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J Version Lasers Operator’s Manual ® An Excel Technology Company 4600 Campus Place Mukilteo, WA 98275 USA 1.800.SYNRAD1 tel 1.425.349.3500 fax 1.425.349.3667 e-mail synrad@synrad.com www.synrad.com...
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Series J48 Lasers Operator’s Manual Model 48-1 Model 48-2 Model 48-5 Version 6.0 Released June 2005 Part number 900-00007-03 ® An Excel Technology Company 4600 Campus Place Mukilteo, WA 98275 USA 1.800.SYNRAD1 tel 1.425.349.3500 fax 1.425.349.3667 e-mail synrad@synrad.com www.synrad.com...
Introduction ......................3-2 Plasma section ......................3-3 Optical resonator ..................... 3-3 Synrad S e r i e s 4 8 S e r i e s 4 8 S e r i e s 4 8 S e r i e s 4 8...
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Operation ......................... A-4 Closed loop specifications ..................A-4 Index Synrad S e r i e s 4 8 S e r i e s 4 8 S e r i e s 4 8 S e r i e s 4 8 operator’s manual...
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Figure 4-2 J Series control board schematic .......... 4-7 Figure A-1 Typical closed loop setup ............. A-3 Synrad S e r i e s 4 8 S e r i e s 4 8 S e r i e s 4 8 S e r i e s 4 8 S e r i e s 4 8 operator’s manual...
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Table 4-2 Series 48 cooling specifications ..........4-10 Table A-1 Closed loop general specifications........A-4 Synrad S e r i e s 4 8 S e r i e s 4 8 S e r i e s 4 8 S e r i e s 4 8 operator’s manual...
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Warranty information This is to certify that Series 48 lasers are guaranteed by SYNRAD, Inc. to be free of all defects in materi- als 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 improper maintenance.
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Email: synrad@synrad.com Sales and Applications SYNRAD’s Regional Sales Managers work with customers to identify and develop the best CO 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.
CO laser radiation can seriously burn human or animal tissue, which may cause permanent damage. Synrad S e r i e s 4 8 S e r i e s 4 8 S e r i e s 4 8 S e r i e s 4 8 S e r i e s 4 8 operator’s manual...
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Synrad S e r i e s 4 8 S e r i e s 4 8 S e r i e s 4 8 S e r i e s 4 8 operator’s manual S e r i e s 4 8...
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Additional laser safety information The SYNRAD web site (http://www.synrad.com/LaserFacts/lasersafety.html) contains an online laser safety handbook that provides information on (1) Laser Safety Standards for OEM’s/System Integrators including product classification, product housing, product features, and other CDRH requirements; (2) Laser Safety Standards for End Users including Class I installations, Class IV installations, laser hazards, ANSI Standard, U.S.
KEYSWITCH VERSION ONLY Figure 1 48-1 hazard label and CE label locations Synrad S e r i e s 4 8 S e r i e s 4 8 S e r i e s 4 8 S e r i e s 4 8 operator’s manual...
21 CFR 1040 or EN 60825. Figure 3 48-5 hazard label and CE label locations Synrad S e r i e s 4 8 S e r i e s 4 8 S e r i e s 4 8 S e r i e s 4 8 operator’s manual...
Standards for complete laser processing systems as specified by 21 CFR, Part 1040 or EN 60825-1. SYNRAD, Inc. assumes no responsibility for the compliance of the system into which OEM laser products are integrated.
Series 48 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 21 CFR, Subchapter 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.
Series 48 OEM lasers are OEM products intended for incorporation as components in laser process- ing 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.”...
1 Keyswitch version only 2 On OEM versions, the Power indicator illuminates and the five-second delay begins when DC power is applied to the laser Synrad S e r i e s 4 8 S e r i e s 4 8 S e r i e s 4 8 S e r i e s 4 8 operator’s manual...
SYNRAD’s Series 48 lasers have demonstrated performance characteristics that have met or exceeded the requirements of EMC Directive 89/336/EEC. When integrating SYNRAD’s Series 48 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, SYNRAD’s testing program has demonstrated that Series 48 lasers comply with the relevant require-...
J48-2 29 October 1998 J48-5 J48-5S-2197 29 October 1998 We, SYNRAD, Inc., hereby declare under our sole responsibility that the equipment specified above conforms to the above Directive(s) and Standard(s). Corporate Officer: European Contact: Excel Technology Europe GmbH Münchner Str. 2a...
Connecting – explains how to connect power and control cables as well as cooling connections for water-cooled models. Synrad S e r i e s 4 8 S e r i e s 4 8 S e r i e s 4 8 S e r i e s 4 8 S e r i e s 4 8 operator’s manual...
Introduction Thank you for purchasing a Series 48 laser from SYNRAD, Inc. The Series 48 family of lasers incorpo- rates the latest developments in sealed carbon dioxide devices, combining the best features of both waveguide and free space CO laser technology in an innovative aluminum tube design.
Inspect the laser housing for any signs of shipping damage. Verify that all external labels are attached to the housing (refer to label location drawings in the “Laser Safety” section). Contact SYNRAD Customer Service if the laser housing is damaged or if any of the required accessory materials or labels are missing.
Spare Fuse(s) ............1 Cooling Kit (water-cooled lasers only) ....1 Final Test Report (not shown) ......1 Synrad S e r i e s 4 8 S e r i e s 4 8 S e r i e s 4 8 S e r i e s 4 8 operator’s manual...
Contents description Each item listed in Table 1-1 is described below. SYNRAD Series 48 Laser – for cutting, welding, drilling, and marking a wide variety of products and materials. Series 48 Lasers Operator’s Manual – provides setup, operation, and maintenance information for your Synrad Series 48 laser.
Install and tighten four capscrews to secure the laser to the Mounting Rail. 48-1 and 48-2 lasers use 6–32 × 1" socket head capscrews while 48-5 lasers use 10–32 × 3/4" fasteners. Synrad S e r i e s 4 8 S e r i e s 4 8 S e r i e s 4 8 S e r i e s 4 8 operator’s manual...
Setting coolant temperature Note: SYNRAD recommends that the laser’s cooling fluid contain no less than 90% water by volume. In applications where biocides containing chlorides are used, concentrations should not exceed 25 parts per million (PPM).
100 (38) (11) (14) (17) (20) (22) (24) (26) (27) (29) (30) (31) (33) (34) (35) (36) (37) Synrad S e r i e s 4 8 S e r i e s 4 8 S e r i e s 4 8 S e r i e s 4 8 S e r i e s 4 8 operator’s manual...
Repeat this step on the other set of lower/upper tubes. Connect the “U” connector between both of the center coolant tubes. Synrad S e r i e s 4 8 S e r i e s 4 8...
The 48-1 laser requires a SYNRAD DC-1 or equivalent power supply capable of providing 30 VDC at 7 A maximum; the 48-2 laser requires a SYNRAD DC-2 power supply (30 VDC at 14 A max.); and the 48-5 requires a SYNRAD DC-5 power supply (30 VDC at 28 A max.).
(–) DC Power cable from the laser to the negative (–) output terminal. Connect the red (+) DC Power cable from the laser to the positive (+) 30 VDC output terminal. Synrad S e r i e s 4 8 S e r i e s 4 8...
The operation of Series 48 lasers requires an external controller that can provide the necessary tickle and pulse width modulated (PWM) Command signals. SYNRAD recommends the use of a UC-2000 Univer- sal Laser Controller to generate the PWM signals that control the laser’s output power. The UC-2000 requires 15–50 VDC @ 35 mA, supplied from either its wall plug transformer or from the Auxiliary Power...
DB9 connections 48 Series lasers are equipped with a female DB9 connector mounted to the sidewall of the laser. This connector provides the user with a convenient method for monitoring fault conditions (over-tempera- ture, control/RF circuitry failure) and adds remote interlock, remote keyswitch (relay or switch), message output, and remote LED indicator capability.
Connecting Figure 1-7 Typical Series 48 system interconnection diagram Synrad S e r i e s 4 8 S e r i e s 4 8 S e r i e s 4 8 S e r i e s 4 8 operator’s manual...
Initial start-up – explains how to start your Series 48 laser while verifying proper operation. Synrad S e r i e s 4 8 S e r i e s 4 8 S e r i e s 4 8 S e r i e s 4 8 S e r i e s 4 8 operator’s manual...
Command signal inputs. The output of the UC-2000 Controller (or FH Series marking head) is attached to this connector. For pure CW operation, a steady +5 V signal can be applied through this Synrad S e r i e s 4 8 S e r i e s 4 8 S e r i e s 4 8 S e r i e s 4 8 operator’s manual...
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Diode Pointer is ordered when the laser is built. This connector provides a regulated +5 VDC, 100 mA output for the optional Diode Pointer, available from SYNRAD. The Diode Pointer connector is internally protected against short circuits by an auto-resetting, solid-state fuse.
Synrad S e r i e s 4 8 S e r i e s 4 8 S e r i e s 4 8 S e r i e s 4 8 operator’s manual S e r i e s 4 8...
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If your Series 48 laser fails to lase, refer to Troubleshooting in the “Maintenance/Troubleshooting” section for troubleshooting information. Synrad S e r i e s 4 8 S e r i e s 4 8 S e r i e s 4 8 S e r i e s 4 8 S e r i e s 4 8 operator’s manual...
0.5 GPM (48-1), 0.8 GPM (48-2), or 1.5 GPM (48-5) at less than 60 psi of pressure. Examine all cooling connections carefully and verify that they do not leak. Synrad S e r i e s 4 8 S e r i e s 4 8 S e r i e s 4 8 S e r i e s 4 8 operator’s manual...
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If your Series 48 laser fails to lase, refer to Troubleshooting in the “Maintenance/Troubleshooting” section for troubleshooting information. Synrad S e r i e s 4 8 S e r i e s 4 8 S e r i e s 4 8 S e r i e s 4 8 S e r i e s 4 8 operator’s manual...
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Model 48-5 package outline drawing – illustrates laser package and mounting dimensions for Keyswitch and OEM 48-5 50 watt lasers. Synrad S e r i e s 4 8 S e r i e s 4 8 S e r i e s 4 8 S e r i e s 4 8 S e r i e s 4 8 operator’s manual...
RF cable runs are required. 48 Series lasers emit a laser beam with a wavelength of 10.6 microns (µm). The beam shape is square at the laser output aperture, changing to circular at distances of approximately one meter or more from the laser.
Small variations in output power (up to 10%) are seen during warm-up as the cavity mirror spacing changes due to thermal expansion of the plasma tube. Synrad S e r i e s 4 8 S e r i e s 4 8...
RF module by disabling the PWM input optoisolator, forcing an “off” state. Synrad S e r i e s 4 8 S e r i e s 4 8 S e r i e s 4 8 S e r i e s 4 8 operator’s manual...
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Refer to Figure 3-4 for the RF Driver IV circuit schematic. Synrad S e r i e s 4 8 S e r i e s 4 8 S e r i e s 4 8 S e r i e s 4 8 S e r i e s 4 8 operator’s manual...
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10 W and 25 W output power levels; therefore, external cooling in the form of forced air- or water-cooling is required. Synrad S e r i e s 4 8 S e r i e s 4 8 S e r i e s 4 8 S e r i e s 4 8 operator’s manual...
“flying optics” setup create this longer beam path. Figure 3-5 “Flying optics” beam path Synrad S e r i e s 4 8 S e r i e s 4 8 S e r i e s 4 8 S e r i e s 4 8 S e r i e s 4 8 operator’s manual...
< 1.0 micron; dried to lower dew point below coolant temperature setpoint Synrad S e r i e s 4 8 S e r i e s 4 8 S e r i e s 4 8 S e r i e s 4 8 operator’s manual...
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 Series 48 laser. If using an alternate method of laser control, thoroughly review this section, Controlling laser power for an understanding of the signal requirements necessary to control SYNRAD Series 48 lasers.
PWM duty cycle. By changing these parameters, you can command the beam to perform a variety of marking, cutting, welding, or drilling operations. Synrad S e r i e s 4 8 S e r i e s 4 8 S e r i e s 4 8 S e r i e s 4 8 operator’s manual...
48-5 dual-tube lasers, maximum current load is 12 mA @ 5 VDC. Table 3-2 shows minimum, maximum, and nominal voltage levels for On and Off logic states. Synrad S e r i e s 4 8 S e r i e s 4 8...
DC to 1 kHz). To pulse or gate the laser, connect a signal providing TTL-level pulses to the Gate connector on the rear panel of the UC-2000. Synrad S e r i e s 4 8 S e r i e s 4 8 S e r i e s 4 8 S e r i e s 4 8 operator’s manual...
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Command signal frequency itself that is the determining factor but rather this behavior happens only when the off time between PWM pulses exceeds 200 µs. Synrad S e r i e s 4 8 S e r i e s 4 8...
(Open Circuit) > 100 kOhms Contact rating = 50 VDC, < 2 mA minimum (dry circuit) Synrad S e r i e s 4 8 S e r i e s 4 8 S e r i e s 4 8 S e r i e s 4 8 operator’s manual...
Connect LED cathodes to pin 2 or 4. Current is limited internally to 20 mA at 3.3 V maximum. Synrad S e r i e s 4 8 S e r i e s 4 8 S e r i e s 4 8 S e r i e s 4 8 S e r i e s 4 8 operator’s manual...
Important Note: Pin 9, the Remote Ready LED Output, is a current- and voltage-limited output meant only for direct connection to an LED or LED-input optoisolator. Synrad S e r i e s 4 8 S e r i e s 4 8 S e r i e s 4 8 S e r i e s 4 8 operator’s manual...
The remote interlock function is internally bypassed on OEM lasers; to enable this feature, please consult the factory for details. Synrad S e r i e s 4 8 S e r i e s 4 8 S e r i e s 4 8 S e r i e s 4 8 S e r i e s 4 8 operator’s manual...
Minimum Flow Rate ........250 CFM × 4 fans ......0.8 GPM, < 60 PSI Coolant Temperature ........< 40 °C, ambient ......18 °C to 22 °C Synrad S e r i e s 4 8 S e r i e s 4 8 S e r i e s 4 8 S e r i e s 4 8 operator’s manual...
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6 Inlet cooling water temperature should always be maintained above the dew point to avoid condensation and water damage to the laser. 7 Published specifications guaranteed at a cooling temperature of 22 °C. Synrad S e r i e s 4 8 S e r i e s 4 8 S e r i e s 4 8 S e r i e s 4 8 S e r i e s 4 8 operator’s manual...
Model 48-1 package outline drawing Figure 3-10 Model 48-1 package outline and mounting dimensions Synrad S e r i e s 4 8 S e r i e s 4 8 S e r i e s 4 8 S e r i e s 4 8 operator’s manual...
Model 48-2 package outline drawing Figure 3-11 Model 48-2 package outline and mounting dimensions Synrad S e r i e s 4 8 S e r i e s 4 8 S e r i e s 4 8 S e r i e s 4 8...
Model 48-5 package outline drawing Figure 3-12 Model 48-5 package outline and mounting dimensions Synrad S e r i e s 4 8 S e r i e s 4 8 S e r i e s 4 8 S e r i e s 4 8 operator’s manual...
Use information in this section to perform maintenance or troubleshoot your SYNRAD Series 48 laser. This section contains the following information: ■ Maintenance – describes typical Series 48 maintenance procedures. ■ Troubleshooting – explains how to troubleshoot common Series 48 problems.
■ Cleaning optical components Disabling the laser Before performing any maintenance on your SYNRAD Series 48 laser, be sure to completely disable the laser by disconnecting the laser from its DC power source. Daily inspections Perform the following steps daily to keep your Series 48 laser in optimum operating condition. Except for the procedures described below, no other service is required or should be attempted.
Before using any cleaning agents, read their Material Safety Data Sheets (MSDS) and observe all necessary safety precautions. Synrad S e r i e s 4 8 S e r i e s 4 8 S e r i e s 4 8 S e r i e s 4 8 S e r i e s 4 8 operator’s manual...
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 S e r i e s 4 8 S e r i e s 4 8 S e r i e s 4 8 S e r i e s 4 8 operator’s manual...
This section is designed to help isolate problems to the module level only. Problems on circuit boards or the laser tube are not within the scope of this guide because they are not user-serviceable assemblies; do not attempt to repair them. Contact SYNRAD or a SYNRAD Authorized Distributor for repair or replacement information.
Figure 4-1 shows Series 48 interconnections for all Model J48 Series lasers. Figure 4-1 Model J48 Series interconnect schematic Synrad S e r i e s 4 8 S e r i e s 4 8 S e r i e s 4 8 S e r i e s 4 8 operator’s manual...
Figure 4-2 schematically illustrates the layout of J Series control boards. Figure 4-2 J Series control board schematic Synrad S e r i e s 4 8 S e r i e s 4 8 S e r i e s 4 8 S e r i e s 4 8 S e r i e s 4 8 operator’s manual...
During any fault shutdown, the Fault Shutdown Output (pin 1 on the DB9 Connector) latches to a low state (0 VDC) until a keyswitched reset occurs. Synrad S e r i e s 4 8 S e r i e s 4 8 S e r i e s 4 8 S e r i e s 4 8 operator’s manual...
Cycle the Keyswitch to the OFF position for a few seconds, then cycle back to ON. Close and then re-open the Shutter Switch. Synrad S e r i e s 4 8 S e r i e s 4 8...
Symptom: ■ Laser power varies or responds intermittently to input PWM Command pulses. Synrad S e r i e s 4 8 S e r i e s 4 8 S e r i e s 4 8 S e r i e s 4 8 operator’s manual...
Refer to Table 3-1, Gas purity specifications, in the “Technical Reference” section for filtering/drying specifications. Synrad S e r i e s 4 8 S e r i e s 4 8...
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■ Closed loop specifications – provides technical specifications for the Closed Loop Stabilization Kit. Synrad S e r i e s 4 8 S e r i e s 4 8 S e r i e s 4 8 S e r i e s 4 8...
Set the UC-2000 to MAN. CLOSED or ANV CLOSED mode. Apply power to both the laser and UC-2000 and then verify proper system operation. Synrad S e r i e s 4 8 S e r i e s 4 8...
* Specifications subject to change without notice. 1 The Closed Loop Stabilization Kit is calibrated for operation at a PWM Command frequency of 5 kHz. Synrad S e r i e s 4 8 S e r i e s 4 8 S e r i e s 4 8 S e r i e s 4 8 operator’s manual...
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1 1 1 1 1 -8, 1 1 1 1 1 -9, 2 2 2 2 2 -4, 2 2 2 2 2 -6, Synrad S e r i e s 4 8 S e r i e s 4 8...
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UC-2000 Controller, 2 2 2 2 2 -6 – 2 2 2 2 2 -7 Inspections daily, 4 4 4 4 4 -2 Synrad S e r i e s 4 8 S e r i e s 4 8 S e r i e s 4 8 S e r i e s 4 8 operator’s manual...
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PWM Command signal 3 3 3 3 3 -10, 3 3 3 3 3 -11, 3 3 3 3 3 -13, 4 4 4 4 4 -8, 4 4 4 4 4 -10 Synrad S e r i e s 4 8 S e r i e s 4 8...
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3 3 3 3 3 -8 general, 3 3 3 3 3 -18 – 3 3 3 3 3 -19 Synrad S e r i e s 4 8 S e r i e s 4 8 S e r i e s 4 8 S e r i e s 4 8 operator’s manual...
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