Synrad Firestar V Series Operator's Manual
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Synrad Firestar V Series Operator's Manual

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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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  • Page 1 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 OEM v40 Operator’s Manual Version 4 SYNRAD is a registered trademark of Novanta Corporation. Novanta Corporation © © 2019. All Rights Reserved. No reproduction without written authorization. DATE: March 2019...

  • Page 3: Table Of Contents

    OEM controls and indicators ...................2-4 OEM v40 front panel ........................2-4 OEM v40 rear panel ........................2-5 OEM v40 side panel (SAB models) ....................2-6 Initial start-up .......................2-7 With a UC-2000 Controller ......................2-7 Without a UC-2000 Controller ....................2-10 SYNRAD OEM v40 Operator’s Manual Version 4...
  • Page 4 Storage/shipping ..........................4-3 Cleaning optical components ....................4-3 Troubleshooting ......................4-6 Introduction............................4-6 Operational flowchart ........................4-7 Functional block diagram ......................4-8 Status LEDs ............................4-9 Laser faults ............................4-11 Resetting faults ..........................4-11 Other laser faults ..........................4-14 Beam delivery optics ........................4-17 Index SYNRAD OEM v40 Operator’s Manual Version 4...
  • Page 5 Figure 3-18 Water-cooled Firestar v40 package outline and mounting dimensions ...............3-28 Figure 3-19 Fan-cooled Firestar v40 package outline and mounting dimensions ...............3-29 Figure 3-20 Air-cooled Firestar v40 (SAB model) package outline and mounting dimensions ..............3-30 SYNRAD OEM v40 Operator’s Manual Version 4...
  • Page 6 List of Figures (cont.) Figure 3-21 Firestar v40 packaging instructions ..........3-31 Figure 4-1 Operational flowchart ...............4-7 Figure 4-2 v40 functional block diagram ............4-8 SYNRAD OEM v40 Operator’s Manual Version 4...
  • Page 7 Table 4-1 Required cleaning materials ............4-4 Table 4-2 Status signals ..................4-9 Table 4-3 Interlock Open condition ..............4-10 Table 4-4 Over Temperature condition ............4-10 Table 4-5 Shutter Open condition ..............4-10 Table 4-6 Laser faults .....................4-11 SYNRAD OEM v40 Operator’s Manual Version 4...
  • Page 8 Trademark/copyright information SYNRAD and Firestar are registered trademarks of SYNRAD All other trademarks or registered trademarks are the property of their respective owners. © 2019 by SYNRAD All rights reserved. Synrad Firestar v40 operator’s manual viii...
  • Page 9 Warranty information This is to certify that v40 lasers are guaranteed by SYNRAD to be free of all defects in materials and workmanship for a period of one year from the date of purchase. This warranty does not apply to any defect caused by negligence, misuse (including environmental factors), accident, alteration, or im- proper maintenance.
  • Page 10 Reference materials Your Regional Sales Manager can provide reference materials including Outline & Mounting drawings, Operator’s Manuals, Technical Bulletins, and Application Newslet- ters. Most of these materials are also available directly from SYNRAD web site at http:// www.synrad.com Synrad Firestar v40 operator’s manual...
  • Page 11 EU headquarters For assistance in Europe, contact SYNRAD European subsidiary, Synrad Europe, at: © Novanta Distribution (USD) GmbH © Parkring 57-59 85748 Garching bei München, Germany Phone: +49-89-31707-0 web: www.synrad.com e-mail: EMEA- service@novanta.com Synrad Firestar v40 operator’s manual...
  • Page 12 Inventory – displays and describes all components shipped with your laser. ■ Mounting – describes how to attach laser components to a mounting surface. ■ Connecting – explains how to connect power and control cables as well as cooling connections for water-cooled models. SYNRAD OEM v40 Operator’s Manual Version 4...
  • Page 13 Introduction The Firestar v40 laser is a small-footprint laser from SYNRAD featuring high power and excellent beam ® quality. The circular beam provides more accurate cutting and faster processing speeds than competing technologies. With an integrated RF power supply, meaning no external RF cables, the compact laser housing mounts easily to flatbed cutters, robotic arms, or gantry systems making integration into your production line simple and fast.
  • Page 14 Upon arrival, inspect all shipping containers for signs of damage. If you discover shipping damage, document the damage (photographically if possible), then immediately notify the shipping carrier and SYNRAD. The shipping carrier is responsible for any damage occurring during transportation from SYNRAD, Inc. to your receiving dock. Packaging guidelines ■...
  • Page 15 SYNRAD Firestar v40 Laser .......1 Firestar v40 Operator’s Manual ......1 Quick Start Plug (except SAB models) ..1 Spare Fuse (not shown) ........2 Cooling Tubing (water-cooled only) .....1 Final Test Report (not shown) ......1 Mounting Bolts .............3 SYNRAD OEM v40 Operator’s Manual Version 4...
  • Page 16 Contents description Each item listed in Table 1-1 is described below. SYNRAD Firestar v40 Laser – for cutting, welding, drilling, and marking a wide variety of products and materials. Quick Start Plug (except SAB models) – connects to Firestar’s User I/O connector. Jumpers are built into the plug to enable Firestar’s shutter and remote interlock circuits for initial start-up and testing.

  • Page 17: Mounting

    To allow proper airflow, air- or fan-cooled units must have at least 2.25" (57.2 mm) of unobstruct- ed clearance between the outside edge of the cooling fan and any enclosure or surface. Caution SYNRAD does not recommend mounting lasers in a vertical “head- down” or “tail-down” orientation. If you must mount your laser in possible this manner, please contact the factory for limitations as vertical orientation increases the risk of damage to the laser’s output optic.
  • Page 18 Insert 1/4–20 × 5/8" UNC capscrews through the mounting surface into the threaded holes of Fire- star’s base plate. Turn the screws by hand until the threads engage. Tighten all three capscrews to a torque of 6 ft lb (8 N m) maximum. SYNRAD OEM v40 Operator’s Manual Version 4...
  • Page 19 When installing new fittings, wrap the threads with teflon tape and then carefully tighten the fittings until they are just snug enough to prevent water leakage. SYNRAD OEM v40 Operator’s Manual Version 4...
  • Page 20 Avoid glycol-based additives because they reduce the coolant’s heat capacity and high concentrations may affect power stability. For SYNRAD lasers, the minimum coolant setpoint is 18 °C (64 °F) so glycol is not necessary unless the chiller is subjected to freezing temperatures. In applications where biocides containing chlorides are used, concentrations should not exceed 25 parts per million (PPM).

  • Page 21: Table 1-2 Dew Point Temperatures

    For example, if the air temperature is 85 °F (29 °C) and the relative humidity is 60%, then the dew point temperature is 70 °F (21 °C). Adjust the chiller’s temperature setpoint to 72 °F (22 °C) to prevent condensation from developing inside the laser. SYNRAD OEM v40 Operator’s Manual Version 4...

  • Page 22: Figure 1-4 Firestar Cooling Connections

    Closely examine all cooling connections and verify that there are no leaks. Caution Operating the laser at coolant temperatures above 22 °C (72 °F) may result in decreased performance and/or premature failure of electronic possible components. equipment damage SYNRAD OEM v40 Operator’s Manual Version 4...

  • Page 23: Figure 1-5 Recommended V40 Cooling Fan Locations

    Because v40 OEM air-cooled lasers are shipped without cooling fans, customers must provide some type of air cooling to prevent overheating. SYNRAD recommends an airflow of at least 140 cubic feet per minute for each of the two required fans. Figure 1-5 illustrates the fan placement necessary to keep the laser’s heat sink temperature below 45 °C.

  • Page 24: Figure 1-6 Rear-Mounted Cooling

    Connecting SYNRAD recommends side-mounted cooling fans for Firestar v40 lasers but a rear-mounted, single-fan cooling scheme is also feasible. Figure 1-6 illustrates the rear-cooling concept. Please review the guide- lines below to ensure that your implementation provides enough airflow to prevent damage to the laser.
  • Page 25 Firestar v40 lasers require a DC power supply that provides 30 VDC at 24 A maximum. We recommend the SYNRAD DC-5 DC power supply that supplies 30 VDC at 33 A. AC input requirements for the DC-5 are 90–132 VAC (low range) or 175–264 VAC (high range), single phase (1ø), 15 A max, 47–440 Hz.
  • Page 26 Connect the other hot wire, typically black or red, from your voltage source to terminal “N” (AC Neutral). Connect the ground (earth) wire, typically green, from your AC voltage source to the terminal labeled with the ground symbol. SYNRAD OEM v40 Operator’s Manual Version 4...
  • Page 27 All control connections to the v40 laser are made through the 15-pin User I/O connector on Firestar’s rear panel. The User I/O port receives power commands from the SYNRAD’s UC-2000 Universal Laser Controller and also serves as the connection point for auxiliary signals between the laser and any parts handling, automation, or monitoring equipment.
  • Page 28 Reference chapter, for detailed instructions on integrating Firestar’s keyswitch, shutter, and remote interlock functions with automated control systems. Figure 3-7, Quick Start Plug wiring diagram, also in the Technical Reference chapter shows the Quick Start Plug wiring diagram. SYNRAD OEM v40 Operator’s Manual Version 4...
  • Page 29 This page intentionally left blank. SYNRAD OEM v40 Operator’s Manual Version 4...
  • Page 30 Do not allow the laser beam to contact a person! This product emits an invisible laser beam that is capable of seriously burning human tissue. Always be aware of the beam’s path and always use a beam block while testing. SYNRAD OEM v40 Operator’s Manual Version 4...

  • Page 31: Terms

    For laser systems being used or sold outside the U.S.A., customers should refer to and follow the laser safety precautions described in European Normative and International Electrotechnical Commission documents IEC/ TR 60825-14:2014, Safety of Laser Products – §14: A User’s Guide. SYNRAD OEM v40 Operator’s Manual Version 4...

  • Page 32: General Hazards

    Do not use air dusters containing difluoroethane in any area adjacent to CO 2 laser systems because difluoroethane persists for long time periods over wide areas. SYNRAD OEM v40 Operator’s Manual Version 4...
  • Page 33 Always wear safety glasses or protective goggles with side shields to reduce the risk of dam- age to the eyes when operating the laser. SYNRAD OEM v40 Operator’s Manual Version 4...
  • Page 34 III, Chapter 6 and Appendix III are good resources for laser safety information. Another excellent laser safety resource is the Laser Institute of America (LIA). Their compre- hensive web site is located at http://www.lia.org. SYNRAD OEM v40 Operator’s Manual Version 4...
  • Page 35 This laser product is manufactured under one or more of the following U.S. Patents: 6,195,379 6,198,758 6,198,759 6,603,794 6,614,826 7,480,323 9,031,110 9,197,028 Other U.S. and International Patents pending. Figure 2-3 Hazard label locations. SYNRAD OEM v40 Operator’s Manual Version 4...

  • Page 36: Agency Compliance

    Standards for complete laser processing systems as specified by 21 CFR, §1040 or EN 60825-1. SYNRAD assumes no responsibility for the compli- ance of the system into which OEM laser products are integrated.

  • Page 37: Federal Communications Commission (Fcc) Requirements

    §§ of 47 CFR, 213. FCC information to the user Interference Potential In our testing, SYNRAD has not discovered any significant electrical interference traceable to laser lasers. System Maintenance Ensure that all exterior covers are properly fastened in position. Measures to Correct Interference...

  • Page 38: European Union (Eu) Requirements

    OEM lasers are OEM products intended for incorporation as components in laser processing systems. As supplied by SYNRAD, these lasers do not meet the requirements of EN 60825-1 without additional safeguards. European Union Directives state that “OEM laser products which are sold to other manufacturers for use as components of any system for subsequent sale are not subject to this Standard, since the final product will itself be subject to the Standard.
  • Page 39 Illuminates green when Remote Interlock circuitry is closed. Illuminates red when interlock circuitry is open. Warning laser exterior labels Labels attached to various external housing locations to warn personnel of potential laser hazards. 1 Not available on laser OEM lasers SYNRAD OEM v40 Operator’s Manual Version 4...
  • Page 40 ® responsible for meeting all applicable Standards to obtain the CE mark. To aid this compliance process, SYNRAD testing program has demonstrated that laser lasers comply with the relevant requirements of Directive 2014/30/EU, the Electromagnetic Compatibility Directive, as sum- marized in the table below.
  • Page 41 EN 61000‐6‐4:2007  Radiated Emissions, Group 1, Class A  EN 61000‐6‐4:2007  Conducted Emissions, Group 1, Class A  EN 61000‐6‐2:2005  Electrostatic Discharge Immunity  EN 61000‐6‐2:2005  RF Electronic Fields Immunity  EN 61000‐6‐2:2005  Electrical Fast Transient/Burst Immunity  EN 61000‐6‐2:2005  Conducted RF Disturbances Immunity    *OEM lasers do not comply with EN 60825‐1:2014, Safety of Laser Products. Buyers of OEM laser products are  solely responsible for meeting applicable Directives and Standards for CE compliance and marking.  Corporate Officer:      European Contact:  Novanta Distribution (USD) GmbH       Parkring 57‐59  85748 Garching bei München, Germany   Tim Freni, Quality Manager of SYNRAD      3/4/19     Dated:  MADE IN THE U.S.A.  900‐20976‐17 Rev B  Figure 2-4 Declaration Document. SYNRAD OEM v40 Operator’s Manual Version 4...
  • Page 42 OEM controls and indicators – displays and describes exterior controls and indicators on the OEM v40 lasers. ■ Initial start-up – explains how to start your Firestar v40 laser while verifying proper operation. SYNRAD OEM v40 Operator’s Manual Version 4...

  • Page 43: Operation

    PWM Command signals are accepted. Optical Accessories Mounting – provides six threaded holes (8–32 UNC) for mounting optional beam delivery components available from SYNRAD. Because excessive weight may damage the laser, consult SYNRAD before mounting components not specifically designed as Firestar options.

  • Page 44: V40 Rear Panel

    WATER IN Port (water-cooled only) – labeled IN, this connection provides the cooling water inlet to Firestar’s water-cooling system. 10 WATER OUT Port (water-cooled only) – labeled OUT, this connection provides the cooling water outlet from Firestar’s water-cooling system. SYNRAD OEM v40 Operator’s Manual Version 4...

  • Page 45: Oem Controls And Indicators

    Laser Aperture – provides an opening in Firestar’s front panel from which the beam exits. Optical Accessories Mounting – provides six threaded holes (8–32 UNC) for mounting optional beam delivery components available from SYNRAD. Because excessive weight may damage the laser, consult SYNRAD before mounting components not specifically designed as Firestar options.

  • Page 46: Oem V40 Rear Panel

    WATER IN Port (water-cooled only) – labeled IN, this connection provides the cooling water inlet to Firestar’s water-cooling system. WATER OUT Port (water-cooled only) – labeled OUT, this connection provides the cooling water outlet from Firestar’s water-cooling system. SYNRAD OEM v40 Operator’s Manual Version 4...

  • Page 47: Oem V40 Side Panel (Sab Models)

    OEM v40 side panel controls and indicators DB-9 connector – provides a Shutter Switch input as well as auxiliary +5 and +24 VDC outputs. See DB-9 connections in the Technical Reference chapter for connection details. SYNRAD OEM v40 Operator’s Manual Version 4...

  • Page 48: Initial Start-Up

    Caution Because of their smaller beam diameter, Firestar lasers have signifi- cantly higher power densities than previous SYNRAD lasers. This possible means that even a small amount of contamination on the laser’s output coupler can absorb enough energy to damage the optic.
  • Page 49 Place the Shutter Switch (if equipped) in the Open position. The blue SHT (Shutter) indicator will illuminate. Rotate the Keyswitch (if equipped) to the ON position. Verify that the yellow RDY (Ready) lamp illuminates. SYNRAD OEM v40 Operator’s Manual Version 4...
  • Page 50 If your Firestar v40 laser fails to lase, refer to Troubleshooting in the Maintenance/Troubleshooting chapter for troubleshooting information. SYNRAD OEM v40 Operator’s Manual Version 4...

  • Page 51: Without A Uc-2000 Controller

    Caution Inlet cooling water temperature must always be maintained above the dew point to prevent condensation and water damage to your Firestar possible laser. equipment damage SYNRAD OEM v40 Operator’s Manual Version 4...
  • Page 52 Because of phase differences, external tickle pulses may combine with the internally-generated tickle signal causing the LASE LED to serious flicker during the transition from tickle to lasing. Laser output may occur if the Lase LED flickers. personal injury SYNRAD OEM v40 Operator’s Manual Version 4...
  • Page 53 If your Firestar v40 laser fails to lase, refer to Troubleshooting in the Maintenance/Troubleshooting chapter for troubleshooting information. SYNRAD OEM v40 Operator’s Manual Version 4...

  • Page 54: Technical Reference

    Firestar v40 package outline drawings – illustrates laser package and mounting dimensions for Keyswitch and OEM v40 lasers. ■ Packaging instructions – illustrates how to package the v40 laser for shipment using SYNRAD-supplied packaging materials. SYNRAD OEM v40 Operator’s Manual Version 4...

  • Page 55: Technical Overview

    Optical setup Laser tube Firestar v-Series lasers were developed using new technology patented by SYNRAD. This patented “v” ® technology, based on a combination of free-space and waveguide resonator designs, enables SYNRAD to economically produce a symmetrical laser beam from a small but powerful laser capable of operating for many years with virtually no maintenance.

  • Page 56: Rf Power Supply

    In fixed-length delivery systems where the laser is positioned only one meter away from the focusing optic and a small spot size is required, an expander/collimator is again the best solution to provide the required beam expansion before reaching the focusing optic. SYNRAD OEM v40 Operator’s Manual Version 4...
  • Page 57 Breathing Grade 99.9996% purity or better Compressed 99.9950% purity or better, water-free; oil filtered to 5 mg/m or better; particulate filtered to < 1.0 micron; dried to lower dew point below coolant temperature setpoint. SYNRAD OEM v40 Operator’s Manual Version 4...

  • Page 58: Controlling Laser Power

    Operating modes Control signals Much of the information provided in this section describes the use of a SYNRAD UC-2000 Universal Laser Controller to provide PWM Command signals to the v40 laser. If using an alternate method of laser control, thoroughly review this section, Controlling laser power, as well as the following section, User I/O connections, for an understanding of the signal requirements necessary to control Firestar lasers.
  • Page 59 Base frequency, the second parameter, is the repetition rate of the PWM input signal. The standard base frequency is 5 kHz, which has a period of 200 microseconds (µs). Maximum PWM frequency is 25 kHz. SYNRAD OEM v40 Operator’s Manual Version 4...

  • Page 60: Operating Modes

    UC-2000 Controller. The Controller is connected normally to the laser and analog voltage or current signals sent to the UC-2000’s ANV/C connector then control both gating and power. SYNRAD OEM v40 Operator’s Manual Version 4...
  • Page 61 Note: SYNRAD lasers are designed for maximum performance at a 95% duty cycle. Increasing the maximum PWM percentage beyond 95% greatly increases the laser’s heat load with little or no corresponding increase in laser output power. Continuous operation at 99% duty cycle may lead to thermal instability and optical degradation.
  • Page 62 While this situation can occur when using PWM Command signal frequencies of 5 kHz and less, it is im- portant to note that it isn’t the Command signal frequency itself that is the determining factor but rather this behavior happens only when the off time between PWM pulses exceeds 200 microseconds. SYNRAD OEM v40 Operator’s Manual Version 4...

  • Page 63: User I/O Connections

    This bi-directional switched output is internally connected to Pin 13, Output Common, when laser temperature is above safe operating limits (TMP indicator illuminated red). The output is open (high impedance) when laser temperature is within operating limits (TMP indicator green). SYNRAD OEM v40 Operator’s Manual Version 4...
  • Page 64 This bi-directional switched output is internally connected to Pin 13, Output Common, when remote interlock circuitry is open (INT indicator illuminated red), indicating that lasing is disabled. The output is open (high impedance) when lasing is enabled (INT indi- cator green). SYNRAD OEM v40 Operator’s Manual Version 4...

  • Page 65: Input/Output Signals

    Failure to do so may damage the laser. equipment damage INT TMP RDY SHT LASE USER I/O Figure 4-5 User I/O connector pinouts SYNRAD OEM v40 Operator’s Manual Version 4...
  • Page 66 This pin is the only User I/O pin that is connected to the laser’s chassis ground. Do not use this pin for grounding if I/O circuits are powered from an external customer-supplied DC power source. SYNRAD OEM v40 Operator’s Manual Version 4...
  • Page 67 95% corresponds to approximately full output power. Refer to Controlling laser power in this chapter for further information on laser control signals. Connect the PWM signal source return to Pin 1, PWM Return. See the following table for input circuit specifications. SYNRAD OEM v40 Operator’s Manual Version 4...
  • Page 68 Pin 15 Pin 9 Figure 4-7 Quick Start Plug wiring diagram The figure on the following page illustrates the input circuit’s equivalent internal schematic while Table 3-4 provides Firestar v40 input circuit specifications. SYNRAD OEM v40 Operator’s Manual Version 4...
  • Page 69 On state (continuous) Vmax ±24.0 VDC @ 40 mA Note: The Remote Reset/Start Request input must not be sent until Firestar’s +5 VDC power supply has stabilized (approximately 200 ms after DC power-up). SYNRAD OEM v40 Operator’s Manual Version 4...
  • Page 70 (INT indicator red), indicating that lasing is disabled. The out- put is open (high impedance) when lasing is enabled (INT indicator green). See the following table for output circuit specifications. SYNRAD OEM v40 Operator’s Manual Version 4...
  • Page 71 FIRESTAR v40 OUTPUT CIRCUITRY Figure 4-9 Output equivalent schematic Table 4-5 Output circuit specifications Output Device Specifications Bi-directional CMOS 20 Ohms Rdson 10 MOhms Off Voltage ±24 VDC, max. Current 50 mA, max. SYNRAD OEM v40 Operator’s Manual Version 4...

  • Page 72: Sample I/O Circuits

    PLC output module when only one Firestar input is used. OUTPUT USER I/O PINS MODULE (3) REMOTE INTERLOCK (+5–24V) (11) INPUT COMMON Figure 4-12 PLC driven interlock signal SYNRAD OEM v40 Operator’s Manual Version 4...
  • Page 73 R1, so that the current draw does not exceed 50 mA. USER I/O PINS (5) +24 VDC AUXILIARY POWER (6) LASER ACTIVE (12) AUX. DC POWER GROUND (13) OUTPUT COMMON Figure 4-14 Firestar output driving warning lamp SYNRAD OEM v40 Operator’s Manual Version 4...
  • Page 74 PLC inputs. INPUT USER I/O PINS MODULE (13) OUTPUT COMMON (+5–24V) (6) LASER ACTIVE (7) OVER TEMPERATURE (8) LASER READY (14) SHUTTER OPEN (15) INTERLOCK OPEN Figure 4-16 Firestar output driving PLC input module SYNRAD OEM v40 Operator’s Manual Version 4...

  • Page 75: Connections (Sab Models Only)

    Fan Power output (Pin 4) can source up to 0.75 A max. This pin is not protected or fused; the control board will be damaged if this pin is inadvertently shorted. The return (ground) path must be through Pin 3, DC Power Ground. SYNRAD OEM v40 Operator’s Manual Version 4...
  • Page 76 Power output (Pin 9) can source up to 0.5 A max. This pin is not protected or fused; the control board will be damaged if this pin is inadvertently shorted. The return (ground) path must be through Pin 3, DC Power Ground. SYNRAD OEM v40 Operator’s Manual Version 4...

  • Page 77: Integrating Firestar Safety Features

    ±5–24 VDC Remote Reset/Start Request input is applied. Your control system can monitor the laser’s ready status on the User I/O connector by connecting your system’s input to Pin 8, Laser Ready, and Pin 13, Output Common (see prior table). SYNRAD OEM v40 Operator’s Manual Version 4...

  • Page 78: Shutter Functions

    Pin 15, Interlock Open, and Pin 13, Output Common (prior figure). This output is closed when remote interlock circuitry is open (INT indicator illuminated red). The output is open (INT LED green) when interlock circuitry is closed. SYNRAD OEM v40 Operator’s Manual Version 4...

  • Page 79: V40 General Specifications

    1 This power level is guaranteed for 12 months regardless of operating hours. 2 Minimum 30 VDC input voltage to obtain guaranteed output power. 3 From cold start (guaranteed). 4 After two minutes (typical). 5 Measured at laser output. 6 Tested at 5 kHz. SYNRAD OEM v40 Operator’s Manual Version 4...
  • Page 80 7 Published specifications guaranteed at a cooling temperature of 22 °C. For air-cooled lasers, some performance degradation may occur in ambient temperatures above 22 °C. Typically output laser power decreases 0.5–1 Watt per degree Celsius increase in ambient temperature. SYNRAD OEM v40 Operator’s Manual Version 4...

  • Page 81: Firestar V40 Package Outline Drawings

    Firestar v40 package outline drawings Figure 4-18 Water-cooled Firestar v40 package outline and mounting dimensions SYNRAD OEM v40 Operator’s Manual Version 4...
  • Page 82 Firestar v40 package outline drawings Figure 4-19 Fan-cooled Firestar v40 package outline and mounting dimensions SYNRAD OEM v40 Operator’s Manual Version 4...
  • Page 83 Firestar v40 package outline drawings Figure 4-20 Air-cooled Firestar v40 (SAB model) package outline and mounting dimensions SYNRAD OEM v40 Operator’s Manual Version 4...

  • Page 84: Packaging Instructions Drawing

    Packaging instructions drawing Figure 4-21 Firestar v40 packaging instructions SYNRAD OEM v40 Operator’s Manual Version 4...
  • Page 85 This page intentionally left blank. SYNRAD OEM v40 Operator’s Manual Version 4...

  • Page 86: Maintenance/Troubleshooting

    Use information in this chapter to perform maintenance or troubleshoot your Firestar v40 laser. This chapter contains the following information: ■ Maintenance – describes typical v40 maintenance procedures. ■ Troubleshooting – explains how to troubleshoot common v40 problems. SYNRAD OEM v40 Operator’s Manual Version 4...

  • Page 87: Disabling Firestar

    A risk of exposure to toxic elements may result when certain optical or beam delivery components are damaged. In the event of damage possible to laser or marking head optics, contact SYNRAD, Inc. or the optics manufacturer for handling instructions. personal injury SYNRAD OEM v40 Operator’s Manual Version 4...

  • Page 88: Storage/Shipping

    When finished, cap all connectors to prevent debris from entering the cooling system. When shipping SYNRAD lasers to another facility, we highly recommend that you ship the unit in its original SYNRAD shipping container. If you no longer have the original shipping box and inserts, contact SYNRAD Customer Service about purchasing replacement packaging.

  • Page 89: Troubleshooting

    Shut off and lock out all power to the laser. You must verify that the laser is in a zero-energy state before continuing with the optical inspection! Visually inspect all optical surfaces in the beam path, including the laser’s output coupler, for con- taminants. SYNRAD OEM v40 Operator’s Manual Version 4...
  • Page 90 Carefully examine the optic under a good light. Certain contaminants or damage such as pitting cannot be removed. In these cases the optic must be replaced to prevent catastrophic failure. Repeat Steps 4 through 6 as required, removing all traces of contaminants and deposits. SYNRAD OEM v40 Operator’s Manual Version 4...

  • Page 91: Introduction

    Contact SYNRAD or a SYNRAD Authorized Distributor for repair/replacement information. To troubleshoot the Firestar v40 laser, it is necessary to understand the sequence of events that must happen before the laser can turn on and operate.

  • Page 92: Operational Flowchart

    (Ready) indicator (Ready) indicator back to ON Yellow? (on OEM lasers, Yellow? cycle DC power) Apply PWM Command signal to laser LASE indicator illuminates Red to indicate laser output Figure 5-1 Operational flowchart SYNRAD OEM v40 Operator’s Manual Version 4...

  • Page 93: Functional Block Diagram

    Troubleshooting Functional block diagram Figure below is a functional block diagram illustrating the v40’s control architecture. Figure 5-2 v40 functional block diagram SYNRAD OEM v40 Operator’s Manual Version 4...

  • Page 94: Status Leds

    Switch Closed or Shutter Open Request signal missing), no power is applied to the RF boards until both RDY and SHT indicators are illuminated. Following tables show how Firestar’s signal status changes when remote interlock, over temperature, or shutter closed conditions occur. SYNRAD OEM v40 Operator’s Manual Version 4...
  • Page 95 Table 5-5 Shutter Open condition LED Indicator LED Status Signal Name User I/O Output Status Green Interlock Open Open Green Over Temperature Open Yellow Laser Ready Closed Shutter Open Open LASE Laser Active Open SYNRAD OEM v40 Operator’s Manual Version 4...

  • Page 96: Laser Faults

    Keyswitch from OFF to ON (or apply a ±5–24 VDC Remote Reset/Start Request pulse with the Keyswitch set to ON). When the RDY indicator illuminates, lasing is enabled after a five-second delay. SYNRAD OEM v40 Operator’s Manual Version 4...
  • Page 97 An RF Drive DC fault is indicated by the RDY indicator flashing 3 blinks. Reset the laser by removing DC power to the laser, wait 30 seconds, and then reapply DC power. If the RF Drive DC fault reappears, contact SYNRAD or a SYNRAD Authorized Distributor. PWM Drive fault A PWM Drive fault is indicated by the RDY indicator flashing 4 blinks.
  • Page 98 An RF Drive DC fault is indicated by the RDY indicator flashing 3 blinks. Reset the laser by removing DC power to the laser, wait 30 seconds, and then reapply DC power. If the RF Drive DC fault reappears, contact SYNRAD or a SYNRAD Authorized Distributor. PWM Drive fault A PWM Drive fault is indicated by the RDY indicator flashing 4 blinks.

  • Page 99: Other Laser Faults

    – Open TMP LED – Red Over Temperature – Closed RDY LED – Off Laser Ready – Open SHT LED – Blue Shutter Open – Closed LASE LED – Off Laser Active – Open SYNRAD OEM v40 Operator’s Manual Version 4...
  • Page 100 DB-15 connector so that Pin 11 (Input Common) is jumpered to Pin 12 (Auxiliary DC Power Ground) and Pin 10 (Shutter Open Request) is jumpered to Pin 4 (+5 VDC Auxiliary Power). SYNRAD OEM v40 Operator’s Manual Version 4...
  • Page 101 Ensure that DC power cable connections are tight and verify that +30 VDC is available on the power sup- ply terminals under full-load. Check the in-line fuse on the laser’s red DC power cable. Install a Bussman KLK25 or equivalent 25-am- pere fast-acting replacement fuse. SYNRAD OEM v40 Operator’s Manual Version 4...

  • Page 102: Beam Delivery Optics

    Beam delivery optics Caution If you operate your laser or marking head in a dirty or dusty environ- ment, contact SYNRAD about the risks of doing so and precautions possible you can take to increase the longevity of your laser, marking head, and associated optical components.
  • Page 103 This page intentionally left blank. SYNRAD OEM v40 Operator’s Manual Version 4...
  • Page 104 Quick Start Plug, 1-17 Keyswitch v-Series rear panel, 2-3 reverse polarity, 1-14 OEM v-Series front panel, 2-4 toxic exposure, 4-2, 4-17 OEM v-Series rear panel, 2-5 User I/O connector, 1-16, 3-12 OEM v-Series side panel, 2-6 SYNRAD OEM v40 Operator’s Manual Version 4...
  • Page 105 Firestar DC power daily inspections, 4-2–4-3 +24 VDC, 3-10, 3-13, 3-19, 3-20 disabling, 4-2 +5 VDC, 3-10, 3-13, 3-19, 4-14, 4-15 faults, 4-11–4-16 Aux. DC Power Ground, 3-11, 3-13, 4-14, features, 1-2 4-15 SYNRAD OEM v40 Operator’s Manual Version 4...
  • Page 106 UC-2000 Controller, 2-7–2-9 without a UC-2000 Controller, 2-10–2-12 Input circuit Label locations 4 equivalent schematic, 3-16 Lase (LASE) indicator 8, 2-3, 2-5, 2-9, 2-11, pin descriptions, 3-14–3-15 3-10, 3-17, 4-9, 4-10, 4-16 SYNRAD OEM v40 Operator’s Manual Version 4...
  • Page 107 3-7 gated operation, 3-8 marking/engraving operation, 3-9 Package outline drawings 3-28–3-30 Operational flowchart 4-7 Packaging guidelines, 1-3 Operator’s manual 1-4, 1-5 Packaging drawing 3-31 Optical accessories mounting 2-2, 2-4 Packaging instructions 1-3 SYNRAD OEM v40 Operator’s Manual Version 4...
  • Page 108 3-10, 3-17, 4-9, 4-10, 4-11, 4-13, 4-14, 3-3, 3-10, 3-14, 3-16, 3-24, 4-11 4-16 description, 3-10, 3-14 Tickle pulse 3-5 specifications, 3-16 Trademark information x Resetting faults 4-11–4-13 Keyswitch lasers, 4-11–4-12 Troubleshooting 4-6–4-17 SYNRAD OEM v40 Operator’s Manual Version 4...
  • Page 109 UC-2000 Gate logic, 3-8 Warning labels 8 Warranty information xi Water cooling 1-8–1-11 chiller guidelines, 1-9 coolants, 1-9 coolant temperature, 1-9–1-10 fittings, 1-8 guidelines, 1-8 tubing connections, 1-11 Water Out/Water In ports 1-11, 2-3, 2-5 SYNRAD OEM v40 Operator’s Manual Version 4...

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