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Series 48 Lasers Operator`s Manual

1. REAR CHAMBER CONTROL CHAMBER FRONT CHAMBER 1 2 18 RED 1 18 RED T 18 YEL 1 2 18 YEL RED F2 22 BLK O 2 RF DRIVER RF 2 20 18 RED 1 18 22 WHT gt J8 810 16798 00 18 ORG 1 2 22 WHT gt WHT STANDARD AND piper 7 m NOTE B OEM VERSIONS SLAVE BOARD 654321 J7 777 Ja 1 2 18 WHT gt 2 DRIVER IV 1 P4 POWER Pun 810 16798 00 lo PF RED 22 RED 1 22 GRY E amp 48J CONTROL BOARD RSS SCH 810 17542 00 Me SHUTTER 22 GRN 1 DD SWITCH 1 2 22 GRY 1 2 LED2 2 NZ LED 2 1 RED G GREEN jr LASE Y POWER 22 GRY 10987654321 2 2 1 1 55 2 30 WHT PAIR 1 5 o 2 22 gt 2 22 RED gt gt K X THERMISTOR 1 gt 22 GRY ji9 rl CLOSED OFF 1 2 22 ORG o 22 ORG 5 DUO LASE VERSION ONLY 5 DUO LASE VERSION ONLY 4 2 z 4 4 22 GRY ALL VERSIONS ALL VERSIONS 22 RED 1 2 422 WHT 1 ES 2 22 GRY 1 a 2 22 GRY gt di Hee WHT gt Js M gt SHUTTER 177 WITCH 22 GRN 1 2 22 BRN 5X GREEN 3 3V 1
2. TOP VIEW O Lx1 X x1 Hg 5 DA CAUTION MODEL J48 1W INPUT POWER 30 VDC CONDENSATION AND MFG October 08 2001 WATER DAMAGE CAN 4600 Campus Place Mukilteo WA 98275 425 349 3500 OCCUR IF COOLING WATER AIVE LEOTE NALE IS BELOW DEW POINT Ser 0481281010390 SEE OPERATION MANUAL WATER COOLED VERSION ONLY This laser product is manufactured under one or more of the following U S Patents 4 805 182 5 065 405 6 195 379 4 837 772 5 215 864 6 198 758 5 008 894 5 062 865 6 198 759 Other U S and International Patents pending MADE IN THE U S A BOTTOM VIEW O LEI MADE INTHE U S A ln o Ain KEYSWITCH VERSION This laser manufactured by Synrad Inc Mukilteo WA 98275 complies with 21 CFR subchapter J at the date of manufacture OR OEM VERSION This laser manufactured by Synrad Inc Mukilteo WA 98275 does not comply with 21 CFR subchapter J at the date of manufacture Figure 48 1 Label Location Diagram IMPORTANT DB9 wiring change Pins 3 and 4 now provide the remote interlock function and pins 6 and 7 now provide the remote REMOTE INTERLOCK JUMPER keyswitch function unused these pins must be jumpered for the laser to operate Refer to manual for details REMOTE KEYSWITCH JUMPER KEYSWITCH VERSION ONLY Series 48 Lasers Operator s Manual Appendix Supporting Documentation CAUTION
3. Lad SEE NOTE Figure 4 4 48 5 Laser Cooling Kit Series 48 Lasers Operator s Manual 27 Ch 4 Interface Requirements 28 Series 48 Lasers Operator s Manual Ch 5 Unpacking and Setup Chapter 5 Unpacking and Setup 5 1 Unpacking Initial Inspection Place the shipping container on a sturdy level surface and open the top of the box Verify that the following items are included in the container Series 48 Laser Operation and Service Manual Spare Fuse s One 10 Amp 48 1 One 20 Amp 48 2 Two 20 Amp 48 5 DB9 Connector DB9 Cover Kit Cooling Kit Final Test Data Report Carefully remove the Series 48 Laser from the container and remove the outer foam packing material Inspect the laser housing for any visible signs of shipping damage Verify that all external labels Do not discard the shipping container or the foam packing since these are required if the laser is ever returned to SYNRAD or a SYNRAD Authorized Service Center are attached to the housing refer to Appendix A for label location diagrams Contact SYNRAD if the laser housing is damaged or if any of the required materials or labels are missing 5 2 Mounting The recommended mounting orientation for Series 48 lasers is horizontal If this cannot be accomplished the lasers may be mounted at an angle of gt 20 to the vertical Consult the factory for limitations if the laser is to be mounted in a vertical orientation The laser may
4. 23 42 DC Power Supply Oe 23 4 2 1 48 1 48 2 Model 23 42222 A83 Model A nivea vu 23 4 3 DB9 uias estet 23 4 4 Coolme Requirements 25 4 4 1 48 1 48 2 Cooling eere 25 4 4 2 48 5 COOLE Os iba p II add iae AMA 2 5 Unpacking and Setup enn 29 5 1 Unpacking Initial Inspection 29 A A ess debe e 29 5 3 System 30 5 3 1 48 1 48 2 Interconnections 30 5 3 2 48 5 30 6 Operating Instructions ci 33 6 1 General O 33 6 2 AAA 33 6 3 Operation in Pulsed Mode 34 6 4 Operation in Continuous Wave CW Mode 6 5 PC Controlot Lastras 35 7 Maintenance and Troubleshooting 37 8 Return for Factory 39 service Request Form standard 40 Appendix A Supporting Documentation Appendix B DC 1 Power Supply Appendix C DC 2 DC 5 Power Supplies 11 Series 48 Lasers Manual List of Figures 1 1 European C
5. 335 51 140 AIGWASSV 04 2 401 Juv vo IIL Y ABVIS 3SIMYSHLO 5531 avav 3YV 530 151534 53109 40051 81 100 HtCVvO T 3905 S2 M3YIS DIN Ps 7 21 T o i svig 40 lv 5 4 AVG xd e 83 15 io M22 60 MOOS T ANN 5 94 07 100 JM 16 DH A 1 l 2111 14 MS 0919 TLN Hu06 390061 29 0 250 213 1101 618 21 01389738 11 0313730 3 184 ONY PH aaaav 98 1 01 128 2 aa NOILdINDS30 31 0 093 38 Series 48 Lasers Operator s Manual Figure 2 8 Driver IV 18 Ch 3 Physical Features Chapter 3 Physical Features The physical features of the Series 48 lasers are shown in Figure 3 1 48 1 and 2 and Figure 3 2 48 5 and described in the following paragraphs 3 1 Controls and Indicators 3 1 1 Shutter Switch The shutter switch is a mechanical shutter that closes the laser aperture The shutter also actuates independent micro switches that interrupt power to the laser section s The shutter should not be used to partially block the beam to control output power The shutter 18 standard on keyswitch versions and can be orde
6. These RF Excited Lasers must be provided with a pre ionizing Tickle signal during standby or This laser product is manufactured under laser low periods This is automatically provided one or more of the following U S Patents with Synrad s UC Series power controller This signal 4 805 182 5 065 405 6 195 379 keeps the plasma ionized during laser low periods 4 837 772 5 215 864 6 198 758 and facilitates breakdown and pulse to pulse fidelity 894 2 86 8 Damage malfunction may occur if this or 5 008 5 60 28 5 6 198 759 1 equivalent drive signals are not used See manual Other U S and International Patents pending for tickle pulse specifications or contact factory TOP VIEW 2 INPUT POWER 30 VDC CONDENSALION AND MFG October 08 2001 WATER DAMAGE CAN 4600 Campus Place Mukilteo WA 98275 425 349 3500 OCCUR IF COOLING WATER IHE ETOILE IS BELOW DEW POINT Ses 0481281010390 SEE OPERATION MANUAL MADE IN THE U S A WATER COOLED VERSION ONLY BOTTOM VIEW o MADE INTHE US A o O O O O O HE KEYSWITCH VERSION This laser manufactured by IMPORTANT DB9 wiring change Pins 3 and 4 Synrad Inc now provide the remote interlock function and pins Mukilteo WA 98275 6 and 7 now provide the remote REMOTE INTERLOCK
7. SYNRAD Series 48 Lasers Operator s Manual J Version Model Numbers 48 1 W 48 2 W 48 5 W Synrad Inc 4600 Campus Place Mukilteo WA 98275 425 349 3500 email synrad synrad com FAX 425 349 3667 In U S 1 800 SYNRAD1 a Series 48 Lasers Operator s Manual J VERSION Version 5 4 Released 12 20 02 Part Number 900 00007 02 SYNRAD Inc 4600 Campus Place Mukilteo WA 98275 1 800 SYNRAD1 TEL 425 349 3500 FAX 425 349 3667 E Mail synrad synrad com Web site http www synrad com Table of Contents 1 Safety and Regulatory 1 1 1 CDRH Requirements Safety 1 1 2 EMI and Safety Compliance 3 1 2 1 Federal Communications Commission FCC amp 3 1 2 2 European Union EU Requirements 4 1 3 Declaration of Conformity a pene rod ids 5 14 cWamme did 6 1 5 Operation and Service Manual Precautionary Notations 6 L6 General Hazards ente 6 2 Theory of Operation oa 9 2 1 Technical Specifications 9 2 2 Technology JVeEVIe 10 2 3 Description of Physical Operation 11 2 31 Plasma Section iii 11 2 3 2 Optical 11 24 aser Powe
8. 1 1 6 1 ae 02200 0805 SOD123 A o HS 84 HS a D2 Tene 11 3K 57771777 11 3K 1 69K NO Sambo lo 24 CERERE T 471 POWANA 0805 x l gt 4 1206 4 716 SMFOMNI Pa Ee W 12 0805 0805 1 2 m 5 GND 1206 INTERLK Y Q2 D9 T R37 22K 2512 1 LD3 LD2 LD1 podre MIC4416BM4 aD 2512 YEL YEL YEL WW TED SOT143 0805 D8 5 4V GND 1206 1206 1206 BE BG BM 010 3LASLEB MMSZ5245B s Jr ls ls Hate 12 SOD123 51 0022 100 2 2K 2 15VH5 SETUP a4 V 1206 2512 MMSZ5245B A DIP8 jd 5 R11 BCX55 PG TERR R36 U4D 619 619 619 619 BE BG BM 2 V Q1 R20 249K 74 14 0805 0805 0805 5 PWMEN 0805 0805 GND GND NDC7002N 619 0805 SSOT6 0805 9 8 PWMANA 8 T 5 4 3 8 02 821 Rie 619 CMDANA 4 50 22 6K U4C UAB 1 1 5 V R38 0805 10 e 1206 0805 74HC14 74HC14 R15 1 0 R22 U4E 1 50 22 6K X7R 11 3K GND PG a 500mA 619 74HC14 1206 7 0805 0805 RXE Lc 3 ARA he 10088 XIR V V 54V na SIP3 GND GND MTI 5 4V R18 GND n MOUNTING HOLES V MAX809L EUR th NOTES KS aa COMMAND 1 RESISTORS GIVEN TO TWO PLACES ARE 5 THREE PLACES 1 GNE 11 3 5 2 RESISTOR POWER RATINGS 0805 100W 1206 125W 2512 1W SHUTDN GND 3 C
9. Dave Clarke President of SYNRAD 20 December 1999 Date Figure 1 2 Declaration of Conformity Series 48 Lasers Operator s Manual 5 Ch 1 Safety and Regulatory Compliance 1 4 Warning Labels Each Series 48 laser 18 shipped with several different types of labels attached to the laser chassis These labels identify apertures from which laser radiation is emitted power output levels and precautions relating to performance characteristics Refer to Appendix A Pages A2 A4 for label location diagrams 1 5 Operation and Service Manual Precautionary Notations There are two types of precautionary notations used throughout this manual WARNING A WARNING notation is used to identify a process or procedure that could result in exposure to laser radiation CAUTION A CAUTION notation is used to identify a process or procedure that could result in damage to the laser if not properly performed 1 6 General Hazards WARNING Always wear eye protection around an exposed laser beam Direct or diffuse laser radiation can inflict corneal injuries Select protective eyewear that blocks 10 6 CO laser radiation Eyewear protects against scattered energy and is not intended to protect against direct viewing of the beam or reflections from metallic surfaces Protective eyewear for 10 6 CO laser radiation is available from SYNRAD Inc Enclose the beam path whenever possible Direct or diffuse laser radiation can seri
10. set keyswitch to OFF or open remote keyswitch circuit as appropriate 14 Set the mechanical shutter to OFF and press the UC 2000 s On Off pushbutton to disable lasing Turn off the external DC power supply 6 3 Operation in Pulsed Mode In applications such as marking and cutting the laser is required to pulse on and off in synchronization with an external pulsing control signal typically from a computer or function generator operating in the range from 0 to 1 kHz To operate the laser in pulsed mode perform the following procedure 1 Perform Section 6 2 Steps 1 through 6 2 Set the UC 2000 to the MANUAL mode of operation See the UC 2000 Laser Controller Operator s Manual for information about other Controller operating modes 3 Connect the pulsing control signal to the GATE input connector on the rear panel of the UC 2000 4 Adjust the UC 2000 s PWM Adj Knob to the desired power level and press the Lase On Off pushbutton Verify that the red Lase indicator on the UC 2000 illuminates 5 Set the mechanical shutter on the laser to the ON open position 6 Turn the laser s keyswitch to ON and or close the remote keyswitch Verify that the green POWER LED on the Laser Head illuminates 7 Verify that the red LASE LED on the laser illuminates dimly after approximately 5 seconds This indicates tickle pulses are being applied to the laser 8 The laser system is now configured to operate in the pulsed m
11. 18 to 20 C Inlet cooling water temperature should always be maintained above the dew point to avoid condensation and water damage to the laser Heat removal from the cooling water is required and can be accomplished using a chiller Water cooling is designed to provide sufficient cooling at up to 100 duty cycle Water enters at the laser s rear plate through the lower side mounted 1 4 inch diameter cooling tubes and exits through the top mounted cooling tubes Both circuits must be used in parallel to maintain thermal balance A cooling intake and outlet manifold using a quick disconnect fitting system refer to Figure 4 3 is shipped as a kit with the laser The two U shaped connections should be installed on the front plate The quick disconnect fittings be removed from the tubing by compressing the front ring of the fitting against the body of the fitting The cooling kit also includes quantities of both straight and elbow fittings Other compatible fittings can be ordered from local fitting supply houses PLATE FRONT PLATE WATER MATER DETAIL a o y STRAIGHT EL FITTING FITTING DETAIL 1 amp LL HTTING3 NEED TO EE PREJ SEDI COMPLETELY OH FITTING OPTION 2 1 10 OF BOTH HTTIMG PES ORE VMTH Lad SEE 2 Figure 4 3 48 1 48 2 Laser Cooling Kit 26 Series 48 Lasers Operator s Manual Ch 4 Interface Requirements 4 4
12. JUMPER complies with 21 CFR subchapter J keyswitch function unused A at the date of manufacture these pins must be jumpered dn for the laser to operate Refer VERSION to manual for details REMOTE KEYSWITCH piii gt KEYSWITCH VERSION ONLY This laser manufactured by Synrad Inc Mukilteo WA 98275 does not comply with 21 CFR subchapter J at the date of manufacture 2 Figure 2 48 2 Label Location Diagram Series 48 Lasers Operator s Manual A 3 Appendix Supporting Documentation This laser product is manufactured under one or more of the following U S Patents 4 805 182 5 065 405 6 195 379 4 837 772 5 215 864 6 198 758 5 008 894 5 602 865 6 198 759 Other U S and International Patents pending CAUTION These RF Excited Lasers must be provided with a pre ionizing Tickle signal during standby or laser low periods This is automatically provided with Synrad s UC Series power controller This signal keeps the plasma ionized during laser low periods and facilitates breakdown and pulse to pulse fidelity Damage or malfunction may occur if this or equivalent drive signals are not used See manual _ for tickle pulse specifications or contact factory TOP VIEW
13. NI H31VM H31VM 8 5 1 8 5 5 QVHNAS HLI M YILAANODO YATIIHO H31VM M0018 INV38 Mold asus Figure 5 1 Typical System Interconnection Diagram Series 48 Lasers Operator s Manual 32 Ch 6 Operating Instructions Chapter 6 Operating Instructions 6 1 General The operating instructions provided in this section are based on the use of a SYNRAD UC 2000 Universal Laser Controller using an alternate method of laser control please consult the factory for information regarding key aspects of laser operation 6 2 Turn On Check Out CAUTION These RF Excited Lasers must be provided with a pre ionizing Tickle signal during standby or laser low periods This is automatically provided with SYNRAD s UC 2000 Laser Controller This signal keeps the plasma ionized during laser low periods and facilitates breakdown and pulse to pulse fidelity Damage or malfunction may occur if this or equivalent drive signals are not used WARNING Harmful laser radiation is emitted through the laser exit aperture when performing the following procedure 1 Confirm the DB9 jumper configuration required for your application refer to Section 4 3 2 Verify that the external DC power supply UC 2000 laser keyswitch and laser shutter are all set to OFF 3 Verify that all electrical and cooling interconnections have been accomplished acco
14. fail to operate contact the SYNRAD Customer Service department at 1 800 SYNRADI outside the U S call 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 Series J48 laser fails within the first 45 days after purchase SYNRAD Inc will pay all shipping charges to and from SYNRAD when shipped as specified by SYNRAD Customer Service After the first 45 days SYNRAD will continue to pay for the costs of shipping the repaired unit or replacement parts back to the customer from SYNRAD The customer however will be responsible for shipping charges incurred when sending the failed unit or parts back to SYNRAD or a SYNRAD Authorized Distributor In order to maintain your product warranty and to ensure the safe and efficient operation of your Series J48 laser only authorized SYNRAD replacement parts can be used This warranty is void if any parts other than those provided by SYNRAD Inc are used SYNRAD Inc and SYNRAD Authorized Distributors have the sole au
15. fam CK ad 1 o irm CAUTION INPUT POWER 30 VDC 30 CONDENSATION AND October 08 2001 WATER DAMAGE CAN 4600 Campus Place Mukilteo WA 98275 425 349 3500 OCCUR IF COOLING WATER TIBI OE UE IS BELOW DEW POINT Ser 0481281010390 SEE OPERATION MANUAL MADE IN THE U S A BOTTOM VIEW ud o o 19 o o o o o Tn 4 Lx Eo od uid KEYSWITCH VERSION KEYSWITCH VERSION ONLY 5 This laser manufactured by IMPORTANT DB9 wiring change Pins 3 and 4 Synrad Inc now provide the remote interlock function and pins Mukilteo WA 98275 6 and 7 now provide the remote REMOTE INTERLOCK JUMPER complies with 21 CFR subchapter J keyswitch function If unused at the date of manufacture these pins must be jumpered c for the laser to operate Refer OEM VERSION to manual for details REMOTE KEYSWITCH JUMPER This laser manufactured by Synrad Inc Mukilteo WA 98275 does not comply with 21 CFR subchapter J at the date of manufacture Figure A 3 48 5 Label Location Diagram Series 48 Lasers Operator s Manual A 4 Appendix A Supporting Documentation 600 0 XXX X 1070 5 Xxx Q310N SSI1NN 53 101 NMOHS LON 9NI1009 v D gt 1 6416 LHDIAM 1H9I3M 82571 15044105 OL SM3HOS 401 SSN LON OG 2 S3HONI NI SNOISNAWIG 11 71 5
16. input with a rise and fall time constant of 100 Us the laser cannot precisely follow the Command input beyond PWM frequencies of 5 kHz with a duty cycle greater than 50 5 kHz 1 100 us x 5096 Typically the depth of modulation at 50 duty cycle is 90 to 100 at 2 kHz and 60 to 80 at 5 kHz Refer to Figure 2 7 for waveforms For high speed motion applications that cannot tolerate any ripple in the optical beam response but still need adjustable power levels we recommend the use of PWM frequencies up to 20 kHz At 20 kHz the optical response no longer follows the Command input and is very nearly a DC value with just a small amount of ripple present 79 Acqs 34 Acqs 500kS s 1 Tek 5 5 T 1 1 Ch2Freq 7 Ch2 Freq 1 2 008kHz 4 4 906kHz 1 Low signal 3 Low signal 1 amplitude amplitude Ch2 Duty 7 J Ch2 Duty 49 4 50 L4 Low signal Ur ainsi pe ck bn py q LOW signal 1 amplitude 1 amplitude y 100mv ch2 1v 100 uS Ch2 2 kHz Modulation 5 kHz Modulation 1 4 E 1 1 740m V 0114 100mv 2v 100 uS Ch2 720 Figure 27 Modulation Waveforms 14 Series 48 Lasers Operator s Manual Ch 2 Theory of Operation A 1 us wide tickle pulse at a frequency greater than 5 kHz may cause unwanted lasing Special prov
17. of the hazards associated with accessible radiation through signs labels and instructions to improve control of laser radiation through protective features and to provide safe usage of laser products by specifying user control measures The European Union s Electromagnetic Compliance EMC directive 89 336 EEC is the sole directive developed to address EMI issues in electronic equipment In particular the directive calls out European Norm EN documents that define the emission and immunity standards for specific product categories For Series 48 lasers the standard EN55011 defines the radiated RF emissions limit The generic standard EN50082 1 defines immunity requirements published by the International Electromechanical Commission IEC Refer to Table 1 2 for a summary of EU performance requirements pertaining to Series 48 lasers Table 1 2 European Union Directives DIRECTIVE SCOPE PROVISION 55011 Limits and methods for measurement of Emitted RF Radiation shall not exceed limits radio frequency disturbance characteristics described in document 5 1 1 for industrial scientific and medical ISM equipment 50082 Generic standard governing ISM Immunity to electrostatic discharge levels defined performance relating to radiated emissions in document IEC801 Part 2 and ESD sensitivity and immunity to transient bursts Equipment shall operate normally when exposed to RF emissions at levels described in document TEC801 Pa
18. see 1f the thermal cutout was activated Check for proper Command input signal The laser will not operate unless an input signal to the CTRL jack 1 present Return keyswitch to the OFF position for a few seconds or cycle source power to reset circuits If the laser still will not start factory authorized servicing of the laser may be required Laser power is low Check waveform of Command input signal if modulation is used Check input voltage level 30 VDC minimum Use mode screen ceramic tile can be used to verify circular optical beam shape at a distance of 3 to 5 feet from the laser If beam spot is not circular and stable the optical mirror alignment is out of adjustment See below If laser power is below specification laser gas may need to be replaced or one of the RF drivers is defective Contact SYNRAD or a SYNRAD Authorized Distributor Laser spot is not circular 1 Check for proper air or water coolant flow or does not stay circular The optical mirrors are adjusted at the factory to give a TEMoo output beam that 15 circular 3 feet or more from the output aperture Severe mechanical forces on the chassis may shift the original alignment of the mirrors temporarily or permanently Contact a factory authorized service center Laser power varies or 1s Verify that the UC 2000 Controller or equivalent has tickle intermittent in response pulses of proper duration Refer to Section 2 4 1 to inp
19. source to Pin 1 N 7 Connect the ground earth wire typically green from your AC voltage source to Pin 3 B 4 Power One DC Power Supply 220V Operation To configure your Power One DC 1 power supply for 220 VAC operation and to connect input and output wiring refer to Figure B 2 and follow the steps below 1 Follow your facilities Lockout Tagout procedures to ensure that AC input power is de energized 2 Remove the four screws holding the power supply cover to the chassis one screw 18 under the label and orient the circuit board as shown in the diagram 3 Locate the black jumper wire leading from pin to pin 110 4 Pull the jumper off of pin 110V and insert it onto pin 220V The supply is now jumpered for 220 VAC operation 5 Locate the 30 VDC output terminals on the power supply board and connect the red DC power cable from the laser to the positive 0UT 30 VDC output terminal 6 Connect the black DC power cable from the laser to the negative RTN output terminal T Locate the 3 pin terminal board strip TB1 on the power supply board and connect one of the two AC hot wires typically black from your 220 VAC source to Pin 2 L 8 Connect the other AC hot wire typically black or red from your 220 source to Pin 1 N 9 Connect the ground earth wire typically green from your AC voltage source to Pin 3 10 Reinstall the power supply cover Series 48 Lasers Operator s Manual B 3 Appendix DC
20. structures packaged together with compact state of the art RF power supplies The laser is self contained requiring only the application of power cooling air or water and a control signal It is therefore ideally suited for overhead installation where the laser is gantry mounted No RF cable runs are required 48 Series lasers emit a laser beam with a wavelength of 10 6 um The beam shape is square at the laser output aperture changing to circular at distances of approximately 1 meter or more from the laser The laser beam diverges due to diffraction at a full angle of 4 milliradians with the beam waist at the output aperture of the laser The method of RF excitation on which the Series 48 is based provides excellent discharge stability easily controlled output power and modulation and convenient interfacing to automated systems Coupling between the RF driver and the laser is based on switching and transmission line technology U S Patents 5 008 894 and 5 602 865 The frequency of RF drive is approximately 45 MHz and is factory calibrated to match the resonant frequency of the plasma tube Power control of the laser beam is achieved by pulse width modulation PWM of the RF drive circuit Modulation control can be used to gate the laser on and off at time intervals synchronized with automated processing equipment It can also be used to control instantaneous power by adjusting the pulse width PWM duty cycle at a fixed modulation frequen
21. substituting power supplies use a well regulated DC power supply in the range of 30 to 32V with no more than overshoot under a 10 90 modulation load Laser current 15 under 7 A for the 48 1 and 14A for the 48 2 The use of short leads is recommended See Appendix B for information about connecting the DC 1 power supply Appendix C contains information about the DC 2 Please note that SYNRAD lasers are built and tested to meet published specifications at an input voltage of 30 VDC 4 2 2 48 5 Model The SYNRAD model DC 5 power supply is used to power the 48 5 laser If substituting use a well regulated DC power supply in the range of 30 to 32V with no more than 3V overshoot under a 10 90 modulation load The use of short leads is recommended and use of appropriate terminations rated for currents up to 28 is recommended See Appendix for information about connecting the DC 5 power supply Please note that SYNRAD lasers are built and tested to meet published specifications at an input voltage of 30 VDC 4 3 DB9 Connector 48 Series lasers are equipped with a female DB9 connector mounted to the sidewall of the laser This connector provides the user with a convenient method for monitoring fault conditions over temperature control RF circuitry failure and adds remote interlock remote keyswitch relay or switch message output and remote LED indicator capability DB9 pin assignments and functions are described in Table 4 1 A shor
22. to accept a 1 20 no lase tickle pulse threshold is preset for 3 us 0 5 us based on a PWM and tickle frequency Command input of 5 kHz lt 200 us 1 us 5VDC 0 VDC Figure 2 5 Tickle Pulse Waveform 2 4 2 PWM Clock Frequency PWM duty cycle controls the laser s power level so you can direct the laser to perform a variety of cutting and marking tasks The standard PWM frequency is 5 kHz which has a period of 200 us The duty cycle of a PWM waveform is the percentage of the period that the output signal is high If the amplitude of the 5 kHz signal is high for 100 us and low for 100 us it has a 50 duty cycle If the signal s amplitude is high for 190 us and low for 10 us it has a 95 duty cycle Refer to Figure 2 6 for waveforms Series 48 Lasers Operator s Manual 13 Ch 2 Theory of Operation ON MEDIUM POWER LEVEL OUTPUT TO LASER FROM CONTROLLER 50 DUTY CYCLE OFF d t 200us GATED ON GATED OFF TICKLE ONLY ON MAX POWER LEVEL OUTPUT TO LASER FROM CONTROLLER 95 DUTY CYCLE OFF t 200 us GATED ON GATED OFF TICKLE ONLY Figure 2 6 Typical 5 kHz Command Input Waveforms for Gated Operation Series 48 lasers are designed to operate at PWM Command input frequencies up to 20 kHz The choice of PWM frequency depends on the application For most applications the UC 2000 s standard 5 kHz frequency has proven to work well Since laser output follows the PWM
23. uses 2 RF electrodes and requires 2 RF channels while the 48 5 uses 4 electrodes and 4 RF channels 2 Control PCB s For the purpose of this description a single channel will be described Model specific details relating to differences in electrical characteristics will be individually discussed 2 5 1 PWM Control Circuitry The Command input modulation source signal must be provided externally to the laser and is connected to the panel mounted BNC connector labeled CTRL This signal is connected to an opto isolator the output of which is applied to the PWM switch control circuit The PWM switch control circuit gates the PWM switch off and on at the frequency and duty cycle controlled by the modulation source When the PWM switch closes a potential of 30 VDC is applied to the RF Driver The PWM control circuit provides on off gating of the PWM switch unless disabled by the 5 second delay shutter switch or the fault shutdown circuits The 5 second delay disables PWM output to the RF amplifier for a period of 5 0 5 0 0 seconds after the panel mounted keyswitch and remote keyswitch link are closed power ON The 5 second delay is defeated for OEM customers who must provide this required safety feature elsewhere as part of their equipment integration Please contact SYNRAD for details The shutter switch allows the operator to temporarily interrupt laser output during active lase modes A mechanical lever physically blocks the exit apertu
24. voltage for the DC 2 power supply is 220 VAC You must jumper terminals 1 and 2 on the input power terminal strip for 110 VAC input Refer to the documentation provided with the power supply or see Appendix C for additional wiring information 3 Make interconnections between your electronic control equipment and the laser s DB9 connector as required 4 Attach the UC 2000 Controller s Power Control cable between the UC 2000 s mini DIN LASER connector and the laser s Auxiliary Power connector The UC 2000 can also be powered from a wall plug by using its wall plug transformer 5 Attach the BNC connector on the UC 2000 s Power Control cable to the laser s CTRL connector 6 If your application uses external gating signals to command on off switching of the laser attach a BNC cable between your Gate signal source such as a computer or PLC and the UC 2000 s GATE connector 7 If your application uses external analog voltage or current signals to control PWM attach a BNC cable between your analog voltage or current source typically a computer or PLC and the UC 2000 s ANV ANC connector 5 3 2 48 5 Interconnections 1 Make coolant connections to the laser as described in Section 4 4 2 2 Connect the red power cable to the positive terminal on the DC power supply Connect the black power cable to the negative terminal on the DC power supply Note Ifusing a SYNRAD DC 5 power supply verify that the input power jumper is pro
25. with the requirements of 47 CFR Part 18 Section 213 Interference Potential In our testing SYNRAD Inc has not discovered any significant electrical interference traceable to Series 48 lasers Measures to Correct Interference If you suspect your Series 48 laser interferes with other equipment take the following steps to minimize this interference 1 Route the 5 DC power cables away from signal cables connected to the equipment that 18 experiencing interference problems 2 Use shielded cables to and from the equipment that is experiencing interference problems 3 Install bisected Ferrite on the 5 DC power cables locate them as close as possible to the laser housing Caution to the User The Federal Communications Commission warns the user that changes or modifications of the unit not expressly approved by the party responsible for compliance could void the user s authority to operate the equipment Series 48 Lasers Operator s Manual 3 Ch 1 Safety and Regulatory Compliance 1 2 2 European Union EU Requirements The European Norm EN document EN60825 1 was developed to protect persons from laser radiation by imposing requirements upon manufacturers of laser products to provide an indication of laser radiation to classify laser products according to the degree of hazard to require both user and manufacturer to establish procedures so that proper precautions are adopted to ensure adequate warning
26. 068 oe 00 lt 0091 m ei a ID oj V fo jd sil oc eree Figure A 5 48 2 Outline Mounting Diagram A 6 Series 48 Lasers Operator s Manual Appendix Supporting Documentation 600 0 10 0 XXX 0 310 SSIINN 39NVH3T1OL LH9I3M 935771 LYOddNS 01 SMIYIS INOLLOS ANY 401 3SN LON 2 3HV SNOISN3WIQ TIV L SALON NOILVYLANAd XVIN 8 L X6 SMIYIS ONILNNOW 26 01 9 ola 00872 co o 5 o 2 000 ojo 0082 ge 8 5 2 gg co N oo 88 PA a yo N al 006 Y 000 0582 gt 74 P4 080 Y A 082 06876 08696 gt 009 G 029 029 C 9 Figure A 6 48 5 Outline Mounting Diagram A 7 Series 48 Lasers Operator s Manual A endix A Supporting Documentation
27. 1 Power Suppl AC Input Pin3 2 Pini LOTY OUT 30 VDC Output RTN Figure 2 SPL250 1024 Wiring Diagram Jumper shown in position for 110 V operation Move jumper to here for 220 V operation AC Input Connections 110V 220V Neutral Hot Ground B 4 Series 48 Lasers Operator s Manual Appendix C_DC 2 DC 5 Power Supplies Appendix C DC 2 DC 5 Power Supplies Series 48 Lasers Operator s Manual 1 Appendix C_DC 2 DC 5 Power Supplies 1 Connecting Your DC 2 or DC 5 Power Supply This section explains how to connect SYNRAD s DC 2 power supply to your 25 J48 2 laser and how to connect SYNRAD s DC 5 power supply to your 50 W J48 5 laser 2 220V Operation As shipped your DC 2 DC 5 power supply is wired for 220 VAC operation To connect input and output wiring refer to Figures C 1 and C 2 and then follow the steps below 1 Follow your facilities Lockout Tagout procedures to deenergize AC input power 2 Locate the 30 VDC output terminals on the power supply s output section and connect the red DC power cable from the laser to the plus 30 VDC output terminal 3 Connect the black DC power cable from the laser to the minus output terminal 4 Locate the 5 termi
28. 1 Series 48 Safety Features FEATURE VERSION DESCRIPTION CDRH REQUIRED Keyswitch Keyswitch Panel control switch Key cannot be removed in the ON position Power Indicator OEM Panel indicator green Indicates that DC power is available Keyswitch for the laser LED illuminates when keyswitch is turned to ON the remote keyswitch is closed and no faults exist Lase Indicator Panel indicator red Indicates that laser is in Lase mode Keyswitch LED illuminates when laser beam is active The brightness of the LED is related to duty cycle Higher duty cycles higher laser output produce brighter illumination 5 Second Delay Circuit element Disables laser output for 5 seconds after Yes Keyswitch keyswitch is turned to ON position and remote keyswitch is closed Defeatable by internal DIP switch Power On Reset OEM Circuit element Disables laser if input power is removed and Keyswitch then later reapplied power failure while the keyswitch and remote keyswitch are still closed Operator must reset the keyswitch or remote keyswitch to restore operation Defeatable by internal DIP switch Remote Interlock Keyswitch Circuit element Allows laser to be shut down from a remote interlock such as a door or housing switch Operator must reset the keyswitch or remote keyswitch to restore operation Remote Keyswitch OEM Circuit element Allows operator to turn laser on or off from a Keyswitch remote locat
29. 2 48 5 Cooling The 48 5 heat load is 800 watts maximum and requires water cooling to prevent damage to the laser Cooling water between 18 and 20 maximum at a minimum flow rate of 1 5 GPM must be used Inlet cooling water temperature should always be maintained above the dew point to avoid condensation and water damage to the laser Heat removal from the cooling water 1s required and can be accomplished using a chiller The cooling water intake is through the lower side mounted tubes plus one central tube located on the rear plate of the laser Exit is from the two top tubes and one of the central tubes also on the rear plate The front central tubes are jumpered using a U fitting while the front side and top are also jumpered at each side using two right angle fittings refer to Figure 4 4 A cooling intake and outlet manifold using a quick disconnect fitting system is shipped as a kit with the laser The quick disconnect fittings can be removed from the tubing by compressing the front ring of the fitting against the body of the fitting The cooling kit also includes quantities of both straight and elbow fittings Other fittings can be ordered from local fitting supply houses REAR PLATE ES lt gus FRONT PLATE 7 WATER gt STRAIGHT EL FITTING FITTING wore DETAIL 1 ALL AT HGJ NEED TO BE ED COMPLETELY FITTING 2 QUANTITIES OF BOTH AMING TY PES ORE
30. 5 9 06 SI S310H 40 S310N 00 6 es 0 2 bo 9 e 1 68 91 1 55 8 pp 9 06 EN 1 to S A 0161 ID 0947 1 4 7 22 056 0055 0091 Ph TEE Or o 1 80 Le 087 2181 O iagram ing D Figure A 4 48 1 Outline Mount A 5 Series 48 Lasers Operator s Manual Appendix A Supporting Documentation 900 0 XXX X 100 xxx 10 xx 0310 SSTINN SAONVYSTIOL NMOHS LON SNIJ 9NI1009 t DA Ft S816 1H9I3M 76 1H5I3M 83571 14044065 01 SM3H9S INOLLOS 401 ISN LON OG 72 S3HONI SNOISNAWIG 77 L SALON 26 9 067 SI H3AOO 631 40 1430 00 7 6 Le UH orz 227 1 did JI n OO TIIVIAONIY vo 88116 26 8 X6 La 9 p 0082 oe ad 5 5 5 5 y 9 62 oisi eu 4 2 27
31. APACITORS ARE GIVEN IN uF WVDC UNLESS NOTED OTHERWISE 5 PANA uC 4 1206 RAMICS 1 50 amp 0022 100 XR7 10 TOLERANCE 4 TMPANA Tame INA 5 08052 RAMICS 1 25 250 M5U OR Y5U 20 TOLERANCE gt 2 AIN3 AINO 0 G NPO TEMPERATURE STABLE TYPES 50V 5 TOLERANCE 1 3 IRAM TOCKI OSC1 CLKIN 5 7000HR 105C LOW Z HI RIPPLE PANASONIC TYPE FA 4 MCLR OSC2 CLKOUT MLX5L 5 VSS VDD OR EQUIV V 5 RB7 7 JEDEC CODES ARE GIVEN FOR PARTS TOO SMALL TO BEAR FULL P N GND 0805 0805 39 7 RB1 RB6 pct i 8 SIGNAL AND POWER GROUNDS CONNECT AT ONE POINT ONLY ON PCB 0805 GND e RB3 DIP18 B lt 9 01 Q3 Q5 AND U1 ARE MOUNTED ON A HEATSINK USING SILPADS N MACHINE PIN SOCKETED 18 2 m y PART NUMBER DESCRIPTION BLINK 0805 OND O 80 017542 02 WITH REMOTE INTERLOCK R28 226K 11 3K 80 017542 03 CHANGED CAPS C2 10 KYSWON 0805 0805 T PULSE STRETCHER C11 013 014 016 018 ORCAD CAPTURE m l 5 SHTCL 0805 1 25 PROPRIETARY Synrad Incorporated R30 1 5 EN cour so at eps 1 8 014 USED OR DISCLOSED IN 8 5 165 1 i WHOLE OR IN PART WITHOUT PHONE 425 349 3500 7 R29 C12 BAV70 A 0805 WRITTEN PERMISSION OF FAX 425 485 4882 6 619 470pF_L_ x 0123 X gt SYNRAD INC 5 NPO T 4 0805 NEN je SO14NB UU SCHEMATIC J48 CONTROL PC
32. As shipped pins 3 and 4 are jumpered to disable the remote interlock function Message Output goes low in reference to pin 2 or pin 4 when laser tube temperature reaches 54 C 42 C and remains low until temperature falls 2 C For connecting a remote relay or switch in series with the laser keyswitch As shipped pins 6 and 7 are jumpered to disable the remote keyswitch function See pin 6 description above Pin 7 is at DC line potential when the keyswitch is on or bypassed Current and voltage limited output for direct connection to LED or LED input opto isolator Current and voltage limited output for direct connection to LED or LED input opto isolator Provides user with control signal to disable external systems in the event of a fault See note 1 Allows an open external interlock switch to shut down the laser Ground pin 3 only do not apply voltage to this pin See note 2 Provides user with a pre shutdown temperature warming Does not shut down the laser See note 1 Allows user to control laser on off reset from a remote location Connect to pin 7 to run open circuit to stop and or reset faults See notes 2 3 Allows user to control laser on off reset functions from a remote location See notes 3 4 Allows user to connect a remote Lase LED indicator See note 5 Allows user to connect a remote Ready LED indicator See note 5 1 Allen Bradley A B compatible outputs pins 1 and 5 are A
33. B ASSY W REMOTE INTRLK 3 02 015 2 pco 2200pF 1 gis 0805 CATEGORY PART No SEE TABLE DRAWING FILE No 81 0 1 7542 02 1 INPUT OPTO ISOLATOR 61N 0805 GND SHEET DRAWN BY 5 DATE MOL NPO 1 OF 1 Morrison 11 17 98 UNITS CHECKED DATE POWLED SIZE B APPROVED DATE Figure A 8 Schematic J Series Control Board Series 48 Lasers Operator s Manual A 9 Appendix B_DC 1 Power Supply Appendix B DC 1 Power Supply ASTEC LPS255 CEF or Power One SPL250 1024 Series 48 Lasers Operator s Manual B 1 Appendix B_DC 1 Power Supply B 1 Connecting Your DC 1 Power Supply This section explains how to connect SYNRAD s DC 1 power supply to your 10 W J48 1 laser Newer lasers are supplied with Astec LPS255 CEF DC power supplies while older systems shipped with Power One SPL250 1024 units B 2 Astec DC Power Supply The Astec DC 1 power supply accepts input voltages ranging from 85 to 264 VAC U S European and UK line cords are available for connecting AC input power to the Astec power supply If the line cord provided does not fit available AC receptacles you will need to provide a cable with the proper AC plug on one end and a standard IEC 320 female connector on the power supply end To connect input and output wiring refer to Figure B 1 and follow the steps below 1 Follow your facilities Lockout Tagout procedures to ensure that AC input power is de energiz
34. N D1 1N5226B d d r Ts 1 1 1 5 1 22 1 2 30 WHT PAIR 1 2 LED2 X 7 RED K y 93V 02 1 5226 22 WHT 177 THERMISTOR 22 a 2 22 WHT E 5 22 BLU a 556 22 amp 22 VIO 1 amp 5 2 1 gt 2 22 VIO BNO 1 5 22 1 2 22 INPUT AND e 22 ORG 2 5 VERSIONS ONLY 22 ORG oe 1 2 418 YEL 30 22 RED TOF JOPI 29 ara PORTER 2 7 7 22 77 46 5 POWER 1 22 YEL 1 an 2 W22 VIO 1 a 2 22 WHT WHT Hore B 22 WHT 22 BRN TUBE 1 lt KEVSWITCH 5 12345678910 12345 12345 E y RF DRIVER IV Da 1 e gt J2 HO 18 ORG gt 810 16798 00 RF 1 22 RED X2 177 2 1 P2 LINK OEM JUMPER 1 177 48J CONTROL BOARD 22 RED ES 2 2 SCH 810 17542 00 4 MTG 4X ALL VERSIONS 422 BLK a 2 56 22 BLK L P4 POWER NOTES VASTERBOKRD A DB9 WIRE DETAILS O E 123456 1 22 WHT 2 22 RED PORT eo EE SYNRAD Inc 18 YEL 5 22 VIO 6500 Harbour Heights Parkway 1BRED _ o 18 RED 1 18 RED 18 BLK Mukilteo WA 98275 22 WHT 22 YEL 425 349 3500 F1 20 18 ORG ean 10 FOR 1 18 RED 1 2 18 RED TITLE DC INPUT AG P PAS TENER TO SCHEMATIC MODEL 48J SERIES LASERS NOTE B BAR
35. No epoxy is used for sealing The screws are secured by adhesive after alignment The 4 8 mm bore in conjunction with the mirror curvature selected limits the output beam to TEMoo modes when the mirrors are properly aligned Small variations in output power up to 10 are seen during warm up as the cavity mirror spacing changes due to thermal expansion of the plasma tube The output wavelength remains at or near 10 6 um 10 57 to 10 63 um Series 48 Lasers Operator s Manual 11 Ch 2 Theory of Operation The beam shape 1 square at the laser output aperture changing to circular at distances of approximately 1 meter or more from the laser The laser beam diverges due to diffraction at an angle of 4 milliradians refer to Figure 2 3 The beam has a near gaussian profile in the far field 0 6m or more 1 5cm 37cm FOR 10W LASER or 1 5 BEAM WAIST DONT GAP 75cm FOR 25W LASER GAP 722 000 OUTPUT FULL ANGLE RF DISCHARGE REGION Co hau 2 DIVERGENCE 4mrad CS 3 METER RADIUS ZnSe FLAT A Si TOTAL REFLECTOR OUTPUT COUPLER Figure 2 3 Beam Characteristics 2 4 Laser Power Control To effectively control output power of Series 48 lasers pulse width modulation PWM is used to vary the power on time of the internal RF amplifier stage s which controls the short term average RF drive applied to the laser electrodes The required modulation source signal refer to Figure 2 4 and the capabilities t
36. RIER PLATE SIZE DOCUMENT NUMBER REV B 810 17609 00 R1 DATE August 20 1998 SHEET 101 1 Figure A 7 Interconnect Schematic Model 48 Series Lasers Series 48 Lasers Operator s Manual A 8 A endix A Supporting Documentation FRONT WALL OTHER BOARD REAR WALL REV ECO DATE DESCRIPTION D B B 1465 8 2 99 ADDED PART NUMBERS TO TABLE DWJ REVERSE SHUNT E 01 5 4 REGULATOR POWER SWITCH PWM SWITCH Y ae ae ifs gt H E TRF4905 D10 IRF4905 65 06 20 MMSZ52428 SUPESP06 20 i DC POWER V vil o HS 54V 560 50 1 50 192209 __ 00123 56050 02200 SMEOMNI PG T 5 LCAP13MM 1206 12 12VH2 LCAP13MM 12 Tr MBR2560CT 22 6K
37. am A 6 48 5 Outline Mounting Diagram A 7 Interconnect Schematic Model 48 Series A 8 A 8 Schematic J Series Control A 9 Appendix B BA Astec LPS255 CEF Wiring Dir tia B 2 2 Power One SPL250 1024 Wiring Diagram B 4 Appendix C CI DC 2 Input Output C 3 C2 uod 2 C 3 Series 48 Lasers Operator s Manual iii 1 1 1 2 2 1 4 1 7 1 List of Tables Series ida 2 European c o de a 4 Series 48 Specification Table 9 DB9 Connector Pin Assignments 24 Series 48 Troubleshooting Table 37 iv Series 48 Lasers Operator s Manual SYNRAD Warranty Information This 15 to certify that Series J48 lasers are guaranteed by SYNRAD Inc to be free of all defects in materials and workmanship for a period of one year from the date of purchase This warranty does not apply to any failure caused by negligence misuse including environmental factors accident alteration or improper maintenance If within one year from the date of purchase any part of your Series J48 laser should
38. and the five second delay begins when DC power is applied to the laser 2 Series 48 Laser Operator s Manual Ch 1 Safety and Regulatory Compliance 1 2 EMI and Safety Compliance Series 48 lasers are designed to comply with certain Federal Communications Commission FCC and European Union EU directives that impose product performance requirements relating to electromagnetic compatibility EMC and product safety characteristics for industrial scientific and medical ISM equipment The associated directives and specific provisions to which compliance is mandatory for Series 48 lasers are identified and described in Section 1 2 1 and Section 1 2 2 1 2 1 Federal Communications Commission FCC Requirements The United States Communication Act of 1934 vested the Federal Communications Commission FCC with the authority to regulate ISM equipment that emits electromagnetic radiation in the radio frequency spectrum The purpose of this regulation is to prevent harmful electromagnetic interference from affecting authorized radio communication services in the frequency range above 9 kHz The FCC regulations that govern ISM equipment are fully described in the Code of Federal Regulations CFR 47 Part 18 Series 48 lasers have been tested and found to comply with 47 CFR Part 18 by demonstrating performance characteristics that have met or exceeded the requirements Information to the User The following information is provided to comply
39. be hard mounted to equipment by removing several of the bottom panel screws and replacing these with longer ones to secure the laser to optical assemblies Use a minimum of 4 screws Model 48 1 or 6 screws Model 48 2 48 5 in a symmetrical pattern to properly distribute mounting forces Do not remove the cover This mounting method is only recommended as long as the screws do not support the weight of the laser For a sturdier attachment the laser may be clamped to optical assemblies by applying clamping forces between top and bottom cover screws Do not apply clamping forces on the longitudinal centerline Refer to Appendix A Pages A5 A7 for the appropriate outline mounting diagram Series 48 Lasers Operator s Manual 29 Ch 5 Unpacking and Setup 5 3 System Interconnections 5 3 1 48 1 48 2 Interconnections Note Refer to Figure 5 1 for an illustration of a typical system interconnection 1 Make coolant connections to the laser as described in Section 4 4 1 2 Connect the red power cable to the positive terminal on the DC power supply Connect the black power cable to the negative terminal on the DC power supply Note Newer DC 1 Astec power supplies accept input voltages ranging from 85 to 264 but older DC 1 Power One power supplies must be user configured for either 110 or 220 VAC operation Refer to the power supply documentation or to Appendix B before connecting your DC 1 power supply The default input
40. ckle signal is present during laser off periods This input is optically isolated from the chassis and power supply ground circuit but must not be subjected to common mode voltages greater than 50V from chassis ground The 48 5 laser has two Command inputs CTRL1 and CTRL2 that should always be driven identically from the Controller by using a Y cable or BNC connector 3 1 8 DC Power Cables The red and black DC power input cables provide 30 VDC operating power to the laser Standard length is 60 inches 3 1 9 Auxiliary Power The Auxiliary Power connector is installed in the side panel of the laser housing and provides an optional 30 VDC 350 mA source for powering the UC 2000 Controller An auto resetting solid state fuse limits line current Connector power is active after 30 VDC is applied to the laser The UC 2000 can also be powered from its 115 VAC wall transformer 3 1 10 Laser Exit Aperture The laser aperture is the opening from which the laser beam is emitted when lasing The beam shape is square at the laser output aperture changing to circular at distances of approximately 1 meter or more from the laser The laser beam diverges due to diffraction at a full angle of 4 milliradians with the beam waist at the output aperture of the laser 3 111 Diode Pointer Power Connector This connector is a regulated 5 VDC output capable of providing 100 mA for the optional Diode Pointer available from SYNRAD The o
41. ctive Low Specifications OFF 15 VDC 5mA into 3KQ ON lt 1 VDC sinking 100mA 2 Dry circuit zero voltage external switches are required since current into remote interlock and debounced remote keyswitch pins is negligible 3 Connecting an LED to pins 6 or 7 to indicate keyswitch status requires an external current limiting resistor 4 The remote keyswitch output pin is not current limited or fused 5 Pins 8 and 9 can be directly connected to the anodes of LEDs LED input opto isolators without external current limiting devices Connect LED cathodes to pin 2 or 4 Current is limited internally to 20 mA 3 3V max 24 Series 48 Lasers Operator s Manual Ch 4 Interface Requirements 4 4 Cooling Requirements Series 48 electronics are mounted opposite the laser tube in the smaller section of the H bay and share the same cooling removal as the plasma tube Typical efficiency of laser plasma tubes operating in a TEMoo mode is 10 to 12 radiation out to RF power in Conversion efficiency of DC electrical power to RF 1 about 60 Off the shelf AC to DC switch mode supplies are typically 85 efficient Since overall wall plug efficiency of these lasers is about 6 to 8 a considerable amount of heat removal must occur even at the 10W and 25W output power level The thermal transport design for cooling Series 48 lasers has been adapted to a wide variety of user applications and laser operating requireme
42. cy Both methods can be used simultaneously LASER OUTPUT POWER ARBITRARY SCALE 50 100 DUTY CYCLE Figure 2 1 Average Laser Output versus Percent PWM Duty Cycle As shown in Figure 2 1 above the PWM on time percentage PWM duty cycle exerts a non linear power function as power saturation is approached flattening out at approximately 95 duty cycle SYNRAD recommends using a 95 maximum PWM signal since little or no increase in laser output power occurs between 95 and 100 PWM duty cycle It is safe to operate at 100 duty cycle by eliminating all PWM control and simply applying on off gating however you can expect a 5 increase in power draw and heat load 10 Series 48 Lasers Operator s Manual Ch 2 Theory of Operation 2 3 Description of Physical Operation The laser consists of an RF excited plasma tube with an adjustable mirror on each end mounted together with the RF drive assembly in a single aluminum chassis Refer to Figure 2 2 for a schematic depicting the physical components of the laser RF FEED THROUGH AND GAS FILL PORT COIL IN RF RESONATOR LASER L PLASMA ANODIZED Sa ALUMINUM M GROUND ELECTRODES SPACERS SMALL GAPS GAS ALUMINUM BALLAST HOUSING Figure 2 2 Physical Schematic 2 3 1 Plasma Section The plasma tube is made of 2 inch square cross section extruded aluminum tubing with pre machined ends welded on The mechanical and electrical arrangement of the i
43. d delay between keyswitch actuation and lasing Incorporation of certain features is dependent on the version OEM or keyswitch All product features are summarized in Table 1 1 The table indicates the laser version on which a feature 18 available the type and description of the feature and if the feature is required by and complies with CDRH regulations In addition to the safety features described above common safe operating practices should be exercised at all times when actively lasing Follow all safety precautions specified throughout this manual to prevent exposure to direct or scattered laser radiation Use of controls or adjustments or performance of procedures other than those specified herein may result in exposure to hazardous invisible laser radiation damage to or malfunction of the laser Severe burns will result from skin exposure to the laser beam Always wear safety glasses with side shields to reduce the risk of damage to the eyes when operating the laser 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 Use firebrick or a similar non scattering non combustible material as the beam block NEVER use organic material or metals as the beam block organic materials in general are apt to combust or melt and metals act as specular reflectors Series 48 Lasers Operators Manual 1 Ch 1 Safety and Regulatory Compliance Table 1
44. d widens the incoming Command input so that the tickle pulses delivered from the RF Driver are sufficient to provide a plasma ready state without emission The RF drive is not centered on a frequency authorized for significant incidental radiation ISM bands around 27 and 40 MHz The power module must therefore be shielded effectively which is accomplished by integrating the plasma tube and drive into a single assembly Refer to Figure 2 8 for the circuit schematic 16 Series 48 Lasers Operator s Manual Ch 2 Theory of Operation 2 6 Duo Lase Operation 48 5 The 48 5 laser combines two laser tubes for twice the output of a standard laser The output beams from two 25 watt sealed CO tubes are combined optically to provide a single diffraction limited beam at 50 watts The 50W unit uses two control boards and four RF drivers The control boards are tied together electronically so that if a failure mode shuts down either board both laser tubes are turned off The control boards are equipped with individual fuses for each RF driver PWM output In the event of an RF driver failure only that fuse will open allowing other RF drivers in the system to continue operating Unless both fuses are open on a given control board no shutdown will occur nor is there a fault output signal In general the two Command inputs of SOW Duo Lase unit CTRL1 CTRL2 should always be driven identically with a or T connector For specia
45. e GATE input connector on the rear panel of the UC 2000 Typically this signal would be generated using an add in digital card and controlling software The UC 2000 s default factory gate logic is set to internal pull up normally on mode A TTL high input signal or an open disconnected gate connector will cause the beam to turn on To gate the beam off a logic low input or short circuit must be applied to the GATE input connector Users who intend to use a gating signal should set the UC 2000 s gate input logic to internal pull down normally off mode This prevents the beam from being enabled unless a TTL logic high 3 5 to 5V signal is applied to the GATE input connector In the pull down normally off mode an asserted logic low state short circuit to ground or an open or disconnected GATE input locks the beam off See the UC 2000 Laser Controller Operator s Manual for information on changing the UC 2000 s gate input mode to suit your application If the user wishes to control laser power using a computer either an analog voltage or an analog current can be connected to the UC 2000 s ANV ANC input connector To generate the analog voltage a digital to analog D A or DAC card capable of generating OV laser off to 10V maximum power must be installed To generate the analog current a D A card capable of generating 4mA laser off to 20mA maximum power must be installed Controlling software is required for either analog vo
46. e to the terminal labeled with the ground symbol 2 Series 48 Lasers Operator s Manual Appendix C DC 2 DC 5 Power Supplies SYNRAD DC 2 DC Power Supply Input Section Output Section S gt gt C gt ale gt EUN C gt S E Coo oS A E E 1 55666 lho Figure DC 2 Input Output Section SYNRAD DC 5 DC Power Supply Input Section Output Section 21 1 1 1019 12 Figure 2 DC 5 Input Output Section Series 48 Lasers Operator s Manual C 3
47. ed 2 Locate the 30 VDC output terminals on the end of the power supply and connect the red DC power cable from the laser to the positive V1 30 VDC output terminal 2 Connect the black DC power cable from the laser to the negative COM output terminal 4 Connect the AC line cord to the AC receptacle located on the fan end of the Astec power supply 30 VDC Output OUTPUT AC Input Figure Astec LPS255 CEF Wiring Diagram B 2 Series 48 Lasers Operator s Manual Appendix B_DC 1 Power Supply B 3 Power One DC Power Supply 110V Operation As shipped your Power One DC 1 power supply is wired for 110 VAC operation To connect input and output wiring refer to Figure B 2 and follow the steps below 1 Follow your facilities Lockout Tagout procedures to ensure that AC input power is de energized 2 Locate the 30 VDC output terminals on the power supply board and connect the red DC power cable from the laser to the positive 0UT 30 VDC output terminal 3 Connect the black DC power cable from the laser to the negative RTN output terminal 4 Orient the power supply as shown in Figure B 2 cover not shown and locate the 3 pin terminal board strip at the upper left hand corner of the power supply board 5 Connect the AC hot wire typically black from your 110 source to Pin 2 1 on 6 Connect the neutral wire typically white from your voltage
48. eries 48 Lasers Operator s Manual Appendix Supporting Documentation Appendix Supporting Documentation List of Supporting Documentation Figure Table Title Page 48 1 Label Location A 2 A 2 48 2 Label Location 3 Ad 48 5 Label Location Diagram 4 4 48 1 Outline Mounting 5 5 48 2 Outline Mounting 6 48 5 Outline Mounting A 7 Interconnect Schematic Model 48 Series A 8 A 8 Schematic J Series Control A 9 Series 48 Lasers Operator s Manual A 1 Appendix Supporting Documentation CAUTION These RF Excited Lasers must be provided with a pre ionizing Tickle signal during standby or laser low periods This is automatically provided with Synrad s UC Series power controller This signal keeps the plasma ionized during laser low periods and facilitates breakdown and pulse to pulse fidelity Damage or malfunction may occur if this or equivalent drive signals are not used See manual for tickle pulse specifications or contact factory
49. if supply voltage falls below 15 VDC or rises above 36 VDC If an electronics failure causes the control board to output PWM power to the RF Drivers in excess of 2096 of the commanded PWM input a fault shutdown will occur To reset after any fault shutdown correct the problem s then cycle the keyswitch or remote keyswitch if one is present or remove power to the laser for 30 seconds During any fault shutdown the fault shutdown output pin 1 of the DB9 connector will latch to low state until a keyswitch reset occurs 2 5 3 Power On Reset The Power On Reset feature will not allow lasing to restart after a power failure or shutdown has occurred until the keyswitch or remote keyswitch is first cycled off open circuit condition and then back on closed circuit Power On Reset is defeated via an internal DIP switch on all OEM no keyswitch versions OEM customers must provide this required safety feature elsewhere as part of their equipment integration 2 5 4 RF Driver IV RF power is provided by a patented 5 602 865 single MOSFET transistor power oscillator operating in a tuned feedback circuit The low impedance MOSFET output is coupled to the relatively high impedance laser tube electrode by a ceramic substrate micro strip transmission line integral to the RF Driver circuit board RF rise time is about 1 us to deliver a striking voltage of over 500 peak to the discharge electrodes A pulse stretching network on the control boar
50. imeters 71 12 113 03 460 50 71 12 113 13 x 841 50 142 24 x 113 03 x 917 70 Specifications subject to change without notice 1 Output power level is guaranteed for 12 months regardless of operating hours 2 Minimum 30 VDC input voltage to obtain guaranteed output power 3 Lasers with output power 250W must be water cooled Lasers with output 50W can be either water or air cooled depending on their duty cycle For duty cycles gt 50 water cooling is strongly recommended Note that water cooling improves power stability at any duty cycle 4 Inlet cooling water temperature should always be maintained above the dew point to avoid condensation and water damage to the laser 5 Overall dimensions including cooling tubes and cooling fins Series 48 Lasers Operator s Manual 9 Ch 2 Theory of Operation 2 2 Technology Overview Series 48 lasers incorporate the latest technology in sealed carbon dioxide devices combining the best features of both waveguide and free space laser technology The all metal laser tube construction U S Patent 4 805 182 features the ruggedness stable optical support and small size of waveguide lasers Its larger bore 4 8 mm eliminates the high optical power density of waveguide lasers with their predisposition to optical degradation and incorporates the mode purity and easy optical alignment of free space TEMoo lasers Low cost is achieved by using simple extruded and welded aluminum
51. ion A series extension of the keyswitch circuit Over Under OEM Circuit element Laser fault shutdown will occur if supply Voltage Protection Keyswitch voltage falls below 15V or rises above 36V Power down sequence keyswitch reset or remote keyswitch reset is required to restore operation Reverse Voltage OEM Circuit element Internal diode protects internal circuitry from Protection Keyswitch reverse input voltages The external fuse will blow Over Temperature OEM Circuit element Over temperature shutdown will occur when Protection Keyswitch the temperature of the tube reaches 60 C 2 C Power down sequence keyswitch reset or remote keyswitch reset is required to restore operation PWM Failure Circuit element Disables laser if output power exceeds the Protection Keyswitch Command input by 20 or more due to electronics failure Power down sequence keyswitch reset or remote keyswitch reset is required to restore operation Fault Signal OEM Signal output Latches to a logic low state to indicate a fault No Keyswitch shutdown has occurred Message Signal OEM Signal output Pre shutdown temperature warning latches to a No Keyswitch logic low state when tube temperature reaches 54 C 2 C Warning Labels OEM Labels Attached to various external locations of the laser Yes Keyswitch housing to warn personnel of potential hazards 1 OEM versions keyswitch the Power indicator illuminates
52. isions must be made for maintaining a ready plasma state without lasing at frequencies greater than 5 kHz For high speed applications that require a PWM frequency beyond 5 kHz consult the factory for more information If a 1 us tickle is supplied at 5 kHz PWM may be set to an in dependent higher frequency but must go to near zero lt 1 duty cycle to ensure laser turn off 2 4 3 Low Frequency Gated Operation If your laser application requires relatively short gating pulses at repetition rates below 500 Hz each gated pulse of laser output will exhibit some leading edge overshoot regardless of the PWM frequency This is because a cooler lasing medium the gas is more efficient than a hotter one The effect is more pronounced at lower gating frequencies since the gas has more time to cool between lasing 2 5 Description of Electrical Operation Control of laser operation and power output levels is essentially performed using a single PCB The Control PCB connects the modulated signal to the RF amplifier It also provides electronics to monitor performance of RF control output circuitry input power temperature PWM accuracy provides outputs to an externally accessible connector and incorporates reverse polarity protection Functional differences between model types generally relate to the number of RF channels Model 48 1 operation uses a single RF electrode requiring a single modulated RF drive input from the Control PCB The 48 2
53. l applications such as redundant or ultra wide dynamic range systems it is permissible to drive only one Command input Under this condition however the random polarization beam quality will be compromised The optical combining technique is based on the fact that each laser is linearly polarized allowing the use of a polarization sensitive beam combiner to achieve 98 efficiency in combining the two beams The two components of the resulting beam are spatially parallel and collinear Combining the output of two lasers reduces the normal temporal and spatial variations of a single laser Output polarization is random and therefore superior for many cutting applications Series 48 Lasers Operator s Manual 17 Ch 2 Theory of Operation 1325 31v0 AB_03MD3H IS INN 31v0 48 NMvHO 30 133HS 10 86 91 018 ON 3114 ONIMVWO 10 80 910 08 ON 1498 3093199 HOS 49530 siubieH 0059 C88v S8gv Szv 3x04 0066 6 0 641286 VM OSILNANIA 20 AVANAS QVHNAS 30 NOISSINYIA N3LUYM 1 1599 NI YO 310HM 0350192510 YO 03SN 38 JON TIVHS ONY OVYNAS OL SI DNIMVYO SIHL YSEWNAN l18Vd SIHI 330NN 0314 WO 8 33S ONILSIT 31314003 404 77 YSEWAN LAVA SI 11 8903 ASSY
54. ltage or analog current operation ANV or ANC control of the laser is not a linear transfer function For example a 12 mA ANC or 5V ANV input does not necessarily generate a 50 power level The general curve is similar to that shown in Figure 2 1 A more precise definition of the curve for your laser can only be obtained experimentally on an individual basis The UC 2000 Controller can also be set to operate in REMOTE mode In REMOTE mode a computer or programmable logic controller PLC can control the laser s desired output power through an RS232 serial link You can command the UC 2000 to report status data through the RS232 link while it is in any operating mode Refer to the UC 2000 Laser Controller Operator s Manual for additional information Series 48 Lasers Operator s Manual 35 Ch 6 Operating Instructions 36 Series 48 Lasers Operators Manual Ch 7 Maintenance and Troubleshooting Chapter 7 Maintenance and Troubleshooting Table 7 1 Series 48 Troubleshooting Table PROBABLE CAUSE Laser beam is off Check power source keyswitch and aperture shutter to verify that they are properly set Allow for the built in five second delay between turning on electrical power and initiation of laser excitation Check for the presence of a remote keyswitch remote interlock or the factory installed DB9 jumper 3 Check fuses and supply voltages If the laser is warm allow it to cool and cycle the source power to
55. nal strip on the power supply s input section under the protective snap on cover 5 Connect one of the two hot wires typically black from your 220 VAC source to the terminal labeled L AC Line 6 Connect the other hot wire typically black or red from your voltage source to terminal N AC Neutral 7 Connect the ground earth wire typically green from your voltage source to the terminal labeled with the ground symbol 3 110V Operation To configure your DC 2 DC 5 power supply for 110 VAC operation and to connect input and output wiring refer to Figures C 1 and C 2 and then follow the steps below 1 Follow your facilities Lockout Tagout procedures to deenergize input power 2 Locate the 30 VDC output terminals on the power supply s output section and connect the red DC power cable from the laser to the plus 30 VDC output terminal 3 Connect the black DC power cable from the laser to the minus output terminal 4 Locate the 5 pin terminal strip on the power supply s input section under the protective snap on cover 5 Connect a jumper wire 16 AWG or heavier between terminals 1 and 2 6 Connect the AC hot wire typically black from your 110 VAC source to the terminal labeled L AC Line 7 Connect the neutral wire typically white from your voltage source to terminal AC Neutral 8 Connect the ground earth wire typically green from your AC voltage sourc
56. nternal electrode structure U S Patent 4 805 182 and others is shown schematically in Figure 2 2 The RF drive power is applied between the lower electrode and the plasma tube The internal resonant circuit induces RF drive on the upper electrode that is 180 degrees out of phase with that of the lower electrode Thus the voltage between the two RF electrodes is roughly twice that on either electrode causing the plasma to form only in the 4 8 mm square bore region The two sidewalls confine the plasma but carry negligible current The RF electrodes are anodized to assure uniform distribution of RF power throughout the excitation volume Waste heat is conducted away by all four metal sides of the bore to the outer walls of the plasma tube where it is transferred to the chassis In contrast to waveguide lasers that have a closed bore periphery the Series 48 lasers have four 0 02 inch slots small gaps extending longitudinally along the length of the bore refer to Figure 2 2 These slots are used for electrical insulation between the two pairs of orthogonal electrodes However these slots are also effective for diffusion cooling of the laser gas 2 3 2 Optical Resonator The optical resonator consists of a 3 meter radius of curvature total reflector and a flat ZnSe output coupler with reflectivities of 95 or 92 The mirrors are held on with Viton fluorocarbon elastomeric o rings for factory adjustment by means of three Torx head 4 40 screws
57. nts When water cooling Series 48 Lasers consult the chiller manufacturer for specific recommendations regarding coolant additives Typically the coolant mixture should contain 80 to 90 filtered tap or de ionized water In applications where biocides containing chlorides are used concentrations should not exceed 25 PPM CAUTION Condensation and water damage can occur if cooling water temperature is below the dew point 4 4 1 48 1 48 2 Cooling Heat load for the 48 1 laser 15 200 watts maximum and 400 watts maximum for the 48 2 In all but very low duty cycle applications external cooling must be applied to the laser chassis this may take the form of either forced air or water cooling Air cooling is accomplished by placing four 4 69 inch fans at the side of the laser and directing air flow perpendicular to the laser cooling fins refer to Figure 4 2 This method will produce sufficient cooling when operating at any duty cycle including CW mode 100 duty cycle Minimum delivery requirements for air cooling are 500 cubic feet per minute CFM of free air for the 48 1 2 fans 250 per fan and 1000 for the 48 2 4 fans 250 per fan TOP VIEW Figure 4 2 48 2 25W Cooling Fan Placement Series 48 Lasers Operator s Manual 25 Ch 4 Interface Requirements When using water cooling the recommended flow rate is 0 5 gallons per minute GPM for the 48 1 and 0 8 GPM for the 48 2 model at an inlet temperature of
58. o control and vary that signal are provided by SYNRAD s UC 2000 Laser Controller Using an alternate method to control laser output power requires consideration of key characteristics of Series 48 lasers as described in the following paragraphs UC 2000 CONTROLLER OUTPUT TO LASER COMMAND INPUT ON COMMAND INPUT OFF Figure 2 4 Typical PWM Drive Signal 12 Series 48 Lasers Operator s Manual Ch 2 Theory of Operation 2 4 1 Tickle Pulse All Series 48 lasers require a 1 us tickle pulse delivered at a 5 kHz clock frequency from the controller If the user 1 supplying on off Command pulses directly to the laser without a tickle pulse the response time from the user s Command pulse until laser emission is unpredictable and optical rise time will be degraded This is due to the finite time required to create a plasma state within the laser tube and depends heavily on the amount of time that the laser has been off no Command signal before a pulse is applied This inconsistent and unstable firing can cause problems in precision industrial uses where even short delays in firing are important The tickle signal pre ionizes the laser gas so that it is just below the lasing threshold In this way the laser can respond predictably and almost instantaneously to the user s Command signal even when there is considerable time delay laser off time between commands This laser contains a precision pulse stretching circuit that is preset
59. ode When the GATE input pulses high gt 3 5 VDC the UC 2000 will turn on the laser at a power level corresponding to the UC 2000 s PWM Adj Knob setting When the GATE input goes low lt 0 5 VDC the UC 2000 terminates lasing and reverts to standby mode tickle pulse only 34 Series 48 Lasers Operator s Manual Ch 6 Operating Instructions 6 4 Operation in Continuous Wave CW Mode In some applications such as high speed marking the finite turn off time of the laser due to modulation causes a series of dots that may be visible on the marking surface instead of a clean line Operating the laser in CW mode will prevent this from occurring however there will be a slight decrease in laser efficiency when the duty cycle is increased beyond 95 refer to Figure 2 1 To operate the laser in CW mode a constant 5 VDC signal can be connected to the Command input of the laser This constant source will force the internal switching electronics to remain on providing continuous and uninterrupted laser output power Note that in CW mode laser power output cannot be adjusted using the UC 2000 If laser power needs to be adjusted refer to Section 2 4 2 for information regarding high frequency operation A tickle signal must still be provided to the laser during standby periods to prevent laser damage 6 5 PC Control of Laser To control on off pulsing of the laser pulsed mode a signal providing TTL level pulses is connected to th
60. ompliance 4 1 2 Declaration of Conformity 5 2 1 Average Laser Output vs Percent PWM Duty Cycle 10 2 2 Physical Schenmiatio ii 11 2 3 a Ib Ss 12 24 Typical PWM Drive 12 2 5 Tickle P lse ae eee ee 13 2 6 Typical 5 kHz Command Input Waveforms For Gated Operation 14 2 7 Modulation Wavetorms o ee 14 2 8 RP Driver ini ios 18 Sel 48 1 48 2 Physical Features Location Diagram 19 3 2 48 5 Physical Features Location Diagram 20 4 1 DBO Plug iS i EA ve aed 24 4 2 48 5 25W Cooling Fan Placement 25 4 3 48 1 48 2 Laser Cooling 26 4 4 48 5 Laser Cooling Kit aces eee eee etse tad oae Ide 27 5 1 Typical System Interconnection 32 Appendix 48 1 Label Location Diagram A 2 A 2 48 2 Label Location DISgratmn caede esie oed ces A 3 48 5 Label Location Diagram A 4 4 48 1 Outline Mounting Diagram A 5 5 48 2 Outline Mounting Diagr
61. ously burn human or animal tissue Refer to and follow the laser safety precautions in ANSI Z136 1 1993 American National Standard for Safe Use of Lasers Procedures listed under the Standard include appointment of a Laser Safety Officer operation of the product in an area of limited access by trained personnel servicing of equipment only by trained and authorized personnel and posting of signs warning of the potential hazards 6 Series 48 Laser Operator s Manual Ch 1 Safety and Regulatory Compliance WARNING Processing of materials can generate air contaminants such as vapors fumes and or particles that may be noxious toxic or even fatal Material Safety Data Sheets MSDS for materials being processed should be thoroughly evaluated and the adequacy of provisions for fume extraction filtering and venting should be carefully considered Review the following references for further information on exposure criteria ANSI Z136 1 1993 American National Standard for 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 venting of vapors CAUTION Use of controls or adjustments or performance of procedures other than those specified herein may result in hazardous radia
62. perly configured The DC 5 is preset for 220 VAC input power You must jumper terminals 1 and 2 on the input power terminal strip for 110 VAC input Refer to the documentation provided with the power supply or see Appendix C for additional wiring information 30 Series 48 Lasers Operator s Manual Ch 5 Unpacking and Setup 3 Make interconnections between your electronic control equipment and the laser s DB9 connector as required 4 Attach the UC 2000 Controller s Power Control cable between the UC 2000 s mini DIN LASER connector and the laser s Auxiliary Power connector The UC 2000 can also be powered from a wall plug by using its wall plug transformer 5 Attach the long leg of the BNC Y control cable to the BNC connector on the UC 2000 s Power Control cable Attach the short legs of the connector to the laser s CTRL 1 and CTRL 2 connectors 6 If your application uses external gating signals to command on off switching of the laser attach a BNC cable between your Gate signal source such as a computer or PLC and the UC 2000 s GATE connector 7 If your application uses external analog voltage or current signals to control PWM attach a BNC cable between your analog voltage or current source typically a computer or PLC and the UC 2000 s ANV ANC connector Series 48 Lasers Operator s Manual 31 Ch 5 Unpacking and Setu 5 H3MOd ONV ANV
63. proven mature laser tube technology and reliable simplified electronic control All information necessary to safely operate and maintain the laser is provided in this manual The information is organized in several chapters and is arranged as follows Chapter 1 Safety and Regulatory Compliance Chapter 2 Theory of Operation Chapter 3 Physical Features Chapter 4 Interface Requirements Chapter 5 Unpacking and Setup Chapter 6 Operating Instructions Chapter 7 Maintenance and Troubleshooting Chapter 8 Return for Factory Service In addition to the information contained in the chapters described above supporting data has been provided in several appendices located after Chapter 8 In the event additional information is required for your application please contact SYNRAD at 1 800 SYNRADI Please read this manual completely before using your laser To prevent injury to personnel or damage to the laser follow all safety precautions handling and setup instructions as described herein Ch 1 Safety and Regulatory Compliance Chapter 1 Safety and Regulatory Compliance 1 1 CDRH Requirements Safety Features Series 48 lasers are designed to comply with requirements imposed by the Radiation Control for Health and Safety Act of 1968 Under this act the Food and Drug Administration issued a performance standard for laser products 21 CFR 1040 10 and 1040 11 This performance standard was developed to protect public health and safety by impo
64. r ia 12 Tickle Pulse 13 242 PWM Clock Frequency 13 2 4 3 Low Frequency Gated Operation 15 25 Description of Electrical Operation 15 2 5 1 PWM Control Circuitry 15 2 5 2 Fault Shutdown Conditions 16 2 5 3 Power OBI 16 DA A aint 16 2 6 Duo Lase Operation 48 9 anida dis 17 3 Physical Features 19 3 1 Controls and Indicators 19 Sal USh tter 19 3 1 2 Power On LED 20 3 1 3 Lase LED ides ene pe pip dee 20 eene dps o b resp itis 20 ZlS US Dacis a 21 3 1 6 Connector itti Pt tad 21 3 1 7 Command 21 DE Power 21 3 1 9 la AA 21 3 1 10 Laser it 21 3 1 11 Diode Pointer Power Connector 21 3 1 12 Mounting of Optical 21 Series 48 Lasers Operator s Manual i Table of Contents Continued 4 Interface Requirements 23 4 1 UC 2000 Universal Laser Controller
65. rding to Section 5 3 Turn on the cooling system If using cooling water examine all connections for leaks Ensure that all personnel in the area are wearing protective eyewear Place a beam block in front of the exit aperture Apply power to the external DC power supply Set the UC 2000 to the MANUAL mode of operation Set the UC 2000 PWM Adj Knob to minimum power 0 0 and press the Lase On Off pushbutton Verify that the red Lase indicator on the UC 2000 illuminates Set mechanical shutter on the laser to the ON open position 9 Turn the laser s keyswitch to ON and or close the remote keyswitch Verify that the green POWER LED on the Laser Head illuminates 10 Verify that the red LASE LED on the laser illuminates dimly after approximately 5 seconds This indicates tickle pulses are being applied to the laser Series 48 Lasers Operator s Manual 33 Ch 6 Operating Instructions 11 Slowly rotate the UC 2000 s PWM Knob control towards maximum power and verify that the intensity of the red LASE LED on the laser increases as UC 2000 output is increased 12 While the UC 2000 is set for maximum power output measure laser output using a laser power meter such as SYNRAD s PW 250 Power Wizard to verify that the output is consistent with the power rating for your respective laser model refer to Table 2 1 for power specifications 13 Reduce power output to minimum then turn off laser power
66. re and at the same time actuates independent micro switches that electrically interrupt power to the RF module by disabling the PWM input opto isolator forcing an off state Series 48 Lasers Operators Manual 15 Ch 2 Theory of Operation 2 5 2 Fault Shutdown Conditions The power input circuit consists of a panel mounted fuse for overcurrent protection a dual Schottky shunt rectifier for reverse voltage protection a panel mounted keyswitch and a normally open MOSFET safety switch Application of reverse voltage will normally require fuse replacement The output of the keyswitch is connected to the control board through the DB9 user port Note that the supplied DB9 jumper plug can be removed to allow the user to insert a remotely located relay or switch in series with the keyswitch If the keyswitch is left on or is electrically bypassed the user can turn the laser on and off and reset fault shutdowns from a remote location The temperature warning message output pin 5 of the DB9 connector goes low when the laser tube temperature reaches 54 C 2 C and remains low until tube temperature falls 2 C below the trigger temperature The warning message output does not shut down the laser Overtemperature fault shutdown occurs when laser tube temperature reaches 60 2 Control board operation begins when the supply voltage rises above 18 VDC and remains below 36 VDC After startup the control board will shut the laser down
67. red if necessary for OEM versions LASER EXIT SHUTTER POWER ON LASE LED APERTURE SWITCH LED lo N OFF al VOID EXPOSURE SYN RA CS CARBON DIOXIDE LASER SZ PWR LASE e 7 FUSE SYNRAD a 5 b P n 823 2 E FRONT VIEW REAR 27 u DIODE POINTER COMMAND INPUT KEYSWITCH FUSE POWER CONNECTOR DB9 CONNECTOR DC POWER CABLES AUXILIARY POWER SIDE VIEW Figure 3 1 48 1 48 2 Physical Features Location Diagram Series 48 Lasers Operator s Manual 19 Ch 3 Physical Features LASER EXIT APERTURE SHUTTER O AVOID EXPOSURE CARBON DIOXIDE LASER O SWITCH FRONT VIEW DIODE POINTER POWER CO NNECTOR DC POWER CABLES POWER ON LED LASE LED COMMAND INPUTS SIDE VIEW Figure 3 2 48 5 Physical Features Location Diagram 3 1 2 Power On LED 2002 A M O Y VA Q REAR VIEW KEYSWITCH FUSE DB9 CONNECTOR AUXILIARY POWER The POWER LED is a panel mounted LED that illuminates green when the keyswitch is turned to the ON position which indicates that power is applied to internal circuitry This LED is standard on both OEM and keyswitch versions 3 1 3 Lase LED The LASE LED is a panel mounted LED that illuminates red to indicate the Lase mode of opera
68. rt 3 Immunity to electrical fast transient bursts at levels defined in document IEC801 Part 4 After a product has met the requirements of all pertinent EU directives the product can bear the official compliance mark of the European Union depicted in Figure 1 1 Figure 1 1 European Compliance Mark 4 Series 48 Laser Operator s Manual Ch 1 Safety and Regulatory Compliance Series 48 lasers have demonstrated performance characteristics that have met or exceeded the requirements of EN 60825 1 and the directive 89 336 EEC 1 3 Declaration of Conformity A Declaration of Conformity is provided to certify that EMC performance levels of Series 48 lasers are compliant with applicable EU directives and standards Declaration Of Conformity Applicable EU Directive s 89 336 EEC EMC Directive Applicable Standards Norms EN55011 Radiated Class A Group 2 EN60825 1 Laser Safety EN50082 1 Generic Immunity 1EC801 2 Electrostatic Discharge 1EC801 3 RF Radiated 1EC801 4 Fast Transients Manufacturer SYNRAD Inc 4600 Campus Place Mukilteo WA 98275 Model Number Date Of Compliance 48 1 20 December 1999 J48 2 20 December 1999 J48 5 20 December 1999 We SYNRAD Inc hereby declare under our sole responsibility that the equipment specified above conforms to the above Directive s and Standard s Corporate Officer European Contact Excel Technology Europe GmbH Maisacher Str 129 82256 F rstenfeldbruck Germany
69. sing requirements upon manufacturers of laser products to provide indication of the presence of laser radiation by providing the user with certain means to control radiation and by assuring adequate warnings to all personnel of the potential hazard through the use of product labels and instructions Federal regulations require that all laser products manufactured on or after August 2 1976 be certified as complying with the performance standard The manufacturer must demonstrate the product s compliance with the standard prior to certification or introduction into commerce by furnishing to the Center for Devices and Radiological Health CDRH reports pertaining to the radiation safety of the product and the associated quality control program Failure to provide the required reports or product certification is a violation of Section 3608 of the Radiation Control for Health and Safety Act of 1968 Product features incorporated into the design of Series 48 lasers to comply with CDRH safety requirements are integrated as panel controls or indicators internal circuit elements or input output signal interfaces terminated at a DB9 connector installed on the side panel of the laser Specifically these features include a keyswitch keyswitch version remote interlock a laser aperture shutter fault output signals to indicate failure of internal electronics control board or RF driver or an actual or impending overtemperature condition and a 5 secon
70. thority to make warranty statements regarding SYNRAD products SYNRAD Inc and its Authorized Distributors neither assumes nor authorizes any representative or other person to assume for us any other warranties in connection with the sale service or shipment of our products SYNRAD Inc reserves the right to make changes and improvements in the design of our products at any time without incurring any obligation to make equivalent changes in products previously manufactured or shipped Buyer agrees to hold SYNRAD harmless from any and all damages costs and expenses relating to any claim arising from the design manufacture or use of the product or arising from a claim that such product furnished Buyer by SYNRAD or the use thereof infringes upon any Patent foreign or domestic Series 48 Lasers Operator s Manual vi Series 48 Lasers Operators Manual Introduction Thank you for purchasing a Series 48 laser from SYNRAD Inc The Series 48 family of lasers incorporates the latest developments in sealed carbon dioxide devices combining the best features of both waveguide and free space laser technology in an innovative aluminum tube design J Series lasers utilize state of the art surface mount electronics newly patented RF excitation technology and fully CE compliant systems for EMI containment heat removal and laser safety In the 10 50W range of continuous optical output these lasers represent an ideal balance between
71. ting plug 15 attached to the DB9 connector on each laser to enable normal operation Two jumpers see Figure 4 1 are wired to the plug One between pins 6 and 7 to close the remote keyswitch function and one between pins 3 and 4 to close the remote interlock If this shorting plug is removed it is essential that Pin 3 be jumpered to Pin 4 or Pin 2 or be connected to external remote interlock circuitry to enable lasing To take advantage of the DB9 functions described in Table 4 1 you must manufacture a connecting cable and configure DB9 connections for proper operation A spare DB9 male connector and cover is included with each laser to facilitate easy cable manufacture Series 48 Lasers Operator s Manual 23 Ch 4 Interface Requirements On lasers manufactured as OEM S version lasers 1 e without a keyswitch the remote interlock function has been bypassed internally For OEM customers wishing to access the remote interlock feature via the DB9 connector please consult the factory for details Figure 41 DB9 Jumper Plug Table 41 DB9 Connector Pin Assignments FAULT Fault Shutdown output indicates failure of internal SHUTDOWN control RF circuitry or existence of overtemperature OUTPUT gt 60 C 2 C overvoltage or undervoltage fault This active low signal in reference to pin 2 or pin 4 transitions from 15V to when a fault occurs Disables laser when opened by a remote door or housing safety interlock
72. tion If a Command signal 1 present the red LED turns on after the 5 second delay and becomes brighter as the Command duty cycle is increased This LED is standard on both OEM and keyswitch versions 3 1 4 Keyswitch The panel mounted keyswitch is used to turn the laser on off and to reset faults The key cannot be removed when the keyswitch is in the ON position For OEM lasers a plug is installed in place of the keyswitch and the keyswitch wires are shorted The remote keyswitch pins of the DB9 connector then become the external power on off control means 20 Series 48 Lasers Operator s Manual Ch 3 Physical Features 3 1 5 Fuse The panel mounted fuse s provides overcurrent protection for the internal circuitry of the laser The required fuse is a fast blow type AGC 3AG rated at 32V minimum with the following current ratings 48 1 10 48 2 20 48 5 20 Amp 2 Req d 3 1 6 DB9 Connector The DB9 connector is a 9 pin female subminiature D connector that provides for inter connection of message fault shutdown remote interlock remote keyswitch and interface signals Refer to Chapter 4 for detailed information on the use of the DB9 connector 3 1 7 Command Input The CTRL connector is a BNC style jack that accepts the Command input control signal The output of the UC 2000 Controller is attached to this connector For pure CW operation a steady 5V signal can be applied through this connector as long as a ti
73. tion exposure Series 48 Lasers Operator s Manual 7 Ch 1 Safety and Regulatory Compliance 8 Series 48 Laser Operator s Manual Ch 2 Theory of Operation Chapter 2 Theory of Operation 2 1 Technical Specifications Technical information regarding Series 48 performance characteristics is summarized in Table 2 1 Table 2 1 Series 48 Specification Table MODEL CHARACTERISTICS 48 5 Wavelength 10 57 to 10 63 microns Guaranteed Y 2 10W 25W 50W Electrical Control Command Input Opto isolated LED input Positive logic 20 kHz max frequency High On 3 5V min 10V max Low Off 0 5V max min 6mA max load 5V 48 1 48 2 12mA max load 5V 48 5 Electrical Control Remote On Contact closure lt 100 Off Open Circuit gt 100 Keyswitch Link Contact Rating 50 VDC lt 2mA minimum dry circuit Electrical Control Remote Interlock On Contact closure lt 100 Off Open Circuit 2 100 Link Electrical Power Input 2 30 32 VDC 7 A max 30 32 VDC 14 max 30 32 VDC 28 max Contact Rating 50 VDC lt 2mA minimum dry circuit Cooling Water 9 Heat Load Max Flow Rate Temperature Thermal Shutdown 60 C 2 warning at 54 C 2 C Beam Exit Vertical Location 1 09 inches from top plate center 1 22 inches from top plate 9 Ib 4 1 kg 18 Ib 8 2 kg 44 Ib 20 kg Dimensions x H x L 6 Inches 2 80 x 4 45 x 18 13 2 80 x 4 45 x 33 13 5 60 4 45 36 13 Mill
74. ut pulses Series 48 Lasers Operator s Manual 37 Ch 7 Maintenance and Troubleshooting 38 Series 48 Lasers Operators Manual Ch 8 Return for Factory Service Chapter 8 Return for Factory Service In the event your Series 48 Laser requires return for factory service SYNRAD must be contacted prior to shipment of the laser for a Return Authorization RA number The Return Authorization number must be included on all shipping documentation included with the returned laser The following information is required by SYNRAD to issue a Return Authorization number Name of company Name and phone number of individual requesting return of the laser Model number Serial number Detailed description of the fault Return the laser in the original packing material and shipping container Write the Return Authorization number on the outside of the shipping container Series 48 Lasers Operator s Manual 39 Ch 8 Return for Factory Service SERVICE REQUEST Company Name Contact Name Company Address Telephone Fax Date originally received Date returned RAF Serial Describe reason for repair Should you need to return a laser for repair please contact SYNRAD Customer Service to obtain a Return Authorization Number RA In the U S call 1 800 SYNRAD1 outside the United States dial 425 349 3500 or fax your request to 425 349 3667 40 S
75. utput is internally protected against short circuits by an auto resetting solid state fuse 3 1 12 Mounting of Optical Accessories The front faceplates of Series 48 lasers are designed with a 6 hole mounting pattern refer to the Outline Mounting diagrams in Appendix A to provide a convenient method for mounting standard beam delivery components available from SYNRAD When considering other components not specifically designed as Series 48 options please consult the factory for restrictions since excessive weight may cause damage to the laser Series 48 Lasers Operator s Manual 21 Ch 3 Physical Features 22 Series 48 Lasers Operator s Manual Ch 4 Interface Requirements Chapter 4 Interface Requirements 4 1 UC 2000 Universal Laser Controller Operation of Series 48 lasers requires an external controller that can provide the necessary Command input drive signal as the modulation source SYNRAD s UC 2000 Controller has been designed to provide control of the laser from a remote source The UC 2000 requires 15 50 VDC 35 mA supplied from its wall plug transformer or can be connected to the Auxiliary Power connector on the side panel of the laser via the power cable provided with the UC 2000 Refer to the UC 2000 Laser Controller Operator s Manual for further information 4 2 DC Power Supply 4 2 1 48 1 48 2 Model SYNRAD power supplies models DC 1 and DC 2 are sized to power 48 1 and 48 2 lasers respectively If

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