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Series 48 Operation/Service Manual

1. REV ECO DATE DESCRIPTION DB J 428 12 9 95 MADE EMC MODIFICATIONS PT TI 65 L3 TI CTRL m m SLT DRIVER Lad Lid PWM 40 68 MHZ 1 m CRYSTAL FEEDTHROUGH TterunoucH en EY DRIVER FILTER BOX is 1 ces IN SPLITTER eno E LA a INPUT E SPLITTER T 5 7 BEAD PCI 57 1 ELECTRONICS eo RO ew E ess 600W 600W us BEAD ii AMPLIFIER AMPLIFIER id E P Fes RF AMP BRD RF AMP BRD m Ie BEAD OUTPUT i Der COMBINER x OUT COMBINER BRO pes CROWBAR BRD CROWBAR MODULE m pco m RESET BRD RESET MODULE pm 0 revswnen 7 onore 057 FAN E iow r Ts T tase ES FE eoni zo Z a Mi MIS T T INTERLOCK Ll
2. CHILLER WOTE GOOLINGINTERCOMMECTION SUPPLY FETU EN ORE MOUNTED OM THE FROMT PAWEL OF THES SUPPLY GL HD ON THE REAR PAR ELS OF THEBT EF aUPPLY AHD THE LAJER HEX Figure 5 1 Cooling Interconnection Schematic If it is necessary to operate with cooling water below the dew point precautions need to be taken to assure that no condensation takes place A minimum requirement is to shut off automatic interlock coolant flow whenever the laser is not activated at sufficient power to drive the chassis or head temperature above the dew point Connection of the cooling tubing to the laser is accomplished using the IN OUT connections on the cooling manifold Fig 5 2 Laser Cooling Kit The quick disconnect fittings can be removed from the tubing by compressing the front ring of the fitting against the body of the fitting CAUTION After all water interconnections have been completed turn on the water cooling system to ensure that all connections are secure and there are no leaks This step must be accomplished before performing electrical connections Figure 5 2 Laser Cooling Kit Series 57 60 Lasers 29 Operation and Service Manual Ch 5 Models 57 0 57 1 Installation and Check Out 5 4 System Interconnections Refer to the System Interconnection diagram Fig 5 3 and the following paragraphs to properly accomplish all required connections 53501 Y 19130 I23HHO2H3LHI T4725 43A
3. Schematic 57 RE Dryer eite re es reed Pea eee elis tees RENI Schematic 60 RE Driver iter ert deese tette beet e eese deese eve coe evolve xt Series 57 60 Lasers Operation and Service Manual Appendix A Supporting Documentation SSH E Thi zr nrudupti mmamnudaciurmd under 0 In ul ia mr 1 NUR F 4 008 152 4 557 772 CH TIEN la amitiud tom D PPIP and ohera hi BEAM BOTTOM WIEN C VIBIELE A4 DINVIBIE awcID EXPOSURE LABEM IB ATED PRO THID Por MA DEIN uda RESA WIE FROHT WIE Series 57 60 Lasers Operation and Service Manual Appendix A Supporting Documentation 57 0 57 1 and 60 1 Label Location Diagram Series 57 60 Lasers A 3 Operation and Service Manual Appendix Supporting Documentation CA ITIN HOH ee SH Wa E CUN ee D RAIN PHL RELA WIE Thi a im zur productia mmnudardurmd under 0 9 4 000 152 4 007 772 and ohera HAT PIF LSP FL aH oA Ei RS TOP Y Ev OW INSIDE GF UNIT Ng Hai F t i0 Dep T eben WIBIBLE OA OTA al BLE LOJER 18 EMTEC FROM THI 3 PERTUR Oo EXPOSURE FRONT WIE 57 2 and 60 2 Label Location Diagram Series 57 60 Lasers Operation and Service Manual Documentation endix A Supportin A 7H3JSVi LNN
4. Series 57 60 Lasers Model Number 57 1 57 2 60 1 60 2 Operation and Service Manual SYNRAD Series 57 60 Evolution Lasers Model Number 57 1 57 2 60 1 60 2 Operation and Service Manual REVISED EDITED 3 1 97 Synrad Inc 6500 Harbour Heights Parkway Mukilteo WA 98275 206 349 3500 email synrad 9 synrad com FAX 206 485 4882 In U S 1 800 SYNRADI Table of Contents IntrodUclloD traditi orien vine eave Rt EN 1 1 Safety and Regulatory 2 1 1 CDRH Requirements Safety Peatures tee ti ts eade 2 1 2 BML Compliance 4 1 2 1 Federal Communications Commission FCC Requirements 4 1 2 2 European Union EU Requirements eene 4 1 3 Declaration of Conformity 5 L4 Warning Labels Placards aeo ese edens a aps ede aui addet 6 1 5 Operation and Service Manual Precautionary Notations 6 2 Theory or Operatloh orc DA to tdt ta buo us ern 7 2 1 Technical Specifications 7 22 aan at dub deam ee ee dam 9 22 Laser Head nte e Ee ig E E 9 2 2 2 34 RF Power Supplies 41 pee CHOR d eet 9 2 2 3 60 RF Power Supply ete Re eestor Tere er leony 10 2 3 Description of Physical Operation iati ettet tte ente eap tea tet 11 2 3
5. eg Figure 8 3 System Interconnection Diagram 5S Series 57 60 Lasers Operation and Service Manual Ch 8 Model 60 2 Installation and Check Out 8 4 1 UC 1000 Power Controller Operation of 60 Series lasers requires an external controller that can provide the necessary TTL drive signal as the modulation source The Synrad UC 1000 Controller has been designed to provide control of the laser output from a remote source The UC 1000 requires 28VDC at 80mA from a wall plug transformer rectifier When connecting the UC 1000 to the RF Power supply a BNC t adapter must be installed on the BNC OUTPUT connector located on the rear panel of the UC 1000 Each of the BNC terminated cables is connected to one of the T s and terminated at the CTRL IN connector of each RF Power Supply 8 4 2 RF Power Supply The 60 2 laser requires 1 RF power supply for each of the two sections of the laser head referred to as Set 1 and Set 2 The two RF power supplies deliver a total of 2 8kW of RF through four RG 8 type coax cables two cables for each RF driver Operation is on the authorized ISM frequency of 40 68MHz Electrical interconnections between the regulated DC power supplies and the RF supplies are shown in the RF Supply DC Power Supply Interconnection Diagram 60 2 Power Connections 255 L Bk Red S Q s HF Naht s A ZS ee Black Red
6. Set mechanical shutter on laser to the ON open position Set the power switch for each of the external DC power supplies to the ON position Verify green LED on each RF power supply illuminates cb DY cnc cec op cjr m Turn RF power supply keyswitch to ON position and or close the remote interlock Verify yellow LED s on RF power supplies and laser head illuminate 8 Set the UC 1000 to MAN manual mode Set UC 1000 POWER ADJ control to MIN and set UC 1000 POWER switch to ON Verify the red POWER ON LED on the front panel of the UC 1000 illuminates 9 Verify red LASE LED s on the RF power supplies and laser illuminate dimly after approximately 5 seconds after keyswitch is set to ON and or remote interlock is closed 10 Slowly rotate UC 1000 POWER ADJ control towards MAX and verify intensity of red LASE LED s on RF power supplies and laser head increases as UC 1000 output is increased 11 Measure laser output power using a laser power meter such as Synrad s PW 250 Power Wizard to verify output is consistent with respective power rating for laser model refer to Specification Table or final test report shipped with laser for power ratings 12 Turn off laser power set keyswitch to off or open remote interlock circuit as appropriate 13 Set UC 1000 power switch to OFF 14 Set mechanical shutter switch to OFF 15 Tum off external DC power supply 62 Series 57 60 Lasers Operation and Service Manual Chapter 9 Oper
7. 2 0 FOR EACH SUPPLY 5 B 22 2 S 0 208V 20A LE SINGLE PHASE 0 25 S 9 kr 4 ZH EN d 2 N HPMS 02 E TEM 1227 Black Wi Red 0 alma ir 3 s S MM o Bik KS CURRENT SHARE CONTROL CONNECT PIN 5 TO PIN 5 Wire 22 ga white Pin Molex 02 06 2103 Plug Molex 03 06 2061 Figure 8 4 RF Supply DC Power Supply Interconnection Diagram Series 57 60 Lasers 59 Operation and Service Manual Ch 8 Model 60 2 Installation and Check Out The BNC terminated cable from the UC 1000 output can be connected to either the front or rear panel mounted BNC CTRL IN connectors These connectors are electrically common and are duplicated as a matter of convenience for the user The interlock cable should be connected between the male DB9 connector on the rear panel of the laser head and the female DB9 connector located on the rear panel of the associated RF power supply For each RF driver Set 1 or Set 2 ensure the interlock cable is connected to respective connector Set 1 or Set 2 on the laser head To prevent improper connection it is recommended that the interlock cable be connected first to the laser and then the RF Power Supply The RF Power Supply also provides an auxiliary signal connector to provide the user with additional signal information to allow specific aspects of system performance to be monitored The auxiliary connector is a male DB9 connector mounted on the rear panel of each R
8. Series 57 60 Lasers Operation and Service Manual Ch 1 Safety and Regulatory Compliance 1 2 EMI Compliance Series 57 60 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 57 60 lasers are identified and described in Para 1 2 1 and Para 1 2 2 1 2 1 Federal Communications Commission FCC Requirements The United States Communication Act of 1934 has vested the Federal Communications Commission FCC with the authority to regulate industrial scientific and medical ISM equipment that emit 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 from 30 MHz to 1 GHz The FCC regulations which govern ISM equipment are fully described in Code of Federal Regulations CFR 47 Part 18 Subpart C Series 57 60 lasers have demonstrated performance characteristics that have met or exceeded the requirements of CFR 47 Part 18 Subpart C 1 2 2 European Union EU Requirements The European Union s electromagnetic compliance EMC directive 89 336 EE
9. interlock cable are plugged in at both ends 2 2 2 57 RF Power Supplies Laser Models 57 1 and 57 2 respectively RF excitation is provided to the lasers from a single external RF power supply that operates off 28 32VDC requiring heavy gauge 6AWG minimum cables for long cable runs Operating frequency is on the 40 68 MHz ISM frequency and is crystal controlled The oscillator section is comprised of a crystal driven MRF 134 FET an MRF 138 amplifier and a single MRF 150 transistor to deliver 100 W of RF to the plasma drivers The 57 RF uses two 500W drivers The plasma driver is a scaled up version of the F version excitation scheme U S Patent 5 008 894 using three pairs of transistors each stage consists of two MRF 429 s connected in a push pull configuration The power is split with a transmission line splitter on the input and recombined with transmission line combiners on the output Series 57 60 Lasers Operation and Service Manual Ch 2 Theory of Operation Other than the paralleling of transistor stages and the crystal controlled drive the operation of the circuit is similar to that used in Synrad s lower powered lasers The external 50 ohm interconnect coaxial cable RG 8 Foam is precisely 1 2 wave long This is electrically equivalent to a direct connection of the laser head to the RF supply The three 47 inch 50 ohm 1 4 wave transmission lines between the output of the supply and transistors serve the pu
10. 1000 power switch to OFF 14 Set mechanical shutter switch to OFF 15 Tum off external DC power supply 44 Series 57 60 Lasers Operation and Service Manual Chapter 7 Model 60 1 Installation and Check Out 7 1 Unpacking Initial Inspection Do not discard the shipping container or the foam packing since these are required if the laser is ever returned to Synrad for factory service The 60 1 laser head and all required support equipment are packaged and shipped in individual containers as indicated below in bold face type In addition some of the containers will also include support materials required to install and operate the laser The support materials included in a particular container are also listed below Open each shipping container individually Place the container on a sturdy level surface and open the top of the box Carefully remove the equipment from the container and remove the outer foam packing material Verify that the associated support material items are included Laser Head Container 1 Each One 60 Series Laser Head Operation and Service Manual Warranty Registration Card Final Test Data Report RF Supply Container 1 Each One RF Power Supply Two RG 8 Coax RF Cables 5 meters in length One DB9 terminated Interlock Cable Two pair of DC Power Cables each pair consists of 1 red and 1 black cable Fuse s Two 15 Amp Type AGC Two 1 2 Amp Pico Fuse Two 2 Amp Pico Fuse One Cooling Kit Two Straigh
11. 2 HNI HNI Deor 5 5 5 5 e 5 5 LEDS acm ue C CS z z z z z z Mus 2 Sosa 2 2 2 s m x 1 1 uns vu 1 1 SH2 Lo o zl Jc 2 a DB9 F BoM ta best DB9 F DB9 M veo 518 8 2 LASER HEAD 85 f 5 s 8 B POR o E PE s 8 5 R 5 F 5 T NOTES 1 ALL DB9 WIRES AND LED WIRES ARE ROUTED THROUGH A FERRITE PROPRIETARY Eee eee CLAMP FAIR RITE 0443164151 2 ACTUAL CONNECTOR PINOUTS ARE AS FOLLOWS 1 2 3 4 THIS DRAWING IS PROPRIETARY TO SYNRAD INC AND SHALL NOT BE USED OR DISCLOSED IN WHOLE OR IN PART WITHOUT WRITTEN SYNRAD SYNRAD INC 4600 Campus Place Mukilteo WA 98275 Phone 425 349 3500 PERMISSION OF SYNRAD INC Fax 425 349 3667 5 6 7 8 9 000090 fo oto o o DESCRIPTION FEED THROUGH FILTER BOX FEED THROUGH RFI SHIELD 57 1 INTERCONNECT DIAGRAM 3 CABLE CB6 IS A 1 1 PINOUT PART NUMBER DRAWING FILE NUMBER 16356 SHEET 1 OF 1 DRAWN BY DATE 11 22 95 UNITS INCHES CHECKED BY DATE SIZE B APPROVED BY DATE 57 Series Interconnect Diagram Series 57 60 Lasers Operation and Service Manual A 9 Appendix A Supporting Documentation 57 Series Interconnect Diagram Series 57 60 Lasers A 11 Operation and Service Manual Appendix A Supporting Documentation A 12 Series 57 60 Lasers Operation and Service Manual Appendix
12. 3 System Interconnection Diagram 48 Series 57 60 Lasers Operation and Service Manual Ch 7 Model 60 1 Installation and Check Out 7 4 1 UC 1000 Power Controller Operation of 60 Series lasers requires an external controller that can provide the necessary TTL drive signal as the modulation source The Synrad UC 1000 Controller has been designed to provide control of the laser output from a remote source The UC 1000 requires 28VDC at 80mA from a wall plug transformer rectifier When connecting the UC 1000 to the RF Power supply BNC OUTPUT connector located on the rear panel of the UC 1000 is connected to CTRL IN connector of the RF Power Supply using a BNC terminated cable 7 4 2 RF Power Supply The 60 1 laser requires 1 RF power supply for the laser head The RF power supply delivers a total of 1 4kW of RF through two RG 8 type coax cables Operation is on the authorized ISM frequency of 40 68MHz Hlectrical interconnections between the regulated DC power supplies and the RF supply are shown in Fig 7 4 2 SUPPLIES 60 1 Power Connections 30VDC 62A ee R fs Ms En AAN FOR EACH POWER SUPPLY MENS 208V 20A SINGLE PHASE fest CE ma 3 0 68 CURRENT SHARE CONTROL CONNECT 5 TO PIN 5 Wire 22 ga white Pin Molex 02 06 2103 Plug Mclex 03 06 2061 Figure 7 4 RF Supply DC Power Supply Interconnection Diagram The BNC terminated cable from the UC 1000 output can be connec
13. 3 OVERTEMP Auxiliary signal to monitor the temperature sensors and the water flow switch No Overtemp 28V Overtemp OV RED LASE LED Auxiliary signal to monitor the state of lasing activity When in active lase mode is a 28V square wave with a duty cycle from 0 5 lus tickle pulse to 95 at 5 kHz VOLTAGE PRESENT Auxiliary signal to monitor externally applied voltage Voltage Applied Vpn 28V No Voltage Vps 0V Auxiliary ground reference point No Connection 5 4 3 DC Power Supply The 57 0 and 57 1 lasers require 55A and 654A respectively at 30VDC recommended operating voltage with dynamic regulation of 4Vp p worst case These specifications can be satisfied using a Synrad DC 100 power supply 5 5 Detailed Setup Procedure 1 Verify the laser head has been properly mounted as described in the Para 5 2 Mounting 2 Using the 30 ft length of the 1 2 polyethylene tubing provided with each RF supply fabricate the necessary lengths to link a the chiller to the laser b the laser to the RF power supply c the RF supply back to the chiller 3 Connect each of the 1 2 x 3 8 reducing unions to the COOLING IN and COOLING OUT ports on the back of the RF supply 4 Connectthe line from the output port of the chiller into the IN port on the cooling manifold of the laser Connect the line from the OUT port on the laser s cooling manifold to the COOLING IN port on the RF supply
14. 4 Lase LED The LASE indicator is a red LED located on the top cover of the laser towards the output end of the housing The LASE LED illuminates to indicate lase mode of operation If the TTL signal is present the red indicator light turns on after a 5 second delay and becomes brighter as the TTL duty cycle is increased This LED is standard on both OEM and Keyswitch versions 3 1 5 Laser Ready LED The LASER READY indicator is a yellow LED located on the top cover of the laser towards the rear of the housing The LASER READY LED illuminates when the laser is ready to lase It indicates the laser is capable of lasing and is awaiting a TTL command signal 3 1 6 Laser 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 0 6 meters or more from the laser The laser beam diverges due to diffraction at a full angle of approximately 4 milliradians with the beam waist at the output aperture of the laser 3 1 7 Mounting of Optical Accessories The front faceplate of Series 57 60 lasers are designed with a 6 hole mounting pattern refer to 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 57 60 options please consult factory for restrictions as exce
15. 5 Detailed Setup Procedure 1 2 Verify the laser head has been properly mounted as described in the Mounting paragraph Using both of the 30ft lengths of of the 1 2 polyethylene tubing provided with both of the RF supplies fabricate the necessary lengths to make the following connections NOTE For best results the lengths from the T union to SET 1 and SET 2 manifolds on the laser must be the same length to insure identical water pressure in each laser tube a the output of the chiller to the T fitting b from one end of the T to the IN port on the SET 1 cooling manifold the other end of the T to the IN port on the SET 2 cooling manifold d the OUT port on the SET 1 manifold to the COOLING IN port on RF supply SET 1 e the OUT port on the SET 2 manifold to the COOLING IN port on RF supply SET 2 f the COOLING OUT port on the RF supply SET 1 to one end of the T at the input port of the chiller g the COOLING OUT port on the RF supply SET 2 to the other end of the T at the input port of the chiller 3 10 11 17 13 14 Connect each of the 1 2 x 3 8 reducing unions to the COOLING IN and COOLING OUT ports on the back of both the RF supplies Connect all the cooling lines as shown in Fig 8 2 After completing all cooling hook ups supply water to the system at the required rate and verify that there is no water leaking from any connection or fitting Turn the water system off C
16. Check Out COCOLI NGH NTEFICICIN 31 PPL Y O40 FETU EN HTTHGS ORE MOUNTED ON THE REAR PANELS OF EACH EF DRIWERE ONO THE LOSER HEUD Figure 6 1 Cooling Interconnection Schematic 37 Ch 6 Model 57 2 Installation and Check Out Figure 6 2 Cooling System Setup 38 Series 57 60 Lasers Operation and Service Manual Ch 6 Model 57 2 Installation and Check Out If it is necessary to operate with cooling water below the dew point precautions need to be taken to assure that no condensation takes place A minimum requirement is to shut off automatic interlock coolant flow whenever the laser is not activated at sufficient power to drive the chassis or head temperature above the dew point Connection of the cooling tubing to the laser is accomplished using the IN OUT connections on each of the cooling manifolds Figure 6 2 The output of the chiller is split using a T fitting and routed as shown in Figure 6 2 to establish a closed loop cooling channel for each laser set The return line from each of the laser sets is combined downstream from the manifold using a second union fitting routed back to the chiller The quick disconnect fittings can be removed from the tubing by compressing the front ring of the fitting against the body of the fitting CAUTION After all water interconnections have been completed turn on the water cooling system to ensure that all connections are secure and there are no
17. Figure 8 1 Cooling Interconnection Schematic 55 Operation and Service Manual Ch 8 Model 60 2 Installation and Check Out Figure 8 2 Cooling System Setup 56 Series 57 60 Lasers Operation and Service Manual Ch 8 Model 60 2 Installation and Check Out If it is necessary to operate with cooling water below the dew point precautions need to be taken to assure that no condensation takes place A minimum requirement is to shut off automatic interlock coolant flow whenever the laser is not activated at sufficient power to drive the chassis or head temperature above the dew point Connection of the cooling tubing to the lasers is accomplished using supply and return manifolds terminated with quick disconnect fittings Fig 8 2 Laser Cooling Kit The quick disconnect fittings can be removed from the tubing by compressing the front ring of the fitting against the body of the fitting CAUTION After all water interconnections have been completed turn on the water cooling system to ensure that all connections are secure and there are no leaks This step must be accomplished before performing electrical connections Series 57 60 Lasers 57 Operation and Service Manual Ch 8 Model 60 2 Installation and Check Out 8 4 System Interconnections Refer to the System Interconnection diagram Fig 8 3 and the following paragraphs to properly accomplish all required connections LASER HEAD g mn our H20 OUT i
18. Suppression Controller C 1 Series 57 60 Lasers Operation and Service Manual List of Figures Figure 1 1 European Compliance Mark ee 5 Figure 1 2 Declaration of 5 Figure 2 1 Average Laser Output Verse Percent Duty 12 Fip re 2 2 Beam oe a Creo tum o edi tu esti tacens 13 Fig re 2 3 Typical TEL Drve Signal uit e ei a a 13 Figure 2 4 Tickle Pulse Output to Laser Controller eee 14 Figure 2 3 Modulation Waveforms qe educa cesis esto qa 14 Figure 3 1 Physical Features Location Diagram Models 57 1 and 60 1 17 Figure 3 2 Physical Features Location Diagram Models 57 2 and 60 2 19 Figure 3 3 57 0 RF Power Supply Physical Features Location 21 Figure 3 4 57 Power Supply Physical Features Location Diagram eese 21 Figure 3 5 60 Power Supply Physical Features Location Diagram eee 22 Figure 5 1 Cooling Interconnection Scheriatle u eiie e tes perte ate as 28 Figure 5 2 Teaser COMM usi ete co base lee Iac atu ataca 29 Figure 5 3 System Interconnection Diagram e rettet 30 Figure 5 4 RF Supply DC 1000 2000 Interconnection Diagram eee
19. Switch The shutter switch is a mechanical shutter that closes the laser aperture Closing the shutter also actuates independent micro switches that temporarily interrupt power to the laser until the shutter switch is opened again The shutter should not be used to partially block the beam or to control output power The shutter is standard on both OEM and Keyswitch versions Series 57 60 Operation and Service Manual Ch 3 Physical Features 3 2 4 Lase LED The LASE indicator is a red LED located on the top cover of the laser towards the output end of the housing The LASE LED illuminates to indicate lase mode of operation If the TTL signal is present the red indicator light turns on after a 5 second delay and becomes brighter as the TTL duty cycle is increased This LED is standard on both OEM and Keyswitch versions There are two LEDs on 57 60 2 lasers one for each of the laser tubes 3 2 5 Laser Ready LED The LASER READY indicator is a yellow LED located on the top cover of the laser towards the rear of the housing The LASER READY LED illuminates when the laser is ready to lase It indicates the laser is capable of lasing and is awaiting a TTL command signal There are two LEDs on 57 60 2 lasers one for each of the laser tubes 3 2 6 Laser Aperture The laser aperture 1s 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
20. an EY EUER e QE Ree E se VIS ene s A 7 54 Series Interconnect Diagram ionn oran vestido A 9 60 Series Interconnect Diagram 11 Schematic 37 cette eiecit evel A 13 Schematic 60 RF Driver ve reete verte eterne teer A 15 iv Series 57 60 Lasers Operation and Service Manual List of Tables Table 1 1 Series 57 60 Safety Features uie EH Ie tete Ee IR TON ERE 3 TTable 1 2 European Union Direeuves zu eee asia 4 Table 2 1 Series 57 Specification Table x oia ceno ml er d d te Dod cS pates 7 Table 22 Senes 60 Specification Table ee s 8 Table 3 1 RF Supply Auxiliary Signal Connector Male DB9 Pin Assignments 23 Table 5 1 RF Supply Auxiliary Signal Connector Male DB9 Pin Assignments 32 Table 6 1 RF Supply Auxiliary Signal Connector Male DB9 Pin Assignments 40 Table 7 1 RF Supply Auxiliary Signal Connector Male DB9 Pin Assignments 50 Table 8 1 RF Supply Auxiliary Signal Connector Male DB9 Pin Assignments 59 Table 10 1 Series 57 60 Troubleshooting 65 Series 57 60 Lasers Operation and Service Manual Introduction Thank you for purchasing a Series 57 60 laser from Synrad Inc The Series 57 60 laser families incorporate the latest developments in sealed carbon dioxide devices
21. block in front of the exit aperture at a distance between 6 inches and 1 foot Set mechanical shutter on laser to the ON open position Set the power switch for the external DC power supply to the ON position Verify green LED on RF power supply illuminates Turn RF power supply keyswitch to ON position and or close the remote interlock Verify yellow LED s on RF power supply and laser head illuminate Set the UC 1000 to MAN manual mode Set UC 1000 POWER ADJ control to MIN and set UC 1000 POWER switch to ON Verify the red power ON LED on the front panel of the UC 1000 illuminates Verify red LASE LED s on the RF power supply and laser illuminate dimly after approximately 5 seconds after keyswitch is set to ON and or remote interlock is closed Slowly rotate UC 1000 POWER ADJ control towards MAX and verify intensity of red LASE LED s on RF power supply and laser head increases as UC 1000 output is increased Series 57 60 Lasers 33 Operation and Service Manual Ch 5 Models 57 0 57 1 Installation and Check Out 11 Measure laser output power using a laser power meter such as Synrad s PW 250 Power Wizard to verify output is consistent with respective power rating for laser model refer to Specification Table or final test report shipped with laser for power ratings 12 Turn off laser power set keyswitch to off or open remote interlock circuit as appropriate 13 Set UC 1000 power switch to OFF 14 Set mechanical shutte
22. cable RG 8 Foam is precisely 1 2 wave long This is electrically equivalent to a direct connection of the laser 1 series 57 60 Lasers Operation and Service Manual Ch 2 Theory of Operation head to the RF supply The 47 inch 50 ohm 1 4 wave transmission lines between the output of the supply serve as 50 ohm 1 4 wave transformers This can be visualized by considering the load to be four 200 ohm plasma sections in parallel driven by four 50 ohm 1 4 wave lines in parallel The input driver splitters are 1 4 wave 50 ohm transmission lines transforming the gate impedance of about 6 ohms to 400 ohms Four of these in parallel result in a 100 ohm port Both drive sections together are then equal to about 50 ohms Over temperature cut out is provided if the laser head or RF chassis temperature exceeds 60 C The over temperature light will illuminate If supply voltage exceeds 40VDC an overvoltage crowbar will short to ground thereby blowing the 15 A fuse F3 This prevents voltage from reaching the control electronics and oscillator circuits The 700W amplifiers have inherent overvoltage protection due to the high voltage breakdown rating of the MRF150 FET s Vdss 2 125VDC A 5 second initial time delay is provided after turning the key switch Protection against reverse voltage is provided by a series diode in the 15A line and also from diodes in series with each RF section DC feed line The driver cannot energize unless the RF cables are plugg
23. combining the best features of both waveguide and free space CO laser technology Combining these innovations with state of the art control electronics and RF power supplies makes Series 57 60 lasers an ideal solution for a wide range of scientific and industrial marking and cutting applications All information necessary to safely operate and maintain the laser is provided in this manual The information is organized in three parts and is arranged as follows Part 1 General Information Chapter Safety and Regulatory Compliance Chapter 2 Theory of Operation Chapter 3 Physical Features Chapter 4 Return for Factory Service Part 2 Installation Check Out Chapter 5 Models 57 1 Chapter 6 Models 57 2 Chapter 7 Models 60 1 Chapter 8 Models 60 2 Part 3 Operation and Maintenance Chapter 9 Operating Instructions Chapter 10 Maintenance and Troubleshooting The information contained in Part 1 and Part 3 is applicable to all models with minor exceptions noted in the text as applicable The information contained in Part 2 is presented in model specific breakdown to provide each user with a complete set of instructions applicable to their particular model In addition to the information contained in the chapters described above supporting data has been provided in several appendices located after Chapter 10 In the event additional information is required for your application please contact Synrad at 1 800 SYNRAD 1 Please read this manual complet
24. connector to provide the user with additional signal information to allow specific aspects of system performance to be monitored The auxiliary connector is a male DB9 connector mounted on the rear panel of each RF power supply refer to the following table for a description of pin assignments If the user intends to take advantage of this feature they must manufacture a connecting cable and then configure its connections for proper operation Table 6 1 RF Supply Auxiliary Signal Connector Male DB9 Pin Assignments NO NAME DESCRIPTION 1 KEYSWITCH ON OFF Auxiliary signal that indicates on off state of keyswitch Key On 28 Key Off Ov LASER RDY Auxiliary signal that indicates Laser Ready to lase operation Laser Ready 28V Not Ready Vpin2 OVERTEMP Auxiliary signal to monitor the temperature sensors and the water flow switch No Overtemp 28V Overtemp OV RED LASE LED Auxiliary signal to monitor the state of lasing activity When in active lase mode is a 28 square wave with a duty cycle from 0 5 lus tickle pulse to 95 at 5kHz DC VOLTAGE Auxiliary signal to monitor externally applied voltage PRESENT Voltage Applied 5 28V No Voltage Vps 0 GROUND 7 8 9 NC 6 4 3 DC Power Supply The 57 2 laser requires 130A at 30VDC recommended operating voltage with dynamic regulation of 4Vp p worst case These specifications can be satisfied using
25. ecei e av Diagram ing ine Mounti 60 1 Outl A 7 Series 57 60 Lasers Operation and Service Manual Documentation endix A Supportin A ATBA3SSV SNIINDION AlBW3SSv ONILNNOW SYJHSYM MVIS IVNYJLNI ONY SL3XOVHB OLW Q3sn FIOK 91A ONILOAId P ONIONS O v 1 v38 z9 vo ve z 2 STOH OLN OS x 027 1 Le cec KIWIS aah at Cos r9 s9z ov oi XOOTH3INI oa Q7104NVN 9N 002 u a 96 7901 00 Zt sva sce 1 29 02 218 AIN NONI 4x3 Wv38 V geviijsoe v W3SVl ANNON OL S310H 9NINDOM S3BIOSSIJOv TWNOUdO ISN LON OQ X NV ZQV4NNS ONILNNON ONY N33M13H 3IlddnS SHJHSVM M IS TWNYJINI ISN t SHON ov ecJoos i vs 0v oos 3 25 02 009 S3ov d 9 310H ANOSS32OY WNOUdO 26 8 fasazjseut 8z vzzi ooz ae cz89zi ee 6v 6192 zezet jer es 3 60 2 Outline Mounting Diagram Series 57 60 Lasers Operation and Service Manual A 8 Appendix A Supporting Documentation Series 57 60 Lasers A 9 Operation and Service Manual Appendix A Supporting Documentation
26. for each of the external DC power supplies to the ON position Verify green LED on each RF power supply illuminates Series 57 60 Lasers S Operation and Service Manual Ch 7 Model 60 1 Installation and Check Out 7 10 11 12 13 14 15 52 Turn RF power supply keyswitch to ON position and or close the remote interlock Verify yellow LED s on RF power supplies and laser head illuminate Set the UC 1000 to MAN manual mode Set UC 1000 POWER ADJ control to MIN and set UC 1000 POWER switch to ON Verify the red power ON LED on the front panel of the UC 1000 illuminates Verify red LASE LED s on the RF power supplies and laser illuminate dimly after approximately 5 seconds after keyswitch is set to ON and or remote interlock is closed Slowly rotate UC 1000 POWER ADJ control towards MAX and verify intensity of red LASE LED s on RF power supplies and laser head increases as UC 1000 output is increased Measure laser output power using a laser power meter such as Synrad s PW 250 Power Wizard to verify output is consistent with respective power rating for laser model refer to Specification Table or final test report shipped with laser for power ratings Turn off laser power set keyswitch to off or open remote interlock circuit as appropriate Set UC 1000 power switch to OFF Set mechanical shutter switch to OFF Turn off external DC power supply Series 57 60 Lasers Operation and Service Manual Chapte
27. leaks This step must be accomplished before performing electrical connections Series 57 60 Lasers 39 Operation and Service Manual Ch 6 Model 57 2 Installation and Check Out 6 4 System Interconnections Refer to the System Interconnection diagram Figure 6 3 and the following paragraphs to properly accomplish all required connections aa L 1 au E ao mS Se F 158 JH 15 daa 98707 ino nzH LIE LL 8 Ln am fores mu Zu I J 13 340 15 EAM Waco gx SBE Dib Series 57 60 Lasers Operation and Service Manual 40 Ch 6 Model 57 2 Installation and Check Out Figure 6 3 System Interconnection Diagram 6 4 1 UC 1000 Power Controller Operation of 57 Series lasers requires an external controller that can provide the necessary TTL drive signal as the modulation source The Synrad UC 1000 Controller has been designed to provide control of the laser output from a remote source The UC 1000 requires 28VDC at 80mA from a wall plug transformer rectifier When connecting the UC 1000 to the RF Power supply a BNC t adapter must be installed on the BNC OUTPUT connector located on the rear panel of the UC 1000 Each of the BNC terminated cables is connected to one of the T s and terminated at the CTRL IN connector of each RF Power Supply 6 4 2 RF Power Supply The 57 2 laser requires 1 RF powe
28. switches are set to OFF Verify all electrical and cooling interconnects have been accomplished Place beam block in front of the exit aperture at a distance between 6 inches and 1 foot Set mechanical shutter on laser to the ON open position Set the power switch for each of the external DC power supplies to the ON position Verify green LED on each RF power supply illuminates cb DY Oe cec op par m Turn RF power supply keyswitch to ON position and or close the remote interlock Verify yellow LED s on RF power supplies and laser head illuminate 8 Set the UC 1000 to MAN manual mode Set UC 1000 POWER ADJ control to MIN and set UC 1000 POWER switch to ON Verify the red power ON LED on the front panel of the UC 1000 illuminates 9 Verify red LASE LED s on the RF power supplies and laser illuminate dimly after approximately 5 seconds after keyswitch is set to ON and or remote interlock is closed 10 Slowly rotate UC 1000 POWER ADJ control towards MAX and verify intensity of red LASE LED s on RF power supplies and laser head increases as UC 1000 output is increased 11 Measure laser output power using a laser power meter such as Synrad s PW 250 Power Wizard to verify output is consistent with respective power rating for laser model refer to Specification Table or final test report shipped with laser for power ratings 12 Turn off laser power set keyswitch to off or open remote interlock circuit as appropriate 13 Set UC
29. 1 Plasina Secti ri i seg Lese detec repeteret t onte ip letting 11 2 3 2 Optical Resonatot neenon 12 24 Taser Power uen deco ibas aaa Mag ds dus 13 24 Feke Pile niti tte eene en erect a 13 2 4 2 PWM Clock Fregen yen nnion entria nennen enne enr 14 2 4 3 Low Frequency On Off Pulsing esee enne 15 2 5 Duo Lase0 Operation utet ua tees ei ler deco re eve ERA TUA UR CUN Dea 15 3 Physical Features uso uenia durer RR Eu aoo geet dos 17 3 1 Laser Head Models 57 1 and 60 1 17 SM REMI EN 17 351 2 IntetloCk etie rte e e eet ots 17 3 L3 Shutter Switch cae eee t eene eee EAE E deeds aoe 18 32 L4 Lase EBD eect ets ce tierna eere EA 18 3 1 5 LED tete Here e ERI HEP SEN Een 18 3 1 6 Laser Apert te 1 ene ertet epe 18 3 1 7 Mounting of Optical Accessories 18 5 1 8 Goolmg Manitold 18 3 2 Laser Head Models 57 2 60 2 sescenti 18 DRI E 18 3 22 InterloCK e re tre tti mee e e a e PR I ded EE E ERR 19 3 2 3 Shutter SWItCh reset ete entities et eode oe ONE eH eek CPP 19 3 24 Case LED pee ab pee tuse pets 20 3 2 5 Laser Ready EBD net tree eee tere tree idet ea 20 3 2 6 Laser Apert te te RR EE EL ERE hi eee eta 20 3 2 7 Mounting of Optical Accessories seen 20
30. 3 2 8 Cooling i ae SU Rer aet ete tes 20 Series 57 60 Lasers Operation and Service Manual Table of Contents Continued 3 3 Power Supply Physical Features dietus tee ie vss drap 20 22 3 3 2 lock nii AIL ee Ea 22 3 3 3 Remote Interlock eret e 22 3 3 4 9 1 amp i i 22 3 3 PTL Control Input au cedi etit ete eerte ce eiie pectet ea 23 3 3 0 DC Power Input oerte ted 23 3 3 7 DC Input Voltage Available LED esee 24 3 3 8 Lease LED teh roe ae ee reus 24 3 39 Ready EBD oeste aee Eee see eb ee 24 3 3 IO Cooling LED e enn HR pete cg HERE eH 24 3 3 11 Fuse Series 57 RF Power Supply Only eee 24 3 3 12 Circuit Breaker Series 60 RF Power Supply Only 24 4 Return for Factory Service 25 5 Models 57 1 Installation and Check Out 27 5 1 Unpackmg Initial Inspection eeicaseseei esce stan oeste eh nne in tane ati nette epe reads 27 2 2 AQUINAS 225 3 hele dipped 28 5 3 Cooling Requirements and Interconnections 28 31 5 ystem Inter COMME CHIOMS sos 30 5 4 1 UC 1000 Power Controller eese enne 31 342 RE Power Supply recie nit
31. 31 Figure 6 1 Cooling Interconnection Scliematic eie tpe erre oda Bana 36 Lip re 0 2 Cooling Systemi Set p dp dude erae Re URDU 37 Drgure 6 5 Laser Cooling ii eo e S 38 Figure 6 4 System Interconnection Diagram iiec eet deed tod ede tua eec d aede 39 Figure 6 5 RF Supply DC 1000 2000 Interconnection Diagram eee 40 Figure 7 1 Cooling Interconnection Sc We matic 46 Figure 7 2 Laser Cooling It oor aue 47 Figure 7 5 System Interconnection Diagram o n ceret eec agenda ede ee ane ced 48 Figure 7 4 RF Supply DC 1000 2000 Interconnection Diagram ee 49 Figure 8 1 Cooling Interconnection Scliematie eee edicuqe ate 54 Bisiire 8 2 Cooling System 55 Figure S S baser Kit Leia pet abet 56 Figure 8 4 System Interconnection Diagram datore dac UL ease caca 57 Figure 8 5 RF Supply DC 1000 2000 Interconnection Diagram eee 58 57 1 and 60 1 Label Location Diagram soo e pot or i MR ND e Seen uti ihre ns br ON FUHR A 2 57 2 and 60 2 Label Location Diagram A 3 57 1 Outline Mounting Diagram rto le ade aie Bode eae A 4 57 2 Outline Mounting Diagram ies oerte epe erre a aUe on pne etr Y e ue eee eu ud A 5 60 1 Outline Mounting Diagram Ae reae d ei A 6 60 2 Outline Mounting Diagram 5 eren ere dea Saee Reed
32. A Supporting Documentation Series 57 60 Lasers A 13 Operation and Service Manual Appendix A Supporting Documentation 60 Series Interconnect Diagram A 14 Series 57 60 Lasers Operation and Service Manual Appendix A Supporting Documentation Series 57 60 Lasers A 15 Operation and Service Manual Appendix A Supporting Documentation A 16 Series 57 60 Lasers Operation and Service Manual Appendix A Supporting Documentation Schematic 57 RF Driver Series 57 60 Lasers A 17 Operation and Service Manual Appendix A Supporting Documentation A 18 Series 57 60 Lasers Operation and Service Manual Appendix A Supporting Documentation Series 57 60 Lasers A 19 Operation and Service Manual Appendix A Supporting Documentation Schematic 60 RF Driver A 20 Series 57 60 Lasers Operation and Service Manual Series 57 60 Laser Operation and Service Manual Appendix B UC 1000 Laser Controller Series 57 60 Lasers B Operation and Service Manual Appendix B UC 1000 Laser Controller UC 1000 Laser Controller The UC 1000 was designed to serve as a general purpose interface between user signals and Synrad s complete line of lasers For additional information consult the UC 1000 manual ay f POWER ADJ POWER STBY MIN GO LASER COHTROLLER Front Panel OFF CL ADAPTOR PUA Z WDC Rear Panel UC 1000 Power Controller UC 1000 Operating Modes The
33. C is the sole directive developed to address EMI issues in electronic equipment In particular the directive calls out European Norm EN documents which define the emission and immunity standards for specific product categories For Series 57 60 lasers the standard EN55011 defines the radiated RF emissions limit The generic standard EN50082 1 defines immunity requirements published by the International Electrotechnical Commission IEC Refer to Table 1 2 for a summary of EU performance requirements pertaining to Series 57 60 lasers Table 1 2 European Union Directives DIRECTIVE SCOPE PROVISION EN55011 Limits and methods for measurement of radio Emitted RF Radiation shall not exceed limits frequency disturbance characteristics for industrial described in document CISPR11 scientific and medical ISM equipment EN50082 Generic standard governing ISM performance relating Immunity to electrostatic discharge levels to radiated emissions and ESD sensitivity and defined in document IEC801 Part 2 frui to anie DIESES Equipment shall operate normally when exposed to RF emissions at levels described in document 801 Part 3 Immunity to electrical fast transient bursts at levels defined in document IEC801 Part 4 Series 57 60 Lasers Operation and Service Manual Ch 1 Safety and Regulatory Compliance After a product has met the requirements of all pertinent EU directives the product can bear the official complianc
34. Connect the line from the COOLING OUT port on the RF supply to the input port on the chiller Series 57 60 Lasers Operation and Service Manual Ch 5 Models 57 0 57 1 Installation and Check Out 10 After completing all cooling hook ups supply water to the system at the required rate and verify that there is no water leaking from any connection or fitting Also verify that flow rate is sufficient to keep the cooling LED from illuminating Turn the water system off Connect the RG 8 RF coax cables between the RF driver RF1 and connectors and laser RF1 and RF2 connectors respectively On 57 0 connect the RG 8 RF coax cable between the RF driver connector RF1 and the splitter on the back of the laser head Install the DB9 terminated interlock cable between laser head and the RF driver Connect the DC power supply to the RF driver as shown in the RF Supply DC Power Supply Interconnection diagram Fig 5 4 Install the BNC terminated cable between the OUTPUT connector on the rear panel of the UC 1000 and the CTRL IN connector on the RF Driver either front or rear panel 5 6 Turn On Check Out WARNING Harmful laser radiation is emitted through the laser exit aperture when performing the following procedure SU Oy rer Suns tubas ces 10 Verify UC 1000 POWER and external DC power supply switches are set to OFF Verify all electrical and cooling interconnects have been accomplished Place beam
35. F power supply refer to the following table for a description of pin assignments If the user intends to take advantage of this feature they must manufacture a connecting cable and then configure its connections refer to Table 8 1 for proper operation Table 8 1 RF Supply Auxiliary Signal Connector Male DB9 Pin Assignments NO NAME DESCRIPTION 1 KEYSWITCH ON OFF Auxiliary signal that indicates on off state of keyswitch Key On 28 Key Off Ov LASER RDY Auxiliary signal that indicates Laser Ready to lase operation Laser Ready Vpin2 28V Not Ready Vei OVERTEMP Auxiliary signal to monitor the temperature sensors and the water flow switch No Overtemp 28V Overtemp OV RED LASE LED Auxiliary signal to monitor the state of lasing activity When in active lase mode Vpm4 is a 28V square wave with a duty cycle from 0 5 lus tickle pulse to 95 at 5kHz DC VOLTAGE PRESENT Auxiliary signal to monitor externally applied voltage Voltage Applied Vpn 28V No Voltage Vps 0V GROUND 7 8 9 NC 8 4 3 DC Power Supply ER The 60 2 laser requires a total of 190A at 30VDC recommended operating voltage with dynamic regulation of 4Vp p worst case These specification can be satisfied using three Synrad DC 100 30VDC power supplies adjusted to within 0 01V of each other 60 Series 57 60 Lasers Operation and Service Manual Ch 8 Model 60 2 Installation and Check Out 8
36. MP Auxiliary signal to monitor the temperature sensors and the water flow switch No Overtemp 28V Overtemp OV RED LASE LED Auxiliary signal to monitor the state of lasing activity When in active lase mode Vpm4 is a 28 square wave with a duty cycle from 0 5 lus tickle pulse to 95 at 5kHz DC VOLTAGE PRESENT Auxiliary signal to monitor externally applied voltage Voltage Applied 28V No Voltage Vps 0V GROUND Auxiliary ground reference point 7 8 9 NC 6 7 4 3 DC Power Supply The 60 1 laser requires 95A at 30VDC recommended operating voltage with dynamic regulation of 4Vp p worst case These specifications can be satisfied using two Synrad DC 100 power supplies adjusted to within 0 01V of each other 30 Series 57760 Lasers Operation and Service Manual Ch 7 Model 60 1 Installation and Check Out 7 5 Detailed Setup Procedure 10 Verify the laser head has been properly mounted as described in Para 7 2 Mounting Using the 30 ft length of the 1 2 polyethylene tubing provided with each RF supply fabricate the necessary lengths to link a the chiller to the laser b the laser to the RF power supply c the RF supply back to the chiller Connect each of the 1 2 x 3 8 reducing unions to the COOLING IN and COOLING OUT ports on the back of the RF supply Connect the line from the output port of the chiller into the IN port on the cooling manifold of the laser Conne
37. No significant power increase occurs above 95 duty cycle LASER OUTPUT POWER ARBITRARY SCALE 50 100 DUTY CYCLE Figure 2 1 Average Laser Output Verse Percent Duty Cycle 2 3 2 Optical Resonator Series 57 60 lasers feature a three bore folded design within a laser tube length of 34 5 inches 0 86m for 57 Series and 41 5 inches 1 0m for the 60 Series This results in an effective resonator length of 99 inches 2 5m for the 57 Series and 119 inches 3 0m for the 60 Series This Z fold design requires 4 optical elements for the three bores as depicted in Fig 2 2 The optical resonator consists of three reflectors each with a 5 meter radius of curvature total reflector and a flat ZnSe output coupler with a reflectivity of 65 The mirrors are held on with Viton fluorocarbon elastomeric o rings for factory adjustment by means of three alignment screws No epoxy is used for sealing The screws are secured by adhesive after alignment The bore size 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 The beam shape is square at the laser output aperture changing to circular at distances of approximately 0 6 meter or more from the laser The la
38. OW Oi 5310 ONILNNOW S3lHOSS32Ov TVNOlidO JSN LON SH3HSVM 15 IVNH31NI ONY SL330V8H OLA 0351 3l 3OVJH S ONILNNOW ONY N33M138 G3MddNS SN3HSVM 3viS TWNH3INI ISN t 53109 99 AIGWASSY ONILNNOW A IBWN3SSV ONILNAOW 9 wI OZ v t 01 96 81 9 52 1 1 a Dieselosv t 61 112 e56 22 8r oc1 ez is INONJ oves rz soz Joos OOTYSLNI Q303INVA 9NI1002 l3xOvHBH ONILNNOW TX nyag 7 59 96 3 8e 82 s2 i1 Ny 53014 9 cree 005 1 976145 2 1 9 6 6 v907 009 i pas 166 00 6 vso1 S tv 57 1 Outline Mounting Diagram A 5 Series 57 60 Lasers Operation and Service Manual Documentation endix A Supportin A ISV INNON OL S310H ONILNNON S3lJOSS302v wNOIdO 3SN LON OO NV Alewassy SH3HSVM tNIS TYNUGLN ONY 13908 OUN HUM 5 41 NEZ NUN TON SNINDOR 73Ov4HDS 9NIINDOA ONY Ni3138 O3rlddnS SYIHSYM 915 VNHiINI i SION OLN DNLOAd ONIGIIS OZ v L LOS Up d g d NIS N e x mas s N 9 99 96 eb Ae tad j oz DM 1 Irsa d i
39. UC 1000 operating modes are selectable by means of a front panel six position rotary switch The operating modes are as follows Standby this mode only the 1 usec wide tickle pulse is generated This tickle signal allows the laser plasma to be ionized without resulting in emission Closed Loop Low Gain CCL Closed loop operation of the laser can provide better than 2 power stability This is achived by splitting a portion of the outgoing laser power to a thermo pile B 2 Series 57 60 Lasers Operation and Service Manual Appendix UC 1000 Laser Controller detector The amplified signal is compared against a reference and regulates the output duty cycle pulse width Reference level is established by a front panel mounted power control potentiometer Operation in the closed loop mode requires 48 CL laser mounted power sensor The 48 CL can be user added in the field to any Series 48 laser Closed Loop High Gain CLH Same as CCL but with higher internal gain Remote Current Control ANC In this mode a 4 20 mA DC current is applied to the UC 1000 at J5 It controls laser power between zero and maximum This is the standard industrial control interface allowing loop supervision Input impedance is low Remote Voltage Control ANV In this mode a 0 to 10VDC voltage controls power between zero and maximum This is high impedance input Manual Mode MAN Laser power control is accomplished with a front panel mounted potent
40. ally received Date returned RA Serial Describe reason for repair Should you need to return a laser for repair please call SYNRAD for an RA at 800 SYNRAD 1 Series 57 60 Lasers Operation and Service Manual Chapter 5 Models 57 0 57 1 Installation and Check Out 5 1 Unpacking Initial Inspection Do not discard the shipping container or the foam packing since these are required if the laser is ever returned to Synrad for factory service The 57 0 57 1 laser head and all required support equipment are packaged and shipped in individual containers as indicated below in bold face type In addition some of the containers will also include support materials required to install and operate the laser The support materials included in a particular container are also listed below Open each shipping container individually Place the container on a sturdy level surface and open the top of the box Carefully remove the equipment from the container and remove the outer bam packing material Verify that the associated support material items are included Laser Head Container 1 Each One 57 Series Laser Head Operation and Service Manual Warranty Registration Card Final Test Data Report RF Supply Container 1 Each One RF Power Supply Two RG 8 Coax RF Cables 5 meters in length one for 57 0 One DB9 terminated Interlock Cable One pair of DC Power Cables pair cons
41. analog voltage a digital to analog D A 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 both configurations 64 Series 57 60 Lasers Operation and Service Manual Chapter 10 Maintenance and Troubleshooting Table 10 1 Series 57 60 Troubleshooting Table FAULT PROBABLE CAUSE Laser beam is off Check power source key switch and optical 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 tube excitation Check fuses If laser is warm allow it to cool and recycle source power to see if the thermal cutout was activated Check for proper input signal Laser does not operate unless an input signal to the CTRL jack is present Return key switch to Off position for a few seconds or recycle source power to reset circuits Tf laser tube will not start factory servicing of laser may be required Laser power is low Check waveform of TTL signal if modulation is used Check input voltage level is appropraite for particular laser Use mode screen ceramic tile can be used to verify circular optical beam shape at a distance of 3 to 5 feet from laser If beam spot is not circular and stable the optical mirror alignment is out of adjustm
42. approximately 0 6 meters or more from the laser The laser beam diverges due to diffraction at a full angle of approximately 4 milliradians with the beam waist at the output aperture of the laser 3 2 7 Mounting of Optical Accessories The front faceplate of Series 57 60 lasers are designed with a 6 hole mounting pattern refer to 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 57 60 options please consult factory for restrictions as excessive weight may cause damage to the laser 3 2 8 Cooling Manifold The only configuration for the IN OUT connections on the cooling manifold is on the front of the manifold There is one connector in and one connector out with the right angle fittings pointing the cooling lines down NOTE The only configuration location for the inflow outflow connections on the 57 60 2 series is stated above The noted alternate location for the 57 60 1 series will NOT work for the 57 60 2 series 3 3 RF Power Supply Physical Features Series 57 60 lasers require an external RF Power Supply to provide the necessary RF excitation for the laser plasma The model of RF supply and the number of supplies required depends upon your particular laser model as follows Laser Model RF Supply Model Quantity Required 57 0 57 0 1 57 1 57 RF 1 57 2 57 RF 2 60 1 60 RF 1 lo
43. ar panel mounted front only on 57 0 BNC CTRL IN connectors These connectors are electrically common and are duplicated as a matter of convenience for the user The interlock cable should be connected between the male DB9 connector on the rear panel of the laser head and the female DB9 connector located on the rear panel of the RF power supply To prevent improper connection it is recommended that the interlock cable be connected first to the laser and then the RF Power Supply The RF Power Supply also provides an auxiliary signal connector to provide the user with additional signal information to allow specific aspects of system performance to be monitored The auxiliary connector is a male DB9 connector mounted on the rear panel of the RF power supply refer to the following table for a description of pin assignments If the user intends to take advantage of this feature they must manufacture a connecting cable and configure its connections refer to Table 5 1 for proper operation Series 57 60 Lasers 31 Operation and Service Manual Ch 5 Models 57 0 57 1 Installation and Check Out Table 5 1 RF Supply Auxiliary Signal Connector Male DB9 Pin Assignments NO NAME DESCRIPTION 1 KEYSWITCH ON OFF Auxiliary signal that indicates on off state of keyswitch Key On Ves 28 Key Off Vein Ov 2 LASER RDY Auxiliary signal that indicates Laser Ready to lase operation Laser Ready Vpin2 28 Not Ready Vpn
44. atic If it is necessary to operate with cooling water below the dew point precautions need to be taken to assure that no condensation takes place A minimum requirement is to shut off automatic interlock coolant flow whenever the laser is not activated at sufficient power to drive the chassis or head temperature above the dew point Connection of the cooling tubing to the laser is accomplished using the IN OUT connections on the coolin manifold Fig 7 2 Laser Cooling Kit The quick disconnect fittings can be removed from the tubing by compressing the front ring of the fitting against the body of the fitting CAUTION After all water interconnections have been completed turn on the water cooling system to ensure that all connections are secure and there are no leaks This step must be accomplished before performing electrical connections of ud 2 bom gor F wt Pen e p 0 SF o 5 2 CSS DESCRIPTION FITTING REDUCING UNION 1 2 8 2 FITTING STRAIGHT 1 2 NPT 3 8 THREADED Figure 7 2 Laser Cooling Kit Series 57 60 Lasers 47 Operation and Service Manual Ch 7 Model 60 1 Installation and Check Out 7 4 System Interconnections Refer to the System Interconnection diagram Fig 7 3 and the following paragraphs to properly accomplish all required connections LASER HEAD H20 OUT DEB T a LL m 2 e Ut 30060 Figure 7
45. ating Instructions 9 1 General The operating instructions provided in this section are based on the use of a Synrad UC 1000 Laser Controller If using an alternate method of laser control please consult the factory for information regarding key aspects of laser operation 9 2 Operation in Pulsed Mode In applications such as marking and cutting the laser is required to pulse on and off in sync with an external pulsing control signal typically from a computer or function generator operating in the range from 0 to 20kHz To operate the laser in pulsed mode perform the following procedure 1 Perform the detailed setup procedure in the appropriate chapter of Part 2 for your particular laser model 2 Set the UC 1000 front panel mode switch to MAN manual mode 3 Adjust the UC 1000 front panel POWER ADJ control to the desired power level If a duty cycle of 100 is required consut factory for modification instructions 4 Connect the pulsing control signal to the GATE connector on the rear panel of the UC 1000 5 The laser system is now configured to operate in the pulsed mode As the control signal pulses TTL high 23 5 VDC the UC 1000 will turn the laser on at a power level corresponding to the UC 1000 POWER ADJ switch setting When the control signal pulses TTL low 0 5 VDC the UC 1000 output duty cycle will approximate OV and will force the laser to turn off 9 3 Operation in Continuous Wave CW Mode In some app
46. cal Input 30VDC 55A 30VDC 65A 30VDC 130A Cooling Heat Load Maximum 2000 2000 4000 Flow Rate 2 GPM 70 psi 2 GPM 70 psi 4 GPM 70 psi Temperature 18 20 C 18 20 C 18 20 C Weight Head 30 Ib 13 6 kg 30 lb 13 6 kg 70 Ib 31 8 kg RF Power Supply 20 lb 9 1 kg 29 Ib 13 2 kg 29 Ib 13 2 kg Dimensions L x W x H Head inches 37 75 x 643 x 4 64 37 75 x 643 x 4 64 41 75 x 10 46 x 6 58 millimeters 1238 25 x 265 68 x 166 62 958 85 x 163 32 x 117 86 1060 45 x 265 68 x 167 13 RF Supply inches 12x13x 8875 12x 19x 8 875 12x 19x 8 875 millimeters 304 8 x 3302 x 225 43 304 8 x 482 6 x 225 43 304 8 x 482 6 x 225 43 1 The output power level is guaranteed for 12 months regardless of operating hours 2 Typical value for 100 200 us pulse width at 596 duty cycle 3 One RF Power Supply required for Model 57 1 two RF Power Supplies required for Model 57 2 4 If rubber feet installed add 0 02 in 0 51 mm to height dimension when shutter switch is closed and 1 0 in 25 4 mm when shutter switch is open Series 57160 Lasers 35 Operation and Service Manual Ch 2 Theory of Operation Table 2 2 Series 60 Specification Table MODEL CHARACTERISTICS a Wavelength 10 59 microns Power Output po o im Power Power Stability Modulation Optical To 5 kHz Response Electrical Control TTL input 3 5V to 20 kHz Electrical Input 30VDC 95A 30VDC 190A Cooling Heat L
47. ct the line from the OUT port on the laser s cooling manifold to the COOLING IN port on the RF supply Connect the line from the COOLING OUT port on the RF supply to the input port on the chiller see Fig 7 2 After completing all cooling hook ups supply water to the system at the required rate and verify that there is no water leaking from any connection or fitting Also verify that flow rate is sufficient to keep the cooling LED from illuminating Turn the water system off Connect the RG 8 RF coax cables between the RF driver RF1 and RF2 connectors and laser RF1 and RF2 connectors respectively Install the DB9 terminated interlock cable between laser head and the RF driver Connect the DC power supplies to the RF driver as shown in the RF Supply DC Power Supply Interconnection diagram Install the BNC terminated cable between the OUTPUT connector on the rear panel of the UC 1000 and the CTRL IN connector on the RF Driver either front or rear panel 7 6 Turn On Check Out WARNING Harmful laser radiation is emitted through the laser exit aperture when performing the following procedure SEC uper pupa ccs Verify UC 1000 POWER and external DC power supply switches are set to OFF Verify all electrical and cooling interconnects have been accomplished Place beam block in front of the exit aperture at a distance between 6 inches and 1 foot Set mechanical shutter on laser to the ON open position Set the power switch
48. d 33725 43371 JOS AWOL aio ze H35v1 L23HHO7H3LHI J4 0 25 83A 4C irae Figure 5 3 System Interconnection Diagram Series 57 60 Lasers Operation and Service Manual 30 Ch 5 Models 57 0 57 1 Installation and Check Out 5 4 1 UC 1000 Power Controller Operation of 57 0 57 1 lasers requires an external controller that can provide the necessary TTL drive signal as the modulation source The Synrad UC 1000 Controller has been designed to provide control of the laser output from a remote source The UC 1000 requires 28VDC at 80mA from a wall plug transformer rectifier When connecting the UC 1000 to the RF Power supply BNC OUTPUT connector located on the rear panel of the UC 1000 is connected to CTRL IN connector of the RF Power Supply using a BNC terminated cable 5 4 2 RF Power Supply The 57 0 57 1 laser requires 1 RF power supply for the laser The RF power supply delivers a total of 500W 57 0 1kW 57 1 of RF through two RG 8 type coax cables one for 57 0 Operation is on the authorized ISM frequency of 40 68MHz Electrical interconnections between the regulated DC power supply and the RF supply is shown in Fig 5 4 i 574 Power Connections 30VDC 80A S Se v x EN 208V 20A SINGLE PHASE Figure 5 4 RF Supply DC Power Supply Interconnection Diagram The BNC terminated cable from the UC 1000 output can be connected to either the front or re
49. e overshoot of laser power for each low frequency turn on pulse For applications where this overshoot is unacceptable Synrad s SSC 1000 Spike Suppression Controller can be used instead of the UC 1000 For more information consult the SSC 1000 data sheet provided in Appendix C In lieu of using either Synrad controller an external function generator may be used to generate the required pulses However please consult the factory for additional information concerning technical requirements associated with operating Synrad lasers with a function generator 2 5 Duo Lasee Operation The 57 2 and 60 2 lasers combine two standard sealed laser tubes to provide a single diffraction limited beam at twice the output power All power and control functions between the two laser sections are totally independent essentially achieving fail safe operation for applications that can be served with the power of one laser Any one electronic or laser tube failure will only affect that section leaving the second channel unaffected and available for temporary use 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 colinear The normal temporal and spatial variations of a single laser are reduced by combining the output of two lasers Output polar
50. e Eee etc eret 31 DAS DC 100055 irit tt ieri e peti o kag aed ees 32 9 2 Detailed Setup PEOCGUUFE 32 3 0 33 6 Models 57 2 Installation and 35 6 1 Unpacking Initial Inspector enden decern dd petiit 35 OVAL oto o APER 36 6 3 Cooling Requirements and Interconnections eee 36 6 4 System Interconnections 39 6 4 1 UC 1000 Power Controller esee 40 6 4 2 RE Power Supply eter te enter eie HERE ee atte 40 6 4 3 DC 20005 Li ueste tre REC EHE M OUI e eR Mt eo ue EHE ERU 41 6 5 Detailed Setup PEOCGUUFGS e D M ted 42 6 6 T rn On Check Qut 43 7 Model 60 1 Installation and 45 7 1 Unpacking Initial oat eflet 45 T2 Monno names ido Unt an do ec base eae Darm M setas 46 7 3 Cooling Requirements and 46 T A System are oue 48 7 4 1 UC 1000 Power Controller eese 49 T 4 2 Power Supply uie eb tos HER EU eet aaa 49 ii Series 57 60 Lasers Operation and Service Manual Table of Contents Con
51. e mark of the European Union depicted in Fig 1 1 MADE IN UE Figure 1 1 European Compliance Mark Series 57 60 lasers have demonstrated performance characteristics that have met or exceeded the requirements of the EMC directive 89 336 EEC 1 3 Declaration of Conformity A Declaration of Conformity is provided refer to Fig 1 2 to certify that EMC performance levels of DECLARATION OF CONFORMITY Applicable EU Directive s 89 336 EEC EMC Directive Applicable Standards Norms EN5501 1 Radiated Class A Group 1 EN50082 1 Generic Immunity IEC801 2 Electrostatic Discharge IEC801 3 HF Radiated IEC801 4 Fast Transients Manufacturer Synrad Inc 6500 Harbour Heights Parkway Mukilteo WA 98275 Model Number Serial Number Date of Compliance Compliant Unit 57 1 ENG 57 1 1 9 20 95 57 2 ENG 57 2 1 9 29 95 60 1 ENG 60 1 1 12 4 95 60 2 ENG 60 2 1 10 15 95 Synrad Inc hereby declares that the equipment specified above conforms to the above Directive s and Standard s Series 57 60 lasers are compliant with applicable EU directives and standards Series 57 60 Lasers 5 Operation and Service Manual Ch 1 Safety and Regulatory Compliance Figure 1 2 Declaration of Conformity 1 4 Warning Labels Placards Each Series 57 60 laser is 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
52. ed in at both ends Overcurrent protection is provided for each 700W output stage Overcurrent can be generated during the time that it takes the plasma to fire If a tube does not fire this current may be 60 A or more for each stage Protection is provided by a magnetic reed switch sensing currents in excess of the normal current of 45 A per output stage Overcurrent will remove RF drive from the output stage by releasing the control relay The circuit will recycle every second thereby limiting dissipation of the output transistors The remote interlock connection 4 terminal strip on the rear of the RF supply allows remote shut down of the laser It is necessary to reset the key switch to restore operations In addition an auxiliary signal interface connector is provided to allow access to fault and monitoring signals refer to Section 3 4 3 for more information 2 3 Description of Physical Operation Each laser tube consists of an RF excited plasma tube with two adjustable mirrors on each end mounted together with the RF drive assembly in an aluminum chassis 2 3 4 Plasma Section A 57 60 Series laser consists of the laser head and an external RF power supply The laser head contains one or two extruded aluminum tubes in which the lasing action takes place This is the source of laser power More than 10 of the RF power is transferred into the laser power in this process The Z folded plasma tube of Synrad s 57 60 Series lasers is compr
53. ely 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 Series 57 60 Lasers 1 Operation and Service Manual Chapter 1 Safety and Regulatory Compliance 1 1 CDRH Requirements Safety Features Series 57 60 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 imposing 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 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 v
54. ent See below If laser power is below specification laser gas may need to be replaced or one of the drivers is defective Contact factory Laser spot is not circular The optical mirrors are adjusted at the factory to give a TEMoo output or does not stay circular beam that is 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 No attempt should be made to realign the laser Return to factory Laser power is intermittent 1 Verify that the UC 1000 controller or equivalent has tickle pulses of or varies in response to proper duration Refer to Chapter 2 input pulses Series 57 60 Lasers 65 Operation and Service Manual Ch 10 Maintenance and Troubleshooting 66 Series 57 60 Lasers Operation and Service Manual Appendix A Supporting Documentation List of Supporting Documentation Figure Title 57 0 57 1 and 60 1 Label Location Diagram eene 57 2 and 60 2 Label Location Diagram ve e Etude 57 1 Outline Mounting Diagram adt ee oneness 57 2 Outline Mounting Diagram 60 1 Outline Mounting Diagram eese enne enne enne enne enne enne 60 2 Outline Mounting Diagram Seo Uh or b DR s UMS SU Series Interconnect Dia srar 60 Series Interconnect Diagram Obr Ei puro ossa Ven
55. f 5kHz has proven to work well Since the laser output follows the clock input with a time constant of 100 the laser output cannot precisely follow the TTL input beyond clock frequencies of 5kHz with a duty cycle greater than 50 5kHz 1 100us x 50 However for applications that cannot tolerate the on off nature of optical beam response but still need adjustable power levels it is recommended to use clock frequencies up to 20kHz At 20kHz the optical response no longer follows the TTL input and is very nearly DC value with just a small amount of ripple present Typically the depth of modulation defined as the peak to peak waveform value divided by the peak value at 50 duty cycle is 90 to 100 at 2kHz and 60 to 80 at 5kHz Refer to Fig 2 5 for waveforms For high speed applications that require a clock frequency beyond 20kHz consult the factory for more information TH orga Damm uen Prag Ch Fra z DDZHHzr 4 008HH Low gnal Low ggn amplitude amplliud Oh Duy Oh Du a 49 495 095 Low ggn mmplldudm mmpildud iUm cc iwo Chip 100m TEN Z4 PAO Che 720m v 2 HHz Modi ation 6 KHz ation 14 Series 57 60 Lasers Operation and Service Manual Ch 2 Theory of Operation Figure 2 5 Modulation Waveforms 2 4 3 Low Frequency On Off Pulsing If the user wishes to pulse the laser on and off at low frequencies 500Hz a standard UC 1000 controller set at 3kHz or 5kHz produces a spik
56. figuration is recommended to secure the laser head to the mounting surface refer to Outline and Mounting diagram for dimensions of mounting holes There are two brackets attached to the bottom of the laser housing The front bracket is a floating position that prevents any thermal expansion from resulting in longitudinal bending movements The rear bracket is a fixed position Three 1 4 x 20 screws or bolts and three No 10 star washers are required to properly secure the laser head to the mounting surface Ensure that no loads are applied to the laser head between the mounting points Refer to Appendix A for appropriate outline mounting diagram 5 3 Cooling Requirements and Interconnections CAUTION Condensation and water damage can occur if cooling water is below dew point The laser tube and RF supply share the same cooling loop as shown in the cooling interconnection schematic in Fig 5 1 The laser should be operated with cooling water below 25 C only Ideal temperature for the cooling water is from 18 C to 20 C provided that the temperature is above the dew point Minimum flow rate is 2 gallons per minute GPM to achieve turbulent flow with pressure 70 pounds per square inch psi Synrad recommends a closed loop chiller Neslab CFI 75D be used to provide a capacity of up to 2kW for operation at maximum duty cycle Series 57 60 Lasers Operation and Service Manual Ch 5 Models 57 0 57 1 Installation and Check Out RF dU PPL
57. ght Reducing Unions 1 2 X 3 8 Two 30 Foot Rolls Polyethylene 1 2 inch Black Tubing Four 3 inch Sections Polyethylene 3 8 inch Black Tubing 2 X NPT x 1 2 Fittings for Chiller Connections Mounting hardware Four No 10 star washers included in only one of the RF Supply containers Regulated DC Power Supply 2 Each Optional Power cord not included UC 1000 Recommended Accessory One UC 1000 Power Controller Two BNC terminated coax cables Series 57 60 Lasers 35 Operation and Service Manual Ch 6 Model 57 2 Installation and Check Out One BNC T connector 115VAC Wall Plug Transformer Inspect each equipment item for any visible signs of shipping damage Contact Synrad if the laser housing is damaged or if any of the required materials labels or placards are missing 6 2 Mounting The recommended mounting orientation for 57 Series 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 laser is to be mounted in a vertical orientation Securing the laser head assembly to a bench or structure must take into consideration thermal effects between the laser head and the mounting structure Additionally the mounting system should not create physical stress on the laser head A three point securing configuration is recommended to secure the laser head to the mounting surface refer to Outline and Mounting diagram for dimensions
58. h the following current ratings Fuse Quantity Model and Rating 57 0 1 15A 1 40A 57 1 1 15A 2 40 57 2 2 15 4 40 60 1 1 15A 60 2 2 15A 3 3 12 Circuit Breaker Series 60 RF Power Supply Only Due to the high current requirements of 60 Series lasers a circuit breaker is used in place of the 40A fuses 3 3 13 UC 1000 Power Connector 57 0 Only This connector provides an optional DC power source for the UC 1000 Current is limited by a 500 resistor in series with the line 24 Series 57 60 Lasers Operation and Service Manual Chapter 4 Return for Factory Service In the event the Series 57 60 Laser requires return for factory service Synrad must be contacted prior to shipment of the laser for a return authorization 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 Brief 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 57 60 Lasers 25 Operation and Service Manual Ch 4 Return for Factory Service SERVICE REQUEST Company Name Contact Name Company Address Telephone Fax Date origin
59. housing The front bracket is a floating position that prevents any thermal expansion from resulting in longitudinal bending movements The rear bracket is a fixed position Three 1 4 x 20 screws or bolts and three No 10 star washers are required to properly secure the laser head to the mounting surface Ensure that no loads are applied to the laser head between the mounting points Refer to Appendix A for appropriate outline mounting diagram 7 3 Cooling Requirements and Interconnections CAUTION Condensation and water damage can occur if cooling water is below dew point The laser tube and RF supply share the same cooling loop as shown in the cooling interconnection schematic in Fig 7 1 The laser should be operated with cooling water below 25 C only Ideal temperature for the cooling water is from 18 C to 20 C provided that the temperature is above the dew point Minimum flow rate is 2 gallons per minute GPM to achieve turbulent flow with pressure 70 pounds per square inch psi Synrad recommends a closed loop chiller Neslab CFT 150 be used to provide a capacity of 3kW for operation at maximum duty cycle 90 EF aUPPLY CHILLER DODOL SUPPLY OHO RETI FER ATINGOJ ORE MOUNTED OM THE FEAR PANELI OF DRYER ANDO THE LOSER HEAD NOTE 46 Series 57 60 Lasers Operation and Service Manual Ch 7 Model 60 1 Installation and Check Out Figure 7 1 Cooling Interconnection Schem
60. ing 2 X NPT x 1 2 Fittings for Chiller Connections Mounting hardware Four No 10 star washers included in only one of the RF Supply containers Regulated DC Power Supply 3 Each Power cord not included UC 1000 Recommended Accessory One UC 1000 Power Controller Two BNC terminated coax cables Series 57 60 Lasers 53 Operation and Service Manual Ch 8 Model 60 2 Installation and Check Out 115VAC Wall Plug Transformer One BNC T Connector Inspect each equipment item for any visible signs of shipping damage Contact Synrad if the laser housing is damaged or if any of the required materials labels or placards are missing 8 2 Mounting The recommended mounting orientation for 60 Series lasers 1s horizontal If this cannot be accomplished the lasers may be mounted at an angle of 220 to the vertical Consult the factory for limitations if laser is to be mounted in a vertical orientation Securing the laser head assembly to a bench or structure must take into consideration thermal effects between the laser head and the mounting structure Additionally the mounting system should not create physical stress on the laser head A three point securing configuration is recommended to secure the laser head to the mounting surface refer to Outline and Mounting diagram for dimensions of mounting holes There are two brackets attached to the bottom of the laser housing The front bracket is a floating position that prevents any ther
61. iolation of Section 360B of the Radiation Control and Health and Safety Act of 1968 Product features incorporated into the design of the Series 57 60 lasers to comply with CDRH safety are integrated as panel controls or indicators internal circuit elements or input output signal interfaces Specifically these features include a keyswitch Keyswitch version remote interlock for power on off a laser aperture shutter switch an output signal to indicate an overtemperature condition and a 5 second delay between power on and lasing Incorporation of certain features is dependent on the laser version OEM or Keyswitch All product features are summarized in Table 1 1 The table indicates the laser version on which a feature is available the type and description of the feature and if the feature 1s required REQ by and complies COM with CDRH regulations In addition to the above described safety features common safe operating practices should be exercised at all time when actively lasing To prevent exposure to direct or scattered laser radiation follow all safety precautions specified throughout this manual Use of controls or adjustments or performance of procedures other than those specified herein may result in exposure to hazardous invisible laser radiation damage to or malfunction of the laser Severe burns will result from exposure to the laser beam Always wear safety or prescription glasses with side shields to reduce the risk of da
62. iometer Gate Function GATE connector BNC provides input for a gate signal to turn the laser on and off in response to an external pulse train The on laser power level is set by the operating controls or remote inputs In the off position tickle is still provided to the laser The gate function can be used in all five active modes A TTL high turns the laser on A choice of input connectors is provided either BNC or sub miniature phono Internal Switches By removing the top cover screws accessible from the bottom the clock rate can be changed from a nominal of 5 kHz required for operation of Series 48 lasers to 3 or 7 5 kHz For more details consult the UC 1000 schematic on the following page Series 57 60 Lasers B Operation and Service Manual Appendix UC 1000 Laser Controller B 4 Series 57 60 Lasers Operation and Service Manual Series 57 60 Laser Operation and Service Manual Appendix C SSC 1000 Spike Suppressor Controller Series 57 60 Lasers Operation and Service Manual Appendix C SSC 1000 Spike Suppressor Controller SSC 1000 Spike Suppressor Controller The SSC 1000 is a laser power controller designed to provide a general purpose interface between the user s control signals and Synrad s complete line of CO lasers It provides functions that are similar to Synrad s UC 1000 controller but is functionally different in that the SSC 1000 operates at a higher clock rate and is designed to suppress the laser
63. ised of two equal RF modules In the case of the 57 1 and 60 1 model lasers each module draws RF power from a separate section of the RF power supply Each module is made of one pair of aluminum electrodes and ground spacers that form the square bore of 5 7 mm or 6 0 mm respectively They are sandwiched in an extruded aluminum housing which provides mechanical support vacuum seal and interfaces for RF feedthrough laser beam output and cooling Both ends of the housing are weld sealed The RF voltage between the two electrodes is twice that between either electrode and the electric ground This results in a confined plasma formation only in the square bore region The ground spacers help confine the plasma but carry negligible current The Series 57 60 Lasers 11 Operation and Service Manual Ch 2 Theory of Operation electrodes are anodized to assure uniform distribution of RF power Heat is conducted away by all four walls of the plasma bore to the outer walls of the housing where it is transferred to cooling water In contrast to waveguide lasers that have a closed bore periphery all Synrad lasers have four 0 02 inch gaps extending longitudinally along the length of the bore These gaps are used for electrical insulation between the two electrodes and two grounded sides that form the plasma bore They are also effective channels for diffusion cooling of the laser gas Typically the lasers are more efficient when operated below 95 duty cycle
64. ists of 1 red and 1 black cable Fuse s Two 40 Amp Type AGC Two 15 Amp Type AGC Two 1 2 Amp Pico Fuse Two 2 Amp Pico Fuse One Cooling Kit Two Straight Reducing Unions 1 2 X 3 8 30 Foot Roll Polyethylene 1 2 inch Black Tubing Two 3 inch Sections Polyethylene 3 8 inch Black Tubing 2 X NPT to 1 2 Fittings for Chiller Connections DB 9 remote interlock plug 57 0 only Mounting hardware Four No 10 star washers Regulated DC Power Supply 1 Each Optional Power cord not included UC 1000 Recommended Accessory One UC 1000 Power Controller One BNC terminated coax cable Series 57 60 Lasers 27 Operation and Service Manual Ch 5 Models 57 0 57 1 Installation and Check Out 115VAC Wall Plug Transformer Inspect each equipment item for any visible signs of shipping damage Contact Synrad if the laser housing is damaged or if any of the required materials labels or placards are missing 5 2 Mounting The recommended mounting orientation for 57 Series lasers 1s 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 laser is to be mounted in a vertical orientation Securing the laser head assembly to a bench or structure must take into consideration thermal effects between the laser head and the mounting structure Additionally the mounting system should not create physical stress on the laser head A three point securing con
65. ization is random and therefore superior for many cutting applications Series 57 60 Lasers LS Operation and Service Manual Ch 2 Theory of Operation 16 Series 57 60 Lasers Operation and Service Manual Chapter 3 Physical Features The physical features of the Series 57 60 lasers are shown in Figure 3 1 57 0 57 1 and 60 1 and Figure 3 2 57 2 and 60 2 The physical features for the RF Power Supplies is shown in Figure 3 3 57 0 and Figure 3 4 57 RF and 60 RF Each feature is also described in the following paragraphs 3 1 Laser Head Models 57 0 57 1 60 1 LOdER Lode TOP E Lad ER 4PERTURE WATCH INTERLCIZ EK Figure 3 1 Physical Features Location Diagram Models 57 0 57 1 60 1 3 1 1 RF In These connectors transfer RF energy from the RF driver to the laser head via two RG8 U cables one for 57 0 3 1 2 Interlock This DB9 connector transfers LED shutter and temperature information between the RF driver and laser head Operation and Service Manual Ch 3 Physical Features 3 1 3 Shutter Switch The shutter switch is a mechanical shutter that closes the laser aperture Closing the shutter also actuates independent micro switches that temporarily interrupt power to the laser until the shutter switch is opened again The shutter should not be used to partially block the beam or to control output power The shutter is standard on both OEM and Keyswitch versions 3 1
66. lications 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 occuring however there will be a slight decrease in laser efficiency when the duty cycle is increased beyond 95 refer to Fig 2 2 To operate the laser in CW mode a constant 4 5 VDC signal can be connected to the TTL 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 1000 The UC 1000 can be modified to achieve 10096 duty cycle operation if required for your application Consult the factory for requirements and details 9 4 PC Control of Laser To control on off pulsing of the laser pulsed mode a signal providing TTL level pulses is connected to the GATE connector on the rear panel of the UC 1000 Typically this signal would be generated using an add in digital I O card and controlling software Series 57 60 Lasers 63 Operation and Service Manual Ch 9 Operating Instructions If the user wishes to control laser power using a computer either a 0 10V analog voltage or a 4 20mA analog current can be connected to the UC 1000 ANV analog voltage or ANC analog current BNC connectors respectively To generate the
67. lug transformer rectifier to convert the 115VAC line into a nominal 24VDC 400mA max For line voltages other than 115 VAC C 2 Series 57 60 Lasers Operation and Service Manual Appendix C SSC 1000 Spike Suppressor Controller compatible transformers can be purchased that will convert the voltage into 24VDC Alternatively power can be provided from any 24V to 32VDC source Series 57 60 Lasers C 3 Operation and Service Manual Appendix C SSC 1000 Spike Suppressor Controller ANV ANC Input The BNC connector is the remote voltage or current input to be used while in the ANV ANC mode of operation Output Two connectors are used to supply the SSC 1000 signals to the laser One is a subminiature phone jack and is used in conjunction with the white cable supplied with the unit Alternatively a BNC output can be used with shielded coaxial cable of up to 25ft in length Gate Input There are two connectors which are TTL compatible inputs that allow the user to turn the laser on and off at a frequency determined by an externally applied pulse train A TTL high signal will turn the laser on During this period the manual power adjust knob or the ANV ANC control signal is used to vary the laser from maximum down to zero power tickle signal only The maximum allowable gate frequency is around 2kHz C 4 Series 57 60 Lasers Operation and Service Manual
68. mage to the eyes when operating the laser Safe operation of the laser requires the use of an external beam block to safely block the laser from traveling beyond the desired work area Use a fire brick or similar non scattering non combustible material as the beam block NEVER use organic material or metals as the beam blocker organic materials in general are apt to combust or melt and metals act as specular reflectors Series 57 60 Lasers Operation and Service Manual Ch 1 Safety and Regulatory Compliance Power Indicator O Keyswitch E Lase Indicator OE Keyswitch 5 Second Delay OE Keyswitch M M M Power Fail Reset Remote OEM Interlock Keyswitch Laser Ready OEM Indicator Keyswitch EM M Overvoltage Protection Keyswitch Reverse Voltage OE Protection Keyswitch Table 1 1 Series 57 60 Safety Features FEATURE VERSION DESCRIPTION RF Driver Panel Control RF Driver Panel LED Green RF Driver Panel and laser head LED Red Circuit Element Circuit Element Circuit Element 2 Terminal Block RF Driver Panel and laser head LED Yellow Circuit Element Circuit Element ON OFF switch to connect applied DC power to the internal circuitry of the RF Driver Key cannot be removed in the ON position Indicates that DC power is available for the RF Driver LED illuminates when DC voltage is applied Indicates that laser is in Lase mode LED illuminates when la
69. mal expansion from resulting in longitudinal bending movements The rear bracket is a fixed position Three 1 4 x 20 screws or bolts and three No 10 star washers are required to properly secure the laser head to the mounting surface Ensure that no loads are applied to the laser head between the mounting points Refer to Appendix A for appropriate outline mounting diagram 8 3 Cooling Requirements and Interconnections CAUTION Condensation and water damage can occur if cooling water is below dew point Each laser tube and associated RF supply share the same cooling loop as shown in the cooling interconnection schematic in Fig 8 1 with a complete depiction of the cooling system setup shown in Fig 8 2 See also Fig 8 3 for additional details The laser should be operated with cooling water below 25 C only Ideal temperature for the cooling water is from 18 C to 20 C provided that the temperature is above the dew point Minimum flow rate is 4 gallons per minute GPM to achieve turbulent flow with pressure 70 pounds per square inch psi Synrad recommends a closed loop chiller Neslab CFT 300 be used to provide a capacity of 6kW for operation at maximum duty cycle 54 Series 57 60 Lasers Operation and Service Manual CHILLER Series 57 60 Lasers Ch 8 Model 60 2 Installation and Check Out COOLING INTERCONNECTION 3l PPL OND FETU RN ATINGOJ ORE MOUNTED ON THE FEAR PANELS OF EACH RF DRIVER THE LG 3 ER HEAD
70. o 00 2 ORE 2 20 Series 57 60 Lasers Operation and Service Manual Ch 3 Physical Features The physical features of the RF power supplies are described in the following paragraphs COOLING OUT COOLING IH a a D C IMPUT READY COOLING LASE WOLTAGE AVAILABLE e um CTRL Uc i1000 LASER AUX Dc PWR EZIGIN ALL 3 LIB TYPE RGC ONLY Figure 3 3 57 0 RF Power Supply Physical Features Location Diagram On e a Ooo boc INPUT READY COOLING CTRL IN Ih VOLTAGE AVAILABLE TYPE OHLY Operation and Service Manual Ch 3 Physical Features Figure 3 4 57 RF Power Supply Physical Features Location Diagram On o to o Dac INPUT COOLING TALIA In WOLTAGE AVAILABLE OHLY Figure 3 5 60 RF Power Supply Physical Features Location Diagram 3 3 1 RF Out These connectors transfer RF energy to the laser head via RG8 U cables two for the 57 1 60 1 and four for the 57 2 60 2 3 3 2 Interlock This DB 9 connector female transfers LED shutter and temperature information between the RF driver and laser head 3 3 3 Remote Interlock This 4 terminal connector block allows the user to remotely turn the laser on and off This function is disabled when shipped 3 3 4 Auxiliary DB9 Connector The auxiliary DB9 connector is a 9 pin male subminiature D connector that provides access
71. oad Maximum 3000 6000 Flow Rate 2 GPM lt 70 psi 4 GPM lt 70 psi Temperature 18 20 C 18 20 C Weight Head 36 lb 16 4 kg 84 Ib 38 2 kg RF Power Supply 29 Ib 13 2 kg 29 Ib 13 2 kg Dimensions L x W x H 1 2 3 4 Head inches 44 75 x 6 5 x 4 76 48 75 x 1046 x 6 56 millimeters 1136 65 x 165 10 x 120 90 1238 25 x 265 68 x 166 62 RF Supply inches 12x 19x 8 875 12 x I9x 8875 millimeters 304 8 x 482 6 x 22543 304 8 x 482 6 x 22543 The output power level is guaranteed for 12 months regardless of operating hours Typical value for 100 200 us pulse width at 596 duty cycle One RF Power Supply required for Model 60 1 two RF Power Supplies required for Model 60 2 If rubber feet installed add 0 02 in 0 51 mm to height dimension when shutter switch is closed and 1 0 in 25 4 mm when shutter switch is open Series 57 60 Lasers Operation and Service Manual Ch 2 Theory of Operation 2 2 Technology Overview 2 2 1 Laser Head Series 57 60 laser heads consist of either a single or dual laser tube depending on the particular model Models 57 1 and 60 1 all utilize a single tube Models 57 2 and 60 2 integrate two laser tubes referred to as Set 1 and Set 2 which are optically combined in a single laser head to double the output power and improve the beam quality for cutting marking and drilling applications Each laser tube consists of a bow tie shaped extrusion featuring two parallel bores in
72. of mounting holes There are two brackets attached to the bottom of the laser housing The front bracket is a floating position that prevents any thermal expansion from resulting in longitudinal bending movements The rear bracket is a fixed position Three 1 4 x 20 screws or bolts and three No 10 star washers are required to properly secure the laser head to the mounting surface Ensure that no loads are applied to the laser head between the mounting points Refer to Appendix A for appropriate outline mounting diagram 6 3 Cooling Requirements and Interconnections CAUTION Condensation and water damage can occur if cooling water is below dew point Each laser tube and associated RF supply share the same cooling loop as shown in the cooling interconnection schematic in Figure 6 1 with a complete depiction of the cooling system setup shown in Figure 6 2 The laser should be operated with cooling water below 25 C only Ideal temperature for the cooling water is from 18 C to 20 C provided that the temperature is above the dew point Minimum flow rate is 4 gallons per minute GPM to achieve turbulent flow with pressure 70 pounds per square inch psi Synrad recommends a closed loop chiller Neslab CFT 150 be used to provide a capacity of 4kW for operation at maximum duty cycle 6 Series 57 60 Lasers Operation and Service Manual CHILLER Series 57 60 Lasers Operation and Service Manual Ch 6 Model 57 2 Installation and
73. onnect RG 8 RF coax cables labeled Set 1 between the Set 1 RF driver RF1 and RF2 connectors and laser Set 1 RF1 and RF2 connectors respectively Connect the RG 8 RF coax cables labeled Set 2 between the Set 2 RF driver 1 and RF2 connectors and laser Set 2 RF1 and RF2 connectors respectively Install one of the DB9 terminated interlock cable between laser head Set 1 and the Set 1 RF driver Install the second DB9 terminated interlock cable between laser head Set 2 and Set 2 RF driver Connect the DC power supplies to the RF drivers as shown in the RF Supply DC Power Supply Interconnection diagram Install the BNC T adapter to the OUTPUT connector on the rear panel of the UC 1000 Connect BNC terminated cable No 1 between the T adapter and the CTRL IN connector on the Set 1 RF Driver either front or rear panel Connect BNC terminated cable No 2 between the T adapter and the CTRL IN connector on the Set 2 RF Driver either front or rear panel Series 57 60 Lasers 61 Operation and Service Manual Ch 8 Model 60 2 Installation and Check Out 8 6 Turn On Check Out WARNING Harmful laser radiation is emitted through the laser exit aperture when performing the following procedure Verify UC 1000 POWER and external DC power supply switches are set to OFF Verify all electrical and cooling interconnects have been accomplished Place beam block in front of the exit aperture at a distance between 6 inches and 1 foot
74. ovides two CTRL connectors One connector is mounted on the front panel and one on the rear panel These connectors are electrically common and are duplicated as a matter of convenience for the user 3 3 6 DC Power Input The red and black DC power input cables provide DC operating power to the laser Standard length is 60 inches The number of cable sets required for particular models is as follows Model No of Cable Sets 57 0 1 57 1 1 57 2 2 Series 57 60 Lasers s 93 Operation and Service Manual Ch 3 Physical Features 60 1 2 60 2 4 3 3 7 DC Input Voltage Available LED This green LED indicates that DC voltage is applied to the RF driver 3 3 8 Lase LED The LASE indicator is a panel mounted red LED that illuminates to indicate Lase mode of operation If the TTL signal is present the red indicator light turns on after a 5 second delay and becomes brighter as the TTL duty cycle is increased This LED is standard on both OEM and Keyswitch versions 3 3 9 Ready LED The READY indicator is a panel mounted yellow LED that illuminates when the laser is ready to lase It indicates the laser is capable of lasing and is awaiting a TTL command signal 3 3 10 Cooling LED The COOLING indicator is a red LED that illuminates if the cooling water flow rate is insufficient 3 3 11 Fuses The panel mounted fuse s provide overcurrent protection for the internal circuitry of the laser Use only type AGC Fast acting fuses wit
75. r 8 Model 60 2 Installation and Check Out 8 1 Unpacking Initial Inspection Do not discard the shipping container or the foam packing since these are required if the laser is ever returned to Synrad for factory service The 60 2 laser head and all required support equipment are packaged and shipped in individual containers as indicated below in bold face type In addition some of the containers will also include support materials required to install and operate the laser The support materials included in a particular container are also listed below Open each shipping container individually Place the container on a sturdy level surface and open the top of the box Carefully remove the equipment from the container and remove the outer foam packing material Verify that the associated support material items are included Laser Head Container 1 Each One 60 Series Laser Head Operation and Service Manual Warranty Registration Card Final Test Data Report RF Supply Container 2 Each One RF Power Supply Two RG 8 Coax RF Cables 5 meters in length One DB9 terminated Interlock Cable Two pair of DC Power Cables each pair consists of 1 red and 1 black cable Fuse s Two 15 Amp Type AGC Two 1 2 Amp Pico Fuse Two 2 Amp Pico Fuse One Cooling Kit Two Union Fittings 1 2 Four Straight Reducing Unions 1 2 X 3 8 Two 30 Foot Rolls Polyethylene 1 2 inch Black Tubing Four 3 inch Sections Polyethylene 3 8 inch Black Tub
76. r supply for each of the two sections of the laser head referred to as Set 1 and Set 2 The two RF power supplies deliver a total of ZKW of RF through four RG 8 type coax cables two cables for each RF driver Operation is on the authorized ISM frequency of 40 68MHz Electrical interconnections between the regulated DC power supplies and the RF supplies are shown in Figure 6 4 2 SUPPLIES 57 2 Power Connections 30VDC 80A FOR EACH SUPPLY 208V 20A SINGLE PHASE Figure 6 4 RF Supply DC Power Supply Interconnection Diagram Series 57 60 Lasers A Operation and Service Manual Ch 6 Model 57 2 Installation and Check Out The BNC terminated cable from the UC 1000 output can be connected to either the front or rear panel mounted BNC CTRL IN connectors These connectors are electrically common and are duplicated as a matter of convenience for the user The interlock cable should be connected between the male DB9 connector on the rear panel of the laser head and the female DB9 connector located on the rear panel of the associated RF power supply For each RF driver Set 1 or Set 2 ensure the interlock cable is connected to its respective connector Set 1 or Set 2 on the laser head To prevent improper connection it is recommended that the interlock cable be connected first to the laser and then the RF Power Supply The RF Power Supply also provides an auxiliary signal
77. r switch to OFF 15 Tum off external DC power supply EEE Series 57 60 Lasers Operation and Service Manual Chapter 6 Model 57 2 Installation and Check Out 6 1 Unpacking Initial Inspection Do not discard the shipping container or the foam packing since these are required if the laser is ever returned to Synrad for factory service The 57 2 laser head and all required support equipment are packaged and shipped in individual containers as indicated below in bold face type In addition some of the containers will also include support materials required to install and operate the laser The support materials included in a particular container are also listed below Open each shipping container individually Place the container on a sturdy level surface and open the top of the box Carefully remove the equipment from the container and remove the outer foam packing material Verify that the associated support material items are included Laser Head Container 1 Each One 57 Series Laser Head Operation and Service Manual Warranty Registration Card Final Test Data Report RF Supply Container 2 Each One RF Power Supply Two RG 8 Coax RF Cables 5 meters in length One DB9 terminated Interlock Cable One pair of DC Power Cables pair consists of 1 red and 1 black cable Fuse s Two 40 Amp Type AGC Two 15 Amp Type AGC Two 1 2 Amp Pico Fuse Two 2 Amp Pico Fuse One Cooling Kit Two T Union Fittings 1 2 Four Strai
78. relating to performance characteristics Refer to Appendix A for label location diagrams 1 5 Operation and Service Manual Precautionary Notations There are two types of precautionary notations used throughout this manual A WARNING is used to identify a process or procedure that could result in exposure to laser radiation Warning notations will be formatted as follows WARNING A WARNING notation is used to identify a process or procedure that could result in exposure to laser radiation A CAUTION is used to identify a process or procedure that could result in damage to the laser if not properly performed and will be formatted as follows CAUTION A CAUTION notation is used to identify a process or procedure that could result in damage to the laser if not properly performed EEE Series 57 60 Lasers Operation and Service Manual Chapter 2 Theory of Operation 2 1 Technical Specifications Technical information regarding performance characteristics is summarized in Table 2 1 for Series 57 lasers and in Table 2 2 for Series 60 lasers All specifications are at 30 VDC unless otherwise specified Table 2 1 Series 57 Specification Table MODEL pm TT 0 5722 Wavelength 10 59 microns Power Output ai cog id Continuous Pulsed Continuous Pulsed 100 210W 200W 420W Power ans ERE RN 5 kHz Modulation Optical Response Electrical Control TTL input 3 5V to 20 kHz Electri
79. res incorporated into the design of the RF supply are a 5 second delay and a remote interlock The 5 second delay circuit disables the laser from actively lasing for a period of 5 seconds after the keyswitch is turned on The remote interlock connection 4 terminal strip on the rear of the RF supply allows remote shut down of the laser Note that for all power fail conditions it is necessary to reset the keyswitch to restore the RF supply to normal operation 2 2 3 60 RF Power Supply for laser Models 60 1 and 60 2 The solid state RF supply operates off 28 32VDC Operating frequency is on the 40 68 MHz ISM frequency and is crystal controlled The oscillator section is comprised of a crystal driven MRF 134 FET followed by an MRF 138 amplifier and then by a single MRF 150 transistor to deliver 100W of RF to the two 700W plasma drivers Since its current consumption is approximately 95A heavy gauge cables are required 6 AWG minimum The power cables should be twisted for long runs to minimize inductance Four pairs of transistors push pull are used to generate 700W of RF each Each push pull stage contains 2 MRF 150 s The power is split before amplification and re combined with transmission line combiners at the output after amplification Other than the paralleling of transistor stages and the crystal controlled drive the operation of the circuit is identical to that used in Synrad s lower powered lasers The external 50 ohm interconnect coaxial
80. rpose as the 50 ohm 1 4 wave transformers This can be visualized by considering the load to be three 200 ohm plasma sections in parallel driven by three 50 ohm 1 4 wave lines in parallel The input driver splitters are 1 4 wave 25 ohm transmission lines transforming the base impedance of about 2 ohms to 300 ohms Three of these in parallel result in a 100 ohm port Both drive sections together are then equal to about 50 ohms A solder fuse 5A is provided in each input line to isolate a failed driver An overvoltage crowbar will short to ground removing drive from the oscillator section if the supply voltage exceeds 40VDC This will cause the 15A fuse F3 to blow and will release the power relays controlling the plasma drives Protection against reverse voltage 1s provided by a diode in the 15A line in series with the master relay This master relay also cannot energize unless the RF cables are plugged in at both ends Overcurrent protection is provided for each 500W output stage Overcurrent can be generated during the time that it takes the plasma to fire If a tube does not fire this current may be 40A or more for each stage Protection is provided by a magnetic reed switch sensing currents in excess of the normal current of 25A per output stage Overcurrent will remove RF drive from the output stage by releasing the control relay The circuit will recycle every second thereby limiting dissipation of the output transistors Additional featu
81. s command pulse until laser emission is unpredictable and can vary between 10 and 100 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 is off no command signal before a pulse is applied This inconsistent and unstable firing can cause problems in precision industrial uses where even microsecond delays in firing are important The tickle signal pre ionizes the laser gas so that it is just below the lasing threshold Any further increase in pulse width will add enough energy to the plasma to cause laser emission In this way the laser can now respond predictably and almost instantaneously to the user s command signal even when there is considerable time delay laser off time between applied pulses EEKJZUCELZSEDIEEEEEE c c SS Operation and Service Manual Ch 2 Theory of Operation PULJE 3ET BELO Lu siNcG THEESHOLD OUTPUT La 3 ER CONTROLLER POMWER LEWEL on 60 DUTY CYCLE OFF lag 200 PULA EVAOTH JET BELO Lagi WCG THRE HOLD OUTPUT TO LAJ EF On CONTROLLER POWER LEVEL FOE POWER PEt DUTY CYCLE OFF tz 2nng ran Figure 2 4 Tickle Pulse Output to Laser Controller 2 4 2 PWM Clock Frequency Series 57 60 lasers are designed to operate at clock frequencies up to 20kHz The choice of clock frequency depends on the application For most applications the UC 1000 frequency o
82. s overshoot spike which occurs at low modulating gate frequencies 500 Hz 54 1000 eS WIN O Qm OFF C LOSER CONTROLLER SSC 1000 Spike Suppressor Controller Operating Modes and Inputs Outputs There are four operating modes supported by the SSC 1000 Standby Remote Current Control Remote Voltage Control and Manual Control In each mode a pre ionizing tickle pulse is provided to keep the plasma ionized during laser low or periods This facilitates plasma breakdown and pulse to pulse fidelity without causing laser emission The four modes are explained as follows Standby This mode is used for initial start up of the laser or for a temporary pause in operations There is no laser emission in this mode since only the tickle pulse is present Remote Current Control ANC In this mode the laser power is controlled by a DC current applied to the ANV ANC input Power output will begin above 4mA and will reach a maximum at 20mA This is the standard industrial control interface allowing loop supervision Remote Voltage Control ANV In this mode the laser power is controlled by a DC voltage applied to the ANV ANC input Power output will begin above OV and will reach a maximum at 10V Manual Mode MAN In this mode the laser power is controlled by varying the power adjust knob on the front panel Power Input The input power connector is used in conjunction with the supplied wall p
83. ser beam diverges due to diffraction at an angle of 3 2 milliradians refer to Fig 2 2 The beam has a near gaussian profile in the far field 0 6m or more OOO series 57 60 Lasers Operation and Service Manual Ch 2 Theory of Operation 1 60m 5 020 m EEAM dmm FULL ANGLE EU Oly EHEZ rrr B METER Radius ante FLA SI TOTAL REFLECTOR OUTPUT CO PL ER Figure 2 2 Beam Characteristics 2 4 Laser Power Control To effectively control output power of Series 57 60 lasers pulse width modulation PWM is used to vary the average voltage applied to the RF oscillator stage which controls the RF drive applied to the laser electrodes The required modulation source signal refer to Fig 2 3 and the capabilities to control and vary that signal are provided by Synrad s UC 1000 Laser Controller refer to Appendix B for more information on the UC 1000 Using an alternate method to control laser output power requires consideration of key characteristics of Series 57 60 lasers as described in the following paragraphs 1000 CONTROLLER War E ROR oT 27 Figure 2 3 Typical TTL Drive Signal 2 4 1 Tickle Pulse All Series 57 60 lasers require a lus tickle pulse normally delivered at a 5KHz clock frequency from the UC 1000 refer to Fig 2 4 If the user is supplying on off TTL pulses directly to the laser without a tickle pulse the response time from the user
84. ser beam is active The brightness of the LED is related to TTL duty cycle Higher duty cycles higher laser output produce brighter illumination Disables RF Driver laser output for 5 seconds after keyswitch is turned to ON position and or remote interlock is closed Disables RF Driver laser if input power is removed and then later reapplied power failure while the keyswitch and or remote interlock are still closed Operator must manually reset the keyswitch and or remote interlock to restore normal operation Allows user to turn the RF Driver laser on off from a remote location RF Driver is shipped with function disabled Indicates that laser has power applied and is capable of lasing Series 57 Disables internal circuitry and blows 15A fuse if input voltage exceeds 40V Operator must replace fuse and manually reset the keyswitch and or remote interlock to restore normal operation Series 60 Inherent protection due to large FET breakdown rating and high voltage capacitors for the RF amplifier Crowbar circuit protects the control electronics and oscillator section Series 57 RF amplifier and oscillator protected by normally open relays Series 60 Internal diodes that protect internal circuitry from reverse input voltag Warning Labels OEM Labels attached to various external locations of the Yes Keyswitch laser housing to warn personnel of potential hazards 1 REQ required by CDRH 2 COM complies with CDRH
85. ssive weight may cause damage to the laser 3 1 8 Cooling Manifold There are two possible configurations for the IN OUT connections on the cooling manifold The primary location for the two connections are on the front of the manifold There is one connector in and one connector out with the right angle fittings pointing the cooling lines down The alternate location for the two connections are on the side of the manifold pointing the cooling lines in the direction of the laser 3 2 Laser Head Models 57 2 60 2 Models 57 2 and 60 2 integrate two laser tubes referred to as Set 1 and Set 2 which are optically combined in a single laser head to double the output power Each of these Duo Lase models have two complete sets of the following features Po Series 57 60 Lasers Operation and Service Manual Ch 3 Physical Features LASER READ LAJE TOF YEW RFIM 2H T REAR VIEW FRONT WIE INTERLOCK LASER APERTURE SHUTTER Figure 3 2 Physical Features Location Diagram Models 57 2 60 2 3 2 1 RF In These connectors transfer RF energy from the RF driver to the laser head via four RG8 U cables Each pair of two cables are mated to each of the 2 laser sets Set 1 and Set 2 in these Duo LASE models 3 2 2 Interlock This DB 9 connector transfers LED shutter and temperature information between the RF driver and laser head DB9 connector There are 2 interlocks one for each of the laser tubes 3 2 3 Shutter
86. t Reducing Unions 1 2 X 3 8 30 Foot Roll Polyethylene 1 2 inch Black Tubing Two 3 inch Sections Polyethylene 3 8 inch Black Tubing 2 X NPT to 1 2 Fittings for Chiller Connections Mounting hardware Four No 10 star washers Regulated DC Power Supply 2 Each Optional Power cord not included UC 1000 Recommended Accessory One UC 1000 Power Controller One BNC terminated coax cable Series 57 60 Lasers AS Operation and Service Manual Ch 7 Model 60 1 Installation and Check Out 115VAC Wall Plug Transformer Inspect each equipment item for any visible signs of shipping damage Contact Synrad if the laser housing is damaged or if any of the required materials labels or placards are missing 7 2 Mounting The recommended mounting orientation for 60 Series lasers 1s 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 laser is to be mounted in a vertical orientation Securing the laser head assembly to a bench or structure must take into consideration thermal effects between the laser head and the mounting structure Additionally the mounting system should not create physical stress on the laser head A three point securing configuration is recommended to secure the laser head to the mounting surface refer to Outline and Mounting diagram for dimensions of mounting holes There are two brackets attached to the bottom of the laser
87. ted to either the front or rear panel mounted BNC CTRL IN connectors These connectors are electrically common and are duplicated as a matter of convenience for the user The interlock cable should be connected between the male DB9 connector on the rear panel of the laser head and the female DB9 connector located on the rear panel of the RF power supply To prevent Series 57 60 Lasers 49 Operation and Service Manual Ch 7 Model 60 1 Installation and Check Out improper connection it is recommended that the interlock cable be connected first to the laser and then the RF Power Supply The RF Power Supply also provides an auxiliary signal connector to provide the user with additional signal information to allow specific aspects of system performance to be monitored The auxiliary connector is a male DB9 connector mounted on the rear panel of each RF power supply refer to the following table for a description of pin assignments If the user intends to take advantage of this feature they must manufacture a connecting cable and then configure its connections refer to Fig 7 1 for proper operation Table 7 1 RF Supply Auxiliary Signal Connector Male DB9 Pin Assignments NO NAME DESCRIPTION 1 KEYSWITCH ON OFF Auxiliary signal that indicates on off state of keyswitch Key On Vp 28 Key Off Ov LASER RDY Auxiliary signal that indicates Laser Ready to lase operation Laser Ready Vpin2 28 Not Ready Vpin2 OVERTE
88. the center web and one interconnection bore at a 2 76 angle connecting the two outside bores to form a Z fold There are two drive ports For the 57 Series lasers each port requires 500W of RF power to excite the plasma For the 60 Series lasers each port requires 700W of RF power The optical resonator system uses two 5 m radius of curvature mirrors rear and two flat mirrors front with 3596 output coupling on one mirror The bore size for 57 Series lasers is 5 7 mm on a side and for 60 Series lasers 6 0 mm per side The plasma section is water cooled using eight 1 4 inch stainless steel tubes arbor pressed into the aluminum envelope At the laser output end these tubes are connected together so that each set of two on 5 inch centers forms 1 4 of the total cooling loop In the rear cooling water input is applied symmetrically feeding all four inside tubes in parallel Cooling water return is from the four outside tubes A manual shutter is provided in front to both mechanically and electrically shut off the beam A red warning light lase indicates that the laser is activated and emission will take place if the shutter is opened A yellow ready light indicates that the laser is ready to accept an on command via the TTL input If the yellow light only is on no emission is taking place but may as soon as a signal is applied to the TTL input Neither the laser head nor the power supply will come on unless the RF cables and the D Sub
89. tinued AU NILUM 50 7 9 Detailed Seni Procedure eios ctione alto DRE DAS RIESCO UM 51 7 0 DLurn Om Check OU I MR SER TOS 51 8 Model 60 2 Installation and 53 8 1 Unpacking Initial aee eie Ba eed di a aes ee 53 SUL NU TI uos a cae ue chen uc ua Dt ce SCA iad pea 54 8 3 Cooling Requirements and Interconnections eee 54 8 4 System e aer ORI P on seed ege 57 8 4 1 UC 1000 Power 58 8 4 2 RE Power Supply A ne ien 58 gk 1 G27 00 e bee et ET 59 5 3 Detailed Setup Procedure oc sae one EU TAER 60 8 6 Turn On Check Out to ire tae tan eo ies 61 9 Operating Instructions nnns 63 maed ol AME UE 63 9 2 Operation in Pulsed Mode S ea tiet 63 9 3 Operation in Continuous Wave CW Mode 63 OA PC Control oE E388 nasi scat ume p em e ndn 63 10 Maintenance and 65 Appx A Supporting Documentation sss A 1 Appx B UC 1000 Laser B 1 Appx C SSC 1000 Spike
90. to fault monitor and remote interlock 57 0 only interface signals For more information on the auxiliary signal connector refer to Table 3 1 Series 57 60 Lasers Operation and Service Manual Ch 3 Physical Features Table 3 1 RF Supply Auxiliary Signal Connector Male DB9 Pin Assignments NO NAME DESCRIPTION 1 KEYSWITCH ON OFF Auxiliary signal that indicates on off state of keyswitch Key On Vp 28 Key Off Vein Ov LASER RDY Auxiliary signal that indicates Laser Ready to lase operation Laser Ready 28 Not Ready Vpn OVERTEMP Auxiliary signal to monitor the temperature sensors and the water flow switch No Overtemp 28V Overtemp OV RED LASE LED Auxiliary signal to monitor the state of lasing activity When in active lase mode Vpm4 is a 28V square wave with a duty cycle from 0 5 lus tickle pulse to 95 at 5 kHz DC VOLTAGE PRESENT Auxiliary signal to monitor externally applied voltage Voltage Applied Vpn 28V No Voltage Vps OV GROUND 7 8 9 NC NOTE pos n Pins 7 and 8 of the auxiliary DB9 connector are used as the remote interlock for the 57 0 only 3 3 5 TTL Control Input The CTRL connector is a panel mounted BNC style connector that accepts the TTL level control signal The output of the UC 1000 is attached to this connector For pure CW operation a straight 5V signal can be applied through this connector NOTE Each RF Power Supply pr
91. to the system at the required rate and verify that there is no water leaking from any connection or fitting Verify red cooling LED is off on RF driver Turn the water system off Connect the RG 8 RF coax cables labeled Set 1 between the Set 1 RF driver 1 and RF2 connectors and laser Set 1 RF1 and RF2 connectors respectively Connect the RG 8 RF coax cables labeled Set 2 between the Set 2 RF driver RF1 and RF2 connectors and laser Set 2 RF1 and RF2 connectors respectively Install one of the DB9 terminated interlock cables between laser head Set 1 and the Set 1 RF driver Install the second DB9 terminated interlock cable between laser head Set 2 and Set 2 RF driver Connect the DC power supplies to the RF drivers as shown in the RF Supply DC Power Supply Interconnection diagram Install the BNC T adapter to the OUTPUT connector on the rear panel of the UC 1000 Connect BNC terminated cable No 1 between the T adapter and the CTRL IN connector on the Set 1 RF Driver either front or rear panel Connect BNC terminated cable No 2 between the T adapter and the CTRL IN connector on the Set 2 RF Driver either front or rear panel Series 57 60 Lasers 43 Operation and Service Manual Ch 6 Model 57 2 Installation and Check Out 6 6 Turn On Check Out WARNING Harmful laser radiation is emitted through the laser exit aperture when performing the following procedure Verify UC 1000 POWER and external DC power supply
92. two Synrad DC 100 power supplies 42 Series 57 60 Lasers Operation and Service Manual Ch 6 Model 57 2 Installation and Check Out 6 5 Detailed Setup Procedure 1 2 Verify the laser head has been properly mounted as described in the Mounting paragraph Using both of the 30ft lengths of of the 1 2 polyethylene tubing provided with both of the RF supplies fabricate the necessary lengths to make the following connections NOTE For best results the lengths from the T union to SET 1 and SET 2 manifolds on the laser must be the same length to insure identical water pressure in each laser tube a the output of the chiller to the T fitting b from one end of the T to the IN port on the SET 1 cooling manifold the other end of the T to the IN port on the SET 2 cooling manifold d the OUT port on the SET 1 manifold to the COOLING IN port on RF supply SET 1 e the OUT port on the SET 2 manifold to the COOLING IN port on RF supply SET 2 f the COOLING OUT port on the RF supply SET 1 to one end of the T at the input port of the chiller g the COOLING OUT port on the RF supply SET 2 to the other end of the at the input port of the chiller 3 10 11 12 13 14 Connect each of the 1 2 x 3 8 reducing unions to the COOLING IN and COOLING OUT ports on the back of both the RF supplies Connect all the cooling lines as shown in Fig 6 2 After completing all cooling hook ups supply water
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Series 48 Operation/Service Manual

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