Novanta i401 User Manual
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Novanta i401 User Manual

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i401 Laser
User Manual
ENGINEERED BY SYNRAD

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  • Page 1 Laser User Manual ENGINEERED BY SYNRAD...

  • Page 2: Table Of Contents

    General Hazards ....................................39 Other Hazards ....................................40 Disposal......................................41 Additional Laser Safety Information ..............................42 i401 label locations ..................................43 Agency Compliance ..................................44 Center for Devices and Radiological Health (CDRH) requirements ....................44 Federal Communications Commission (FCC) Requirements ......................45 European Union (EU) requirements ..............................
  • Page 3 DC power cables ....................................81 DC voltage sense cable ..................................81 I401 i401 web interface ................................... 82 Accessing the i401 web page ................................82 Home page layout.................................... 83 Event log page layout ..................................86 Changing the i401’s IP address ................................ 87 Alternate Ethernet connection ................................
  • Page 4 Figure 2-1 Hazard label locations..............................43 Table 2-1 Class 4 safety features..............................47 Table 2-2 European Union Directives.............................. 48 Figure 2-2 i401 Declaration of conformity ............................49 Figure 3-1 i401 front panel controls and indicators ........................50...
  • Page 5 Figure 4-23 Local Area Connection Properties dialog........................90 Figure 4-24 Internet Protocol (TCP/IP) Properties dialog ........................ 90 Figure 4-25 Configure IP Address link on I401 home page ......................91 Figure 4-26 i401 Change IP Address page ............................91 Figure 4-27 I401 web browser display ............................. 92 Table 4-6 i401 general specifications ..............................

  • Page 6: Important Information

    For your protection, carefully read these instructions before installing and operating the scan head. Retain these instructions for future reference. Novanta reserves the right to update this user manual at any time without prior notification. If product ownership changes, this manual should accompany the product. Safety Symbols DANGER: Indicates a hazardous situation which, if not avoided, will result in serious injury or death.
  • Page 7 Devices and Radiological Health) certification. Customer Support Before contacting Novanta for assistance, review appropriate sections in the manual that may answer your questions. After consulting this manual, please contact one of our worldwide offices between 9 AM and 5 PM local time.
  • Page 8 Novanta Europe GmbH, Wackersdorf, Germany Phone: +49 9431 7984-0 Email: photonics@novanta.com Milan, Italy Phone: +39-039-793-710 Email: photonics@novanta.com China Novanta Sales & Service Office, Shenzhen, China Phone: +86-755-8280-5395 Email: photonics.china@novanta.com Novanta Sales & Service Office, Suzhou, China Phone: +86-512-6283-7080 Email: photonics.china@novanta.com Japan Novanta Service &...

  • Page 9: Introduction

    Warranty Information This is to certify that ® i401 lasers are guaranteed by Novanta, Inc. to be free of all defects in materials and workmanship for a period of one year from the date of purchase. This warranty does not apply to...

  • Page 10: Worldwide Headquarters

    If no discrepancies are reported, Novanta shall assume the shipment was delivered complete and defect-free. If, within one year from the date of purchase, any part of the I401 laser should fail to operate, contact the Novanta Customer Service department at 1. 800.NOVANTA1 (outside the U.S. call 1.425.349.3500) and report the problem.

  • Page 11: Technical Support

    PAGE Sales & Application Novanta Regional Sales Managers work with customers to identify and develop the best CO2 laser solution for a given application. Because they are familiar with you and your laser application, use them as a first point of contact when questions arise. Regional Sales Managers also serve as the liaison between you and our Applications Lab in processing material samples per your specifications.

  • Page 12: Getting Started

    • Model numbers The i401 laser is a new addition to Novanta i401 series of high-power lasers. This single tube 400 W laser features an integrated RF power supply with no external RF cables. The compact, single- tube design mounts easily to flatbed cutters, robotic arms, or gantry systems making integration into your production line simple and fast.

  • Page 13: Unpacking

    (Switch-less) for OEM models. The next letter indicates the cooling method: “W” for water-cooled units, “F” for fan-cooled units, and “A” for air-cooled lasers (the cooling method, the “W,” is omitted on all i401 lasers since they are all water-cooled lasers). The last letter in the model number indicates the current model version beginning with “B.”...
  • Page 14 Packaging guidelines Warning: Serious Personal Injury Lifting or moving the i401 laser poses a potential for injury. Use appropriate lifting techniques and/or equipment to prevent a risk of injury. In some cases, you may require assistance from additional personnel to safely unpack and move this equipment.

  • Page 15: Figure 1-1 Unpacking The Laser

    Remove the upper lid and set it aside. Carefully lift or hoist the sling containing the i401 laser out of the container and place it on a solid surface. To prevent injury to personnel or damage to the laser, always use at least two people to lift and move the sling.

  • Page 16: Figure 1-2 Removing The I401 Lifting Handles

    Remove the 1/4–20 × 5/8" cap screws from two locations on each of the three handles as shown in the figure below. Save the lifting handles and cap screws so the handles can be reinstalled if the i401 is moved to another location.

  • Page 17: Inventory

    INVENTORY PAGE Inventory Figure 1-3 i401 shipping box contents. Table 1-1 i401 ship kit contents. Shipping Box Contents Shipping Box Contents i401 400 W Laser Quick Start Plug Customer Communication Flier 1/2" Tubing Fitting Kit Ethernet Crossover Cable Mounting Hardware Kit...
  • Page 18 12 mm O.D. by 30 feet and must be cut to length. DC Power Cables – carry DC power from the 48 V power supply to your i401 laser. Standard cable length is 2.0 meters (6.5 feet) while optional 5.0 m (16 ft) power cables are available.

  • Page 19: Mounting

    • Three-point mount without feet The i401 base plate is designed so that the laser is easily mounted in various configurations as described in the subsections below. Refer to the i401 package outline drawing in the Technical Reference section for mounting locations and dimensions.

  • Page 20: Figure 1-4 Mounting Locations For Four-Point Mount With Feet

    When removing the mounting feet, raise the laser by placing support blocks under the base plate. Do not lay or place the i401 laser on its side or top, even temporarily, because the sheet metal covers are not designed to support the weight of the laser. Always support and mount the laser using the mounting feet or base plate to avoid damaging the laser.

  • Page 21: Figure 1-5 Mounting Locations For Four-Point Mount Without Feet

    35 mm cap screws the ship kit are for use with the factory-installed mounting feet. When fastening the i401 to your mounting surface from the bottom up, use M10 × 1.5 mounting screws with a length of 30 mm ± 2 mm plus the thickness of the mounting plate and any washers between the bolt head and the...

  • Page 22: Figure 1-6 Mounting Locations For Three-Point Mount Without Feet

    When removing the mounting feet, raise the laser by placing support blocks under the base plate. Do not lay or place the i401 laser on its side or top, even temporarily, because the sheet metal covers are not designed to support the weight of the laser. Always support and mount the laser using the mounting feet or base plate to avoid damaging the laser.

  • Page 23: Connecting

    The second option is to remove the 12 mm Tri Thread fittings from the laser’s cooling manifold and install 1/2" Tri Thread fittings—which are included in the i401 ship kit. The Tri Thread fittings used on i401 lasers (from Pneuforce.com) are designed to seal on the face of the O-ring, which allows them to seal properly even when re-used.
  • Page 24 Avoid glycol-based additives because they reduce the coolant’s heat capacity and high concentrations may affect power stability. For Novanta lasers, the minimum coolant setpoint is 18 °C (64 °F) so glycol is not necessary unless the chiller is subjected to freezing temperatures. If tap water is used, chloride levels should not exceed a concentration of 25 parts per million (PPM) and total hardness should be below 100 PPM.
  • Page 25 CONNECTING PAGE • Use the Gas Purge port to introduce nitrogen or dry, filtered air into the laser housing. • Air-condition the room or the enclosure containing the laser • Install a dehumidifier to reduce the humidity of the enclosure containing the laser. •...

  • Page 26: Figure 1-7 I401 Cooling Connections

    Cooling tubing connections To connect cooling tubing to your i401 laser, refer to Figure 1-7 and perform the following steps. The numbered items in Figure 1-7 correspond to the step numbers in the following procedure.
  • Page 27 DC power supply. i401 lasers require a DC power source capable of supplying a minimum of 135 A at 48 VDC. A supply with remote sense capability that can compensate for a minimum load lead loss (round trip) of 1.0 V is highly recommended.

  • Page 28: Figure 1-8 Ps-401 Voltage Selection Access Panel

    CONNECTING PAGE Figure 1-8 PS-401 voltage selection access panel AC three-phase connections Caution: Possible Equipment Damage All AC input wiring and fusing to the DC power supply must be sized and connected in accordance with applicable local, state, and national requirements. Local, state, and national code requirements (like NEC, CSA, and IEC 60364) supersede any recommendations provided in this manual.

  • Page 29: Figure 1-9 Ps-401 Input Section

    Connect the third hot wire, typically blue, to the input terminal labeled L3. DC power/DC voltage sense cables To connect DC power and the DC voltage sense cables between your i401 laser and PS-401 DC power supply, refer to Figure 1-10 and Figure 1-11 and perform the following steps:...

  • Page 30: Figure 1-10 Dc Power Connection Locations - Rear View

    CONNECTING PAGE Caution: Possible Equipment Damage Do not reverse polarity when connecting the DC power or DC sense cables to your DC power source. Reversed DC polarity may damage the laser’s internal RF power supply. Carefully follow the directions below to ensure that DC power cables are properly connected to the correct DC output terminals.
  • Page 31 DC sense connections. In either case, attach the sense cable as described below. 1 Locate DC Power Cables and DC Voltage Sense Cable in the i401 and PS-401 ship kits. Remove the two 6–32 cap screws and acrylic shield covering the +48V POWER terminal block on the rear of the laser.
  • Page 32 1.0 V. Control connections All control connections to i401 lasers are made through the 15-pin User I/O connector on the rear panel. The User I/O port receives power commands from Novanta’s UC-2000 Universal Laser Controller, or FH Flyer marking head, and serves as the connection point for auxiliary signals between the laser and any parts handling, automation, or monitoring equipment.
  • Page 33 Locate the Quick Start Plug in the ship kit. Connect the Quick Start Plug to the User I/O connector on the rear of the i401 laser. Attach the BNC connector on the end of the UC-2000’s Power/Control cable to the BNC connector on the rear of the Quick Start Plug.

  • Page 34: Figure 1-12 Gas Purge Kit Assembly

    Refer to Figure 1-12A and fasten the filter support bracket to the rear of the i401 laser using the 6– 32 Allen cap screws and # 6 flat washers provided in the kit.
  • Page 35 Purge gas specifications. The Gas Purge port on the i401 laser must be connected to a source of nitrogen or clean, dry air only; do not use any other gases for purging. Purge gas specifications are listed in Table 1-4 below.
  • Page 36 IP address that allows a simple Ethernet connection between the i401 laser and a host. To connect your host computer to the i401 laser using a peer-to-peer Ethernet connection, perform the steps in the following sections: Important Note: Connection to a local network is permitted if the laser’s fixed IP address is...

  • Page 37: Laser Safety

    The i401 web page is not compatible with the Google Chrome browser. Figure 1-13 I401 home page To use the i401’s web page capability to monitor various operating or service parameters, see the I401 i401 web interface section in the Technical Reference section for additional information. If you have problems connecting to the i401 web page, refer to the Troubleshooting –...

  • Page 38: Hazard Information

    PAGE • Additional Safety Information – describes how to find additional information about your i401 laser. • Compliance – explains in the subsections therein applicable and appropriate regulation information. Important Note: Read the entire safety section. This will ensure you are familiar with the hazards and warnings prior to starting.

  • Page 39: General Hazards

    Specific warnings and cautions not appearing in this section are found throughout the manual. i401 lasers should be installed and operated in manufacturing or laboratory facilities by trained personnel only. Due to the considerable risks and hazards associated with the installation and operational use of any equipment incorporating a laser, the operator must follow product warning labels and instructions to the user regarding laser safety.

  • Page 40: Other Hazards

    OTHER HAZARDS PAGE Warning: Serious Personal Injury Do not allow laser radiation to enter the eye by viewing direct or reflected laser energy. CO2 laser radiation can be reflected from metallic objects even though the surface is darkened. Direct or diffuse laser radiation can inflict severe corneal injuries leading to permanent eye damage or blindness.

  • Page 41: Disposal

    This product contains components that are considered hazardous industrial waste. If a situation occurs where the laser is rendered non-functional and cannot be repaired, it may be returned to Novanta® who, for a fee, will ensure adequate disassembly, recycling and/or disposal of the product.

  • Page 42: Additional Laser Safety Information

    PAGE Additional Laser Safety Information The Novanta web site (http://www.Novanta.com/LaserFacts/safetyinfo.html) contains an online laser safety handbook that provides information on (1) Laser Safety Standards for OEM’s/System Integrators, (2) Laser Safety Standards for End Users, (3) References and Sources, and (4) Assistance with Requirements.

  • Page 43: I401 Label Locations

    I401 LABEL LOCATIONS PAGE i401 label locations Figure 2-1 Hazard label locations.

  • Page 44: Agency Compliance

    OEM lasers are OEM products intended for incorporation as components in laser processing systems. As supplied by Novanta, these lasers do not meet the requirements of 21 CFR, Subsection J without additional safeguards. In the U.S., the Buyer of these OEM laser components is solely responsible for the assurance that the laser processing system sold to an end user complies with all laser safety requirements before the actual sale of the system.

  • Page 45: Federal Communications Commission (Fcc) Requirements

    §§ 213 Information to the user. Interference Potential In o ur testing, Novanta has not discovered any significant electrical interference traceable to our lasers. System Maintenance Ensure that all exterior covers are properly fastened in position. Measures to Correct Interference...

  • Page 46: European Union (Eu) Requirements

    OEM lasers are OEM products intended for incorporation as components in laser processing systems. As supplied by Novanta, 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 47 Warnings to personnel of potential laser hazards. Not available on OEM lasers When integrating Novanta OEM lasers, the Buyer and/or integrator of the end system is responsible for meeting all applicable Standards to obtain the CE mark. To aid this compliance process, Novanta testing program has demonstrated that lasers comply with the relevant requirements of 2014/30/EU, the Electromagnetic Compatibility Directive, as summarized in the table below.
  • Page 48 LASER SAFETY PAGE Table 2-2 European Union Directives. Applicable Standards/ Norms 2014/30/EU Electromagnetic Compatibility Directive 2014/35/EU Low Voltage Directive 2015/863/EU RoHS Directive Safety Requirements for Electrical Equipment for Measurement, Control, EN 61010-1:2010 and Laboratory Use - Part 1: General Requirements EN 61000-6-4:2007 Radiated Emissions Group 1, Class A EN 61000-6-4:2007...

  • Page 49: Declaration Of Conformity

    DECLARATION OF CONFORMITY PAGE Declaration of conformity Figure 2-2 i401 Declaration of conformity...

  • Page 50: Operation

    OPERATION PAGE Operation Use information in this section to familiarize yourself with i401 controls and indicators and to begin operating the laser. This section contains the following information: • Controls and indicators – display and describes exterior controls and indicators on i401 lasers.

  • Page 51: Figure 3-2 I401 Rear Panel Controls And Indicators

    Gas Purge Port/Assembly – provides a low-pressure nitrogen (or pure air) connection to prevent dust and debris from damaging electronic or optical components inside the housing. WATER IN Port – provides a 12 mm inlet connection to i401 cooling system for 12 mm O.D. cooling tubing.

  • Page 52: Initial Start-Up

    Danger: Serious Personal Injury Remote interlock faults are not latched on i401 OEM lasers. Clearing the fault condition re-enables the RDY indicator and the laser will fire after the five-second delay provided the SHT indicator is lit and a PWM Command signal is applied. Because exposure to 10.6 μm CO...
  • Page 53 INITIAL START-UP PAGE Important Note: For safety reasons, the i401 laser contains an internal electromechanical shutter assembly that is controlled by the Shutter Open Request input signal (Pin 10 on the DB-15 User I/O connector). The shutter opens only when a Shutter Open Request signal is applied and the RDY LED is on (Remote Interlock input active and no over-temperature fault exists).
  • Page 54 Starting your i401 laser Unlike other I401 lasers, the SHT LED on i401 lasers is dependent on the state of the RDY indicator. Although a Shutter Open Request signal is applied, the SHT LED will not light while the RDY LED is Off.
  • Page 55 Press the UC-2000’s Lase On/Off button to stop lasing. Lase indicators on the UC-2000 and the laser should both turn off. If you are connected to the i401’s Ethernet port, access the i401 web page to verify operating conditions and functionality (refer back to Figure 1-13). See the Getting Started or Technical Reference sections for details on accessing the I401 web page.
  • Page 56 INITIAL START-UP PAGE When performing the initial start-up, you must first connect the Quick Start Plug or provide the required Remote Interlock and Shutter Open Request signals to the User I/O connector. See User I/O connections in the Technical Reference section for pinouts and signal descriptions. Starting auxiliary equipment Caution: Possible Equipment Damage Remove the aperture seal before firing the laser.
  • Page 57 Starting your I401 laser Unlike other I401 lasers, the SHT LED on i401 lasers is dependent on the state of the RDY indicator. Although a Shutter Open Request signal is applied, the SHT LED will not light while the RDY LED is Off.

  • Page 58: Technical Reference

    User I/O connections – describes input/output signals and specifications for the 15-pin User I/O connector. DC power/DC sense cables – provides information about i401 DC power and voltage sense cables. I401 web interface – explains details about the I401 i401’s Ethernet interface.

  • Page 59: Laser Design

    The optical resonator, in conjunction with the electrodes and the gas mixture, generates the laser beam. I401 optical resonators are comprised of three optical elements: a front mirror, a rear mirror, and an output window. These optical elements are fastened to the tube’s exterior and are exposed to its interior through holes in the end caps.

  • Page 60: Figure 4-2 I401 Beam Ellipticity

    Beam conditioning The i401 laser incorporates a novel beam conditioning system that first converts the beam to a circular profile, cleans up the beam to remove side lobes and improve beam quality, and then rotates the polarization through 45 degrees as an aid in applications where a circular polarizer is used.

  • Page 61: Rf Power Supply

    Technical overview To reduce the complexity and cost of beam delivery components, the i401 laser was designed with the beam polarized at 45° to the base plate (see Figure 3-19 for details). This de- sign allows the use of a simple reflective phase retarder and eliminates the need for additional mirrors or complex mounting schemes.

  • Page 62: Optical Setup

    OPTICAL SETUP PAGE Important Note: Optical components in the beam path must always be aligned to the actual beam path, not the laser faceplate. Because of slight variations in laser construction, the beam path may not always be centered in, or perpendicular to, the aperture in the faceplate. Optical setup After selecting a laser for a CO laser processing system, the two most important elements to consider...

  • Page 63: Controlling Laser Power

    Much of the information provided in this section describes the use of a Novanta UC-2000 Universal Laser Controller to provide PWM Command signals to the i401 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 I401 lasers.
  • Page 64 RF drive averaged over any 200-μs interval. Pulse Width Modulation (PWM) Pulse Width Modulation, or PWM, controls laser power by varying the duty cycle of I401’s RF amplifiers, which in turn control the time-averaged RF power applied to the laser. The percentage of optical output increases as duty cycle increases (at a constant PWM frequency) or as PWM frequency decreases (at a constant duty cycle).

  • Page 65: Operating Modes

    Figure 4-4 PWM Command signal waveform I401 User I/O PWM input consists of a high-speed opt isolator LED with a forward voltage drop (Vf) of 1.5 VDC. The PWM input frequency can range from DC (0 Hz) to 100 kHz. Table 3-2 on the following page provides minimum, maximum, and nominal PWM signal specifications.
  • Page 66 Important Note: Novanta lasers are designed for maximum performance using 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 67: User I/O Connections

    The PWM Command signal and all input/output (I/O) control signals are connected to the User I/O port, a 15-pin female D-type subminiature connector, on the i401’s rear panel. Figure 3-5 below illustrates the pin arrangement of the User I/O connector.

  • Page 68: User I/O Connection Summary

    PAGE Figure 4-5 User I/O connector pinouts. User I/O connection summary Table below provides a quick reference summary to i401 User I/O connections. Table 4-3 User I/O pin descriptions Description Function PWM Return Use this input pin as the return side of the PWM Command signal.
  • Page 69 USER I/O CONNECTION SUMMARY PAGE This connection provides +24 VDC for driving external inputs or + 24 VDC outputs. The +24 VDC Auxiliary Power output can source up to 0.5 A Auxiliary Power and is protected by a 0.5 A self-resetting fuse. The return (ground) path must be through Pin 12, Auxiliary DC Power Ground.

  • Page 70: Input/Output Signals

    User I/O port. Pin 4, +5 VDC Auxiliary Power, and Pin 5, +24 VDC Auxiliary Power, are protected by self-resetting fuses rated at 0.5 A. Pin 12, Auxiliary DC Power Ground, is connected to chassis ground while all other User I/O pins are floating with respect to chassis ground. Figure 3-6 illustrates I401’s internal DC supply wiring.

  • Page 71: Figure 4-6 Auxiliary Dc Power Diagram

    Input signals A total of four user inputs allows control of I401 lasers. Remote Interlock, Shutter Open Request, and Remote Reset/Start Request inputs are optoisolated and bi-directional, allowing for positive or negative polarity signal inputs. These three signals also share a common return connection, Input Common, which is separate from chassis ground to completely isolate control signals for optimal EMI performance.
  • Page 72 INPUT/OUTPUT SIGNALS PAGE Remote Interlock faults (INT LED illuminates red) are not latched. Re-applying a voltage to Pin 3 enables the RDY indicator and lasing is possible after the five-second delay, provided that the SHT indicator is also lit. Use the interlock function to provide maximum operator safety. When the Remote Interlock input is opened (voltage source removed), the internal shutter automatically closes to block the beam path, the RDY LED turns Off, the SHT LED turns Off (regardless of the state of the Shutter Open Request input), and all DC power is removed from the RF boards.

  • Page 73: Figure 4-7 Quick Start Plug Wiring Diagram

    INPUT/OUTPUT SIGNALS PAGE Figure 4-7 Quick Start Plug wiring diagram Figures below illustrates the input circuit’s equivalent internal schematic while the following table provides i401 input circuit specifications.

  • Page 74: Figure 4-8 Input Equivalent Schematic

    INPUT/OUTPUT SIGNALS PAGE Figure 4-8 Input equivalent schematic Table 4-4 Input circuit specifications Important Note: The Remote Reset/Start Request input must not be sent until I401’s +5 VDC power supply has stabilized (approximately 200 ms after DC power-up).
  • Page 75 EMI performance. I401’s optically isolated outputs are useful for sending laser status to a Programmable Logic Controller (PLC) or computerized control system. Each of the five outputs can source 50 mA at ±24 VDC maximum for a total load of 250 mA.

  • Page 76: Figure 4-9 Output Equivalent Schematic

    INPUT/OUTPUT SIGNALS PAGE The figure below illustrates the output circuit’s equivalent internal schematic and below provides i401 output circuit specifications. Figure 4-9 Output equivalent schematic Table 4-5 Output circuit specifications Output Device Specifications 2.5 Ohms Rdson 10 MOhms Off Bi-directional MOSFET Voltage ±24 VDC, max.

  • Page 77: Sample I/O Circuits

    Figure below illustrates one method of supplying a Remote Interlock signal using a customer-supplied limit switch. I401’s +24 VDC Auxiliary Power output powers the circuit. Note that Pin 4, +5 VDC Auxiliary Power, could have been used instead, depending on circuit voltage requirements.

  • Page 78: Figure 4-12 Plc Driven Interlock Signal

    Figure 4-12 PLC driven interlock signal When multiple PLC outputs are used, connect I401 inputs to the PLC as shown in Figure 3-13. By supplying voltage (+VDC) to Pin 11, Input Common, and pulling individual inputs to ground, each input can be independently activated by the PLC’s output module.

  • Page 79: Figure 4-14 I401 Output Driving Warning Lamp

    Ensure that the relay coil’s pull-in current does not exceed 50 mA. A diode or surge sup- pressor must be installed across the relay coil to prevent voltage spikes from damaging I401 outputs. Figure 4-15 I401 output driving relay...

  • Page 80: Figure 4-16 I401 Output Driving Plc Input Module

    SAMPLE I/O CIRCUITS PAGE Figure below illustrates how I401’s outputs can drive the DC Input Module of a Programmable Logic Controller (PLC). By supplying voltage (+VDC) to Pin 13, Output Common, each I401 output is inde- pendently switched to activate individual PLC inputs.

  • Page 81: Dc Power/Dc Sense Cables

    DC voltage sense cable The DC voltage sense cable shipped with the i401 laser is matched to the length of the DC power cable— either the standard length of 2.0 m (6.5 ft) or an optional length of 5.0 m (16 ft). The laser end of the voltage sense cable is finished with an M10 ring terminal to fit the +48 VDC POWER terminal and an M4 spade terminal to fit the end of the –VDC GND terminal.

  • Page 82: I401 I401 Web Interface

    IP address that allows a simple Ethernet connection between the i401 laser and a host. To connect your host computer to the i401 laser using a peer-to-peer Ethernet connection, perform the steps in the following sections: Important Note: Connection to a local network is permitted as long as the laser’s fixed IP address...

  • Page 83: Home Page Layout

    Ethernet router or hub. Home page layout i401 lasers feature a web-based Internet interface that allows you to access read-only information about LED and RF module status–including voltage, current, and temperature measurements—using a standard web browser as shown in Figure below.
  • Page 84 When the home page opens, the I401 laser begins sending status data based on the laser’s current condition. Once the initial data is loaded, the Get Data button becomes active. Click this button to begin updating the static home page once a second.
  • Page 85 Displays the heat sink temperature of each RF module. Relative Humidity: Displays the measured relative humidity (RH) within the i401 laser housing. When purge gas is flowing, the RH value should drop to 0% (± 10%) within 10–15 minutes. If the relative humidity never drops below approximately 10%, then slightly increase the purge gas flow rate.

  • Page 86: Event Log Page Layout

    I401 event log page i401 web interface To access the i401’s event log page (prior figure), open your web browser, type “http://192.168.50.50/ service.html” (without the quotes,) and then press Enter. The event log page opens and displays infor- mation recorded over the life of the laser. This information includes power-on cycles as well as total on- time/total lase time;...

  • Page 87: Changing The I401'S Ip Address

    Launch your web browser, type the new IP address (http://xxx.xxx.xxx.xxx), and then press Enter. The i401 home page will appear as shown back in Figure 3-17. To reach the event log page, enter “http://xxx.xxx.xxx.xxx/service.html” (without the quotes); where xxx.xxx.xxx.xxx is the new IP address.

  • Page 88: Firmware Upgrade Procedure

    Firmware upgrade procedure Important Note: The firmware upgrade must be performed using a peer-to-peer connection between the i401 laser and host computer as described below. The i401 web interface is not compatible with Google Chrome browsers. Disable your computer’s firewall If your computer’s firewall is enabled, notify your IT Administrator and disable the firewall before...

  • Page 89: Figure 4-21 Programs And Features Dialog

    FIRMWARE UPGRADE PROCEDURE PAGE Figure 4-21 Programs and Features dialog In the Windows Features dialog (Figure below), check “TFTP Client” and then click OK. Figure 4-22 Windows Features dialog A progress bar window will appear while the TFTP Client feature is being activated. When the window closes, continue with the next section.

  • Page 90: Figure 4-23 Local Area Connection Properties Dialog

    FIRMWARE UPGRADE PROCEDURE PAGE Figure 4-23 Local Area Connection Properties dialog In the Internet Protocol Version 4 (TCP/IPv4) Properties dialog (Figure below), select “Use the following IP address:” and enter the following information: IP Address: 192.168.50.100 Subnet Mask: 255.255.255.0 The Default Gateway field can be left blank. Figure 4-24 Internet Protocol (TCP/IP) Properties dialog Click OK to submit the changes.

  • Page 91: Figure 4-25 Configure Ip Address Link On I401 Home Page

    Apply 48 VDC power to the laser and wait 15 seconds for the firmware to initialize. If you have changed the i401’s IP address (the factory default is 192.168.50.50), you must change it back. If not, proceed to the next section, Perform the firmware upgrade.

  • Page 92: Integrating I401 Safety Features

    Figure 4-27 I401 web browser display If necessary, click the Configure IP Address link at the bottom of the i401 web page and reset the default IP address to the specific address required for your application. Re-enable your computer’s firewall If your computer’s firewall was disabled for this procedure, notify your IT Administrator and re-enable...

  • Page 93: Key Switch Functions

    I401’s key switch, shutter, and remote interlock functions serve to enable or disable DC power to I401’s RF drive. Without DC power, the RF driver cannot supply RF energy to the resonator, causing the CO2 gas to remain in a zero-energy state. I401 status indicators provide users with a quick visual indication of the laser’s operational status.

  • Page 94: I401 General Specifications

    Interlock signal via Pin 3 on the User I/O connector. To use I401’s remote interlock feature to initiate lasing, apply a voltage in the range of ±5–24 VDC to Pin 3, Remote Interlock. Applying a Remote Interlock signal causes the INT LED to turn green, the RDY indicator to turn yellow, and sends DC power to the laser’s RF boards.
  • Page 95 Measured at 100 Hz, 10% duty cycle. Measured at 48 VDC input, 100% duty cycle i401 lasers can be operated at coolant temperatures up to 28 °C (82 °F) in order to reduce problems associated with condensation; however, this may result in decreased laser performance and/or reduced laser lifetime.

  • Page 96: I401 Outline & Mounting Drawings

    I401 OUTLINE & MOUNTING DRAWINGS PAGE i401 outline & mounting drawings Figure 4-28 i401 outline & mounting dimensions...

  • Page 97: Figure 4-29 I401 Outline & Mounting Dimensions

    I401 OUTLINE & MOUNTING DRAWINGS PAGE Figure 4-29 I401 outline & mounting dimensions (mounting feet removed.

  • Page 98: I401 Packaging Instructions

    I401 PACKAGING INSTRUCTIONS PAGE i401 packaging instructions Figure 4-30 i401 packaging instructions...

  • Page 99: Maintenance/Troubleshooting

    DC Power Cables from the DC power supply. Daily inspections Perform the following steps daily to keep your i401 laser in optimum operating condition. Except for the procedures described below, no other service is required or should be attempted.

  • Page 100: Storage/Shipping

    See Setting coolant temperature in the Getting Started section for details on preventing condensation. When using compressed air as a purge gas on your i401 laser, empty water traps and oil separators on each filter and/or dryer between the laser and your compressed air source.
  • Page 101 In dirty environments, purge laser optics using filtered air or nitrogen to prevent vapor and debris from accumulating on optical surfaces. Important – i401 lasers have several beam conditioning optics between the output aperture and the faceplate. To prevent dust and debris from damaging these optical surfaces, always connect nitrogen or filtered air to the laser’s Gas Purge port.
  • Page 102 CLEANING OPTICAL COMPONENTS PAGE Required cleaning materials Table below lists the type and grade of materials required to properly clean optical surfaces. Table 5-1 Required cleaning materials Cleaning Material Requirements Latex gloves or finger Powder-free cots Air bulb Clean air bulb Ethyl or isopropyl alcohol Spectroscopic or reagent grade Acetone...

  • Page 103: Troubleshooting

    The Troubleshooting section is designed to help isolate problems to the module level only. Problems on circuit boards or the laser tube are outside the scope of this guide because they are not user-serviceable assemblies; do not attempt to repair them. Contact Novanta or a Novanta Authorized Distributor for repair information.
  • Page 104 TROUBLESHOOTING PAGE To troubleshoot i401 lasers, it is necessary to understand the sequence of events that must happen before the laser can operate. Before attempting any service, we advise you to read the entire troubleshooting guide and review both the operational flowchart and the functional block diagram.

  • Page 105: Operational Flowchart

    OPERATIONAL FLOWCHART PAGE Operational flowchart The flowchart in the figure below illustrates i401 start-up sequence. Figure 5-1 I401 operational flowchart...

  • Page 106: Figure 5-2 I401 Functional Block Diagram

    OPERATIONAL FLOWCHART PAGE Functional block diagram Figure below is a functional block diagram illustrating the i401’s control architecture. Figure 5-2 I401 functional block diagram...
  • Page 107 True. Table 5-2 Status signals On DC power-up of an i401 laser, the RDY lamp illuminates yellow when INT and TMP indicators illumi- nate green. After the RDY indicator illuminates, internal tickle is enabled, and a five-second delay begins before lasing is permitted. When a Shutter Open Request signal is applied, the internal shutter opens, the SHT LED illuminates blue, and application of a PWM Command signal causes the LASE indicator to illuminate red as lasing begins.
  • Page 108 PAGE Table 5-3 Effect of Remote Interlock input on operating parameters Tables 5-4 through 5-9 show how the I401 i401’s LED and output signal status changes as various operating and fault conditions occur. Fault conditions are shown in bold. Table 5-4 Normal operating condition...
  • Page 109 OPERATIONAL FLOWCHART PAGE Table 5-5 Quick Start Plug or interlock/shutter inputs not connected Table 5-6 Interlock Open condition Table 5-7 Over Temperature fault...
  • Page 110 Table 5-9 No-Strike condition Laser fault indications i401 lasers can indicate five specific fault conditions. In the event of certain faults, the RDY LED will blink an error code, pause four seconds, and then repeat the error code. This sequence continues until the fault is corrected and the laser is reset by cycling DC power to the laser.
  • Page 111 Web page fault annunciation The i401 web interface displays errors and warnings in real-time on the home page in either the error message area or the warning message area. Hard faults that require a DC power cycle are always shown in the error message area.
  • Page 112 PAGE Troubleshooting On i401 lasers, a remote interlock condition is not latched. Re-establish the Remote Interlock signal input (INT LED changes from red to green and the Interlock Open output Opens) to enable the RDY indicator and begin lasing after the five-second delay...
  • Page 113 5 kHz). This fault is annunciated by the SHT indicator flashing continuously and an error message appears on the i401’s web page. To clear the No-Strike condition, apply tickle pulses or a PWM Command signal (< 5% duty cycle) for 30 to 60 seconds. When the gas breaks down into a plasma state, the laser will recover and begin lasing at the commanded power level without cycling DC power.
  • Page 114 On i401 lasers, the over-temperature fault (indicated by the TMP indicator turning red) is latched. This means that if an over-temperature condition occurs the TMP indicator will turn red, the Fault Detected output will Close, the RDY light goes out, and lasing is disabled.
  • Page 115 OPERATIONAL FLOWCHART PAGE Symptom: The SHT LED is flashing continuously because of a No-Strike condition as indicated by the following status LEDs and I/O states: Possible Causes: • A No-Strike condition has occurred, possibly due to cold environmental conditions that may prevent the gas from breaking down into a plasma state.
  • Page 116 OPERATIONAL FLOWCHART PAGE Symptom: Your OEM i401 laser has quit lasing or lasing halted and then restarted. The LASE LED may be Off or On depending on whether PWM Command signals are being applied, but no fault is indicated. Possible Causes: •...
  • Page 117 If you are connected to the i401’s Ethernet port, access the i401 web page to verify the fault condition. If you are not connected to the i401’s web page, refer to the Getting Started or Technical Reference sections for details on accessing the I401 i401 web page.

  • Page 118: Figure 5-3 Enable Java Script In Browser

    IP address and click Add. Click Close and then click OK twice. To add the i401 web page as a trusted web site (Figure 5.4), click the Trusted sites icon and then click the Sites button. In the Trusted sites dialog, type the laser’s IP address in the Add this website to the...

  • Page 119: Figure 5-4 Add Ip Address To List Of Authorized/Trusted Websites

    PAGE Figure 5-4 Add IP address to list of authorized/trusted websites Symptom: It is necessary to isolate the i401 laser from the IT network, but still important to access the i401 web page from a networked control computer. Possible Causes: •...
  • Page 120 Table 4-1) to prevent scratching delicate optical surfaces. If the focusing optic is pitted, it must be replaced immediately. Because of the extremely high-power density of I401 lasers, pits or debris on the lens surface may absorb enough energy from the focused beam to crack the lens. If this happens, other...
  • Page 121 In the event of damage to laser, marking head, or beam delivery optics, contact Novanta, Inc. or the optics manufacturer for handling instructions. carefully filtered and dried before use as a purge or assist gas. Refer to the Purge gas specifications, in...

  • Page 122: Index

    INDEX PAGE Index Symbols 1/2” tubing fitting kit 1-6, 1-7, 1-13 12 mm cooling tubing 1-6, 1-7, 1-14, 1-16 + 24 VDC Auxiliary Power 3-19, 3-21 signal description, 3-11, 3-13 +48V POWER terminal block 1-20, 1-21, 2-3, 3-23 +5 VDC Auxiliary Power 3-19, 4-16, 4-17 signal description, 3-11, 3-13 Beam attenuator (shutter) 5, 8, 1-2, 1-22, 3-3, 3- 34, 4-9...
  • Page 123 INDEX PAGE aperture seal, 2-5, 2-8 Compliance 5–10 condensation damage, 1-16, 2-5, 2-7, 2-8, 2-9 CDRH, 5 coolant temperature, 1-15 Class 4 safety requirements, 8 cooling fittings, 1-13 Declaration of Conformity, 10 definition, 1 EU, 6–9 dirty/dusty environments, 4-2, 4-3, 4-21 FCC, 6 dew point, 1-16, 2-5, 2-8 RoHS, 6...
  • Page 124 1-14, 1-16, 2-2, 2-5, 2-8, 3-37, 4-14, 4-16 Relative Humidity sensor, 1-24, 2-7, 2-9, 3-26, 4- temperature setpoint, 1-14, 1-15, 1-16, 2-5, 2-8, 4-16 Copyright information ix Disabling I401 4-2 Customer Service xi Divergence 3-2, 3-4, 3-5 Customer-supplied interlock 3-19 specifications, 3-36 Daily inspections 4-2–4-3...
  • Page 125 4-6–4-22 indications, 4-12–4-13 web interface, 3-24–3-28 No-Strike condition, 4-13, 4-15 i401 base plate mounting, 1-8–1-12 over temperature fault, 4-11, 4-14, 4-16 Firmware upgrade procedure 3-29–3-33 Over Voltage fault, 4-13, 4-14 Five-second delay 5, 8, 2-2, 2-4 2-6, 2-9, 3-11, 3-...
  • Page 126 3-19–3-20 cator specifications, 3-16 Introduction 1-2 Input Common 3-11, 3-14, 3-20, 4-15, 4-16, 4-17 I401 nomenclature, 1-2 signal description, 3-12, 3-15 Inventory Input/Output signals 3-13–3-18, 4-9, 4-10, 4-11, 4- ship kit contents, 1-6, 1-7 12, 4-15, 4-16, 4-17, 4-18...
  • Page 127 INDEX PAGE i401, 3-24–3-25 cleaning optical components, 4-3–4-5 daily inspections, 4-2–4-3 disabling I401, 4-2 Key switch 5, 8, 1-2 storage/shipping, 4-3 Key switch functions 1-22, 3-11 integrating, 3-34 Marking/engraving operation 3-9 Material Safety Data Sheets (MSDS) 2, 4-4 Model numbers 1-2...
  • Page 128 INDEX PAGE gated operation, 3-9 Shutter Open, 3-12, 3-17, 3-18, 3-35, 4-9, 4-10, 4- 11, 4-12, 4-15, 4-16, 4-17, 4-18 marking/engraving operation, 3-9 Over Temperature fault 2-4, 3-4, 3-17, 3-34, 4-11, 4-16 Operational flowchart 4-7 description, 4-14 Operator’s laser manual CD 1-6, 1-7 Optical accessories mounting 2-2 Over temperature indictor.
  • Page 129 INDEX PAGE PWM Command signal 1-7, 1-21, 1-22, 2-4, 2-5, 2- signal description, 3-11, 3-14 6, 2-7, 2-9, 3-7–3-8, 3-9, 3-10, 3-11, 3-12, 3-14, 3-17, signal specifications, 3-16 4-9, 4-13, 4-15, 4-17, 4-18 Remote Reset/Start Request input 3-4, 3-12, 3- 15, 3-34, 4-18 PWM Drive fault 4-13 signal description, 3-11, 3-14...
  • Page 130 1-3 beam conditioning, 3-3–3-4 packing guidelines, 1-3 heat removal, 3-3 removing lifting handles, 1-5 optical resonator, 3-2–3-3 unpacking the i401 laser, 1-4 optical setup, 3-4–3-5 polarization, 3-3–3-4 Upgrading firmware. See Firmware upgrade procedure RF power supply, 3-4 USB to Ethernet adapter 4-21 Technical Support xi User I/O connections 3-10–3-22...
  • Page 131 INDEX PAGE set-up, 1-25–1-26 troubleshooting, 4-19–4-21 Warning Worldwide headquarters xi aerosol dusters, 2, 4-21 air contaminants, 2 definition, 1 electrical noise, 1-22, 3-7 hazardous radiation exposure, 2, 2-4, 4-13, 4-15 laser output, 1-22, 2-4, 2-6, 2-9, 3-6, 3-7, 3-15 laser radiation, 4-13, 4-15 laser safety precautions, 2 lifting, 1-3 OEM faults, 2-4, 4-13, 4-15...
  • Page 132 INDEX PAGE...
  • Page 133 Engineered by Synrad, part of Novanta Novanta Headquarters, Bedford, USA Phone: +1-781-266-5700 Email: photonics@novanta.com ###### Revision X August 2022 © 2022, Novanta Corporation. All rights reserved.

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