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p100/150operator’smanual

4600 Campus PlaceMukilteo, WA 982751.800.SYNRAD1tel 1.425.349.3500fax 1.425.349.3667e-mail [email protected] www.synrad.com

®

100/150

100/150

Operators Manual

p100/150 version 2.1

SYNRAD© 2016 all rights reserved. No reproduction without permission.

Part number 900-20388-01

DATE: January 2017

3

Synrad Pulstar p100/150 operation manual version 2.1

Table of contents

Introduction ...............................................................................................................................................7 Trademark/copyright, EU headquarters ...................................................................................7-11 Introduction ........................................................................................................................................12 Laser handling guidelines ..............................................................................................................13 Daily inspections ...............................................................................................................................14 Pulstar Nomenclature ......................................................................................................................16 System Overview...............................................................................................................................17 Electrical Requirements ..................................................................................................................18 Cooling Requirements ....................................................................................................................20

Introduction 1

Purpose ........................................................................................................................................................ 38 Features ................................................................................................................................................ 39 Unpacking ........................................................................................................................................... 40 Inventory .............................................................................................................................................. 41 Mounting ............................................................................................................................................. 43 Connecting .......................................................................................................................................... 46

Laser Safety 2

Getting Started 3

Laser Safety ................................................................................................................................................. 24 Terms .....................................................................................................................................................25 General hazards ................................................................................................................................ 26 Hazard labeling .................................................................................................................................. 29 Agency Compliance ......................................................................................................................... 31 Declaration of Conformance ......................................................................................................... 36

Controls and Indicators .......................................................................................................................... 56 Front and rear panel ......................................................................................................................... 57Initial startup .............................................................................................................................................. 61 Initial Startup ...................................................................................................................................... 62 Auxiliary equipment ........................................................................................................................ 65

Operation 4

Purpose ....................................................................................................................................................... 67 Technical overview ......................................................................................................................... 68

Technical Reference 5

4


Table of contents

Maintenance .............................................................................................................................................108

Troubleshooting ......................................................................................................................................113

Maintenance & Troubleshooting 6

Controlling laser power ........................................................................................................................ 74User I/O connections ............................................................................................................................. 84DC Power cables ..................................................................................................................................... 97Integrating Pulstar safety features ................................................................................................... 98Pulstar p100/150 general specifi cations ...................................................................................... 100Pulstar p100/150 Outline and Mounting drawings ......................................................... 102-107

Technical Reference 5

Figure 1-1 Anatomy of a model number ....................................................................... 17Figure 1-2 DC Power Cable Connect and VDC Ground Bus .................................... 20

Figure 2-1 Pulstar p100/150 hazard label locations ..................................................... 29Figure 2-2 EU Compliance Mark ................................................................................... 35Figure 3-1 Unpacking the p100/150 laser ..................................................................... 39Figure 3-2 Removing the p100/150 lifting handles .................................................. 40Figure 3-3 Pulstar p100/150 shipping box components .............................................. 41Figure 3-4 Mounting locations for four-point mount with feet ................................. 44Figure 3-5 Mounting locations for four-point mount without feet ........................... 45Figure 3-6 Mounting locations for three-point mount without feet.......................... 47Figure 3-7 Pulstar p100/150 cooling connections........................................................ 52Figure 3-8 DC power connection locations – rear view .............................................. 54Figure 3-9 Gas purge Assembly– rear view ................................................................... 57Figure 3-10 Pulstar p100/150 web page ........................................................................... 60Figure 4-1 Pulstar p100/150 front panel controls and indicators .............................. 50Figure 4-2 Pulstar p100/150 rear panel controls and indicators ................................ 51Figure 5-1 Hybrid waveguide/unstable resonator design ........................................... 73Figure 5-2 Pulstar p100/150 beam ellipticity ................................................................ 74Figure 5-3 Converting 45° linear polarization to circular polarization..................... 75Figure 5-4 PWM command signal waveform .............................................................. 80Figure 5-5 Representative output energy profi le-10% DS-1kHz ................................ 81

Index (List of Figures)


5

InformationIndex (List of Figures continued)

Figure 5-6 Representative output energy profi le-10% DS-1kHz ................................ 81Figure 5-7 Representative output energy profi le-20% DS-1kHz .................................82Figure 5-8 Representative output energy profi le-50% DS-1kHz .................................83Figure 5-9 Representative output energy profi le-50% DS-5kHz-500 μs ....................83Figure 5-10 Representative output energy profi le-50% DS-10kHz-500 μs ..................84Figure 5-11 Representative output energy profi le-50% DS-10kHz-500 μs ..................84Figure 5-12 Representative output energy profi le-50% DS-10kHz-50 μs ....................85 Figure 5-13 Representative output energy profi le-50% DS-20kHz-500 μs ..................85Figure 5-14 Representative output energy profi le-50% DS-20kHz-50 μs ....................86Figure 5-15 User I/O connector pinouts ..........................................................................88Figure 5-16 Auxiliary DC power diagram .......................................................................91Figure 5-17 Quick Start Plug wiring diagram ..................................................................93Figure 5-18 Input equivalent schematic ...........................................................................94Figure 5-19 Output equivalent schematic ........................................................................97Figure 5-20 Customer-supplied interlock ........................................................................99Figure 5-21 Customer-supplied interlock, negative voltage ...................................................99Figure 5-22 PLC driven interlock signal. ..........................................................................100Figure 5-23 Multiple PLC driven inputs ...........................................................................100Figure 5-24 Pulstar output driving warning lamp...........................................................101Figure 5-25 Pulstar output driving relay ..........................................................................101Figure 5-26 Pulstar output driving PLC input module ..................................................102Figure 5-27 Pulstar p100/150 home page .........................................................................106Figure 5-28 Pulstar p100/150 event log page ..................................................................108Figure 5-29 Pulstar p100/150 Change IP Address page .................................................109Figure 5-30 Windows Control Panel .................................................................................111Figure 5-31 Programs and Features dialog .......................................................................111Figure 5-32 Windows Features dialog ..............................................................................111Figure 5-33 Local Area Connection Properties dialog ...................................................112Figure 5-34 Internet Protocol (TCP/IP) Properties dialog ............................................113Figure 5-35 Confi gure IP Address link on Pulstar p100/150 home page ....................114Figure 5-36 Pulstar p100/150 change IP address page ...................................................114Figure 5-37 Pulstar p100/150 web browser display ........................................................115Figure 5-38 Pulstar p100/150 outline & mounting dimensions ....................................120

6Synrad Pulstar p100/150 operation manual version 2.1

Information

Figure 5-39 Pulstar p100/150 outline & mounting dimensions (no feet) ................... 121Figure 5-40 Pulstar p100/150 packaging instructions ................................................... 122

Figure 6-1 Pulstar p100/150 operational fl owchart ..................................................... 129Figure 6-2 Pulstar p100/150 functional block diagram ............................................... 130Figure 6-3 Status signals for Normal Operation Idle ................................................... 132Figure 6-4 Status signals for Normal Operation Lasing .............................................. 133Figure 6-5 Status signals for a Remote Interlock Fault ................................................ 133Figure 6-6 Status signals for a shutter closed condition .............................................. 133Figure 6-7 Status signals for a disconnected I/O fault ................................................. 134Figure 6-8 Status signal for a temperature Fault ........................................................... 134Figure 6-9 Blinking Ready LED Fault ............................................................................ 135Figure 6-10 Blinking Shutter LED Fault .............................................................................. 137Figure 6-11 Java script enabling ........................................................................................ 138

Figure 6-12 Adding IP address ......................................................................................... 142

Table 1-1 p100/150 Flow Rate ....................................................................................... 22Table 1-2 Dew Point Temperature ................................................................................ 24Table 2-1 Class 4 Safety Features .................................................................................. 33Table 2-2 EU Directives ................................................................................................. 34Table 3-1 Pulstar Ship Components ............................................................................. 41

Table 3-2 Dew Point Temperatures .............................................................................. 51Table 3-3 Purge Gas Specifi cations ............................................................................... 58Table 5-1 Assist Gas Purity Specifi cations ................................................................... 78Table 5-2 PWM Command Signal Specifi cations ...................................................... 86Table 5-3 User I/O Pin Descriptions ............................................................................ 88-92Table 5-4 Input Circuit Specifi cations .......................................................................... 95

Table 5-5 Output Circuit Specifi cations....................................................................... 98Table 5-6 Pulstar p100/150 General Specifi cations .................................................... 118-124Table 6-1 Pulstar Output & LED Status Signals.......................................................... 131Table 6-2a Pulstar p100/150 Blinking Ready LED codes ............................................ 136Table 6-2b Pulstar p100/150 Blinking Shutter LED codes .......................................... 138

Index (List of Figures continued)

Index (List of Tables)

7Synrad Pulstar p100/p150 Operator’s manual version 2.1

Introduction

1The Introduction chapter includes the following information:

Trademark and warranty information

Laser handling guidelines

Daily inspections

Pulstar nomenclature

System overview

Electrical requirements

Cooling requirements

Important

Note: This Operation Manual explains operation activities related to Pulstar p100/150 lasers. If you cannot operate the unit using the information described in this manual, contact SYNRAD (+1.425.349.3500) or an authorized SYNRAD Distributor.

Lift the laser only by the mounting feet or baseplate. Do not lift or support the laser by its cooling fittings.Please reference the Quick Start Guide for unpacking, mounting, and connecting.Failure to properly package the laser using SYNRAD shipping box and foam/cardboard inserts as shown in Packaging Instructions may void the warranty. Customers may incur additional repair charges due to shipping damage caused by improper packaging.Before beginning any maintenance or inspections of your Pulstar p100/150 laser, be sure to completely disable the laser by disconnecting the DC Power cable (or cables) from the rear of the laser.

Synrad Pulstar p100/p150 Operator’s manual version 2.1

8

Introduction

SYNRAD and Pulstar are registered trademarks of SYNRAD©.

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

© 2013 by SYNRAD©. All rights reserved.

Trademark/copyright information

9Synrad Pulstar p100/p150 Operator’s manual version 2.1

Introduction

This is to certify that Pulstar® p100/150 lasers are guaranteed by SYNRAD© 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 environmen-tal 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© 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 p100/150 laser should fail to operate, contact the SYNRAD Customer Service department at 1.800.SYNRAD1 (out-side 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 p100/150 laser fails within the fi rst 45 days after purchase, SYNRAD© will pay all shipping charges to and from SYNRAD when shipped as specifi ed by SYNRAD Customer Service. After the fi rst 45 days, SYNRAD will continue to pay for the costs of shipping the re-paired 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 effi cient operation of your Pulstar p100/150 laser, only authorized SYNRAD replacement parts can be used. This warranty is void if any parts other than those provided by SYNRAD© are used.

SYNRAD© and SYNRAD Authorized Distributors have the sole authority to make warranty statements regarding SYNRAD products. SYNRAD© and its Authorized Distributors neither assumes nor authorizes any representative or other person to assume for us any other warran-ties in connection with the sale, service, or shipment of our products. SYNRAD© 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 expens-es 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.

Trademark/copyright information


10

IntroductionTrademark/copyright information

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

4600 Campus Place Mukilteo, WA 98275 U.S.A.

Phone us at: 1.800.SYNRAD1 (1.800.796.7231)Outside the U.S.: +1.425.349.3500Fax: +1.425.349.3667E-mail: [email protected]

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 appli-cation, use them as a fi rst 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 specifi cations. 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 rep-resentative, or you can email us by sending a message to [email protected].

Technical Support

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

Reference materials

Your Regional Sales Manager can provide reference materials including Outline & Mounting drawings, Operator’s Manuals, Technical Bulletins, and Application Newsletters. Most of these materials are also available directly from SYNRAD’s web site at http://www.synrad.com.

11


IntroductionEuropean 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 31 707-0Fax: +49 (0) 89 31 707-222E-mail: [email protected]


12

IntroductionGuidelines

Follow these guidelines when installing and operating your Pulstar p100/150 laser. The Laser handling guidelines section includes subsections:

Unpacking

Mounting

Connecting

Cooling

Storage/shipping

Unpacking

Save all laser packaging. This specially designed packaging will protect the laser from damage when it must be shipped to another location. See Chapter 5, Drawings, for illustrations show-ing the correct method for re-packaging p100/150 lasers for shipment.

Mounting

When mounting the Pulstar laser, use only one metric or SAE fastener per mounting tab on the baseplate. Do not use any type of jackscrew arrangement as this will twist the baseplate and may distort the tube.

Connecting

DC Power cable

Do not reverse polarity when connecting the DC Power cable between the DC power supply and the p100/150 laser. Attach the red (+) wire(s) from the DC Power cable to the positive (+) 48 VDC output terminal and attach the black (-) wire(s) from the DC Power cable to the nega-tive (-) 48 VDC output terminal.

Gas Purge port

Apply a gas purge pressure between 0.14–0.34 bar (2–5 PSI) or a flow rate of 849–1699 liters/hour (30–60 SCFH). Do not exceed a pressure of 0.34 bar (5 PSI). Use only nitrogen or CDA (clean dry air) as a purge gas. Do not use any other gas as this could damage the laser.

13


IntroductionCoolants

When filling your chiller, use at least 90% distilled or tap water by volume. If you must use glycol, do not add more than 10% by volume. See the Pulstar p100/150 technical reference section in this manual for detailed information.

Coolant temperature

Set a chiller temperature set-point between 18–22 °C (64–72 °F). The set-point temperature MUST be maintained above the dew point temperature. Operating the laser with a coolant temperature below the dew point of the surrounding air may cause condensation to occur that will damage the laser.

Condensation

Inspect the laser daily for signs of water condensation during operation. Condensation causes damage to electrical and optical components.

Do NOT operate the laser in a condensing environment—the laser will be damaged! Refer to the Pulstar p100/150 Technical Reference section in this manual for steps you can take to pre-vent condensation damage.

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 less than 29 PSI (wear safety glasses!) to remove any residual water. When finished, cap all connectors to pre-vent 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 box. If you no longer have the box, contact SYNRAD Custom-er Service about obtaining a replacement. Refer to the appropriate Packaging Instructions (included with the replacement box, in Chapter 5 of this manual, or from the SYNRAD web site at: http://www.synrad.com/Service/packaging.htm) for detailed instructions on properly packaging the laser for shipment.

Daily inspections

Perform the following steps daily to keep your Pulstar p100/150 laser in optimum operating condition.

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


14

Introduction

2 Inspect external beam delivery components for signs of dust or debris and clean as required. When cleaning the optical surfaces, carefully follow the manufacturer’s instructions.

3 When using compressed air as a purge gas on your laser, empty water traps and oil separators on each fi lter and/or dryer between the laser and your compressed air source. Purge gas purity must meet the specifi cations shown in Table 3-2 in the Getting Started Chapter.

4 Visually inspect the exterior housing of the laser to ensure that all warning labels are present. Refer to the Laser Safety chapter for Pulstar p100/150 label types and locations in the P100/150 this Manual.

Caution A risk of exposure to toxic elements 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, or the optics manufacturer for handling instructions.

If you operate your laser dirty or dusty environments, 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.

Possible

equipment

damage

15


Introduction

Pulstar nomenclature & model numbers

The Pulstar nomenclature section includes:

p100/150 laser versions

Model numbers

The Synrad Pulstar high peak power line of pulse CO2 lasers includes: p100, p150, p250 and the p400. Pulstar p100 lasers are currently available only as OEM lasers and are designed primarily 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.

As an Original Equipment Manufacturer or (OEM) laser, the p100/150 do not comply with 21 CFR, Subchapter J or EN 60825-14 without additional safeguards.

Designed primarily for pulse operation, the p100/150 is still controlled by a PWM Command signal; however, the duty is limited to maximum duty cycle of 37.5% and a maximum pulse length of 600 microseconds (μs) typical. The p100/150’s pulsed RF design overdrives the laser gas, resulting in substantially higher peak power (600W typical) than our ti-Series CW laser even though the average power output of these two lasers is almost the same. Like our in-tegrated ti-Series lasers, the p100/150 features a built-in RF power supply so no external RF cables are required. This compact, lightweight design mounts easily to flatbed cutters, robotic arms, or gantry systems making integration into your production line simple and fast.

The last three characters in the Pulstar model number serve to designate the functional cate-gory, 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 meth-od: “W” for water-cooled units, “F” for fan-cooled units, and “A” for air-cooled lasers (the “W” is omitted on p-Series lasers because they are all water-cooled). The last letter in the model number indicates the current model version beginning with “B”. The Pulstar OEM p100 laser is available only in an OEM water-cooled configuration so model number PSP100SB designates a “B” version OEM water-cooled laser.


16

Introduction

System overview

The System overview section includes:

Laser tube

Optical resonator

DC power supply

Control circuit

Optical setup

Laser tubePulstar® p100/150 lasers were developed using new technology patented by SYNRAD. Pul-star’s patented “p” technology, include RF components that are integrated within the laser body itself, completely eliminating the need for external RF boxes and cables. The net result is 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 technolo-gies. 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 compo-nents.

p100/150 Technology

The p100/150's peak pulse power takes materials processing a step further by allowing users to cut faster and drill deeper through a variety of materials, with minimal heat affect zone and superior cut edge quality.

Cooling

Heat generated by excited CO2 molecules is transferred to the bore walls by diffusion. Collect-ed 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 temperature for maximum stability.

Optical resonatorThe optical resonator, in conjunction with the electrodes and the gas mixture, generates the laser beam. Pulstar p100/150 resonators are comprised of three optical elements: a front mir-ror, a rear mirror, and an output coupler (window). These elements are fastened to the tube’s exterior and 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 cush-ion that allows the slight movement necessary for alignment.

17


Introduction

Electrical requirements

The Electrical Requirements section includes:

DC power supply

Electrical isolation

AC power requirements

DC power supply

Please refer to the appropriate power supply manual.

Hazardous DC voltages exist on DC power supply output terminals whenthe power supply is energized. Contacting energized terminals may result in serious personal injury or death. Protect all 48 VDC connections from incidental contact in accordance with local, state, and national code requirements for electrical insulation and labeling.All AC input wiring and fusing to the DC power supply must be sized and connected in accordance with applicable local, state, and National Electrical Code (NEC) requirements. Local, state, and national code requirements supersede any recommen-dations provided in this manual.

Warning

Seriouspersonalinjury

Do not plug and unplug the DC Power cable on the rear of the laser to switch DC power to the laser. Switching power under load causes arcing that will damage the connector and laser control board. To properly cycle power to the laser, switch the AC power source controlling the DC power supply.Do not reverse polarity when connecting the DC Power cable to your DC power source. Reversed DC polarity may damage the laser’s internal circuitry.

Caution

Possibleequipmentdamage


18

IntroductionDC laser supply connections

Please refer to the Getting Started chapter to reference Pulstar p100/150 laser DC laser con-nections.

User I/O connection summary

Please refer to the table in the Getting Started Chapter to reference Pulstar p100/150 User I/O connections.

Cooling requirements

The Cooling requirements section includes subsections:

Laser cooling fittings

Coolant guidelines

Temperature set-point

Flow rate

Dew point

Laser cooling fi ttings

If your laser application uses 1/2 inch cooling tubing, we recommend the installation of tubing adapters to convert the laser’s existing WATER IN/WATER OUT fittings from 12 mm standard to 1/2 inch tubing. If required, many tubing and fitting manufacturers can supply 1/2-inch to 12-mm fittings.

19


Introduction

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.

Coolant guidelines

SYNRAD recommends that the laser’s cooling fluid contain at least 90% water (distilled or tap) by volume.

In closed-loop systems, use a corrosion inhibitor/algaecide such as Optishield® Plus or equiva-lent.

Avoid glycol-based additives because they reduce the coolant’s heat capacity and high con-centrations 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.

In applications where biocides containing chlorides are used, concentrations should not exceed 25 parts per million (PPM).

Maintain a coolant pH level above 7.0. We recommend the installation of a fi lter on the chiller’s return line, especially in areas where water hardness is a problem.

Pulstar p100/150 lasers incorporate the following wetted materials in the coolant path- brass, copper, Delrin®, PBT, polyethylene, stainless steel, and Viton®.


20

IntroductionTemperature set-point

Choosing the correct coolant temperature is important to the proper operation and longev-ity 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 electronics and damage to optical surfaces.

The greatest risk of condensation damage occurs when the laser is in a high heat/high hu-midity 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.

Stop coolant flow when the laser is shut down.

Increase coolant flow by an additional 1.0 GPM. Do not exceed a coolant pressure of 60 PSI (4.1 bar).

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

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

Purge the laser - See Gas Purge Port in the Getting Started Chapter for details.

Flow rate

Set coolant fl ow according to the following. Ensure that coolant pressure does not exceed 60 PSI (4.1 bar).

Table 1.1 p100/150 water fl ow rate.

Laser Type Minimum Water Flow Rate Recommended Water Flow Rate

p100/150 1.5 GPM (5.7 LPM) 2 GPM (7.58 LPM)

21


IntroductionDew point

The dew point table 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, but should not exceed 22 °C (72 °F).

To use the table, 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 Rela-tive 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 exam-ple, 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 pre-vent condensation from forming inside the laser or RF power supply.

Condensation forming inside the laser or RF power supply will damage the system.

Caution

Possibleequipmentdamage


22

IntroductionA

ir

Te

mp

°F

/°C

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

60 °F - - - 32 36 39 41 44 46 48 50 52 54 55 57 59

16 °C - - - 0 2 4 5 7 8 9 10 11 12 13 14 15

65 °F - - 33 37 40 43 46 48 51 53 55 57 59 60 62 64

18 °C - - 1 3 4 6 8 9 11 12 13 14 15 16 17 18

70 °F - 33 37 41 45 48 51 53 56 58 60 62 64 65 67 69

21 °C - 1 3 5 7 9 11 12 13 14 16 17 18 18 19 21

75 °F - 37 42 46 49 52 55 58 60 62 65 67 68 70 72 73

24 °C - 3 6 8 9 11 13 14 16 17 18 19 20 21 22 23

80 °F 35 41 46 50 54 57 60 62 65 67 69 71 73 75 77 78

27 °C 2 5 8 10 12 14 16 17 18 19 21 22 23 24 25 26

85 °F 40 45 50 54 58 61 64 67 70 72 74 76 78 80 82 83

29 °C 4 7 10 12 14 16 18 19 21 22 23 24 26 27 28 28

90 °F 44 50 54 59 62 66 69 72 74 77 79 81 83 85 87 88

32 °C 7 10 12 15 17 19 21 22 23 25 26 27 28 29 31 31

95 °F 48 54 59 63 67 70 73 76 79 81 84 86 88 90 92 93

35 °C 9 12 15 17 19 21 23 24 26 27 29 30 31 32 33 34

100

°F52 58 63 68 71 75 78 81 84 86 88 91 93 95 97 98

38 °C 11 14 17 20 22 24 26 27 29 30 31 33 34 35 36 37

Table 1.2 Dew point temperatures.

Relative Humidity (%)

Synrad Pulstar p100/150 operators manual version 2.1

23

2Laser Safety

This chapter contains safety information that you will need to know prior to getting started.

Hazard Information – includes equipment label terms and hazards, please familiarize yourself with all defi nitions and their signifi cance.

General & Other Hazards – provides important information about the hazards and unsafe practices that could result in death, severe injury, or product damage.

Disposal – information on your p100/150 laser parts and/or components as they pertain to disposal.

Additional Safety Information – describes how to fi nd additional information about your p100/150 laser.

Compliance – explains in the subsections therein applicable and appropriate regula- tion information.

Note: Read the entire safety section. This will ensure you are familiar with the hazards and warnings prior to starting.

Danger

Serious personal injury

This Class 4 laser product that emits invisible infrared laser radiation in the 9.3–10.6 μm CO2 wavelength band.

Because direct or diff use laser radiation can infl ict 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.


24

Introduction

Laser Safety

WarningSerious 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 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 IEC/TR 60825-14:2004, Safety of Laser Products – Part 14: A User’s Guide.

Caution- potential hazards or unsafe practices which, if not avoided, may result in product damage.

Important information or recommendations concerning the subject under discussion.

Hazard InformationHazard 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.

TermsCertain terms are used throughout this manual or on the equipment labels. Please familiarize yourself with their defi nitions and signifi cance.

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.

Hazards which, if not avoided, could result in minor or moderate injury.

Alerts the operator of dangerous voltages.

Alerts the operator of hazardous radiation.

Two

Person Lift

Alerts the operator of lift ing dangers.

Alerts the operator of serious dangers.

Alerts the operator of equipment dangers.

Alerts the operator of vapor dangers.

Note:Important Note: Tip:

Figure 2-1 Labeling terms and defi nitions.

Alerts the operator of refl ective dangers.


25

Hazard Information

Laser Safety

DangerSerious 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 re-fl ected laser energy. CO2 laser radiation can be refl ected from metallic objects even though the surface is darkened. Direct or diff use laser radiation can infl ict 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 refl ections from metallic surfaces.

Enclose the beam path whenever possible. Exposure to direct or diff use 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 explo-sive, atmospheres.


Materials processing with a laser can generate air contaminants such as vapors, fumes, and/or particles that may be noxious, toxic, or even fatal. Material Safety Data Sheets (MSDS) for materials being pro-cessed should be thoroughly evaluated and the adequacy of provi-sions for fume extraction, fi ltering, and venting should be carefully considered. Review the following references for further information on exposure criteria:

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

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

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

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

The use of aerosol dusters containing difl uoroethane causes “bloom-ing”, a condition that signifi cantly expands and scatters the laser beam. This beam expansion can eff ect mode quality and/or cause laser energy to extend beyond the confi nes of optical elements in the system, possibly damaging acrylic safety shielding. Do not use air dusters containing difl uoroethane in any area adjacent to CO2 laser systems because difl uoroethane persists for long time periods over wide areas.

General hazards

Following are descriptions of general hazards and unsafe practices that could result in death, severe injury, or product damage. Specifi c warnings and cautions not appearing in this sec-tion are found throughout the manual.


26

Hazard Information

Laser Safety

Pulstar p100/150 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 specifi ed through-out this manual and exercise safe operating practices per ANSI Z136.1-2007, Safe Use of Lasers at all times when actively lasing.

Figure 2-2 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 con-ditions. Never operate the laser in the presence of fl ammable or explosive materials, gases, liquids, or vapors.The use of controls or adjustments or performance of procedures other than those specifi ed herein may result in exposure to hazardous invisible laser radiation, damage to, or malfunc-tion 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 combusti-ble 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 materi-al or metals as the beam blocker; organic materials, in general, are apt to combust or melt and metals act as specular refl ectors which may create a serious hazard outside the immediate work area.Always wear safety glasses or protective goggles with side shields to reduce the risk of dam-age to the eyes when operating the laser.

Due to the specifi c properties of laser light, a unique set of safety hazards that diff er from oth-er light sources must be considered. Just like light, lasers can be refl ected, refracted, diff racted or scattered.

Adversive lightwarning!


27

Hazard Information

Laser Safety

Other hazardsThe 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 expo-sure to hazardous laser energy and injury due to failure of personnel to use proper eye pro-tection 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.

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

Additional laser safety informationThe SYNRAD web site (http://www.synrad.com/LaserFacts/safetyinfo.html) contains an online laser safety handbook that provides information on (1) Laser Safety Standards for OEM’s/Sys-tem 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). Sec-tion III, Chapter 6 and Appendix III are good resources for laser safety information.Another excellent laser safety resource is the Laser Institute of America (LIA). Their compre-hensive web site is located at http://www.lia.org.


28

Agency Compliance

Laser Safety

Pulstar p100 label locations

Front

DANGER: INVISIBLE LASER RADIATION

AVOID EYE OR SKIN EXPOSURE TODIRECT OR SCATTERED RADIATION

CLASS 4 LASER PRODUCT

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AVOID EXPOSUREInvisible laser radiation

is emitted fromthis aperture.



700 WATTS MAX10200-10800 nm

EN-60825-1, 2007

CAUTIONCONDENSATION ANDWATER DAMAGE CAN

OCCUR IF COOLING WATERIS BELOW DEW POINT.

SEE OPERATION MANUAL.

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This laser product is manufactured underone or more of the following U.S. Patents:

4,805,182 5,065,405 6,195,379 6,603,7944,837,772 5,215,864 6,198,758 6,614,8265,008,894 5,602,865 6,198,759 Other U.S. and International Patents pending.

MODEL #: PSP100SBSERIAL #: P100067120009TESTED AT 48 Volts MFG March 07, 2012

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

SYNRAD. 4600 Campus Place, Mukilteo WA 98275 425.349.3500

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Bottom

Rear


Figure 2-3 Pulstar p100 hazard label locations.


29

Agency Compliance

Laser Safety

Figure 2-4 Pulstar p150 hazard label locations.

DANGER: INVISIBLE LASER RADIATIONAVOID EYE OR SKIN EXPOSURE TODIRECT OR SCATTERED RADIATION

CLASS 4 LASER PRODUCT

INVI

SIBL

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CAUTIONCONDENSATION ANDWATER DAMAGE CAN

OCCUR IF COOLING WATERIS BELOW DEW POINT.

SEE OPERATION MANUAL.

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Top View

MODEL #: PSP150SASERIAL #: P15034414BETA3TESTED AT: 48V MFG: December 10, 2014

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

SYNRAD, a GSI division. 4600 Campus Place, Mukilteo WA 98275 425.349.3500

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Front


is emitted fromthis ape rture.

This laser product is manufactured underone or more of the following U.S. Patents:

4,805,182 5,065,405 6,195,379 6,603,7944,837,772 5,215,864 6,198,758 6,614,8265,008,894 5,602,865 6,198,759 Other U.S. and International Patents pending.

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Rear


Pulstar p150 label locations


30

Agency Compliance

Laser Safety

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 certifi ed to comply with certain United States (U.S.) and European Union (EU) regulations. These regulations impose product performance re-quirements related to electromagnetic compatibility (EMC) and product safety characteris-tics for industrial, scientifi c, and medical (ISM) equipment. The specifi c provisions to which systems containing Pulstar p100/150 lasers must comply are identifi ed 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 radi-ated emission standards fall under the jurisdiction of the U.S. Federal Communications Com-mission (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, 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 process-ing system, they do not meet all of the Standards for complete laser processing systems as specifi ed by 21 CFR, Part 1040 or Z136.1-2007, Safe Use of Lasers. SYNRAD, assumes no re-sponsibility for the compliance of the system into which OEM laser products are integrated.

Center for Devices and Radiological Health (CDRH) requirementsProduct features incorporated into the design of Pulstar p100/150 lasers to comply with CDRH requirements are integrated as panel controls or indicators, internal circuit elements, or input/output signal interfaces. Specifi cally, these features include a lase and laser ready indicators, remote interlock for power on/off , a laser aperture shutter switch, and a fi ve-second delay between power on and lasing. Incorporation of certain features is dependent on the laser ver-sion (Keyswitch or OEM). Table 2-1, Class 4 safety features, indicates which features are avail-able on p100/150 lasers, the type and description of the feature, and if the feature is required by CDRH regulations.

OEM modelsPulstar p100/150 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.


31

Agency Compliance

Laser Safety

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 inte-grate the laser so that it complies with all applicable laser safety standards as set forth above.

Federal Communications Commission (FCC) Requirements

The United States Communication Act of 1934 vested the Federal Communications Commis-sion (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 aff ecting authorized radio communication services. The FCC regulations that govern industrial, scientifi c, and medical (ISM) equipment are fully described in 47 CFR, Part 18, Subpart C.SYNRAD’s Pulstar p100/150 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 PotentialIn our testing, SYNRAD, has not discovered any signifi cant electrical interference traceable to Pulstar p100/150 lasers.

System MaintenanceEnsure that all exterior covers are properly fastened in position.

Measures to Correct InterferenceIf you suspect that your Pulstar laser interferes with other equipment, take the fol-lowing steps to minimize this interference:

1 Use shielded cables to and from the equipment that is experiencing interfer-ence problems.

2 Ensure that the Pulstar laser is properly grounded to the same electrical poten-tial as the equipment or system it is connected to.

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


32

Agency Compliance

Laser Safety

European Union (EU) requirements RoHS complianceSYNRAD Pulstar p100/150 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.

Laser safety standardsUnder the Low Voltage Directive, 2006/95/EC, the European Norm (EN) document EN/TR 60825-14 was developed to provide laser safety guidance and includes clauses on Engineer-ing Specifi cations, Labeling, Other Informational Requirements, Additional Requirements for Specifi c Laser Products, Classifi cation, 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, As-sociated Hazards, Evaluating Risk, Control Measures, Maintenance of Safe Operation, Incident Reporting and Accident Investigation, and Medical Surveillance.

OEM modelsPulstar p100/150 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/TR 60825-14 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 fi nal 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 com-ponent is incorporated into another device or system, the entire machinery installation may be required to conform to IEC/EN/TR 60825-14, 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-us-er must integrate the laser so that it complies with all applicable laser safety standards as set forth above. Table 2-1, Class 4 safety features, summarizes Pulstar p100/150 product features, indicating the type and description of features and whether those features are required by European Union regulations.

Electromagnetic interference standardsSYNRAD’s Pulstar p100/150 lasers have demonstrated performance characteristics that have met or exceeded the requirements of EMC Directive 2014/108/EC.


33

Agency Compliance

Laser Safety

Table 2-1 Class 4 safety features. Required by: Available on:Feature Location / Description CDRH EN60825-14 OEM p100/150

Keyswitch1 Rear panel control Yes Yes No On/Off /Reset Keyswitch controls power to laser electronics. Key cannot be removed from switch in the “On” position.Shutter Laser control Yes Yes Yesfunction Functions as a beam attenuator to disable RF driver/laser output when closed.Shutter Rear panel indicator (Blue) No No Yesindicator Illuminates blue to indicate shutter is open.Ready Rear panel indicator (Yellow) Yes Yes Yesindicator Indicates that laser has power applied and is capable of lasing.Lase Rear panel indicator (Red) No No Yesindicator Indicates that Pulstar is actively lasing. Lase LED illuminates when the duty cycle of the Command signal is long enough to produce laser output.Five second Pulstar circuit element Yes No Yesdelay Disables RF driver/laser output for fi ve seconds after Keyswitch is turned to “On” or remote reset/start pulse is applied when Keyswitch is in “On” position.Power fail Pulstar circuit element Yes Yes Nolockout1 Disables RF driver/laser output if input power is removed then later reapplied (AC power failure or remote interlock actuation) while Keyswitch is in “On” position.Remote Rear panel connection Yes Yes YesInterlock 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 YesInterlock Illuminates green when Remote Interlock circuitry is closed. Illuminates red whenindicator interlock circuitry is open.Over Pulstar circuit element No No Yestemperature Temperature shutdown occurs if temperature of the laser tube rises above safeprotection operating limits.Temp Rear panel indicator (Green/Red) No No Yesindicator Illuminates green when laser temperature is within operating limits, changing to red when thermal limits are exceeded.Warning Pulstar exterior Yes Yes Yeslabels Labels attached to various external housing locations to warn personnel of potential laser hazards.

1 Not available on p400 OEM lasers


34

Agency Compliance

Laser Safety

When integrating SYNRAD’s Pulstar p100/150 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 p100/150 lasers comply with the relevant requirements of 2014/30/EU, the Electromagnetic Compatibil-ity Directive, as summarized in Table 2-2 below.

Table 2-2 European Union Directives.

Applicable Standards / Norms

2014/30/EU Electromagnetic Compatibility Directive

2006/95/EC Low Voltage Directive

2011/65/EU RoHS Directive

EN 61010-1 Safety Requirements for Electrical Equipment for Measure- ment, Control, and Laboratory Use - Part 1: General Requirements

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

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

EN 61000-6-2 Electrostatic Discharge Immunity

EN 61000-6-2 RF Electromagnetic Field Immunity

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

EN 61000-6-2 Conducted RF Disturbances Immunity

After a laser or laser processing system has met the requirements of all applicable EU Direc-tives, the product can bear the offi cial compliance mark of the European Union as a Declara-tion of Conformity.


35

Agency Compliance

Laser Safety

Figure 2-5 p100 Document.


36

Agency Compliance

Laser Safety

Figure 2-6 p150 Document.

37

Synrad Pulstar p100/p150 Operators manual version 2.1

Getting Started

3The Getting Started chapter includes the following information:

Introduction Covers the p100/150 laser(s) features, model number, and guidelines.

Unpacking-Provides key unpacking information, please refer to the appropriate Quick Start Guide.

Inventory- Describes shipping components.

Mounting- Explains how to attach p100/150 lasers to a mounting surface, please refer to the appropriate Quick Start Guide.

Connecting- Instructs how to connect electrical, cooling, and controls. The associated Quick Start guide may be used initially to get up and running.

Important Note:

The Quick Start Guide (QSG) explains how to quickly unpack and assemble Pulstar p100/150 lasers. Please reference the QSG while reading this chapter, feel free to contact SYNRAD, (+1.425.349.3500) or an authorized SYNRAD Distributor.Lift the laser only by the mounting feet or baseplate. Do not lift or support the laser by its cooling fittings. DO NOT use de-ionized (DI) water as a coolant. DI water is unusually corrosive and is not recommended for mixed material cooling systems.Failure to properly package the laser using SYNRAD shipping box and foam/cardboard inserts as shown in Packaging Instructions may void the warranty. Customers may incur additional repair charges due to shipping damage caused by improper packaging.

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.

Caution Possible

equipment

damage

Pulstar OEM p100/150 lasers can be operated at coolant temperatures up to 30 °C to reduce prob-lems associated with condensation; however, this may result in decreased laser performance and/or reduced laser lifetime.

Note:


38

Introduction

Getting Started

Pulstar featuresPlease refer to the p100/150 specifications in the Technical Reference chapter.

Model numbersThe last three characters in the Pulstar model number serve to designate the functional cate-gory, cooling method, and model version. The functional category is indicated by “S” (Switch-less) for OEM models. The next letter indicates the cooling method: “W” for water-cooled units. The last letter in the model number indicates the current model version beginning with “B”. The Firestar OEM p100/150 laser is available only in a water-cooled (SW) configuration.

Unpacking

39


Getting Started

GuidelinesFollow these guidelines when unpacking, mounting, and connecting your Pulstar p100/150 laser. Please feel free to reference the Quick Start Guide. The Laser handling guidelines sec-tion includes subsections:

Unpacking and Inspection

Mounting

Connecting

Cooling

Storage/shipping

Unpacking and InspectionSave all laser packaging. This specially designed packaging will protect the laser from damage when shipping to another location. See the Quick Start Guide and engineering drawings, for illustrations showing the correct method for re-packaging p100/150 lasers for shipment with-in the Technical Reference chapter.

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.

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

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 fi ttings; lift the laser by the lifting handles or base plate 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.


40

Unpacking

Getting Started

Refer to Packaging instructions drawings in the Technical Reference chapter for details on packaging p100/150 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 fi ttings to prevent debris from entering the coolant path.

Contents descriptionEach item below is also listed in tables that follow:

Pulstar p100 Pulsed Laser – The Pulstar p100 laser is a compact laser generating 100 W aver-age power and peak power greater than 390 W with rise times less than 40 microseconds (μs).

Customer Communication Flier p100- Instead of the laser manual CD, please follow the instructions for our latest laser manual(s) located here: http://www.synrad.com/Manuals/man-uals_laser.htm

Quick Start Plug p100 – connects to the User I/O connector. Jumpers are built into the plug to enable the laser’s interlock circuits for initial start-up and testing.

DC Power Cable Set (not shown) p100 – connects 48 VDC from the DC power supply to the Pulstar p100 laser. Standard cable length is 1.8 meters (6.0 ft).

Cooling Tubing p100– carries cooling water from the chiller (not included) to the laser and back. This black polyethylene tubing is 12mm O.D. by 30 feet and must be cut to length.

Mounting Bolts & Metric Mounting Screws (not shown) p100– Three each 1/4–20 × 5/8” UNC capscrews are provided for mounting the Firestar p100 laser to your mounting surface. Two sets of three (3) M6x1x16mm mounting screws are included.

Gas Purge Kit p100– provides a filtering and connection point to the laser from your facility’s gas purge system.

Cooling Kit p100– adapts the laser’s straight 1/2-inch coolant fittings to 90° adapter fittings for either 1/2-inch standard or 12-mm metric cooling tubing.

Spare Fuses (not shown) p100– fast-acting mini ATO-type fuses protects the Pulstar internal circuitry.

Final Test Report (not shown) p100– contains data collected during the laser’s final pre-ship-ment test.

Pulstar p150 Pulsed Laser – The Pulstar p150 laser is a compact laser generating 150 W aver-age power and peak power greater than 600 W with rise times less than 50 microseconds (μs).

Customer Communication Flier p150- Instead of the laser manual CD, please follow the instructions for our latest laser manual(s) located here: http://www.synrad.com/Manuals/man-uals_laser.htm

Quick Start Plug p150 – connects to the User I/O connector. Jumpers are built into the plug to enable the laser’s interlock circuits for initial start-up and testing.

Unpacking

41


Getting Started

Table 3-1 Pulstar p100 ship kit contents.

Shipping Box Contents Qty Shipping Box Contents Qty

Firestar p100 Pulsed Laser ................1 Mounting Bolts .................................3

Laser Manual url...................................1 Gas Purge Kit ......................................1

Quick Start Plug ..................................1 Cooling Kit .........................................1

Cooling Tubing .....................................1 Spare Fuses (not shown) ................2

DC Power Cable Set (not shown) ...1 Final Test Report (not shown) .....1

Table 3-2 Pulstar p150 ship kit contents.

Shipping Box Contents Qty Shipping Box Contents Qty

Firestar p150 Pulsed Laser ................1 Mounting Bolts .................................3

Laser Manual url...................................1 Gas Purge Kit ......................................1

Quick Start Plug ..................................1 Cooling Kit .........................................1

Cooling Tubing .....................................1 Spare Fuses (not shown) ................2

DC Power Cable Set (not shown) ...1 Final Test Report (not shown) .....1

DC Power Cable Set (not shown) p150 – connects 48 VDC from the DC power supply to the Pulstar p150 laser. Standard cable length is 1.8 meters (6.0 ft).

Cooling Tubing p150– carries cooling water from the chiller (not included) to the laser and back. This black polyethylene tubing is 12mm O.D. by 30 feet and must be cut to length.

Mounting Bolts & Metric Mounting Screws (not shown) p150– Three each 1/4–20 × 5/8” UNC capscrews are provided for mounting the Firestar p150 laser to your mounting surface. Two sets of three (3) M6x1x16mm mounting screws are included.

Gas Purge Kit p150– provides a filtering and connection point to the laser from your facility’s gas purge system.

Cooling Kit p150– adapts the laser’s straight 1/2-inch coolant fittings to 90° adapter fittings for either 1/2-inch standard or 12-mm metric cooling tubing.

Spare Fuses (not shown) p150– fast-acting mini ATO-type fuses protects the Pulstar internal circuitry.

Final Test Report (not shown) p150– contains data collected during the laser’s final pre-ship-ment test.


42

Getting StartedMounting

2 Place the p100/150 laser on the mounting surface so the threaded holes in the base plate line up with the thru holes in your mounting surface, refer to the fi gure above.

Mounting

Mounting from below into p100/150 base plate

Mounting from above using the optional mounting feet

When mounting the Pulstar laser, use only one metric or SAE fastener per mount-ing tab on the baseplate. Do not use any type of jackscrew arrangement as this will twist the baseplate and may distort the tube.

The Pulstar p100/150 base plate is designed so that the laser is easily mounted using only three 1/4—20 UNC or M6 × 1 ISO fasteners. Three ball bearing “feet” pressed into the base plate eliminate any possible distortion of the laser tube caused by variations in the flatness of the mounting surface. See the Pulstar p100/150 outline & mounting drawing in the Technical Reference chapter for mounting locations and dimensions.

Please review the Quick Start Guide, and the outline and mounting drawings carefully, the threads in the baseplate can be damaged if these fasteners are threaded into the wrong holes.

p100/150 Mounting from below (into a base)

To fasten the Pulstar OEM p100/150 laser to your mounting surface using a base or ‘mounting plate’, perform the following steps:

1 Refer to the p100/150 outline and mounting drawing for hole locations in the Technical References section. Then drill three thru holes in the fi nal mounting surface. These holes should correspond with either the ISO (metric) or UNC fastener pattern shown in the O&M drawing.

Figure 3-1 Attaching the laser to the mounting plate.

Important Note:

43



Verify the correct fastener length for your mounting application. When fastening the Pulstar p100/150 to your mounting surface, be sure the fasteners do not extend further than 11.0 mm (0.433”) into the laser’s base plate.

3 Insert three M6 × 1 ISO or 1/4–20 UNC fasteners through the mounting surface into the corresponding threaded holes in the p100/150 base plate. Turn the screws by hand until the threads engage.

4 Evenly tighten all three fasteners to a maximum torque of 6.1 N m (54 in lb).

p100/150 Mounting from above (using optional mounting feet)

To fasten the Pulstar OEM p100/150 laser onto a mounting surface, you will need to purchase and install the optional p100/p150 mounting feet. The mounting kit, for p100/p150 SYNRAD P/N 250-20440-01 is available separately from the factory.

To attach the optional mounting feet to the OEM p100/150 laser, perform the following steps:

1 Locate the mounting feet in the optional mounting kit. Carefully place the p100/150 laser upside down on a padded work surface with the beam exit facing towards the left.

2 Orient the feet as shown in the fi gure below. The arrow machined on the front foot should be visible and point towards the front of the laser.

Figure 3-2 Attaching the mounting feet.

Front Holes - SAE Fasteners - 1/4–20 × 5/8” UNC Black Oxide FinishRear Holes - ISO Fasteners - M6 × 1 × 12 mm Stainless Steel Finish

Important Note:


44


3 Locate the six fl athead screws in the optional p100/p150 mounting kit (refer to the p100/ 150 O&M drawing) for ISO and UNC fastener locations on the base plate.

4 Insert the three M6 × 1 metric fasteners (stainless steel fi nish) through the rear holes in each mounting foot and thread into the metric threaded holes in the p100/150 base plate. Then insert the three 1/4–20 UNC fasteners (black oxide fi nish) through the front holes in each mounting foot and thread into the p100/150 base plate. Turn the screws by hand until the threads engage.

5 Evenly tighten all six fasteners to a maximum torque of 6.1 N m (54 in lb).

Fasten the laser onto mounting surface

To fasten the OEM p100/150 laser (with feet) to your mounting surface, perform the following steps:

1 Refer to the p100/150 outline and mounting drawing for hole locations, then drill and tap three M6 × 1 or 1/4–20 holes in your mounting surface. These holes locations should correspond with the two slots labeled “A” and the thru hole labeled “B” as shown in the fi gure below.

2 Place the p100/150 laser on the mounting surface so the slots/hole on the mounting feet line up with the threaded holes in your mounting surface.

3 Insert three M6 × 1 ISO or 1/4–20 UNC fasteners through the slots/hole on the mounting feet into the corresponding threaded holes in the mounting surface. Turn the screws by hand until the threads engage.

4 Evenly tighten all three fasteners to a maximum torque of 6.1 N m (54 in lb).

Caution

possible equipment damage

The optional p100/150 mounting feet are fastened using three M6 × 1 metric and three 1/4–20 UNC fasteners. The M6 screws (stain-less steel) fit the rear holes in each mounting foot while the 1/4–20 fasteners (black oxide finish) fit the front holes. Please review the drawings carefully because the threads in the p100/150 base plate can be damaged if these fasteners are threaded into the wrong holes.

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Figure 3-3 Attaching the mounting feet (top view).

45


Getting StartedConnecting

The Connecting section includes subsections:

Cooling, connections, fi ttings, guidelines, setpoints, dew points, and fl ow rates.

48 V power supply connections

Control connections

Other connections

CoolingHeat generated by excited CO2 molecules is transferred to the bore walls by diffusion. Collect-ed 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 temperature for maximum stability.

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 prop-erly. 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. Tub-ing 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 (0.5”) from its end before reconnecting. Trim-ming the end of the tubing before reconnecting the fitting provides an undisturbed sealing surface.

Caution possible equipment damage

Operating the laser at coolant temperatures above 22 °C (72 °F) may result in de-creased performance and/or premature failure of electronic components. Do not overtighten the water IN/OUT cooling fittings. Over tightening the cooling fittings may crack the cooling manifold, causing coolant leakage, or may partially block the cooling channel, leading to reduced coolant flow and premature laser failure.If you must install new fittings, wrap the threads with Teflon pipe tape and careful-ly tighten the fittings, making sure the maximum insertion depth is no more than 6.6 mm (0.26") into the cooling manifold.


46


Laser cooling fi ttings

Pulstar p100/150 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 adapter is available from McMaster-Carr (P/N 51495K416).

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.

Coolants

When filling your chiller, SYNRAD recommends using at least 90% distilled water by volume. In closed-loop systems, use a corrosion inhibitor/algaecide such as Optishield® Plus or equiv-alent as required. For SYNRAD lasers, the minimum coolant setpoint is 18 °C (64 °F)- 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 hard-ness should be below 100 PPM. Install a filter on the chiller’s return line and inspect frequent-ly. Pulstar p100/150 lasers incorporate the following wetted materials in the coolant path—nickel-plated brass, copper, Acetal®, nitrile, and stainless steel.

Avoid glycol-based additives because they reduce the coolant’s heat capacity and high con-centrations may affect power stability. If you must use glycol, do not add more than 10% by volume. See the Operation and/or Technical Reference sections in this Manual for detailed information. Glycol is not necessary unless the chiller is subjected to freezing temperatures.

Coolant temperature

Set a chiller temperature setpoint between 18–22 °C (64–72 °F). The setpoint temperature MUST be maintained above the dew point temperature. Operating the laser with a coolant temperature below the dew point of the surrounding air may cause condensation to occur that will damage the laser. In cases where this is not possible within the specified c oolant 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 contain-ing the laser.


Stop coolant fl ow when the laser is shut down.

Increase coolant flow by an additional 3.8 LPM (1.0 GPM). Do not exceed a coolant pressure of 414 kPa (60 PSI).

Refer to Table 1-2 and gradually increase coolant temperature until it is above the dew point tem-perature and condensation disappears. Do not exceed a coolant temperature of 30 °C (86 °F).

47



Coolant guidelines

In applications where biocides containing chlorides are used, concentrations should not exceed 25 parts per million (PPM).

Maintain a coolant pH level above 7.0. We recommend the installation of a fi lter on the chiller’s return line, especially in areas where water hardness is a problem.

Pulstar p100/150 lasers incorporate the following wetted materials in the coolant path, brass, copper, Delrin®, PBT, polyethylene, stainless steel, and Viton®.

CondensationInspect the laser daily for signs of water condensation during operation. Condensation causes damage to electrical and optical components.

Do NOT operate the laser in a condensing environment—the laser will be damaged! Refer to the Pulstar p100/150 Operator’s Manual for steps you can take to prevent condensation dam-age.

Connection information for storage/shippingWhen 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 less than 29 PSI (wear safety glasses!) to remove any residual water. When finished, cap all connectors to pre-vent 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 box. If you no longer have the box, contact SYNRAD Custom-er Service about obtaining a replacement. Refer to the appropriate Packaging Instructions (included with the replacement box, in Chapter 5 of this manual, or from the SYNRAD web site at: http://www.synrad.com/Service/packaging.htm) for detailed instructions on properly packaging the laser for shipment.


48


Gas Purge port

Apply a gas purge pressure between 0.14–0.34 bar (2–5 PSI) or a flow rate of 849–1699 liters/hour (30–60 SCFH). Do not exceed a pressure of 0.34 bar (5 PSI). Use only nitrogen or CDA (clean dry air) as a purge gas. Do not use any other gas as this could damage the laser.

Connection information for daily inspectionsPerform the following steps daily to keep your Pulstar p100/150 laser in optimum operating condition.

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

2 Inspect external beam delivery components for signs of dust or debris and clean as re quired. When cleaning the optical surfaces, carefully follow the manufacturer’s instructions.

3 When using compressed air as a purge gas on your laser, empty water traps and oil separators on each fi lter and/or dryer between the laser and your compressed air source. Purge gas purity must meet the specifi cations shown in the table below.

Table 3.3 Purge gas specifi cations.Purge Gas Specifi cation

Nitrogen High Purity Grade 99.9500% purity or better

Air Breathing Grade 99.9996% purity or better

Air Compressed 99.9950% purity or better, water-free; oil fi ltered to 5 mg/m3 or better; particulate fi ltered to < 1.0 micron; dried to lower dew point below coolant temperature setpoint

4 Visually inspect the exterior housing of the laser to ensure that all warning labels are present. Refer to the Laser Safety chapter for Pulstar p100/150 label types and locations in the p100/150 Operations Manual.

49



Temperature setpointChoosing the correct coolant temperature is important to the proper operation and longev-ity 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 electronics and damage to optical surfaces.

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

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

Stop coolant flow when the laser is shut down.

Increase coolant flow by an additional 1.0 GPM. Do not exceed a coolant pressure of 60 PSI (4.1 bar).

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


Flow rateSet coolant flow according to the following. Ensure that coolant pressure does not exceed 60 PSI (4.1 bar). Please see table 1.1 in the Introduction Chapter for cooling water flow rates for the laser.

Dew pointTo use the table below, look down the Air Temp column and locate an air temperature in Fahr-enheit or Celsius (°C values are shown in parentheses) that corresponds to the air temperature in the area where your laser is operating. The table below provides dew point temperatures for a range of air temperature and relative humidity values. Remember that the laser’s coolant


50


temperature must be set above the dew point temperatures given in the chart, but should not exceed 22 °C (72 °F).Follow this row across until you reach a column matching the relative humidity in your loca-tion. The value at the intersection of the Air Temp and Relative Humidity columns is the Dew Point temperature in °F (or °C).

The chiller’s temperature setpoint must be set above the dew point temperature. For exam-ple, if the air temperature is 85 °F (29 °C) and the relative humidity is 60%, then the dew point temperature is 70 °F (21 °C). Adjust the chiller’s temperature setpoint to 72 °F (22 °C) to pre-vent condensation from forming inside the laser or RF power supply. Please see the Dew Point Temperature table 1.2 in the Introduction Chapter.

51



Note: Feel free to reference the Operation, Technical Reference chapters in this manual and the p100/150 Quick Start Guide where appropriate.

Hazardous DC voltages exist on DC power supply output terminalswhen the power supply is energized. Contacting energized terminals may result in serious personal injury or death. Protect all 48 VDC connections from incidental contact in accordance with local, state, and national code requirements for electrical insulation and labeling.

All AC input wiring and fusing to the DC power supply must be sized and connected in accordance with applicable local, state, and National Electri-cal Code (NEC) requirements. Local, state, and national code requirements supersede any recommen-dations provided in this manual.

WarningSeriouspersonalinjury

The Electrical Requirements section includes:

Power supply & connection

User I/O summary

Power supplyDo not reverse polarity when connecting the DC Power cable between the DC power supply and the p100/150 laser. The p150 requires a minimum of 65A at 48V (100A for less than 700 μsec). Synrad recommends the PS-48-4000 supply for powering a single laser.


52


Do not plug and unplug the DC Power cable on the rear of the laser to switch DC power to the laser. Switching power under load causes arcing that will damage the connector and laser control board. To properly cycle power to the laser, switch the AC power source controlling the PS-48/4000 DC power supply.

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 directions in the Pulstar Operator’s Manual to ensure that DC Power cable leads are properly connected to the correct DC output terminals.

DC Laser connections

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

2 Attach the black (negative) DC power lead to the DC Ground Bus on the laser using M6 fasteners, see the fi gure below.

CautionPossibleequipmentdamage

Note: If you are not using a DC supply recommended by Synrad, 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.

C on bottom+ VDC

Figure 3-4 Attaching the power leads.

und on topGrou

Important

Note: Only M6 (brass) fasteners provided should be used on all DC-connections on the laser.

*p150 Only.

53



User I/O connection summaryPlease see the User I/O table in the Technical Reference chapter.

Important Note:

Before beginning any maintenance or inspections of your Pulstar p100/150 laser, be sure to completely disable the laser by disconnecting the DC Power cable (or cables) from the rear of the laser.

If you operate your laser or marking head in a dirty or dusty environment, contact SYNRAD about the risks of doing so and precautions you can take to increase the longevity of your laser, marking head, and associated optical components. A risk of exposure to toxic elements 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, or the optics manufacturer for handling instructions.

Caution Possible

equipment

damage

3 Attach the red (positive) DC power lead to the +48 VDC Bus Bar on the laser using M6 fasteners.

4 Connect the black power lead to the (-) DC bus bar on the power supply.

5 Connect red power lead to the (+) VDC bus bar on the power supply.


54


The System overview section includes:

Laser tube

p100/150 technology

Optical resonator

Laser tubePulstar p100/150 lasers were developed using new technology patented by SYNRAD. Pulstar’s patented “p” technology, include RF components that are integrated within the laser body it-self, completely eliminating the need for external RF boxes and cables. The net result is a sym-metrical 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. Be-sides 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.

p100/150 Technology

Based on the same proven technology behind the success of Synrad's T-series, the p100/150's peak pulse power takes materials processing a step further by allowing users to cut faster and drill deeper through a variety of materials with minimal heat affect zone and superior cut edge quality. The p150's longer tube design provides excellent power stability, making it ideal for applications that demand the highest levels of consistency and precision.

Optical resonatorThe optical resonator, in conjunction with the electrodes and the gas mixture, generates the laser beam. Pulstar p100/150 resonators are comprised of three optical elements: a front mir-ror, a rear mirror, and an output coupler (window). These elements are fastened to the tube’s exterior and 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 cush-ion that allows the slight movement necessary for alignment.

Synrad p100/150 operators manual version 2.1

55

OperationControls and Indicators

Use information in this chapter to familiarize yourself with Pulstar p100/150 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 p100/150 lasers.

Start-up and pulsed operation – explains how to start your Pulstar p100/150 laser while verifying proper operation and how to operate the laser in pulsed mode.

Danger


Any Class 4 laser product that emits invisible infrared laser radiation in the 9–11 μm CO2 wavelength band. CO2 lasers emit an invisible beam that is capable of seriously burning human tissue.


Do not allow the laser beam to contact a person.




56

OperationControls & Indicators

The Controls and indicators section includes subsections:

OEM p100/150 front panel

OEM p100/150 rear panel

OEM p100/150 front panel

4

2

1

AAVOID EXPOSUREInnnvisible laser r onadiatioo

is emitted fromthis ape rture.

I

3

Figure 4-1 Pulstar OEM p100/150 front panel controls and indicators.

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

2 Laser Aperture – provides an opening in the p100/150’s front panel from which the beam exits.

3 Output Window – seals the internal beam path from contamination and is fi eld-replace able if it becomes damaged. See Output window replacement in the Maintenance/Trou- bleshooting chapter for details.

4 Optical Accessories Mounting – provides four threaded holes (8–32 UNC) for mounting optional beam delivery components. Because excessive weight may damage the laser, consult SYNRAD before mounting components not specifi cally designed as Pulstar op- tions. Refer to the OEM p100/150 package outline drawings in the Technical Reference chapter for mounting dimensions.

When mounting optical components to OEM p100/150 lasers, the 8–32 UNC fasteners must extend no further than 4.8 mm (0.25”) into the laser’s faceplate.

Note:


57


Open/create a mark fi le

1 Open an existing WinMark Pro .mkh mark fi le or create a new drawing and set drawing/ object automation, marking, and format parameters to suit your needs.

Marking operationMarking operation is the same as with previous FH Series marking heads. Open existing Win-Mark Pro .mkh mark fi les or create new mark fi les. The polylines comprising each mark object are marked in the plane of the Drawing Canvas at the specifi ed working distance.

Determine the operating method

Important Note:

Backup existing mark fi les before opening them in WinMark Pro v7. If an existing fi le is inadvertently saved in the latest v7 build format, it cannot be opened by earlier WinMark builds.

1 To operate Flyer 3D using a method other than WinMark control, refer to the following sources for information on Flyer 3D’s many control methods within the Flyer 3D Marking Head System Operator’s Manual:

Chapter 4, Flyer 3D Operation Manual, Stand-alone operation, to setup stand-alone control or access a network share.

Chapter 5, Technical reference, to use hard-wired I/O between Flyer and your automation controller.

Appendix C, Flyer 3D Operation Manual, Master Control File, for information on creating a Master Control File scheme.

Appendix D, Flyer 3D Operation Manual, Tracking, for a description of the tracking (on-the-fl y part marking) function.

WinMark Pro Application Note # 5 for controlling Flyer 3D via Ethernet MODBUS® TCP/IP.

Tip: When using fi le automation, test the fi le under WinMark control fi rst before running in Stand- alone mode or with a .NET or ActiveX application.

Begin marking

1 Place the material or part to be marked in position on the marking surface at the proper working distance.

2 Check that a beam block ,an anodized aluminum plate is ideal, is in place to prevent the laser beam from traveling beyond the work area. The beam block should be slightly larger than the mark fi eld.


58


3 Ensure that all safety precautions discussed earlier such as safety glasses for personnel and shielding around the beam area are in place.

4 Verify that Flyer 3D is confi gured for the desired operating method—WinMark control mode, Stand-alone control mode, or automation mode.

5 Enable marking. This step will vary depending on the control method you are using. In WinMark control mode, click the Mark button, or select Mark from the File menu. After the Synrad WinMark (Launcher) dialog opens, click the Start-F1 button to begin marking.


Pressing the F1 function key on the computer keyboard causes Win-Mark Pro to mark immediately without opening the Launcher dialog!

When using WinMark Pro, the F1 key is designated as a “quick mark” key meaning that the mark is lased immediately. To prevent injury, always ensure that all personnel in the area are wearing the appropriate protective eye-wear and are physically clear of the mark area before beginning a mark session.


59


OEM p100/150 rear panel

Figure 4-2 Pulstar OEM p100/150 rear panel controls and indicators.

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

6 +48 VDC Input Terminal – M6 threaded stud receives 48 VDC from the DC power supply.

7 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.

8 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 laser temperature rises above safe operating limits.

9 RDY (Ready) LED – illuminates yellow when the laser is enabled to indicate that lasing will begin when a PWM Command signal is applied, provided the SHT LED is illuminated.

10 SHT (Shutter) LED – illuminates blue to indicate that a Shutter Open Request signal is connected to the User I/O port and lasing may be enabled.

11 LASE LED – illuminates red to indicate the OEM p100/150 is actively lasing. The LASE LED is off when tickle pulses are being generated and illuminates red when PWM Command signal pulses are long enough to produce laser output.

12 GND (–) Terminal – M6 threaded stud provides connection point for negative (ground) side of the 48 VDC power supply.

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

14 WATER IN Port – provides a 12 mm inlet connection to the p100/150 laser’s cooling system for 12 mm O.D. cooling tubing.


14

6 5

7

11

9

8

10

12

13

15


60


15 WATER OUT Port – provides a 12 mm outlet connection from the p100/150 laser’s cooling system for 12 mm O.D. Cooling tubing.

Start-up and pulsed operationThe Start-up and pulsed operation section includes subsections:

Initial start-up with UC-2000 Controller

Pulsed operation from PWM signal source

Danger


This Class 4 laser product that emits invisible infrared laser radiation in the 9.3–10.6 μm CO2 wavelength band. CO2 lasers emit an invisible beam that is capable of seriously burning human tissue.


Do not allow the laser beam to contact a person!




Remote interlock faults are not latched on Pulstar OEM p100/150 lasers. Clearing the fault condition re-enables the RDY indicator and the laser will fi re immediately provided the SHT indicator is lit and a PWM Command signal is applied. Because exposure to 10.6 μm CO2 laser radi-ation can infl ict 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 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 qualifi ed personnel. In normal operation, the la-ser’s Remote Interlock input should be connected to the machine’s safety interlock circuitry.


61

OperationInitial Start-up

Caution


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

The Flyer 3D Marking Head’s operating system requires approximately 15–20 seconds to boot up. Repeatedly cycling power during the boot up sequence may cause corruption of Flyer 3D’s fl ash memory and operating system.

Contamination on the laser’s output window (or on any beam deliv-ery optic) can absorb enough energy to damage optical components in the beam path. Periodically inspect the p100/150’s output window and all other beam delivery optics for signs of contaminants and then carefully clean as required. In dirty environments, purge laser optics using fi ltered air or nitrogen to prevent vapor and debris from accumulating on optical surfaces.

Initial start-upBefore your Pulstar OEM p100/150 laser is put into service for the fi rst time, follow this proce-dure to verify the laser system is operating at optimum performance.

Starting auxiliary equipment

1 Ensure that all personnel in the area are wearing protective eye-wear.

2 Remove the red self-adhesive aperture seal covering the laser aperture.

3 Place a power meter, or appropriate beam block, 61 cm (24 in) from the laser aperture to prevent the beam from traveling beyond the work area.

4 Connect the Quick Start Plug to the User I/O connector on the rear of the laser and then connect the PWM signal source) to the BNC connector on the Quick Start Plug.

5 Turn on the chiller and set a temperature set-point between 18 °C–22 °C. Verify that the chiller is delivering a fl ow rate and Pressure Drop specifi ed in the specifi cations in the Technical References section pg 92.

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


Use external tickle may cause laser to fi re!


62


Caution


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

-Or-Use purge gas to prevent condensation damage if the dew

point is over 22°C

6 Examine all cooling connections carefully and ensure that they do not leak.

7 If needed, start purge gas fl ow 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 fl ow-meter is not available, set a purge pressure between 13.8–34.5 kPa (2–5 PSI).

Caution


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 3-2, Purge gas specifi cations.

8 Set the PWM signal source to provide zero percent output (0.0%).

9 Turn on the +48 VDC power supply. If input signals are properly applied to the user I/O connector, or 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.


63


Note: Pulstar RDY and SHT LEDs denote separate control functions. Although the RDY lamp may light while the SHT LED is Off (Shutter Open Request signal missing), no power is applied to the RF drivers until both RDY and SHT indicators are illuminated. On cold starts, provide fi ve to ten seconds of tickle before sending PWM Commands to the laser.

Caution


Do not fl ow coolant through the laser for an extended period of time when the laser is shutdown. This causes condensation to form inside the laser which may result in catastrophic damage to internal optics and electronic circuits.

Important Note:

If your Pulstar OEM p100/150 laser fails to lase, refer to the Troubleshooting section in the Maintenance/Troubleshooting chapter for information.

Starting up your Pulstar OEM p100/150 laser

1 Slowly increase power by increasing the duty cycle of the PWM Command signal (up to a maximum of 37.5%). The LASE LED turns red when PWM Command signal pulses are long enough to produce laser output and the power meter should indicate increased power output.

2 Reduce the PWM duty cycle to 0.0%. The lase indicator on the laser should turn off .

3 Remove DC power from the laser.

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

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


64


4 Connect your PWM pulse signal source so that the output is connected to PWM Input (Pin 9) on the User I/O connector and connect the ground or return of the source to PWM Return (Pin 1).

5 Turn on the chiller and set a temperature set point between 18 °C–22 °C. Verify that the chiller is delivering a fl ow rate of 5.7–7.6 LPM (1.5–2.0 GPM) at less than 414 kPa (60 PSI) of pressure. Please refer to the General Specifi cations in the Technical References Chapter.

6 If needed, start purge gas fl ow 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 fl ow-meter is not available, set a purge pressure between 13.8–34.5 kPa (2–5 PSI).

7 Ensure that your PWM pulse signal source is set to zero percent output (0.0%) at the intended pulse frequency (repetition rate).

Pulsed operation from PWM signal sourceFollow these basic steps to operate the OEM p100/150 as a pulsed laser. Although a tickle sig-nal is not required, you will need to provide PWM Command signal pulses as well as Remote Interlock and Shutter Open Request input signals to the p100/150’s User I/O connector. Refer to User I/O connections in the Technical Reference chapter for interface details and refer to Controlling laser power in the Technical Reference chapter for PWM Command signal descrip-tions.

Starting auxiliary equipment

1 Ensure that all personnel in the area are wearing protective eye-wear.

2 Assure the red self-adhesive aperture seal covering the laser aperture.

3 Use an appropriate beam block to prevent the beam from traveling beyond the work area.

Caution


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

Or-

Use Purge gas to prevent condensation damage if the dew point is over 22 °C


65


Starting your Pulstar OEM p100/150 laser

1 Assure all safety precautions discussed earlier such as safety glasses for personnel and shielding around the beam area are in place.

2 Apply PWM Command pulses between PWM Input (Pin 9) and PWM Return (Pin 1) on the p100/150’s User I/O connector at pulse frequencies ranging from a single-shot to 100 kHz with pulse widths up to 600 microseconds (μs).

3 When laser processing is complete, halt PWM pulse signals to the laser. The LASE indicator will turn off .

4 Remove DC power from the laser.


Note: The Pulstar OEM p100/150 laser is limited to a maximum pulse width of 600 μs for any single pulse. The laser’s maximum duty cycle percentage is limited to 37.5% across the entire operating frequency range of a single-shot to 100 kHz. If the duty cycle limit is exceeded, internal control circuitry limits the duty cycle applied to the RF driver and continues lasing. The laser will begin following the actual commanded duty cycle percentage when it is lowered to 37.5% or below.

Caution


Do not fl ow coolant through the laser for an extended period of time when the laser is shutdown. This causes condensation to form inside the laser which may result in catastrophic damage to inter-nal optics and electronic circuits.


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

7 Turn on the +48 VDC power supply. If input signals are properly applied to the User I/O connector or 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.

6 Shut off gas purge fl ow to the laser. In dirty or dusty environments; however, it ma be necessary to purge the laser continuously to prevent contamination of internal optics. As always, if your Pulstar p100/150 laser fails to lase, refer to Troubleshooting in the Main- tenance/Troubleshooting chapter for troubleshooting information.


66


Open/create a mark fi le

1 Open an existing WinMark Pro .mkh mark fi le or create a new drawing and set drawing/ object automation, marking, and format parameters to suit your needs.

Marking operationMarking operation is the same as with previous FH Series marking heads. Open existing Win-Mark Pro .mkh mark fi les or create new mark fi les. The polylines comprising each mark object are marked in the plane of the Drawing Canvas at the specifi ed working distance.

Determine the operating method

Important Note:

Backup existing mark fi les before opening them in WinMark Pro v7. If an existing fi le is inadvertently saved in the latest v7 build format, it cannot be opened by earlier WinMark builds.

1 To operate Flyer 3D using a method other than WinMark control, refer to the following sources for information on Flyer 3D’s many control methods within the Flyer 3D Marking Head System Operator’s Manual:

Chapter 4, Flyer 3D Operation Manual, Stand-alone operation, to setup stand-alone control or access a network share.

Chapter 5, Technical reference, to use hard-wired I/O between Flyer and your automation controller.

Appendix C, Flyer 3D Operation Manual, Master Control File, for information on creating a Master Control File scheme.

Appendix D, Flyer 3D Operation Manual, Tracking, for a description of the tracking (on-the-fl y part marking) function.

WinMark Pro Application Note # 5 for controlling Flyer 3D via Ethernet MODBUS® TCP/IP.

Tip: When using fi le automation, test the fi le under WinMark control fi rst before running in Stand- alone mode or with a .NET or ActiveX application.

Begin marking

1 Place the material or part to be marked in position on the marking surface at the proper working distance.

2 Check that a beam block ,an anodized aluminum plate is ideal, is in place to prevent the laser beam from traveling beyond the work area. The beam block should be slightly larger than the mark fi eld.


67


3 Ensure that all safety precautions discussed earlier such as safety glasses for personnel and shielding around the beam area are in place.

4 Verify that Flyer 3D is confi gured for the desired operating method—WinMark control mode, Stand-alone control mode, or automation mode.

5 Enable marking. This step will vary depending on the control method you are using. In WinMark control mode, click the Mark button, or select Mark from the File menu. After the Synrad WinMark (Launcher) dialog opens, click the Start-F1 button to begin marking.


Pressing the F1 function key on the computer keyboard causes WinMark Pro to mark immediately without opening the Launcher dialog!

When using WinMark Pro, the F1 key is designated as a “quick mark” key meaning that the mark is lased immediately.

To prevent injury, always ensure that all personnel in the area are wearing the appropriate protective eye-wear and are physically clear of the mark area before beginning a mark session.


68

Technical Reference

Use information in this chapter as a technical reference for your Pulstar p100/150 laser.This chapter contains the following information:

Technical overview – briefl y describes Pulstar’s technology, design RF power supply and basic optical setup.

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

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

DC power cables – provides information about p100/150 DC power cables.

Integrating Pulstar safety features – describes how to integrate Pulstar p100/150 safety features into your automated control system.

Pulstar p100/150 general specifi cations – provides specifi cations for the Pulstar p100/150 laser.

Pulstar p100/150 outline and mounting drawings – illustrates laser package outline and mounting dimensions for p100/150 lasers.

Pulstar p100/150 packaging instructions – illustrates how to package Pulstar p100/150 lasers for shipment.

5

Important Note:

Except for bench testing, we do not recommend using a UC-2000 Controller with the Pulstar OEM p100/150 laser. The automatically-generated tickle signal from the UC-2000 may interfere with the lasers pulsing performance.


69

Technical OverviewTechnical Reference

The p100/150 incorporates Pulstar’s patented “t” technology, based on a combination of free-space and waveguide resonator designs, which 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 off ers excellent heat transfer, long gas life, and low operating costs in contrast to other laser tube technol-ogies. In addition to 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.

The Technical overview section includes subsections:

Laser design

Optical setup

RF power supply

Laser designThe Pulstar p100/150 is a pulsed 100-watt laser based on SYNRAD’s popular ti-Series laser. While the average power of the p100 is similar to the ti100 at 100 W, the p100’s peak pulsed output power is typically 400 W and the p150’s peak pulsed output power is 600 W. The p150 laser is based on the p100 design, providing 50% more power by increasing the resonator length. The p150 uses a hybrid waveguide/unstable resonator design with a sophisticated beam conditioning system to produce a symmetrical beam. This high peak power in combina-tion with a maximum duty cycle of 37.5% provides high-intensity, short duration pulses that are excellent for minimizing the Heat Aff ected Zone (HAZ) on many materials.

Figure 5-1 Hybrid waveguide/unstable resonator design.


70


Heat removal

Heat generated by the plasma is transferred to the bore walls by diff usion. 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 reg-ulate laser temperature for maximum stability.

Optical resonator

The optical resonator, in conjunction with the electrodes and the gas mixture, generates the laser beam. Pulstar p100/150 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 fl exible 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 output beam is quite circular as it exits the resonator, transitions to a Gaussian-like mode quality (M2 factor) of < 1.2. Beam waist diameter is typically 7.5 mm (p100) – 8 mm (p150) at the output aperture and full-angle divergence due to diff raction is approximately 1.9 milli-radians (a 1.9 mrad divergence means that beam diameter increases 1.9 mm over every one meter distance traveled).

RF and control circuitry

The p100/150 is driven by two compact radio frequency (RF) power supplies mounted inter-nally in the laser chassis. The 48 VDC input voltage is converted into a high-power RF signal using an RF power oscillator. The output from the RF oscillator (nominally at 83.5 MHz) drives the laser directly by exciting carbon dioxide (CO2) gas in the tube to produce lasing.

Control circuitry 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 inter-rupted in response to the following conditions: (1) the Shutter Open Request input signal is missing; (2) an over temperature condition occurs; (3) the Remote Reset/Start Request input signal is enabled; (4) the Remote Interlock input signal is missing; or (5) any fault is present.

Beam conditioning

The p100/150 laser incorporates a sophisticated beam conditioning system that cleans up the beam to remove the side lobes and improve beam quality. This is accomplished by turning the laser beam back onto itself after the beam exits the resonator through a ‘folding block’ that directs the ‘beam through’ an internal lens system. First the beam is focused through an aperture, a second lens then collimates the beam at an expanded size with lower divergence than the raw beam. Finally, a protective output window on the laser’s front plate ensures that the internal beam conditioning optics stay clean. In addition, the beam conditioning system incorporates a beam expander that converts the 2.0 mm diameter resonator beam to a 7.5-8 mm diameter output beam. This larger beam diameter reduces the power density incident on


71


the laser’s output window thereby reducing the likelihood of damaged optics.

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 diff erences in cut quali-ty 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 signifi cant 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-eff ective solution, a refl ective phase retarder, laser polarization must be rotated by 45°.

The p100/p150 is vertically polarized at the faceplate. Rotating the polarization is usually done by mounting the laser at 45° to the horizontal or by using two or more mirrors. A CQE typically incorporates the turning mirrors and phase retarder into one housing.

Optical setupAfter 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.

Electric Vector Polarization

45°

Reflective Phase Retarding Mirror

45°

Reflected Beam is oppositely Circularly Polarized from 90°incident beam.

Laser

Isolator

Shiny surface

Isolator blocks incorrectly polarized beams, letting only correctly polarizedbeams through!

Figure 5-3 Converting 45° linear polarization to circular polarization (original Pulstar p150 Operation Manual Version 1 illustration courtesy of II-VI inc.). The Output Beam is Linearly Polarized perpendicular with respect to the Baseplate.


72


Optical isolatorAn optical isolator is an optical component that allows only the desired linearly polarized light through, preventing unwanted feedback back into the laser. p100/150 lasers do not have internal isolation. If isolation is required, an external third party unit is needed. An optical iso-lator only works with linearly polarized light and in conjunction with a (quarter wave) phase retarder. Beam delivery manufacturers may package the phase retarder and isolator inside one component commonly marketed as a “Beam Quality Enhancer.” Always double check the system with your supplier to ensure the isolator is present.

When laser processing refl ective metals like iron, steel or aluminum, problems can occur if CO2 laser energy is refl ected by the workpiece back through the beam-delivery path and into the laser cavity. Back refl ection can result in unwanted fl uctuations of laser power, or even dam-age the cavity optics inside the laser. When a refl ective material is processed, the use of a back refl ection isolator is required.

An optical isolator only works with linearly polarized light and in conjunction with a (quarter wave) phase retarder. The isolator has to be oriented in a very specifi c rotational orientation relative to the linear polarization. Failure to do so will eliminate the protection of the isolator and incorrectly polarized outgoing lasing energy will not be blocked. Beam delivery manufac-turers may package both the phase retarder and the isolator inside one component common-ly marketed as a “Beam Quality Enhancer” or BQE. For example, the Haas Laser Technology Part Number BQE-25-10.6-SYN incorporates both polarization and isolation into one housing that can easily be mounted onto the face plate of the laser. Always double check the system with your supplier to ensure the isolator is present.

Beam deliveryDivergence, or expansion, of the laser beam is important in materials processing since a larger beam entering the focusing optic produces a smaller focused spot.

WarningSerious personal injury &

Equipmentdamage

The long 10.6 μm wavelength of CO2 lasers is easily refl ected

or scattered off metallic surfaces which can lead to personnel injury and/or damage to equipment.

Enclose the processing area in an interlocked enclosure and ensure proper safety glasses are worn.

Use an optical isolator to protect the laser from damage.

Failure to do this, may void the warranty as equipment dam-age can occur.


73


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.

Note:

Expander/collimators are optical devices that reduce beam divergence while at the same time increasing beam diameter by a selectable magnifi cation factor. Adding an expander/collima-tor substantially reduces beam divergence and any variance in beam diameter caused by the changing optical path length in an XY (“fl ying optics”) table application. In fi xed-length deliv-ery systems where the laser is positioned only one meter away from the focusing optic and a small spot size is required, an expander/collimator is again the best solution to provide the required beam expansion before reaching the focusing optic.

Focusing opticsWhen selecting a focusing optic, the primary consideration should be material thickness and any vertical tolerances that occur during fi nal 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 fi eld 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 aff ecting 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 fi ltered to the specifi cations shown in the following table.


74


Table 5.1 Assist gas purity specifi cations.

Assist Gas Typical Purpose Specifi cation

Air Cutting/Drilling Breathing Grade > 99.9996% purity; fi ltered to ISO Class 1 particulate level

Air Cutting/Drilling Compressed Instrument-grade air fi ltered and dried to ISO 8573-1:2010 Class 1, 2, 1 (< 10 1.0– 5.0 μm particles/m3; < –40 °F (–40 °C) dew point; < 0.01 mg/m3 oil vapor)

Argon Welding High Purity Grade > 99.998% purity; fi ltered to ISO Class 1 particulate level

Helium Welding High Purity Grade > 99.997% purity; fi ltered to ISO Class 1 particulate level

Nitrogen Cutting/Drilling High Purity Grade > 99.9500% purity; fi ltered to ISO Class 1 particulate level

Oxygen Cutting/Drilling Ultra Pure Grade > 99.9998% purity; fi ltered to ISO Class 1 particulate level

RF power supplyPulstar p100/150 lasers are driven by two 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 amplifi ed 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 inter-rupted 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 fl ow 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.


75

Controlling Laser Power

Technical Reference

The Controlling laser power section includes subsections:

Control signals

Operating modes

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 suffi cient 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.

Control signalsPulstar’s fi ve user outputs correspond to the status functions described in the following Out-put Signal Section. 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 chas-sis ground to allow high-side or low-side switching and to isolate control signals for optimum EMI performance. The optically-isolated outputs are useful for sending laser status to a Pro-grammable Logic Controller (PLC) or computerized control system. Each of the fi ve outputs: Pin 6, 7, 8, 13, and 14 can source 50 mA at ±24 VDC maximum for a total load of 250 mA. When controlling larger loads, use these outputs to drive a control relay.

Note: Because all Pulstar OEM p100/150 lasers incorporate a built-in tickle generator (2- 6μs pulses at 5kHz), there is no need to supply external tickle pulses. The application of external tickle pulses may aff ect the p100/150’s pulsing performance.

Tickle pulse

Tickle pulses pre-ionize the laser gas to just below the lasing threshold so that a further in-crease 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 p100/150 lasers incorporate a built-in tickle generator, freeing customers from the need to supply external tickle pulses between lasing commands.

Warning


Caution! Lasing can occur when the READY light is on regardless

of RED LED status.

Because of phase diff erences, external tickle pulses may combine with the internally-generated tickle signal causing the LASE LED to fl icker during the transition from tickle to lasing.

Laser output may occur if the LASE LED fl ickers.


76


Technical Reference

Operation modes

Pulse Width Modulation (PWM)

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

Pulstar p100/150 lasers are designed to operate at Command signal base frequencies up to 100 kHz (p100)/200 kHz (p150); however, the choice of PWM frequency depends on the user’s specifi c application. When considering Command frequencies at 5 kHz or below, please review Marking/engraving operation later in this section. For high-speed motion applications that cannot tolerate any ripple in the optical beam response but still need adjustable pow-er levels, we recommend the use of higher PWM frequencies, up to 100 kHz (p100)/200 kHz (p150) 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 p100/150 laser has two parameters: pulse frequen-cy, and PWM duty cycle. By changing these two parameters, you can command the beam to perform a variety of marking, cutting, welding, or drilling operations.

Signal amplitude, is either logic low—corresponding to laser beam off , or logic high—cor-responding 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. Please refer to the specifi cations Tables 5.2-5.3. The two parameters below better explains the specifi cation limits.

Pulse frequency, the fi rst command signal parameter, is the repetition rate of the PWM input signal. The p100/150’s pulse frequency can range from a single-shot up to a maximum fre-quency of 100 kHz (p100)/200 kHz (p150) with pulse widths up to 600 μs.

The second 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 75 μs and low for 125 μs, it has a 37.5% duty cycle. The duty cycle is also 37.5% if the amplitude (at 1 kHz) is high for 375 μs and low for 625 μs. As shown in the following fi gures, 5.6-5.14 at higher frequencies (625 Hz) and high duty cycles (37.5%).

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.



77


Technical Reference

0

50

100

150

200

0 5 10 15 20 25 30 35 40

Lase

r Pow

er (W

)

Duty Cycle (%)

1000 Hz

5000 Hz

10000 Hz

20000 Hz

50000 Hz

100000 Hz

150000 Hz

198000 Hz

As the duty cycle is increased from 20% to 37.5% (as seen in the fi gure below), p100/150 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.

Important Note:

When the Pulstar p100/150 pulsed laser PWM > 37.5% duty cycle, the laser does not stop, it only is limited to 37.5% maximum duty cycle.

If this occurs, the status LEDs/outputs will indicating a ‘no strike fault’ condition (see Maintenance and Troubleshooting chapter for further information).

0 VDC

5 VDC75 µs

200 µs 1 ms

375 µs

5 kHz Command Signal at 37.5% Duty Cycle 1 kHz Command Signal at 37.5% Duty Cycle

Figure 5-4 PWM command signal wave form.

Laser power is nominally linearly proportional to the PWM duty cycle. As PWM frequency increases, it will take a larger duty cycle before the laser starts to fi re. However, at high PWM frequencies there is a signifi cant threshold eff ect as shown in the fi gure below.

1000 Hz

5000 Hz

10000 Hz

20000 Hz

50000 Hz

100000 Hz

150000 Hz

198000 Hz

Figure 5-5 Typical power curve.

00 5

Typical Lase Th resh-Typical Lase Thresh-old v.s. Frequency Freeqequequeenccy


78


Technical Reference

0 200 400 600 800 1000 1200

Typical Power Pulse – PWM: 37.5%, PRF: 625 Hz

Time (µs)

Pow

er O

utpu

t (A

rbitr

ary

Uni

ts)

As PWM frequency and/or duty cycle increases above a certain point, the p100/150 transi-tions 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 above and below illustrates the p100/150 laser delivering full peak power (approximately 400W (p100) and 600W (p150) and peak pulse energy (at the maximum 600 μs pulse width) with 100% depth of modulation. The leading edge of the out-put energy pulse reaches full peak power and then drops off slightly as the tube gain dimin-ishes due to plasma heating.

Figure 5-6 Pulstar p100 pulse profi le – 37.5% duty cycle at 625 Hz.


79


Technical Reference

Figure 5-7 Pulstar p150 pulse profi le – 37.5% duty cycle at 625 Hz.

Figure 5-8 Pulstar p100 pulse profi le – 37.5% duty cycle at 20 kHz.

0 20 40 60 80 100 120

Typical Power Pulse – PWM: 37.5%, PRF: 20 kHz

Time (µs)

Pow

er O

utpu

t (A

rbitr

ary

Uni

ts)

These fi gures illustrate representative temporal pulse profi les of the OEM p100/150 laser at various PWM duty cycles and pulse repetition frequencies (PRF).


80


Technical Reference


0 20 40 60 80 100 120 140 160 180 200


Time (µs)

Pow

er O

utpu

t (A

rbitr

ary

Uni

ts)



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Technical Reference



100 200 300 400 500 600 700


Time (µs)

Pow

er O

utpu

t (A

rbitr

ary

Uni

ts)


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Technical Reference

0 200 400 600 800 1000 1200


Time (µs)

Pow

er O

utpu

t (A

rbitr

ary

Uni

ts)


0 100 200 300 400 500 600 700 800 900 1000

Pow

er O

utpu

t (Ar

bitr

ary

Uni

ts)

Time ( s)

P150 Typical Output Pulse 5kHz, 37.5% Duty Cycle



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Technical Reference

Table 5.2 PWM Command signal specifi cations.

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 (p100), 200 kHz (p150)

Typical Duty Cycle 1% — — 37.5%

0 100 200 300 400 500 600 700 800 900 1000

Pow

er O

utpu

t (Ar

bitr

ary

Uni

ts)

Time ( s)

P150 Typical Output Pulse 10kHz, 37.5% Duty Cycle



84


Technical Reference

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 eff ectively merge with a PWM signal that follows closely afterwards. When the PWM pulse that follows is short, causing the tickle pulse to become a signifi cant fraction of the PWM pulse dura-tion, then the tickle pulse eff ectively 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 aff ect 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 deter-mining factor but rather this behavior happens only when the off time between PWM pulses exceeds 200 microseconds.

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 trig-ger uncommanded lasing.



85

User I/O ConnectionsTechnical Reference

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 fi gure below for the 15 pin female D-type sub-miniature con-nector on the p100/150’s rear panel. The fi gure below illustrates the pin arrangement of the User I/O connector.

Pin 9Pin 15

Pin 8 Pin 1

INT TMP RDY

USER I/O ETHERNET

SHT LASE

Figure 5-16 User I/O connector pinouts.

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 connec-tions are made to the appropriate pins and that the appropriate signal levels are applied. Failure to do so may damage the laser.


86


User I/O connection summaryThe table below provides a quick reference summary to Pulstar p100/150 User I/O connec-tions.

Table 5.3 User I/O pin descriptions.

Pin Function Description

1 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. Th e laser remains disabled while voltage is applied. Removing voltage from the Remote Reset/Start Request input causes the laser’s RDY indi-cator to illuminate and begins a fi ve-second countdown aft er which lasing is enabled.

Note: When connecting fi eld wiring to the Remote Reset/Start Request input, use twisted pair and/or shielded cabling. Refer to SYNRAD Technical Bulletin #021 for details.

3 Remote Interlock input

Apply a positive or negative voltage (±5–24 VDC) with respect to Pin 11, Input Common, to enable lasing. If your system does not use a remote interlock, this pin must be con-nected to a voltage source in the range of ±5–24 VDC. Refer to Figure 5-17 for a diagram showing how the Remote Interlock input is factory-jumpered on the Quick Start Plug.

4 + 5 VDC Auxiliary Power

Th is connection provides +5 VDC for driving external inputs or outputs. Th e +5 VDC Auxiliary Power output can source up to 0.5 A and is protected by a 0.5 A self-resetting fuse. Th e return (ground) path must be through Pin 12, Auxiliary DC Power Ground.

5 + 24 VDC Auxiliary Power

Th is connection provides +24 VDC for driving external inputs or outputs. Th e +24 VDC Auxiliary Power output can source up to 0.5 A and is protected by a 0.5 A self-resetting fuse. Th e return (ground) path must be through Pin 12, Auxiliary DC Power Ground.

6 Laser Active output

Th is bi-directional switched output is internally connected to Pin 13, Output Common, when the laser is actively lasing (LASE indicator illuminated red). Th is output is open (high impedance) when no beam is being emitted (LASE indicator Off ).

7 Fault Detected output

Th is 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 fl ashing). Th e output is open (high impedance) when laser operation is within limits (TMP LED green and SHT LED blue).


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Pin Function Description

8 Laser Ready output

Th is 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 fi ve-second delay during which lasing is inhibited. Th is 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. Th is 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 5-17 for a diagram showing how the Shutter Open Request input is factory-jumpered on the Quick Start Plug. Th e 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

Th is connection provides a ground (earth) connection for +5 and +24 VDC auxiliary power outputs. Th is 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 cus-tomer-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). Th e Output Common line is protected by a 0.3 A self-resetting fuse.

14 Shutter Open output

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

15 Interlock Open output

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


88


Input/output signals The Pulstar p100/150’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 fl oating with respect to chassis ground. The fi gure below illustrates Pulstar’s internal DC supply wiring.

DC POWER INPUT

+48 V TO DC POWER BOARDS

VOLTAGE REGULATORSAND

48 V SWITCH

CHASSIS GROUND (EARTH)

0.5 A FUSESELF-RESETTING

0.5 A FUSESELF-RESETTING

USER I/O AUX DC PINS

+24 VDC

+5 VDC

(12) (4) (5)

+48 VDC (+)

DC RETURN (–)

Figure 5-17 Auxiliary DC power diagram.

Table 5-3 User I/O pin descriptions continued.

Pin 4 + 5 VDC Auxiliary PowerTh is connection provides +5 VDC for driving external inputs or outputs. Th e +5 VDC Auxiliary Power output can source up to 0.5 A and is protected by a 0.5 A self-resetting fuse. Th e return (ground) path must be through Pin 12, Auxiliary DC Power Ground.

Pin 5 + 24 VDC Auxiliary PowerTh is connection provides +24 VDC for driving external inputs or outputs. Th e +24 VDC Auxiliary Power output can source up to 0.5 A and is protected by a 0.5 A self-resetting fuse. Th e return (ground) path must be through Pin 12, Auxiliary DC Power Ground.

Pin 12 Auxiliary DC Power GroundTh is connection provides a ground (earth) connection for +5 and +24 VDC auxiliary power outputs. Th is 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.

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


89


connection, Input Common, which is separate from chassis ground to completely isolate con-trol 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 specifi ed with respect to their cor-responding return line.

Pin 1 PWM ReturnConnect the return side of your PWM Command signal to this pin. Refer to Table 5-4 for input circuit specifi cations.

Pin 2 Remote Reset/Start RequestApply a positive or negative voltage (±5–24 VDC) with respect to Pin 11, Input Common, to disable the laser. Th e laser remains disabled while voltage is applied to this pin. Re-moving voltage from the Remote Reset/Start Request pin causes the laser’s RDY lamp to illuminate and begins a fi ve-second countdown aft er 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 5-4 for input circuit specifi ca-tions.

Note: When connecting fi eld wiring to the Remote Reset/Start Request input, use twisted pair and/or shielded cabling. Refer to SYNRAD Technical Bulletin #021 for details.

Pin 3 Remote InterlockApply 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 con-nected to a voltage source in the range of ±5–24 VDC. Refer to Figure 5-17 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 specifi cations.

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 aft er the fi ve-second delay, pro-vided that the SHT indicator is also lit.

Note: 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 InputConnect your PWM Command signal (+5 VDC, 5 kHz nominal, 100 kHz max) to Pin 9. Th is 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 37.5% 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 5-4 for input circuit specifi -cations.


90


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 con-nected to a voltage source in the range of ±5–24 VDC. Refer to the fi gure below for a diagram showing how the Shutter Open Request input is factory-jumpered on the Quick Start Plug. See Table 5-4 for input circuit specifi cations.

Figure 5-18 Quick Start Plug wiring diagram.

Pin 1 PWM ReturnPin 9 PWM Input

Pin 3 Remote InterlockPin 4 +5 VDCPin 10 Shutter Open Request

Pin 11 Input CommonPin 12 Aux. DC Power Ground

Pin 15 Pin 9

Pin 8 Pin 1

PWM Input BNC

Rear (Solder Side)of Male DB15"Quick Start"Shorting Plug

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 Re-mote Reset/Start Request lines. Refer to Table 5-4 for input circuit specifi cations.

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


The use of the Quick Start Plug bypasses the laser’s safety in-terlock 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 qualifi ed personnel. In normal operation, the laser’s Remote Interlock input should be connected to the ma-chine’s safety interlock circuitry.


91


Figure 5-19 Input equivalent schematic.

Table 5.4 Input circuit specifi cations.Input Signal Name Input Device Type and Specifi cations

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 (p100) 200kHz (p150)

Max PWM = 37.5% Max Pulse Length = 600 microseconds

Remote Reset/Start Request Bi-directional optoisolator LED, forward voltage drop (Vf) 1.15 VDCRemote Interlock Off state Vmax < 1.0 VDCShutter Open Request On state Vmin ±5.0 VDC @ 7 mA On state (continuous) Vmax ±24.0 VDC @ 40 mA

USER I/O INPUT SIGNAL PINS

PWM INPUT (+) (9)

PWM RETURN (–) (1)

REMOTE RESET/START REQUEST (2)

REMOTE INTERLOCK (3)

SHUTTER OPEN REQUEST (10)

INPUT COMMON (11)

600 Ohm, 2W

600 Ohm, 2W

600 Ohm, 2W

Pulstar p100/150INPUT Circuitry

220 Ohm, 1/8W 430 Ohm, 1/10W

The fi gure below illustrates the input circuit’s equivalent internal schematic while the table below provides Pulstar p100/150 input circuit specifi cations.

Note: The Remote Reset/Start Request input must not be sent until Pulstar’s +5 VDC power sup ply has stabilized (approximately 200 ms after DC power-up).


92


Output signals

Pulstar’s fi ve 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 fi ve 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.

Pin 6 Laser ActiveTh is bi-directional switched output is internally connected to Pin 13, Output Common, when the laser is actively lasing (LASE indicator red). Th is output is open (high imped-ance) when no beam is being emitted (LASE indicator Off ). Refer to Table 4-5 for output circuit specifi cations.

Pin 7 Fault DetectedTh is 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 fl ashing) has occurred. Th e output is open (high impedance) when laser operation is within limits (TMP LED green and SHT LED blue). Refer to Table 5-5 for output circuit specifi cations.

Pin 8 Laser ReadyTh is 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 fi ve-second delay during which lasing is inhibited. Th is output is open (high impedance) when the laser is disabled (RDY LED Off ). Refer to Table 5-5 for output circuit specifi cations.

Pin 13 Output CommonUse this pin to complete the return (ground) path for any output connection (Pin 6, 7, 8, 14, or 15). Th e Output Common line is protected by a 0.3 A self-resetting fuse.

Pin 14 Shutter OpenTh is 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. Th is output is open (high impedance) when the laser is disabled (SHT LED Off ). Refer to Table 5-5 for output circuit specifi ca-tions.

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).


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Pin 15 Interlock OpenTh is 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. Th is output is open (high impedance) when the laser is enabled (INT indicator green). When this output is initially switched open, there is a fi ve-second delay during which lasing is inhibited. See Table 5-5 for output circuit specifi cations.

Figure below illustrates the output circuit’s equivalent internal schematic and the table below provides Pulstar p100/150 output circuit specifi cations.

PULSTAR p100/150OUTPUT CIRCUITRY

USER I/O OUTPUT SIGNAL PINS

SOLIDSTATERELAY

SOLIDSTATERELAY

SOLIDSTATERELAY

SOLIDSTATERELAY

SOLIDSTATERELAY

0.3 A FUSE,SELF-RESETTING

(6) LASER ACTIVE

(7) FAULT DETECTED

(8) LASER READY

(14) SHUTTER OPEN

(15) INTERLOCK OPEN

(13) OUTPUT COMMON

Figure 5-20 Output equivalent schematic.

Table 5.4 Output circuit specifi cations.Output Device Specifi cations

Bi-directional MOSFET 2.5 Ohms Rdson 10 MOhms Off

Voltage ±24 VDC, max.

Current 50 mA, max.


94


Sample I/O circuits Sample inputs

Figure below illustrates one method of supplying a Remote Interlock signal using a custom-er-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 volt-age requirements.

(12) AUX. DC POWER GROUND

Close switch toenable interlock

USER I/O PINS

(5) +24 VDC AUXILIARY POWER

(3) REMOTE INTERLOCK

(11) INPUT COMMON

Figure 5-21 Customer-supplied interlock.The fi gure below 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 toenable interlock

USER I/O PINS


(11) INPUT COMMON

–12 VDC

0 VDC

Figure 5-22 Customer-supplied interlock, negative voltage.


95


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

Figure 5-23 PLC driven interlock signal.

USER I/O PINS


(11) INPUT COMMON

PLCDC

OUTPUTMODULE

+V(+5–24V)

When multiple PLC outputs are used, connect Pulstar inputs to the PLC as shown in the fi gure below. 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.

PLCDC

OUTPUTMODULE

+V(+5–24V)

USER I/O PINS

(11) INPUT COMMON

(2) REMOTE RESET/START REQUEST


(10) SHUTTER OPEN REQUEST

Figure 5-24 Multiple PLC driven inputs.


96


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 fi gure 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.

Figure 5-25 Pulstar output driving warning lamp. The fi gure below 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.


(6) LASER ACTIVE

(12) AUX. DC POWER GROUND

(13) OUTPUT COMMON

LR1

USER I/O PINS


(6) LASER ACTIVE

(12) AUX.DC POWER GROUND

(13) OUTPUT COMMON

+V

L

USER I/O PINS

Figure 5-26 Pulstar output driving relay.


97


The fi gure below illustrates how Pulstar’s outputs can drive the DC Input Module of a Pro-grammable Logic Controller (PLC). By supplying voltage (+VDC) to Pin 13, Output Common, each Pulstar output is independently switched to activate individual PLC inputs.

Figure 5-27 Pulstar output driving PLC input module.

USER I/O PINS

PLCDC

INPUTMODULE

(13) OUTPUT COMMON

(6) LASER ACTIVE

(7) FAULT DETECTED

(8) LASER READY

(14) SHUTTER OPEN

(15) INTERLOCK OPEN

V+(+5–24V)


98

DC Power Cables

Technical Reference

The DC power cable section:

DC power cables

DC power cablesThe DC power cables shipped with the Pulstar p100/150 lasers are manufactured with 6 AWG wire to a standard length of 2.0 m (6.5 ft). Diameter 0.162 in requires a minimum bend radius of 1.944 in. Terminals on the laser end of the cables fi t the laser’s M6 studs while terminals on the power supply ends are sized to fi t M6 (0.25") bolts.

When using a power supply other than the PS-48-4000, you can fabricate your own DC volt-age 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. Please refer to the power source manual for details.

Important Note:

If you lengthen the DC Power Cables shipped with the p100/150 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. Keep in mind, depending on the additional length required, you may need to use larger gauge (2/0) wire.


99

Integrating Pulstar Safety FeaturesTechnical Reference

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-en-ergy 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 functionsOEM lasers

On p100/150 OEM lasers, the RDY LED illuminates on DC power-up (when the Remote Inter-lock input is enabled) and fi ve seconds later, DC power is applied to the RF driver. When the Shutter Open Request input is inactive (SHT indicator Off ) no tickle pulse is 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 fi ve 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 fi ve-second countdown after which lasing is enabled (RDY LED illuminates yellow). The RF driver is disabled as long as voltage is applied to Pin 2.

Your control system can monitor the laser’s ready status on the User I/O connector by con-necting your system’s input between Pin 8, Laser Ready, and Pin 13, Output Common (see the fi gure above).

Note: When connecting fi eld wiring to the Remote Reset/Start Request input, use twisted pair and/or shielded cabling. Refer to SYNRAD Technical Bulletin #021 for details. After the Laser Ready output closes, a fi ve-second delay occurs before lasing is enabled.

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


100


Shutter functions

An internal EM shutter is optional for p100/150 lasers, but the electronic shutter is available on all lasers. Lasing is enabled when the shutter is open (SHT LED illuminated blue) and dis-abled when the shutter is Closed (SHT LED off ).

For p100/150 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, Shutter Open Request. This input signal causes the SHT LED to illuminate (provided the RDY indicator is On) and opens the physical shutter to allow lasing. Removing voltage from the Shutter Open Request input causes the physical shutter to close and block the beam path, extinguishing the SHT lamp and allowing only tick-le signals to reach the tube.

Your control system can monitor the laser’s shutter status on the User I/O connector by con-necting 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 func-tionality 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 fi ve-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 4-25). This output is closed when remote interlock circuitry is open (INT LED illuminat-ed red). The output is open (INT LED green) when interlock circuitry is closed.


101


Table 5.5 Pulstar p100 general specifi cations.

Parameter p100 (10.2 μm) p100 (10.6 μm)

Output Specifi cations

Wavelength typical† 10.25 μm ±0.1 μm 10.6 μm ±0.1 μm

Average Power Output (minimum)2 90 W 100 WPeak Power, typ1 375 W 400 W

Peak Pulse Energy, (maximum) 180 mJ (tested at 625 Hz, 37.5% Duty

Cycle)190 mJ (tested at 625 Hz, 37.5%

Duty Cycle)

Power Stability, from cold start (typ)3 ±7%Power Stability, after 3 min (typ)3 ±5%Mode Quality3 M2 ≤ 1.2

Beam Waist Diameter (at 1/e2)3 7.5 mm ±1.1 mm

Beam Waist Diameter at faceplate (at 1/e2)3 7.5 mm ±1.1 mm 8.0 mm ±1.0 mmBeam Divergence, full angle (at 1/e2)3 1.8 mrad ±0.4 mrad 2.0 mrad ±0.4 mradEllipticity3 & Ellipticity far fi eld3 ≤ 1.2Polarization Linear, verticalRise and Fall Time1 < 40 μs (Rise) < 80 μs (Fall) < 40 μs (Rise) < 100 μs (Fall)

Input Specifi cations

Power Supply

Input Voltage / Current (maximum) 48 VDC / 40 A

Peak / RMS Current Amps 75 A (for < 700 μs) / 65 Amps

Command Input Signal

Voltage +3.5 to +6.7 VDC (5V nominal)

Current 10 mA @ +6.7 VDCFrequency Range Single shot to 100 kHzDuty Cycle Range1 ≤ 37.5%Pulse Length, max 600 μs

Logic Low State (Vmin–Vmax) 0.0 to +0.8 VDCLogic High State (Vmin–Vmax) +3.5 to +6.7 VDC

Environmental Specifi cations

Operating Temperature7 15 °C–40 °C

Humidity 0-95%, non-condensing


102

Pulstar p100 /150 General Specifi cationsTechnical Reference

Parameter p100 (10.2 μm) p100 (10.6 μm)

Cooling Specifi cations

Maximum Heat Load, laser 2000 WattsFlow Rate 1.5–2.0 GPM, < 60 PSI (5.7-7.6 LPM, <414 kPa)

Pressure Drop (Supply Input) 18 PSI @ 1.5 GPM/32 PSI @ 2.0 GPM, (124 kPa @ 5.7 LPM/221 kPa @ 7.6 LPM)

Coolant Temperature4 18–22 °CCoolant Temperature Stability ± 1.0 °CCoolant Water

Physical Specifi cations

Length 23.2 in (590 mm)Width 5.2 in (132 mm)Width 6.1 in (155 mm)Weight 30.0 lb (13.6 kg)* Specifi cations subject to change without notice. Measurements performed at 5 kHz, 37.5% duty cycle unless otherwise noted.

† Typical wavelength band for 10.6 μm nominal, but laser can operate in 10.2–10.7 μm range.

1 Measured at 1kHz, 10% Duty Cycle.

2 Power level guaranteed for 24 months from date of shipment, regardless of hours, provided laser is operated within the recommended cool-ant fl ow-rate and operating temperature range.

3 At coolant temperatures above 22 °C, derate power 0.5 W/°C to 1 W/°C up to a coolant temperature of 28 °C.



103



Parameter p150 (9.3 μm) p150 (10.2 μm) p150 (10.6 μm)

Output Specifi cations

Wavelength typical† 9.3 μm ±0.1 μm 10.25 μm ±0.1 μm 10.60 μm ±0.1 μm

Average Power Output (minimum)2 150 W

Peak Power, typ1 600 W 550 W 600 WPeak Pulse Energy, (maximum) 335 mJ Tested at 625Hz, 37.5% Duty Cycle

Power Stability, from cold start ±5% ±6%

Power Stability, after 3 min (typ) ±3%

Mode Quality M2 ≤ 1.2

Beam Waist Diameter (at 1/e2) 8.0 mm ±1.1 mm Beam Waist Diameter at faceplate (at 1/e2) 8.5 mm ±1.0 mm

Beam Divergence, full angle (at 1/e2) 1.9 mrad ±0.4 mrad

Ellipticity3 & Ellipticity far fi eld ≤ 1.2Polarization Linear, verticalRise and Fall Time1 < 50 μs (Rise) < 100 μs (Fall)

Input Specifi cations

Power Supply

Input Voltage / Current 48 VDC / 50 ACurrent and Peak & RMS Current 100 A for < 700 μs & 65 Amps

Command Input Signal

Voltage +3.5 to +6.7 VDC (5V nominal)Current 10 mA @ +6.7 VDCFrequency Range Single shot to 200 kHzDuty Cycle Range1 ≤ 37.5%Pulse Length, max 600 μsLogic Low State (Vmin–Vmax) 0.0 to +0.8 VDCLogic High State (Vmin-Vmax) + 3.5 to + 6.7 VDC


Operating Temperature 15 °C–40 °CHumidity 0-95%, non-condensing


104


Parameter p150 (9.3 μm) p150 (10.2 μm) p150 (10.6 μm)

Cooling Specifi cations

Maximum Heat Load, laser 3500 W

Flow Rate 2.0 GPM at < 60 PSI (15.1 LPM at <414 kPa)

Pressure Drop 19 PSI @ 1.5 GPM/34 PSI @ 2.0 GPM, (131 kPa @ 5.7 LPM/234 kPa @ 7.6 LPM)

Coolant Temperature3 18–22 °CCoolant Temperature Stability ± 1.0 °CCoolant Water


Length 31.4 in (798 mm)Width 5.2 in (132 mm)Height 6.1 in (155 mm)Weight 40.0 lb (18.1 kg)* Specifi cations subject to change without notice. Measurements performed at 5 kHz, 37.5% duty cycle unless otherwise noted.

† Typical wavelength band for 10.6 μm nominal, but laser can operate in 10.2–10.7 μm range.

1 Measured at 1kHz, 10% Duty Cycle.

2 Power level guaranteed for 24 months from date of shipment, regardless of hours, provided laser is operated within the recommended coolant fl ow-rate and operating temperature range.

3 At coolant temperatures above 22 °C, derate power 0.5 W/°C to 1 W/°C up to a coolant temperature of 28 °C.



105

Pulstar p100/150 Outline & Mounting DrawingsTechnical Reference

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107


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Synrad Pulstar p100/150 operation manual ver 2.1

109

6Maintenance/

TroubleshootingMaintenance

This Class 4 laser product that emits invisible infrared laser radiation in the 9.3–10.6 μm CO2 wavelength band. Because direct or diff use laser radiation can infl ict severe corneal inju-ries, 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.

Use information in this chapter to perform maintenance or troubleshoot your Pulstar p100/150 laser.

This chapter contains the following information:

Maintenance – describes typical Pulstar p100/150 maintenance procedures.

Troubleshooting – explains how to troubleshoot common Pulstar p100/150 problems.


Important Note:

Th is section of the Operation Manual explains how to conduct regular main-tenance and/or basic troubleshooting to Pulstar p100/150 lasers. If you cannot attend to the unit using the information described in this manual, contact SYN-RAD, (+.425.349.3500) or an authorized SYNRAD Distributor.


110

Maintenance

Maintenance/ Troubleshooting

The Maintenance section includes subsections:

Disabling the p100/150 laser

Daily inspections

Storage/shipping

Cleaning optical components

Disabling the p100/150 laserBefore performing any maintenance on your Pulstar p100/150 laser, be sure to completely disable the laser by disconnecting the DC Power Cables from the DC power supply.

Daily inspecti onsPerform the following steps daily to keep your Pulstar p100/150 laser in optimum operating condition. Except for the procedures described below, no other service is required or should be attempted.

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 SYN-RAD or the optics manufacturer for handling instructions.

Warning



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 com-ponents.

1 Inspect all cooling tubing connections for signs of leakage. Check for signs of condensa-tion that may indicate the cooling water temperature has been set below the dew point temperature. Condensation will damage electrical and optical components inside the la-ser. 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 p100/150 laser, empty water traps and oil separators on each fi lter and/or dryer between the laser and your compressed air source. Compressed air purity must meet the purge gas specifi cations shown in the Getting Started chapter’s Table 3-3 in the Operators Manual.


111

Maintenance


3 Inspect beam delivery components for signs of dust or debris and clean as required. When cleaning the optical surfaces of beam delivery components, carefully follow the manufacturer’s instructions.

4 Visually inspect the exterior housing of the laser to ensure that all warning labels are present. Refer to the Laser Safety chapter for p100/150 label types and locations.

Storage/shippingWhen 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 fi nished, 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 proper-ly packaging the laser for shipment.


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 fi ltered air or nitrogen to prevent vapor and debris from accumulating on optical surfaces.

Important – Pulstar p100/150 lasers have several beam conditioning op-tics between the output aperture and the faceplate. To prevent dust and debris from damaging these optical surfaces, always connect nitrogen or fi ltered air to the laser’s Gas Purge port.

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.

Danger


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 dam-age caused by improper packaging.


112

Maintenance


Cleaning guidelines

Wear latex gloves or fi nger cots (powder-free) to prevent contamination of optical surfaces by dirt and skin oils.

Never handle optics with tools; always use gloved hands or fi ngers.

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 fl uff ed 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 ob- serve all necessary safety precautions.

Required cleaning materialsThe table below lists the type and grade of materials required to properly clean optical surfac-es.

Table 6.1 Required cleaning materials.Cleaning Material Requirements

Latex gloves or fi nger 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 optical components

Debris or contaminants on external beam delivery components may aff ect 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.

Important Note:

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


113

Maintenance


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. Use a clean lens wipe on each pass. The wipe will pick up and carry surface contaminants that may scratch optical surfaces or coatings.

Caution

Possible lensdamage

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 sur-face.

Do not use compressed shop air to blow contamination from the optic. Compressed air contains signifi cant amounts of water and oil that form adsorbing fi lms 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.

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.

Important Note:

If acetone is used as a cleaning solvent, a second follow-up cleaning of the optical surface using alcohol is required.

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.

To prevent streaking during the fi nal alcohol cleaning, drag the lens wipe slowly across the surface so that the cleaning liquid evaporates right behind the wipe.

Note:


114

Troubleshooting


The Troubleshooting section includes subsections:

Operational fl owchart

Functional block diagram

Status LEDs

Laser fault indications

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 SYN-RAD Authorized Distributor for repair information.

To troubleshoot Pulstar p100/150 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 fl owchart and the functional block diagram.


Attempting repair of a SYNRAD Pulstar laser without the express autho-rization of SYNRAD, will void the product warranty. If troubleshooting or service assistance is required, please contact SYNRAD Customer Service.

This Class 4 laser product emits invisible infrared laser radiation in the 10.6 μm CO2 wavelength band. Since direct or diff use laser radiation can infl ict 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 per-son. This product emits an invisible laser beam that is capable of seriously burning human tissue.




115

Troubleshooting


Operational fl owchart

INT indicatorGreen?

SHT indicator

Blue?

Apply interlock signalto Remote Interlock inputor install factory-supplied

Quick Start Plug

Check that cooling water is flowing

through laser, and coolant temp is

within specified limits

Troubleshoot/correctfault condition then

cycle DC power

Apply PWM Command

signal to laser

Apply 48 VDCpower to laser

LASE indicatorilluminates Red to

indicate laser output

Laser Start Sequence

Blinking Code

Cycle DC power (remove DC power,

wait 15 seconds,reapply DC power)

SHT indicatorFlashing?

No

Yes

FlashingPulse width >1 ms Or

PWM > 37.5%

Apply tickle pulses or aPWM Command signal

(< 5% duty cycle) for30 to 60 seconds

No

Yes

Apply shutter opensignal to Shutter Open

Request input or installfactory-supplied Quick

Start Plug

No

Yes

TMP indicatorGreen?

No

Yes

RDY indicatorYellow?

Yes

Apply tickle pulses OR PWM Command signal

< 5% duty cycle) for 30 to 60 seconds

Figure 6-1 Pulstar p100/150 operational fl owchart.


116

Troubleshooting


Tabl

e 6.

2 p

100,

p15

0 In

put/

Out

put &

LED

Sta

tus

Sign

als.

Status LEDs

/

Remote Interlock

Remote Reset / Start Request

Shutter Open Request

PWM

Interlock Open

Fault Detected

Laser Ready

Shutter Open

Laser Active

DC P

ower

Off

xx

xx

XX

XX

XN

o RF

to tu

be

0x

xx

x1

xx

xx

0x

DC P

ower

App

lied,

La

ser E

nabl

ed1

01

0G

GY

BX

CC

Tick

le a

pplie

d to

tube

for 5

se

cond

s, th

en la

ser m

ay fi

re

Lase

r Firi

ng1

01

GG

YB

RC

CC

Nor

mal

lase

r ope

ratio

n

Inte

rlock

Ope

n0

01

xR

GX

BX

CC

No

RF to

tube

Ove

r Tem

pera

ture

10

1x

GR

XB

XC

CCo

olin

g pr

oble

m

Mec

hani

cal S

hutt

er

Not

Ope

n1

01

xG

GY

XX

CN

o RF

to tu

be

Und

er V

olta

ge1

x1

xG

G1

blin

kB

XC

Volta

ge b

elow

46V

DC

Ove

r Vol

tage

1x

1x

GG

2 bl

ink

BX

CVo

ltage

ove

r 50V

DC

RF D

rive

Switc

h Fa

ult

1x

1x

GG

3 bl

ink

BX

CLa

ser s

ervi

ce re

quire

d

PWM

Driv

e Fa

ult

1x

1x

GG

4 bl

ink

BX

CLa

ser s

ervi

ce re

quire

d

No

Strik

e Co

nditi

on1

01

xG

GY

blin

kX

CC

CTe

chni

cal R

efer

ence

cha

pter

in

the

Ope

ratio

n M

anua

l

TABL

E KE

Y:C

:Clo

sed

x =

Does

not

mat

ter

LASE

R CO

NDI

TIO

N /

FA

ULT

COM

MEN

TS

INPU

T ST

ATU

SO

UTP

UT

STAT

US

Blin

king

LED

; "C"

repr

esen

ts

cont

inuo

us b

linki

ng se

quen

ce

Blin

king

LED

; num

ber r

epre

sent

s bl

ink

sequ

ence

0 =

Inpu

t OFF

1 =

Inpu

t ON

LED

STAT

US

No

RF to

tube

DC P

ower

App

lied,

La

ser D

isab

led

C

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117

Troubleshooting


Pulstar p100/150 LED indicators, also mirrored as output signals on the User I/O connector, provide status information to the user. Table 6-2 shows Pulstar input/output signal and LED in-dicator states during normal and fault conditions. User I/O outputs are Closed when the state indicated by the signal name is logically True.

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 fi ve-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 caus-es the LASE indicator to illuminate red as lasing begins.

For safety reasons, the shutter function on p100/150 lasers is dependent on the state of the Remote Interlock input. The Remote Interlock Input status is refl ected 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).

The following section 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).

On DC power-up of a p100/150 laser, the RDY lamp illuminates yellow provided INT and TMP indicators illuminate green. Once the RDY indicator illuminates yellow, an internal tickle is en-abled and after a fi ve-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 appli-cation of a PWM Command signal causes the LASE indicator to illuminate red as lasing begins.

Remote interlock conditionA 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 p100/150 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 fi ve-second delay provided the SHT indicator is illuminated blue and a PWM Command signal is applied.


118

Troubleshooting


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 Refer-ence 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 in-hibited 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.

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 fi eld wiring to the DB-15 User I/O con-nector. See User I/O connections in the Technical Reference chapter for wiring details.

Laser fault indicationsPulstar p100/150 lasers have the ability to indicate eight specifi c 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 fl ashes continuously until the gas breaks down into a plasma state.

Refer to the table above for a status list, the corresponding fault, and description in the com-ments for basic corrective action. See the Resetting faults section for detailed corrective actions.

On Pulstar p100/150 OEM lasers, remote interlock faults are not latched. Clearing the fault condition re-enables the RDY indicator and the laser will fi re after the fi ve-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 infl ict severe corneal injuries and seriously burn human tissue, the OEM or System Integrator must ensure that appropriate safe-guards are in place to prevent unintended lasing.

Warning



119

Troubleshooting


If water temperature is OK, check the fl ow rate. If a fl ow 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 fi ve-gallon bucket. After 30 seconds, a minimum of 1.5 gallons or (5.8 L) should be col-lected. 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 fi lter.

On p100/150 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 De-tected 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 suffi ciently to begin operation. To reset an over temperature fault, lower coolant temperature below 28 °C and then cycle DC power (remove DC power, wait 30 seconds, reapply DC power). When the RDY indicator illuminates, lasing is enabled after the fi ve-second delay. If the TMP indicator remains red after cycling power, continue to fl ow cooling water through the laser for a few more minutes and/or verify the coolant fl ow rate and then cycle DC power again.

Under Voltage faultAn 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 fl ashing 1 blink. The Laser Ready output Opens under these conditions. To reset an under voltage fault, fi rst 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 fi ve-second delay. Apply a PWM Command signal, provided the SHT indicator is illu-minated blue.

Over Voltage faultAn 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 fl ashing 2 blinks. Under these conditions the Laser Ready output Opens. To reset an over voltage fault fi rst correct the voltage problem and ensure 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 a fi ve-second delay) provided a PWM Command signal is applied, and the SHT indicator is illuminated blue.

Possible Causes:

Coolant temperature is above 28 °C (82 °F) or there is inadequate coolant fl ow through the laser. Check that your chiller is maintaining a water temperature between 18 °C–28 °C (64 °F–82 °F) at a fl ow 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 fl ow rate of 11.4 liters per minute (3.0 GPM).


120

Troubleshooting


RF Drive Switch faultAn 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 fl ashes 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 faultA PWM Drive fault signals a problem in the laser’s internal RF circuitry and is indicated by a fl ashing 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 faultA 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 fl ash 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 faultA 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 specifi ed frequency during PWM signal applica-tion. In addition to the SHT indicator fl ashing continuously an error message appears on the p100/150’s web page.

Humidity faultDuring laser operation, monitor information on the p100/150’s web page including the relative humidity (RH) value. When properly conditioned purge gas is fl owing, 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 fl ow rate to the maximum specifi ed value. Refer to purge gas specifi cations in the Getting Started chapter within the connection section. If the RH value continues to rise and reach 95%, lasing is halted and a fault is displayed in red within the error message section of the web page.

Blinking Shutter LED fault

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.


121

Troubleshooting


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 com-manded 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 Cycle/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.

When a duty cycle or pulse width limit fault is detected, the SHT LED fl ashes 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 con-dition 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.


122

Troubleshooting


Caution


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 fi ltered air or nitrogen to pre-vent vapor and debris from accumulating on optical surfaces.Important – Pulstar p100/150 lasers have several beam conditioning op-tics between the output aperture and the faceplate. To prevent dust and debris from damaging these optical surfaces, always connect nitrogen or fi ltered air to the laser’s Gas Purge port.

DangerSeriouspersonalinjury

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.

WarningSeriouspersonalinjury

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, or the optics manufacturer for handling instructions.

Cleaning optical componentsDebris or contaminants on external beam delivery components may aff ect laser processing and lead to damage or failure of the optics and/or the laser. Please refer to the Optics Clean-ing and Inspection within section 4 inside this Service Manual.


123

Troubleshooting


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 re-quires cleaning, refer back to Maintenance for cleaning instructions. Use only recommended cleaning materials (see Table 3-1) to prevent scratching delicate optical surfaces. If the focus-ing 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.

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 dam-age optical surfaces, it must be carefully fi ltered and dried before use as a purge or assist gas. Refer to the purge gas specifi cations, in the Introduction chapter of this manual and the get-ting started chapter in the Operation Manual for fi ltering and drying specifi cations.

124 Synrad Pulstar p100/150 operator’s manual ver 2.0

indexSynbols

+5 VDC Auxiliary Power 80+5 VDC output 82

signal description, 82+24 VDC 90+24 VDC Auxiliary Power 80+24 VDC output 82

signal description, 82

A

American National Standards Institute (ANSI) 21Analog current control 77Analog voltage control 77Aperture

see Laser apertureAssist gas purity

specifi cations, 65, 66, 69, 72Aux. DC Power Ground 82

signal description, 82Auxiliary DC power 82

+5 VDC, 82, 83+24 VDC 82+24 VDC, 82Aux. DC Power Ground 82Aux. DC Power Ground, 82internal wiring diagram, 82

Auxiliary DC Power Groundpin description, 81

B

Beam block 54, 57

C

Cautioncondensation, 8, 15, 31, 47, 54dirty optics, 103, 105, 114single-phase operation, 38, 39, 55, 56, 57, 59, 79voiding warranty, 102, 106

CDRH 24Chiller

temperature setpoint, 40, 54, 57Class IV safety features 27Code of Federal Regulations (CFR) 24, 25Collimator 68Command signal 71, 78

base frequency, 71duty cycle, 71signal amplitude, 71

Condensation damage 102Control signals 70–71

Pulse width modulation (PWM), 71Tickle pulse, 70

Cooling kit 34Cooling tubing 34

D

Daily inspections 102Danger

eye protection, 18, 53, 101laser radiation, 18, 19, 20, 53, 101OEM faults, 110

DC Power cable 102DC Power Cables 34, 92

min bend radius, 92Delivery optics 68Disabling Firestar 102Divergence 68

E

Expander/collimator 68

F

Final Test report 34Flowchart

laser start-up, 107Flow rate 54, 57, 111Food and Drug Administration (FDA) 24Fuse 34

G

Gas Purge connector 52Gas purge kit 34Gas Purge port 40, 52GND terminal 52

H

Hazard information 19label locations, 22terminology, 19

I

Input circuitequivalent schematic, 85specifi cations, 85

Input Common 84pin description, 81

Input signalsPWM Return, 83Remote Interlock, 83

Inspectionsdaily, 102

Interlocksee Remote Interlock

Interlock Openpin description, 81, 87

K

Keyswitch functionsintegrating, 93

L

Label locations 22

125Synrad Pulstar p100/150 operator’s manual ver 2.0

indexLase indicator 52, 56, 59Laser Active 80

pin description, 86Laser aperture 51Laser Institute of America (LIA) 21Laser Ready 86

pin description, 81, 86Lift ing handles 33

M

Maintenancedaily inspections, 102disabling Firestar, 102storage/shipping, 103

Mounting bolts 34MSDS 104

O

Occupational Safety and Health Administration (OSHA) 21Operating modes

analog current control, 77analog voltage control, 77

Optical accessories mounting 51Optics

cleanliness, 103, 105, 114Output circuit

equivalent schematic, 87specifi cations, 87

Output Common 86, 91, 94pin description, 81, 86

Output signalsLaser Ready, 86Output Common, 86Over Temperature, 86

Over Temperature 86Over Temperature output 111

P

Packaging instructions 34PLC

multiple inputs, 91multiple outputs, 89Remote Interlock output, 89

Pulse Width Modulation (PWM) 71PWM 71

signal levels, 77PWM Input 71, 58, 83

pin description, 81PWM Input signal

description, 83specifi cations, 85

PWM Return 71, 58, 80, 83PWM Return signal

description, 83

Q

Quick Start Plug 34, 55, 58

wiring diagram, 84

R

Ready indicator 52, 58, 111Remote Interlock 80, 83

customer-supplied circuit, 88from PLC, 89

Remote Interlock functions 94Remote Interlock indicator 55, 94, 58Remote Interlock input 93, 68, 94, , 54, 109Remote Interlock (INT) indicator 109Remote Interlock signal

specifi cations, 85Remote Reset/Start Request 80, 83Remote Reset/Start Request input 68Remote Reset/Start Request signal

specifi cations, 85RoHS 26

S

Shorting plugsee Quick Start Plug

Shutter indicator 52, 58Shutter Open

pin description, 81, 86Shutter Open request

pin description, 81Shutter Open Request 84Shutter Open request input 68Shutter Open Request input 54Shutter Open Request signal

specifi cations, 85Shutter switch 68Specifi cations

assist gas purity, 65, 66, 69, 72Status indicators 52Storage/shipping 103

T

Technical overviewlaser tube, 65

Temperature setpoint 54, 57Temp indicator 55, 58, 111Tickle pulse 70Troubleshooting 104

operational fl owchart, 107

U

UC-2000 Laser Controller 54, 55, 70, 56connecting, 58

User I/Oconnection summary, 79pin descriptions, 80

User I/O connections 79input/output signals 79

126 Synrad Pulstar p100/150 operator’s manual ver 2.0

indexsample input circuits, 88

User I/O connector 52, 93, 94, 54, 57, 58

W

Warningair contaminants, 20, 53, 55, 58, 61, 70, 71, 78, 84eye protection, 18, 53, 101laser radiation, 11, 45, 103, 114, OEM faults, 106

Water Out/In ports 52, 53

Tables and

FiguresTable 1.1 Water Flow Rate 17Table 1.2 Dew Point Temperatures 19Figure 2-1 Warning, Danger, and Caution Labeling 21Figure 2-2 Adversive Light Warning 23 Figure 2-3 Pulstar p100 Label Locations 25Figure 2-4 Pulstar p150 Hazard Label Locations 26Table 2.1 Class 4 Safety Features 30Table 2.2 European Union Directives 31Figure 2-5 p100 Declaration of Conformity 32Figure 2-6 p150 Declaration of Conformity 33Table 3.1 Pulstar p100 Ship Kit Contents 38Table 3.2 Pulstar p150 Ship Kit Contents 38Figure 3-1 Attaching the Laser to the Mounting Plate 35Figure 3-2 Attaching the Mounting Feet (side view) 39Figure 3-3 Attaching the Mounting Feet (top view) 41Table 3.2 Purge Gas Specifi cations 40Table 3.3 p100/150 Water Flow Rate 45Figure 3-4 Attaching the Power Leads 49Figure 4-1 Pulstar OEM p100/150 Front Panel Controls and

Indicators 53Figure 4-2 Pulstar OEM p100/150 Rear Panel Controls and

Indicators 54Figure 5-1 Hybrid waveguide/unstable resonator design 67Table 5.1 Assist Gas Purity Specifi cations 67Figure 5-2 PWM Command Signal Wave Form 70Figure 5-3 Typical power curve 70Figure 5-4 Pulstar p100 pulse profi le -37.5% Duty Cycle, 625Hz,

71Figure 5-5 Pulstar p150 pulse profi le -37.5% Duty Cycle, 625Hz,

72Figure 5-6 Pulstar p100 pulse profi le -37.5% Duty Cycle, 20kHz,

72Figure 5-7 Pulstar p150 pulse profi le -37.5% Duty Cycle, 20kHz,

73Figure 5-8 Pulstar p100 pulse profi le -37.5% Duty Cycle, 10kHz

73Figure 5-9 Pulstar p150 pulse profi le -37.5% Duty Cycle, 10kHz

74

Figure 5-10 Pulstar p100 pulse profi le -37.5% Duty Cycle, 5kHz, 74




Table 5.2 PWM Command Signal Specifi cations 76Figure 5-14 User I/O connector pinouts 78Table 5.3 User I/O pin descriptions 79Figure 5-15 Auxiliary DC power diagram 81Figure 5-16 Quick Start Plug wiring diagram 83Figure 5-17 Input Equivalent Schematic 84Table 5.4 Input Circuit Specifi cations 84Figure 5-18 Output Equivalent Schematic 86Table 5.5 Output Circuit Specifi cations 86Figure 5-19 Customer-supplied Interlock (one example) 87Figure 5-20 Customer-supplied Interlock neg voltage 87Figure 5-21 PLC Driven Interlock Signal 88Figure 5-22 Multiple PLC Driven Outputs 88Figure 5-23 Pulstar Output Driving Warning Lamp 89Figure 5-24 Pulstar Output Driving Relay 89Figure 5-25 Pulstar Output Driving PLC Input Module 90Table 5.6-7 Pulstar p100/150 General Specifi cations 94-97Figure 5-26 Pulstar p100/150 Outline & Mounting Drawings 98Figure 5-27-28 Pulstar p100/150 Outline and Mounting 99Figure 5-28 Pulstar p150 Packaging Instructions 100Figure 5-29 Pulstar Outline and Mounting 101Table 6.1 Required Cleaning Materials 105Figure 6-1 Pulstar p100/150 Operational Flowchart 108Table 6.2 P100/150 Input/Output & LED Status Signals 109

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