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Synrad 32-1 Operator's Manual

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32-1
Operator's Manual
4600 Campus Place
Mukilteo, WA 98275
1.800.SYNRAD1
tel
1.425.349.3500
fax
1.425.349.3667
e-mail
synrad@synrad.com
web
www.synrad.com
®

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Summary of Contents for Synrad 32-1

  • Page 1 32-1 Operator’s Manual ® 4600 Campus Place Mukilteo, WA 98275 1.800.SYNRAD1 1.425.349.3500 1.425.349.3667 e-mail synrad@synrad.com www.synrad.com...
  • Page 2 32-1Operator’s Manual Model 32-1 Version 2.2 SYNRAD is a registered trademark of Novanta Corporation. Novanta Corporation 2018. All Rights Reserved. No © reproduction without written authorization. DATE: December 2018...

  • Page 3: Table Of Contents

    Optical resonator ............................32 Cooling .................................33 Optical setup ..............................33 Control signals ............................36 Operating modes .............................41 UC-2000 Universal Laser Controller ....................42 Continuous wave (CW) operation ......................42 DB-9 connections .............................44 User I/O connections ..........................45 I/O Fault Diagrams ...........................46 SYNRAD® 32-1 Operator’s Manual Version 2.2...

  • Page 4: Technical Reference 4

    Disabling the 32-1 laser .........................54 Daily inspections ............................54 Storage/shipping ............................55 Cleaning guidelines ..........................56 Cleaning optics ............................57 Troubleshooting ............................58 Troubleshooting Introduction ......................58 Beam delivery optics ..........................59 Possible Causes: ............................59 Input/Output/Fault Conditions ......................61 Index Index ................................62 SYNRAD® 32-1 Operator’s Manual Version 2.1...

  • Page 5: Introduction

    Before beginning any maintenance or inspections of your 32-1 laser, be sure to completely disable the laser by disconnecting the DC Power cable (or cables) from the rear of the laser.

  • Page 6: Trademark, Warranty & Copyright Information

    Introduction Trademark/copyright information Trademark, Warranty & Copyright Information SYNRAD® and 32-1 are registered trademarks of SYNRAD. All other trademarks or registered trademarks are the property of their respective owners. 2018 by SYNRAD. All rights reserved. SYNRAD® 32-1 Operator’s Manual Version 2.2...
  • Page 7 If no discrepancies are reported, SYNRAD shall assume the shipment was delivered complete and defect-free. If, within one year from the date of shipment, any part of the 32-1 laser should fail to operate, contact the SYNRAD Customer Service department at 1.800.SYNRAD1 (outside the U.S. call 1.425.349.3500) and report the problem.
  • Page 8 Regional Sales Managers also serve as the liaison between you and our Applications Lab in processing material samples per your specifications. To speak to the Regional Sales Manager in your area, call SYNRAD at 1.800. SYNRAD1.
  • Page 9 Introduction European headquarters For assistance in Europe, contact SYNRAD® at: Novanta Distribution (USD) GmbH © Parkring 57-59 85748 Garching bei München, Germany Phone: +49 89 31707-0 Fax: +49 (0) 89 31707-222 E-mail: service-europe@synrad.com web: www.synrad.com For assistance in China, contact SYNRAD® at: Novanta SYNRAD China Sales and Service Center ©...

  • Page 10: Guidelines & Content

    Contents description Each item below is also listed in tables that follow: SYNRAD OEM 32-1 Laser – for cutting, welding, drilling, and marking a wide variety of prod- ucts and materials. Customer Communication Flier – Instead of the laser manual CD, please follow the instruc- tions for our latest laser manual(s) located here: http://synrad.com/synrad/docroot/resources/...
  • Page 11 Introduction Guidelines & Content Description SYNRAD CO ® Web Flier Spare Fuse(s) Figure 1-1 32-1 Ship kit contents. Table 1-1 32-1 ship kit contents. Shipping Box Contents Shipping Box Contents Laser ..........1 Mounting Bolts ........3 32-1 Customer flier ........1 Final Test Report (not shown) ..1 Spare Fuses ....(As Required)

  • Page 12: 32-1 Nomenclature

    OEM and Air cooled models are the only options available for the 32-1. The last letter in the model number indicates the current model version “C”. For example, the model number 32-1 SAC designates the 32-1 laser as a Standard OEM, Air-cooled version C.
  • Page 13 Other Options 10.6 µ 9.3 µ 10.2 µ 10.2 Closed Loop Kit Customer Other Speci c Options Safety Options Model Standard OEM Version Number (A-Z) Cooling Options Figure 1-2 Anatomy of a model number. SYNRAD® 32-1 Operator’s Manual Version 2.2...

  • Page 14: Laser Safety

    General & Other Hazards – provides important information about the hazards and unsafe practices that could result in death, severe injury, or product damage. Disposal – information on your 32-1 laser parts and/or components as they pertain to disposal. Additional safety Information – describes how to find additional information about your 32-1 laser.

  • Page 15: Hazard Information

    Hazards which, if not avoided, could result in minor or moderate injury. Caution- potential hazards or unsafe practices which, if not avoided, may result in product damage. Important information or recommendations concerning the subject under discussion. SYNRAD® 32-1 Operator’s Manual Version 2.2...
  • Page 16 Alerts operator of equipment dangers. IMPORTANT NOTES & TIPS: Important Note: Content specific information and/or recommendations. Tip: Note: Figure 2-1 Warning, danger, caution and content specific information icons and definitions. SYNRAD® 32-1 Operator’s Manual Version 2.2...

  • Page 17: General Hazards

    Do not use air dusters containing difluo- roethane in any area adjacent to CO laser systems because difluoroethane persists for long time periods over wide areas. SYNRAD® 32-1 Operator’s Manual Version 2.2...
  • Page 18 Laser Safety 32-1 lasers should be installed and operated in manufacturing or laboratory facilities by trained personnel only. Due to the considerable risks and hazards associated with the instal- lation and operational use of any equipment incorporating a laser, the operator must follow product warning labels and instructions to the user regarding laser safety.

  • Page 19: Additional Laser Safety Information

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

  • Page 20: 32-1 Label Locations

    Damage or malfunction may occur if this or equivalent drive signals are not used. See manual SYNRAD, Inc. 4600 Campus Place, Mukilteo WA 98275 425.349.3500 for tickle pulse specifications or contact factory. OEM version...

  • Page 21: Compliance

    Incorporation of certain features is dependent on the laser version (Key- switch or OEM). See the Class 4 safety features, located in the following table, that indicate which features are available on 32-1 lasers, the type and description of the feature, and if the feature is required by CDRH regulations.
  • Page 22 The FCC regulations that govern industrial, scientific, and medical (ISM) equipment are fully described in 47 CFR, Part 18, Subpart C. SYNRAD® 32-1 lasers have been tested and found to comply by demonstrating performance characteristics that have met or exceeded the requirements of 47 CFR, Part 18, Radiated and Conducted Emissions.

  • Page 23: European Union (Eu) Requirements

    The following table shows the Class 4 safety features, summarizes 32-1 product features, indicating the type and description of features and whether those fea- tures are required by European Union regulations.
  • Page 24 Labels attached to various external housing locations to warn personnel of potential laser hazards. 1 On OEM versions, the Power indicator illuminates and the five (5) second delay begins when DC power is ap- plied to the laser. SYNRAD® 32-1 Operator’s Manual Version 2.2...
  • Page 25 SYNRAD® 32-1 lasers have demonstrated performance characteristics that have met or ex- ceeded the requirements of EMC Directive 2014/30/EU. When integrating SYNRAD 32-1 OEM lasers, the Buyer and/or integrator of the end system is responsible for meeting all applicable Standards to obtain the CE mark. To aid this compliance...
  • Page 26 Corporate Officer: European Contact: Novanta Distribution (USD) GmbH Parkring 57-59 85748 Garching bei München, Germany Mel Lima, Sr. Quality and Reliability Director of SYNRAD Dated: MADE IN THE U.S.A. 900-20976-23 Rev B Figure 2-5 32-1 Declaration Document. SYNRAD® 32-1 Operator’s Manual Version 2.2...

  • Page 27: Operation

    Operation Use information in this chapter to familiarize yourself with 32-1 controls and indicators. Refer- ence the Quick Start Guide for the initial startup process. This chapter contains the following information: Controls and indicators – displays and describes exterior controls and indicators on 32-1 OEM lasers.

  • Page 28: Controls And Indicators

    Laser Exit Aperture – provides an opening from which the beam is emitted when lasing. 32-1 rear panel The back panel is just a black plate. SYNRAD® 32-1 Operator’s Manual Version 2.2...

  • Page 29: Side Panel

    DB-9 Connector – provides an interconnection for message, fault shutdown, remote interlock, remote keyswitch, and interface signals. Refer to the DB-9 connections section in the Techni- cal Reference chapter for information on pin assignments and function. SYNRAD® 32-1 Operator’s Manual Version 2.2...

  • Page 30: Technical Reference Summary

    Technical overview – briefly describes 32-1 technology, design RF power supply and basic optical setup. Control circuitry & cooling – introduces various aspects of the 32-1 control signals & cooling. DB-9 connections – describes input/output signals and specifications for the side mounted DB-9 connector.

  • Page 31: Technical Overview

    RF power supplies. 32-1 lasers emit a laser beam with a wavelength of 10.6 microns (µm). The laser beam diverges due to diffraction at a full angle of 8 mrad (milliradians), with the beam waist at the output aperture of the laser.

  • Page 32: Controlling Circuitry

    Model 32-1 lasers use a single RF electrode requiring a single modulated RF drive input from the Control PCB. The modulated input PWM signal is generated externally to the laser and connected to the input connector.

  • Page 33: Cooling

    Cooling 32-1 electronics are mounted opposite the laser tube in the smaller section of the “H” bay and share the same cooling removal as the plasma tube. Typical efficiency of CO...
  • Page 34 Because the laser beam diverges slowly, increasing 8 mm in diameter over every meter, 32-1 lasers should be mount- ed a distance of 1.0–1.5 m (40–60 in) away from the work area. Right angle turning mirrors are often used in conjunction with the laser mounting position to obtain this distance.
  • Page 35 High Purity Grade > 99.997% purity; filtered to ISO Class 1 particulate level Nitrogen Cutting/Drilling High Purity Grade > 99.9500% purity; filtered to ISO Class 1 particulate level Oxygen Cutting/Drilling Ultra Pure Grade > 99.9998% purity; filtered to ISO Class 1 particulate level SYNRAD® 32-1 Operator’s Manual Version 2.2...

  • Page 36: Control Signals

    6 mA (32-1 / 32-1); 12 mA (32-1) Tickle pulse 32-1 lasers require a 1 µs tickle pulse delivered at a nominal 5 kHz clock frequency from the Controller. Tickle pulses pre-ionize the laser gas to just below the lasing threshold so that any further increase in pulse width adds enough energy to the plasma to cause laser emission.
  • Page 37 0 VDC Figure 4-3 Tickle pulse waveform. 32-1 lasers are designed to operate at a tickle frequency of 5 kHz, which allows the laser to meet published specifications. Tickle frequencies lower than 4.5 kHz may compromise laser performance, particularly optical rise times, and stress the RF electronics thereby reducing long term reliability while tickle frequencies greater than 5 kHz may cause unintended lasing.
  • Page 38 Low signal amplitude Ch 2 Ch 1 100mV Ch 2 100 µS 740m V 2 kHz Modulation Figure 4-4 32-1-2 kHz waveform. The upper waveform is laser output, the lower wave form is PWM input. SYNRAD® 32-1 Operator’s Manual Version 2.2...
  • Page 39 Low signal amplitude Ch 2 Ch 2 Ch 1 100mV µS 720m V 5 kHz Modulation Figure 4-5 32-1-5 kHz waveform. The upper waveform is laser output, the lower wave form is PWM input. SYNRAD® 32-1 Operator’s Manual Version 2.2...
  • Page 40 Technical Reference User I/O Connections 32-1 lasers are designed to operate at PWM signal base frequencies up to 20 kHz; however, the choice of PWM frequency depends on the user’s specific application. In the majority of laser applications, the UC-2000’s default PWM signal frequency of 5 kHz has proven to work well.

  • Page 41: Operating Modes

    Operating modes External control In addition to controlling your 32-1 laser using a UC-2000 Controller, controlling the laser externally, without a UC-2000, is also possible. The two primary elements of laser control are gating, the ability to turn the laser on and off at the appropriate times, and power, the ability to control the laser’s output energy.

  • Page 42: Uc-2000 Universal Laser Controller

    15–50 VDC @ 35 mA, supplied from either its wall plug transformer or from the Aux- iliary Power connector on the side of 32-1 lasers. Refer to the UC-2000 Laser Controller Opera- tor’s Manual for information about UC-2000 operation.
  • Page 43 When operating in CW mode, laser power output cannot be adjusted. If you require Note: an adjustable output power level, refer to the Pulse width modulation (PWM) sec- tion for information regarding high frequency operation. SYNRAD® 32-1 Operator’s Manual Version 2.2...

  • Page 44: Db-9 Connections

    Damage DB-9 connections 32-1 lasers are equipped with a female DB-9 connector mounted to the sidewall of the laser. The DB-9 connector provides the user with a convenient method for monitoring fault condi- tions (over temperature, control/RF circuitry failure, etc.) and adds, remote keyswitch (relay or switch), and remote LED indicator capability.

  • Page 45: User I/O Connections

    The figure below illustrates the pin arrangement of the User I/O connector. DB-9 connections The figure below shows the physical layout and pin identification of the 32-1 DB-9 Connector. Refer to the following tables in the next two pages describing input/output signal specifica- tions.

  • Page 46: I/O Fault Diagrams

    LED cathodes to Pin 2. Current is limited internally to 20 mA at 3.3 V maximum. 5 The output of Pin 8, the Remote Lase LED Output, is a Pulse Width Modulated (PWM) signal based on the PWM input signal. It is not a steady state (on/off ) output. SYNRAD® 32-1 Operator’s Manual Version 2.2...
  • Page 47 PWM signal frequency, not a steady state on/off signal. Remote Ready LED Output Current-limited to 11 mA @ 2.4 VDC maximum. Signal Ground Signal ground for pins 1, 8, and 9. SYNRAD® 32-1 Operator’s Manual Version 2.2...

  • Page 48: Sample Db-9 Connector I/O Circuits

    Remember that Remote Keyswitch and Remote Interlock inputs are “dry circuit” or zero-voltage inputs. DB-9 CONNECTOR PINS (7) REMOTE KEYSWITCH OUTPUT RELAY CONTACT OR LIMIT SWITCH (6) REMOTE KEYSWITCH INPUT Figure 4-8 Remote Keyswitch circuit. SYNRAD® 32-1 Operator’s Manual Version 2.2...

  • Page 49: Sample Output Circuits

    The Fault Shutdown Output function signals a laser shutdown due to an under/over voltage condition, an over temperature condition, or failure of internal circuitry. DB-9 CONNECTOR PINS (1) FAULT SHUTDOWN INPUT OUTPUT (2) SIGNAL GROUND Figure 4-10 Fault Shutdown Output to PLC input. SYNRAD® 32-1 Operator’s Manual Version 2.2...

  • Page 50: Integrating 32-1 Safety Features

    The Integrating 32-1 safety features section includes subsections: Remote Keyswitch functions The 32-1 DB-9 Connector allows system integrators or end-users to integrate 32-1 laser safety features into their control system. In particular, the 32-1 Remote Keyswitch function serves to disable DC power to the laser’s RF driver. Without power, the RF driver cannot supply PWM or tickle signals to the resonator, causing the CO2 gas to remain in a zero-energy state.

  • Page 51: General Specifications

    Measured at laser output. 32-1 lasers are designed to operate at a tickle frequency of 5 kHz, which allows the laser to meet published specifications. Tickle frequencies lower than 4.5 kHz may compromise laser performance, particularly optical rise times, and stress the RF electronics thereby reducing long term reliability while tickle frequencies greater than 5 kHz may cause laser emission.

  • Page 52: Outline And Mounting Diagrams

    Technical Reference Outline and Mounting Diagrams Figure 4-11 Model 32-1 package outline and mounting dimensions, 1 of 1. SYNRAD® 32-1 Operator’s Manual Version 2.2...

  • Page 53: Maintenance/Troubleshooting

    This section of the Operation Manual explains how to conduct regular main- Important Note: tenance and/or basic troubleshooting to 32-1 lasers. If you cannot attend to the unit using the information described in this manual, contact SYNRAD®, (+.425.349.3500) or an authorized SYNRAD Distributor.

  • Page 54: Maintenance

    Serious aged. In the event of damage to laser, marking head, or beam personal delivery optics, contact SYNRAD or the optics manufacturer for injury handling instructions. Ensure that DC power to the laser is turned off and locked out before inspecting optical components in the beam path.

  • Page 55: Storage/Shipping

    Refer to Packaging instructions in the Technical Reference chapter and/or appropriate quick start guide for detailed instructions on properly packaging the laser for shipment. If you no longer have the original shipping box and inserts, contact SYNRAD® Customer Ser- vice about purchasing replacement packaging.

  • Page 56: Cleaning Guidelines

    Powder free Air bulb Clean air bulb Ethyl or isopropyl alcohol Spectroscopic or reagent grade Acetone Spectroscopic or reagent grade Lens wipe (preferred) Optical (cleanroom) quality Cotton balls or cotton swabs High-quality surgical cotton/high-quality paper-bodied SYNRAD® 32-1 Operator’s Manual Version 2.2...

  • Page 57: Cleaning Optics

    Do not exert pressure on the surface of the optic during cleaning. Optical surfaces and coatings are easily scratched by dislodged con- taminants. Use a new lens wipe on each pass as contaminants picked up by the wipe may scratch the optical surface. SYNRAD® 32-1 Operator’s Manual Version 2.2...

  • Page 58: Troubleshooting

    Contact SYNRAD® or a SYNRAD Autho- rized Distributor for repair or replacement information. To troubleshoot the 32-1 laser, it is necessary to understand the sequence of events that must happen before the laser can turn on and operate. Before you attempt to perform any service, we advise you to read the entire troubleshooting guide and review the relevant schematic diagrams.

  • Page 59: Beam Delivery Optics

    Caution If you operate your laser or marking head in a dirty or dusty en- vironment, contact SYNRAD® about the risks of doing so and the Possible precautions you can take to increase the longevity of your laser.

  • Page 60: Input/Output/Fault Conditions

    Over Voltage Fault TABLE KEY: C = circuit closed L = output low O = circuit open H = output high/open x = Does not matter 3/24/2017 Table 5-2 Input/Output/Fault Conditions for the 32-1 series lasers. SYNRAD® 32-1 Operator’s Manual Version 2.2...

  • Page 61: Index

    20 terminology, 15 Inspections daily, 54 Label locations 20 Laser Institute of America (LIA) 19 Maintenance daily inspections, 54 disabling Firestar, 54 storage/shipping, 55 Occupational Safety and Health Administration (OSHA) 19 Reference materials 8 SYNRAD® 32-1 Operator’s Manual Version 2.2...

  • Page 62: Index

    Figure 4-9. Remote Ready output to PLC..............50 Figure 4-1. Fault Shutdown Output to PLC input............50 Table 4-9. Model 32-1 general specifications..............52 Figure 4-11. Model 32-1 package O and M..............53 Table 5-1. Required cleaning materials.................57 Table 5-2. LED and I/O states.....................61...

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