHOUT WRITTEN
PERMISSION OF SYNRAD INC.
CL
1.875
47.63
E WATER OUTLET
(12mm TUBE FITTING)
1.450
36.83
DESCRIPTION
UPDATE TO SHOWN BASE PLATE CHANGES
ADD/UPDATE NOTES
CHANGE TO 12mm FITTINGS
DATE
16-Nov-11
3-Jan-12
19-Mar-13
.
.
FINISH:
ANGLE = ± .5
TOLERANCES UNLESS NOTED:
.x = ± .1
.xxx = ± .005
.
.
C
D
E
.64
16.38
ECO
4470
4474
4702
REV
Technical Reference
Pulstar p400 Outline & Mounting Drawings
.252 6.40
.375[9.53]
2.010
51.05
2.010
51.05
.252
6.40
.375[9.53]
1.500
38.10
2X R
4X M10X1.5
2X DETAIL B
BEAM ALIGNMENT SLOT
.500
12.70
7.185
182.50
25mm 2
.xx = ± .01
MATERIAL:
2.265
57.53
SYNRAD INC.
4600 Campus Place
Mukilteo, WA 98275
Phone: (425)349-3500
Fax: (425)349-3667
CATEGORY: .
UNITS: Inches
SIZE: B
.
FINISH CLASS: .
ENG: .
DATE: 6-Jan-11
DATE:
DATE:
CHECKED BY:
APPROVED BY:
DRAWN BY: D. DUVALL
DWG/FILE NUMBER: 300-20151-01
OUTLINE & MOUNTING, p400
PART NUMBER: 300-20151-01 OPTION B
DESCRIPTION:
PROPRIETARY
THIS DRAWING IS PROPRIETARY TO
SYNRAD INC. AND SHALL NOT BE
USED OR DISCLOSED IN WHOLE
OR IN PART WITHOUT WRITTEN
PERMISSION OF SYNRAD INC.
SHEET 2 of 2
ANGLE = ± .5
B
DB
DMD
DMD
DMD
OPTION 'B' MOUNTING
DESCRIPTION
UPDATE TO SHOWN BASE PLATE CHANGES
ADD/UPDATE NOTES
CHANGE TO 12mm FITTINGS
DATE
16-Nov-11
3-Jan-12
19-Mar-13
.
.
FINISH:
.
.
C
D
E
TOLERANCES UNLESS NOTED:
.x = ± .1
.xxx = ± .005
36.200
919.48
ECO
4470
4474
4702
REV
Technical Reference
Pulstar p400 Outline & Mounting Drawings
Figure 4-39 Pulstar p400 outline & mounting dimensions (mounting feet removed).
Synrad Pulstar p400 operator’s manual ver 1.0
99
Figure 4-40 Pulstar p400 packaging instructions.
Synrad Pulstar p400 operator’s manual ver 1.0
100
A
B
FRONT OF LASER
MATERIAL:
1
DESCRIPTION
RELEASE TO PRODUCTION
UPDATE INSTRUCTIONS
.
5.
4.
2.
1.
CONTAINS FOAM CAVITIES, ORIENT FOR PROPER FIT.
WRITE SYNRAD RETURN AUTHORIZATION NUMBER ON
LIFT LASER SLING OUT OF SHIPPING CONTAINER AND
PLACE ON SOLID SURFACE.
PLACE LASER INSIDE FOAM CAVITIES ON LASER SLING,
MAKING SURE FRONT OF LASER IS ON LEFT SIDE.
USE TWO OR MORE PEOPLE TO LIFT LASER/LASER
SLING AND PLACE INTO BOTTOM SHIPPING CONTAINER.
COVER WITH TOP SHIPPING CONTAINER AND SECURE
B PACKAGING INSTRUCTIONS:
SHEET
1 of 1
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DOC, INSTRUCTION, PACKAGING, p400
PART NUMBER: 900-20408-01
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PROPRIETARY
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FINISH:
SEE BOM
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TOP SHIPPING
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DATE
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ECO
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Technical Reference
Pulstar p400 Outline & Mounting Drawings
Maintenance/
Troubleshooting
5
Use information in this chapter to perform maintenance or troubleshoot your Pulstar
p400 laser.
This chapter contains the following information:
Maintenance – describes typical Pulstar p400 maintenance procedures.
Troubleshooting – explains how to troubleshoot common Pulstar p400 problems.
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Maintenance/
Troubleshooting
Maintenance
The Maintenance section includes subsections:
Disabling the p400 laser
Daily inspections
Storage/shipping
Cleaning optical components
Disabling the p400 laser
Before performing any maintenance on your Pulstar® p400 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 Pulstar p400 laser in optimum operating condition. Except for the
procedures described below, no other service is required or should be attempted.
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
Caution
Possible
equipment
damage
If you operate the 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 for the laser system and associated optical components.
Warning
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.
Serious
personal
injury
electrical and optical components inside the laser. See the Setting coolant temperature section in the Getting
Started chapter for details on preventing condensation.
2
When using compressed air as a purge gas on your p400 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 2-3 in the Getting Started chapter.
3
Inspect beam delivery components for signs of dust or debris and clean as required. When cleaning the optical
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Maintenance/
Troubleshooting
Maintenance
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 p400 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 200 kPa (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
Caution
Possible
equipment
damage
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 – Pulstar p400 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.
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.
Danger
Serious
personal
injury
Ensure that DC power to the laser is turned off and locked out before inspecting optical components in the beam path. Invisible CO2 laser radiation
is emitted through the aperture. Corneal damage or blindness may result
from exposure to laser radiation.
Synrad Pulstar p400 operator’s manual ver 1.0
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Maintenance/
Troubleshooting
Maintenance
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 latex gloves or finger cots (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 on a tissue or suitable equivalent material 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 5-1 lists the type and grade of materials required to properly clean optical surfaces.
Table 5-1 Required cleaning materials.
Cleaning Material
Requirements
Latex gloves or finger cots
Powder-free
Air bulb
Clean air bulb
Ethyl or isopropyl alcohol
Spectroscopic or reagent grade
Acetone
Spectroscopic or reagent grade
Lens wipe (preferred)
Optical (clean-room) quality
Cotton balls or cotton swabs
High-quality surgical cotton/high-quality paper-bodied
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.
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.
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Maintenance/
Troubleshooting
Maintenance
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.
Important Note:
If acetone is used as a cleaning solvent, a second follow-up cleaning of the optical surface using
alcohol is required.
4
Dampen a lens wipe with the selected cleaning agent. Alcohol (least aggressive) is best for initial surface cleaning. Acetone (moderately aggressive) is best for oily residue or minor baked-on vapors and debris.
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 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 suitable lighting. 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.
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Maintenance/
Troubleshooting
Troubleshooting
The Troubleshooting section includes subsections:
Operational flowchart
Functional block diagram
Status LEDs
Laser fault indications
Web page fault annunciation
Resetting faults
General laser fault conditions
Web interface
Beam delivery optics
The Troubleshooting 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 information.
To troubleshoot Pulstar p400 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.
Danger
Serious
personal
injury
This Class 4 laser product emits invisible infrared laser radiation in the 10.6
µm CO2 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.
Caution
Possible
equipment
damage
Attempting repair of a SYNRAD Pulstar 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.
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Maintenance/
Troubleshooting
Troubleshooting
Operational flowchart
Laser Start Sequence
Apply 48 VDC
power to laser
INT indicator
Green?
No
Apply interlock signal
to Remote Interlock input
or install factory-supplied
Quick Start Plug
Yes
TMP indicator
Green?
No
Check that cooling water
is flowing through laser
and that coolant temp
is within specified limits
Cycle DC power
(remove DC power,
wait 15 seconds,
reapply DC power)
Yes
RDY indicator
Yellow?
Blinking Code
Troubleshoot/correct
fault condition then
cycle DC power
Yes
Pulse width
is >1 ms
Or
PWM > 40%
Apply tickle pulses or a
PWM Command signal
(< 5% duty cycle) for
30 to 60 seconds
Flashing
SHT indicator
Blue?
No
Apply shutter open
signal to Shutter Open
Request input or install
factory-supplied Quick
Start Plug
Yes
Apply PWM Command
signal to laser
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 5-1 Pulstar p400 operational flowchart.
Synrad Pulstar p400 operator’s manual ver 1.0
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Figure 5-2 Pulstar p400 functional block diagram.
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108
RJ45
Ethernet Interface
DB-15
USER I/O
+48 VDC
+48 VDC
Power Board 2
Over/Under Voltage Fault
Current Fault
p400 Control Board
Over/Under Voltage Fault
Current Fault
Power Board 1
RF Module 1
RF Module 3
PWM/Fault Detection
Switched 48 VDC
RF Module 2
RF Module 4
Shutter Open Command/Fault Detection
PWM/Fault Detection
Humidity/
Flow Sense
Sensors
Switched 48 VDC
Shutter
Maintenance/
Troubleshooting
Troubleshooting
Functional block diagram
Figure 5-2 is a functional block diagram illustrating the p400’s control architecture.
Maintenance/
Troubleshooting
Troubleshooting
Status LEDs
Pulstar p400 LED indicators, also mirrored as output signals on the User I/O connector, provide status information to
the user. Table 5-2 shows Pulstar 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 5-2 Pulstar Output & LED Status Signals.
LED
LED Status(Output Signal Name)
(Output Status)
Normal
FaultNormal
Fault
INT
Green
– –
– –
Red
Interlock Open Open
Interlock Open – –
––
Closed
TMP
Green
– –
– –
Red
Fault Detected Open
Fault Detected – –
––
Closed
RDY
Yellow
– –
– –
Off/Flashing
Laser Ready Closed
Laser Ready – –
––
Open
SHT
Blue
– –
– –
– –
Off
Flashing
Shutter Open Closed
Shutter Open – –
Fault Detected – –
––
Open
Closed
LASE
Red
– –
– –
Off
Laser Active Closed
Laser Active – –
––
Open
On DC power-up, the RDY lamp illuminates yellow when INT and TMP indicators illuminate green. After the RDY
indicator illuminates an internal tickle is enabled. There is a five-second delay 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 p400 lasers is dependent on the state of the Remote Interlock input. The
Remote Interlock Input status 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 indicator is green (and the RDY LED is yellow).
Table 5-3 (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.
Possible Causes:
No voltage is applied to Pin 3 (Remote Interlock) of the User I/O connector.
On systems using remote interlocks, check to see that a positive or negative voltage in the range of 24 ±5 VDC is applied to Pin 15. For remote Interlocks, with respect to Pin 11 and Input Common on the User I/O Connector please
refer to User I/O connections in the Technical Reference chapter for details. For systems not using interlocks, wire a
male DB-15 connector to the User I/O connector so that Pin 11 (Input Common) is jumpered to Pin 12 (Auxiliary
DC Power Ground) and Pin 15 (Remote Interlock) is jumpered to Pin 4 (+5 VDC Auxiliary Power).
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Maintenance/
Troubleshooting
Troubleshooting
INT
TMP
RDY
SHT
LASE
Interlock
Open
Fault
Detected
Laser
Ready
Shutter
Open
Laser
Active
Pin
Pin 15
Pin 7
Pin 8
Pin 14
Pin 6
Output State
OPEN
OPEN
CLOSED
CLOSED
OPEN
LED Indicator
Output Signal
Figure 5-3 Status signals for Normal Operation Idle.
INT
TMP
RDY
SHT
LASE
Interlock
Open
Fault
Detected
Laser
Ready
Shutter
Open
Laser
Active
Pin
Pin 15
Pin 7
Pin 8
Pin 14
Pin 6
Output State
OPEN
OPEN
CLOSED
CLOSED
CLOSED
LED Indicator
Output Signal
Figure 5-4 Status signals for Normal Operation Lasing.
On DC power-up of a p400 laser, the RDY lamp illuminates yellow provided INT and TMP indicators illuminate
green. Once the RDY indicator illuminates yellow, an internal tickle is enabled and after a five-second period lasing
is then permitted. When the Shutter Open Request signal is applied, the internal (EM) shutter opens, the SHT LED
illuminates blue, and an application of a PWM Command signal causes the LASE indicator to illuminate red as lasing
begins.
Remote interlock condition
A remote interlock condition occurs when the Remote Interlock input opens. The INT LED is red and the Interlock is
closed. The (EM) internal shutter mechanism closes and lasing is halted immediately. On OEM p400 lasers, a remote
interlock condition is not latched. Re-apply the Remote Interlock signal by reapplying input voltage to that pin and
enabling the INT LED to change from red to green. The the interlock (shutter) opens to enable the RDY indicator.
Lasing can begin after the five-second delay provided the SHT indicator is illuminated blue and a PWM Command
signal is applied.
INT
TMP
RDY
SHT
LASE
Interlock
Open
Fault
Detected
Laser
Ready
Shutter
Open
Laser
Active
Pin 15
Pin 7
Pin 8
Pin 14
Pin 6
CLOSED
OPEN
OPEN
OPEN
OPEN
LED Indicator
Output Signal
Pin
Output State
Figure 5-5 Status signals for a Remote Interlock Fault.
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Maintenance/
Troubleshooting
Troubleshooting
INT
TMP
RDY
SHT
LASE
Interlock
Open
Fault
Detected
Laser
Ready
Shutter
Open
Laser
Active
Pin
Pin 15
Pin 7
Pin 8
Pin 14
Pin 6
Output State
OPEN
OPEN
CLOSED
OPEN
OPEN
LED Indicator
Output Signal
Figure 5-6 Status signals for the Shutter Closed Condition.
Possible Causes:
No voltage is applied to Pin 14 (Shutter open) of the User I/O connector.
Verify 24 ±5 VDC is applied to Pin 14 (Shutter Open Request). For Pin 15 Input Common on the User I/O Connector please refer to the User I/O connections section in the Technical Reference chapter for details. If your system does
not provide a Shutter Open Request signal, wire a male DB-15 connector to the User I/O connector so that Pin 15
(Input Common) is jumpered to Pin 12 (Auxiliary DC Power Ground) and Pin 14 (Shutter Open Request) is jumpered to Pin 4 (+5 VDC Auxiliary Power).
When a Shutter Open Request signal is applied to the laser, PWM Command signals are inhibited until the shutter is
fully open. It takes approximately 30 ms for the EM shutter to fully open. When the Shutter Open Request signal is
removed from Pin 10, PWM Command signals are inhibited immediately even though it takes approximately 120 ms
for the EM shutter to fully close. Tickle pulses signals continue to be applied to the RF modules during the close/open
EM shutter interval.
INT
TMP
LED Indicator
Output Signal
Pin
Output State
RDY
Off O
SHT
LASE
Off
Off
Interlock
Open
Fault
Detected
Laser
Ready
Shutter
Open
Laser
Active
Pin 15
Pin 7
Pin 8
Pin 14
Pin 6
CLOSED
OPEN
OPEN
OPEN
OPEN
Figure 5-7 Disconnected I/O Condition.
Possible Causes:
The (Optional) Quick Start Plug or Remote Interlock/Shutter Open Request inputs are not connected to the User I/O connector.
Connect the Quick Start Plug or interlock/shutter input field wiring to the DB-15 User I/O connector. See User I/O
connections in the Technical Reference chapter for wiring details.
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Maintenance/
Troubleshooting
Troubleshooting
Laser fault indications
Pulstar p400 lasers have the ability to indicate eight 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 5-3a on the following page lists error codes, the corresponding fault, and describes basic corrective action. See
the Resetting faults section for detailed corrective actions.
INT
TMP
RDY
SHT
LASE
Interlock
Open
Fault
Detected
Laser
Ready
Shutter
Open
Laser
Active
Pin
Pin 15
Pin 7
Pin 8
Pin 14
Pin 6
Output State
OPEN
CLOSED
OPEN
OPEN
OPEN
LED Indicator
Output Signal
Figure 5-8 Status signals for a Temperature Fault.
Warning
Serious
personal
injury
On Pulstar p400 OEM lasers, remote interlock faults are not latched. 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 CO2 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.
Possible Causes:
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 15.1 liters per minute (4.0 GPM).
Note:
OEM lasers can be operated at coolant temperatures up to 28 °C (64 °F to 82 °F) at a flow rate of 11.4 liters
per minute (3.0 GPM).
If water temperature is OK, check the flow rate. If a flow meter is not available, disconnect the cooling tubing from
the chiller inlet (or the drain) and run the cooling water for 30 seconds into a five-gallon bucket. After 30 seconds,
a minimum of 1.5 gallons or (5.8 L) should be collected. If there is less than 1.5 gallons or (5.8 L), check the cooling
path for kinked or pinched cooling tubes or check the chiller for a clogged or dirty filter.
On p400 lasers, the over-temperature fault is indicated by a red TMP indicator (latched status). If an over-temperature condition occurs, the TMP indicator will turn red, the Fault Detected output will latch, and the RDY indicator
light will turn off. Lasing will become disabled. Due to the 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
Synrad Pulstar p400 operator’s manual ver 1.0
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Maintenance/
Troubleshooting
Troubleshooting
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.
INT
TMP
LED Indicator
Output Signal
Pin
Output State
RDY
SHT
LASE
O
Interlock
Open
Fault
Detected
Laser
Ready
Shutter
Open
Laser
Active
Pin 15
Pin 7
Pin 8
Pin 14
Pin 6
CLOSED
OPEN
OPEN
OPEN
OPEN
Figure 5-9 Blinking Ready LED Fault.
Table 5-3a Pulstar p400 Blinking Ready LED codes.
LED
# of Blinks
Fault Condition
Corrective Action in Field
RDY
1 blink
Under Voltage fault1
Verify 48.0 VDC (measured at laser)
RDY
2 blinks
Over Voltage fault1
Verify 48.0 VDC (measured at laser)
RDY
3 blinks
RF Drive Switch fault1
Contact SYNRAD Customer Service
RDY
4 blinks
PWM Drive fault1
Contact SYNRAD Customer Service
RDY
5 blinks
DC Pre-Charge fault1
Contact SYNRAD Customer Service
1 The Laser Ready output opens (switches to a high impedance state) when a fault occurs.
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. The Laser Ready output Opens under these conditions. 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. Next,
cycle DC power off and then on again. When the RDY LED illuminates, the Laser Ready output Closes, and lasing is
enabled after the five-second delay. Apply a PWM Command signal, provided the SHT indicator is illuminated blue.
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. Under these conditions the Laser Ready output Opens. To reset an over voltage fault
first correct the voltage problem and ensure 48 VDC is measured at the laser’s DC power terminals. Next, cycle DC
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Maintenance/
Troubleshooting
Troubleshooting
power off and then on again. When the RDY LED illuminates, the Laser Ready output Closes, and lasing is enabled
(after a five-second delay) provided a PWM Command signal is applied, and the SHT indicator is illuminated blue.
RF Drive Switch fault
An RF Drive Switch fault occurs during power-up. RF drive switch faults are triggered by either of the following: the
tube fails to breakdown, or the RF Driver’s 48-volt switching circuitry fails. A RF drive switch fault is indicated when
the RDY LED flashes 3 blinks and the Laser Ready output Closes. If a RF Drive Switch fault occurs, the laser requires
service-Contact Contact SYNRAD Customer Service or a SYNRAD Authorized Distributor.
PWM Drive fault
A PWM Drive fault signals a problem in the laser’s internal RF circuitry and is indicated by a flashing RDY LED that
blinks 4 times. If a PWM Drive fault appears, the laser requires service—please contact SYNRAD Customer Service
or a SYNRAD Authorized Distributor.
DC Pre-Charge fault
A DC Pre-Charge fault indicates that 48 VDC is not available at the input of one or more of the RF modules. The
RDY LED will flash in a 5 blink pattern. When this occurs, the Laser Ready output Opens. If a DC Pre-Charge fault
appears, the laser requires service—please contact SYNRAD Customer Service or a SYNRAD Authorized Distributor.
No-Strike fault
A No-Strike fault occurs when the laser discharge does not strike (gas does not breakdown). During No-Strike faults
lasing is limited to a maximum 6.25% duty cycle (at a PWM Command frequency of 5 kHz), or 5% at the user’s
specified frequency during PWM signal application. In addition to the SHT indicator flashing continuously an error
message appears on the p400’s web page.
Humidity fault
During laser operation, monitor information on the p400’s web page including the relative humidity (RH) value.
When properly conditioned purge gas is flowing, the measured RH value should drop below 10% within 10-15
minutes. If the RH value doesn’t drop below approximately 10% increase the gas flow rate to the maximum specified
value. Refer to purge gas specifications in the Getting Started chapter within the connection section. If the RH value
continues to rise and reach 95%, lasing is haulted and a fault is displayed in red within the error message section of
the web page.
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Maintenance/
Troubleshooting
Troubleshooting
Blinking Shutter LED fault
INT
TMP
RDY
LED Indicator
SHT
LASE
O
Interlock
Open
Fault
Detected
Laser
Ready
Shutter
Open
Laser
Active
Pin
Pin 15
Pin 7
Pin 8
Pin 14
Pin 6
Output State
OPEN
CLOSED
CLOSED
CLOSED
CLOSED
Output Signal
Figure 5-10 Blinking Shutter LED Fault.
Table 5-3b Pulstar p400 Blinking Shutter LED codes.
LED
# of Blinks
Fault Condition
Corrective Action in Field
SHT
Continuous
No-Strike fault Apply single 20 µs PWM pulse (at 5 kHz), check
Fault Detected output, repeat until fault clears2
SHT
2 blinks
Frequency Limit fault2
SHT
3 blinks
Duty Cycle/Pulse Width
Limit fault3
Lower PWM frequency below 100 kHz
1
Lower PWM duty cycle below 50% or lower pulse width below 1000 µs
1 A continuously flashing SHT LED indicates a No-Strike condition and the laser is limited to 6.25% duty cycle. When the No-Strike condition
clears, the fault clears automatically 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 52 ms or until the No-Strike condition clears. When
applying 20 µs breakdown pulses, allow the output to open before applying another pulse. Applying 20 µs breakdown pulses in rapid succession
may cause laser output.
2 The SHT LED flashes a repeating sequence of 2 blinks followed by 2 pauses to indicate a frequency limit condition. The fault will clear automatically, without cycling power, when the incoming PWM Command signal frequency is lowered below 100 kHz. The Fault Detected output
closes for a minimum of 52 ms or until the frequency limit condition clears.
3 The SHT LED flashes a repeating sequence of 3 blinks followed by 2 pauses to indicate (1) a 100% duty cycle condition (when a constant 5V
signal is applied, (2) the applied duty cycle signal is above the 50% limit, or (3) the incoming pulse width exceeds 1000 µs. In all cases, the
fault will clear automatically, without cycling power, when the incoming PWM signal is within the limits described above. The Fault Detected
output closes for a minimum of 52 ms or until the duty cycle/pulse width limit condition clears.
Possible Causes:
A No-Strike fault has occurred, possibly due to cold environmental conditions (common when overnight temperatures are low) that may prevent the gas from breaking down into a plasma state.
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When this occurs, it may take 30 to 60 seconds for gas breakdown so the laser can begin normal daily operation. There
are three methods to force breakdown and clear the no-strike fault: (1) Apply tickle pulses or a PWM Command signal
(< 6.25% 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. (2) Apply a single 20 µs PWM pulse (at 5 kHz) while
monitoring the Fault Detected output. If the output closes, wait a minimum of 52 ms for the output to open and then
apply another 20 µs PWM pulse. Repeat this sequence until no fault is detected—which typically occurs in less than
one second. Be aware that applying 20 µs breakdown pulses in rapid succession may cause laser output. (3) Apply a
PWM Command signal (at < 5% duty cycle) until the fault clears—typically less than 30 seconds. With either method,
when breakdown does occur, lasing will begin immediately at the commanded PWM parameters without cycling DC
power. If the No-Strike condition persists, contact SYNRAD or a SYNRAD Authorized Distributor.
Frequency Limit fault
Possible Causes:
The 100 kHz PWM frequency limit has been exceeded.
Lasing is disabled when the input frequency limit is exceeded. When the input drops below 100 kHz, the laser will
begin lasing immediately at the commanded PWM parameters without cycling DC Power.
Duty Cylce/Pulse Width Limit fault
Possible Causes:
The applied PWM Command signal is outside the laser’s operating parameters.
Lasing is disabled when a constant 5V signal (100% duty cycle) is applied. When the PWM duty cycle drops below
100%, the laser will begin lasing immediately at its 50% PWM duty cycle limit. If the commanded duty cycle is above
50% or the PWM pulse length exceeds 1000 µs, adjust the pulse length until the PWM input is brought within limits.
The laser will then lase at the commanded PWM parameters.
Duty Cycle/Pulse Width Limit fault
When a duty cycle or pulse width limit fault is detected, the SHT LED flashes 3 blinks and the Fault Detected output
Closes to indicate (1) a constant 5V PWM signal is applied, forcing the PWM duty cycle
to 100%—full continuous wave operation; (2) the applied duty cycle is above the 50% limitation; or (3) the applied
pulse length exceeds 1000 µs in duration. When condition 1 occurs, the laser begins lasing immediately at 50% once
the PWM duty cycle drops below 100%. For condition 2, the laser begins lasing immediately at the commanded
PWM parameters,the duty cycle is automatically limited to 50%. For condition 3, the laser begins lasing immediately
at the commanded PWM parameters, the pulse duration is automatically limited to 1000 µs.
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Troubleshooting
Web page fault annunciation
The Pulstar p400 web interface displays errors and warnings in real-time on the home page in either the error
message area or the warning message area. Hard faults that require a DC power cycle are always shown in the error
message area. Operating data is not archived or displayed if the web interface is inactive when the fault occurs. The
event log page displays fault information recorded over the life of the laser. See the Pulstar p400 web interface section
in the Technical Reference chapter for web page access details.
Web interface
Symptom:
DC power is applied, but the Pulstar p400 web interface cannot be accessed.
Possible Causes:
The peer-to-peer connection was made using a straight-through Ethernet cable.
Use an Ethernet crossover cable for a peer-to-peer connection between the Pulstar p400 laser and the computer. Use
a straight-through cable when connecting to a network using a network router, switch, or hub.
The factory-default IP address was changed.
Pulstar p400 lasers are pre-configured at the factory with a fixed IP address of 192.168.50.50. If this address was
changed in the field, then you must locate the new IP address, it cannot be remotely reset.
Symptom:
The Pulstar p400 is connected to a network; however, the p400 web interface does not open or locks up while
receiving data from the laser.
Possible Causes:
The p400 laser was connected to the network using a crossover cable.
A straight-through cable is required if connecting an p400 to a network via a network router, switch, or hub.
Java script is not enabled in the web browser.
Locate your browser’s Internet Options menu and configure it to enable Java script. As shown in Figure 5-11, the Java
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Troubleshooting
feature is located on the Internet Options dialog’s Advanced tab (under Tools/Internet Options). The dialog boxes in
your particular browser may appear differently.
Figure 5-11 Enable Java script in browser.
Multiple p400’s are connected to the same network with identical IP addresses.
Make sure only one p400 laser is connected to the network at a time or, if multiple p400’s are connected, be sure they
have distinct IP addresses to prevent IP addressing conflicts.
The laser’s IP address is not recognized as an authorized site on your local intranet network or a trusted site on
the Internet.
Add the laser’s IP address to the list of authorized and/or trusted websites. In your browser, locate the Internet Options dialog’s Security tab. The dialog boxes in your particular browser may appear differently.
To authorize the p400 web page on a local intranet (Figure 5.12), click the Local intranet icon and then click the Sites
button. In the Local intranet dialog, click Advanced. In the Add this website to the zone: text box, type the laser’s IP
address and click Add. Click Close and then click OK twice.
To add the p400 web page as a trusted web site (Figure 5.12), click the Trusted sites icon and then click the Sites button. In the Trusted sites dialog, type the laser’s IP address in the Add this website to the zone: text box, and then click
Add. Click Close and then click OK twice.
Solution:
It is necessary to isolate the p400 laser from the IT network using peer-to-peer, but still important to access the
p400 web page from a networked control computer.
Use a USB to Ethernet adapter to isolate the Pulstar p400 laser from the network.
In situations where it is necessary to isolate the Pulstar p400 laser from your internal IT network, but still access
the p400 web page from a networked control computer, you can connect the p400 laser to the networked computer
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using a USB to Ethernet adapter. Devices like the TRENDnet TU2-ET100 USB to 10/100 Mbps Adapter allow your
networked computer to access the Pulstar p400 web page over the computer’s USB port, which isolates the laser from
your computer network. In this case, use a crossover Ethernet cable between the p400 laser and the USB to Ethernet
adapter.
Figure 5-12 Add IP address to list of authorized/trusted websites.
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Beam delivery optics
Danger
Serious
personal
injury
Ensure that DC power to the laser is turned off and locked out before inspecting
optical components in the beam path. Invisible CO2 laser radiation is emitted
through the aperture. Corneal damage or blindness may result from exposure to
laser radiation.
Warning
Serious
personal
injury
The use of aerosol dusters containing difluoroethane 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 difluoroethane in
any area adjacent to CO2 laser systems because difluoroethane persists for
long time periods over wide areas.
Caution
Possible
equipment
damage
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.
Symptom:
The laser loses power over time; laser output power must be increased to maintain performance.
Possible Causes:
Beam delivery optics are coated by vapor residue or debris.
Shut down the laser and carefully inspect each optic in the beam delivery path. If the optic requires cleaning, refer
back to Maintenance for cleaning instructions. Use only recommended cleaning materials (see Table 5-1) 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 Pulstar 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.
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Warning
Serious
personal
injury
A risk of exposure to toxic elements, like zinc selenide, may result when certain
optical or beam delivery components are damaged. In the event of damage
to laser, marking head, or beam delivery optics, contact SYNRAD, Inc. or the
optics manufacturer for handling instructions.
When the application requires air (instead of nitrogen) as an assist gas, we recommend the use of 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 2-4, Purge gas specifications, in the Getting Started chapter for filtering and drying
specifications.
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index
Symbols
+5 VDC Auxiliary Power 69
+5 VDC output 71
signal description, 71
+24 VDC 79
+24 VDC Auxiliary Power 69
+24 VDC output 71
signal description, 71
48V POWER terminal 48
A
American National Standards Institute (ANSI)
15
Analog current control 67
Analog voltage control 67
Aperture
see Laser aperture
Assist gas purity
specifications, 56, v, 57
Aux. DC Power Ground 71
signal description, 71
Auxiliary DC power 71
+5 VDC, 71, 72
+24 VDC 71
+24 VDC, 71
Aux. DC Power Ground 71
Aux. DC Power Ground, 71
internal wiring diagram, 71
Auxiliary DC Power Ground
pin description, 70
B
Chiller
connection, 37
coolant temperature, 35
dew point temperature, 35
fittings, 29
temperature setpoint, 35, 38, 50, 53
Chiller fittings 29
Class IV safety features 20
Code of Federal Regulations (CFR) 17, 18
Collimator 58
Command signal 61, 67
base frequency, 61
duty cycle, 61
signal amplitude, 61, 62
Condensation damage 102
Connecting
cooling, 34
f100/f201 lasers, 37
other connections, 42
Contact information
European headquarters, 10
Control signals 60
Pulse width modulation (PWM), 60
Tickle pulse, 60
Cooling connections 34
Cooling tubing 29
connecting, 37
guidelines, 34
Cooling water
temperature setpoint, 38
Copyright information 8
Customer Service 10
Beam block 50, 53
D
Beam delivery optics
troubleshooting, 118, 119
Daily inspections 102
Block diagram 108
BNC Control cable 29
C
Caution
condensation, 50, 51, 53
condensation damage, 52, 54
dirty optics, 103, 105
single-phase operation, 30, 31, 33, 35, 36, 38
, 39, 41, 45, 51, 53
voiding warranty, 106, 120, 122
CDRH 17
Danger
laser radiation, 13, 14
OEM faults, 112
DC power
connecting, 38
DC Power cable 102
DC Power Cables 29, 81
min bend radius, 81
Delivery optics 58
Dew point temperature 36
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chart, 36
Disabling Pulstar 102
Divergence 58
Input signals
PWM Return, 72
Remote Interlock, 72
E
Inspections
daily, 102
Ethernet cable 29
Interlock
see Remote Interlock
Ethernet port 48
EU 18 –19
Interlock Open
pin description, 70, 76
European headquarters 10
Interlock Open output 109
Expander/collimator 58
IP Address 44, 83
changing, 86
F
Final Test report 29
Pulstar p400
nomenclature, 24
Flowchart
laser start-up, 107
Flow rate 50, 53, 112
Food and Drug Administration (FDA) 17
Functional block diagram 108
K
Keyswitch functions
integrating, 94
L
Label locations 16
Lase indicator 47, 52, 54
Lase (LASE) indicator 109
Fuse 29
Laser Active 69
pin description, 75
G
Laser Active output 109
Gas Purge connector 48
Gas purge kit 29
Gas Purge port 35, 42, 48
connecting, 42
Gas purge specifications 43
Laser aperture 47
Laser Institute of America (LIA) 14
Laser Ready 75
pin description, 70, 75
Laser Ready output 109
GND terminal 48
Lift handles
removing, 27
H
Lifting handles 25, 48
Hazard information 13
label locations, 16
terminology, 13
M
I
Initial start-up
with a UC-2000 Controller, 49
without a UC-2000 Controller, 52
Maintenance
daily inspections, 102
disabling Pulstar, 102
storage/shipping, 103
MSDS 104
O
Input circuit
equivalent schematic, 74, vi
specifications, 74, vii
Occupational Safety and Health Administration
(OSHA) 15
Input Common 73
pin description, 70
Operating modes
analog current control, 67
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index
Optical accessories mounting 47
Optics
cleanliness, 103, 105
Output circuit
equivalent schematic, 76
specifications, 76
Output Common 75, 80, 95
pin description, 70, 75
Output signals
Interlock Open, 109
Laser Active, 109
Laser Ready, 75, 109
Output Common, 75
Over Temperature, 75, 109
Shutter Open, 75, 109
Over Temperature 75
Over Temperature output 109, 112
P
Packaging
guidelines, 25
Packaging instructions 25
PLC
multiple inputs, 80
multiple outputs, 78
Remote Interlock output, 78
Pulse Width Modulation (PWM) 60
PWM 60
signal levels, 67
PWM Input 54, 61, 72
pin description, 70
PWM Input signal
description, 72
specifications, 74
PWM Return 54, 61, 69, 72
PWM Return signal
description, 72
Q
Quick Start Plug 29, 51, 52, 53
wiring diagram, 73
R
Ready indicator 47, 53, 112
Ready (RDY) indicator 109
Reference materials 10
124
Synrad Pulstar p400 operator’s manual ver 1.0
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