Synrad f201 Operator's Manual

f201

Operator’s Manual

®

4600 Campus Place
Mukilteo, WA 98275

1.800.SYNRAD1
tel [phone]
fax [phone]
e-mail [e-mail]
web www.synrad.com

f201

SYNRAD© is a registered trademark of Novanta Corporation. ©Novanta Corporation 2019. All

Rights Reserved. No reproduction without written authorization.

Operator’s Manual

Version 3.2

DATE: March 2019

table of contents

Laser Safety 1

Warranty information vii
Sales and Applications viii
Customer Service viii
Technical Support viii
Reference materials viii
Hazard Information 11
Terms 11
General hazards 12
Other hazards 14
Disposal 14
Additional laser safety information 14
Agency compliance 18
Center for Devices and Radiological Health (CDRH) requirements 18
OEM model 18
Federal Communications Commission (FCC) 19
Requirements 19
European Union (EU) requirements 20
Introduction 26
Firestar nomenclature 26
Unpacking 26

Getting Started 2

Introduction 26
Firestar nomenclature 26
Unpacking 27
Incoming inspection 27
Packaging guidelines 27
Removing the lifting handles 29
Inventory 30
f201 lasers 30
Connecting 34
Cooling connections 34
PS-96 power supply connections 38
PS-96 AC input section 39
Control connections 42
Other connections 43

SYNRAD f201 Operator’s Manual Version 3.2

i

table of contents

Getting Started 2

Incoming inspection 27
Packaging guidelines 27
Unpacking 27
Unpacking the laser 27

Operation 3

Unpacking 28
Removing the lifting handles 29
Inventory 29
f100/f201 lasers 30
Inventory 30
Mounting 32
f100/f201 mounting 32

Technical Reference 4

Mounting 33
Mounting 33
f201 mounting 33
Mounting 35
Cooling connections 36
PS-96 power supply connections 41
Other connections 50
Controls and indicators 53
f201 lasers 53
Initial start-up 55
With a UC-2000 Controller 55
Initial start-up 57
Without a UC-2000 Controller 57
Initial start-up 58
Technical overview 64
Laser tube 64
Optical resonator 64
Technical overview 65

SYNRAD f201 Operator’s Manual Version 3.2

ii

table of contents

Maintenance/Troubleshooting 5

Internal RF power supply 65
Optical setup 66
Technical overview 67
Controlling laser power 68
Control signals 68
Operating modes 70
User I/O connections 73
Input/output signals 74
DC Power cables 86
Integrating Firestar safety features 87
OEM lasers 87
Integrating Firestar safety features 88
Remote interlock functions 88
f201 general specications 90
Maintenance 94
Disabling f201 lasers 94
Daily inspections 94
Storage/shipping 95
Cleaning optical components 95
Troubleshooting 98
Introduction 98
Troubleshooting 99
Operational owchart 99
Troubleshooting 100
Functional block diagram 100
Troubleshooting 101
Status LEDs 101
Troubleshooting 102
Laser fault indications 104
Resetting faults 104
Troubleshooting 105
Other laser faults 106
Troubleshooting 107
Beam delivery optics 109
Troubleshooting 110

SYNRAD f201 Operator’s Manual Version 3.2

iii

table of contents

List of Figures

Figure 1-1 Labeling terms and denitions. 12
Figure 1-2 Safety goggles. 14
Figure 1-5 F 201 hazard label locations. 18
Table 1-1 Class 4 safety features. 22
Table 1-2 European Union Directives. 23
Figure 1-7 F201 declaration of conformity. 25
Figure 2-1 Unpacking the laser. 29
Figure 2-2 Removing lifting handles. 30
Figure 2-3 F201 shipping box contents. 31
Table 2-1 f100/f201 ship kit contents. 32
Figure 2-5 Fastening f100/f201 from above. 33
Figure 2-7 Improper mounting method. 34
Figure 2-8 Detail of fastening into mounting surface 35
Figure 2-8 Fastening f201 from above. 35
Figure 2-10 Fastening f201 from below. 36
Figure 2-11 Detail of fastening into laser. 36
Table 2-3 Dew point temperatures. 39
Figure 2-12 F100/f201 cooling connections 40
Figure 2-13 F201 cooling connections. 41
Figure 2-14 PS-96 rear view. 43
Table 2-4 Three-phase AC electrical recommendations. 44
Table 2-5 Single-phase AC electrical recommendations. 45
Table 2-6 Purge gas specications. 49
Figure 3-1 F201 controls and indicators (front). 51
Figure 3-2 F201 controls and indicators (rear). 52
Figure 4-1 beam characteristics. 59
Figure 4-2 “Flying optics” beam path. 60
Table 4-1 Assist gas purity specications. 61
Figure 4-3 Typical Firestar f201 waveforms. 63
Figure 4-4 PWM Command signal waveform. 64
Table 4-2 PWM Command signal specications. 64
Table 4-3 User I/O pin descriptions. 67
Table 4-4 Input circuit specications. 72
Table 4-5 Output circuit specications. 74

SYNRAD f201 Operator’s Manual Version 3.2

iv

table of contents

List of Figures (cont.)

Figure 4-5 User I/O connector pinouts. 69
Figure 4-6 Auxiliary power supply wiring. 70
Figure 4-8 Input equivalent schematic. 72
Figure 4-7 Quick Start Plug wiring diagram. 73
Figure 4-10 Customer-supplied interlock. 75
Figure 4-11 Customer-supplied interlock, negative voltage. 75
Figure 4-12 PLC driven interlock signal. 76
Figure 4-13 Multiple PLC driven inputs. 76
Figure 4-14 Firestar output driving warning lamp. 77
Figure 4-15 Firestar output driving relay. 77
Figure 4-16 Firestar output driving PLC input module. 78
Figure 4-17 Wiring Set 1 and Set 2 to power external circuits. 79
Table 4-7 f201/f400 DC Power connector pinouts. 80
Table 4-10 Firestar f201 general specications. 84
Table 5-1 Required cleaning materials. 90
Figure 5-1 Operational owchart. 93
Figure 5-2 f-Series functional block diagram. 94
Table 5-2 Status signals. 95
Table 5-3 Normal operating condition. 96
Table 5-4 Quick Start Plug or interlock/shutter inputs not connected. 96
Table 5-5 Interlock open condition. 96
Table 5-6 Over Temperature fault. 97
Table 5-7 Shutter closed condition. 97
Table 5-8 VSWR fault. 97
Table 5-9 Laser error codes. 98

SYNRAD f201 Operator’s Manual Version 3.2

v

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 f201 Operator’s Manual Version 3.2

vi

Warranty information

This is to certify that Firestar® f-Series 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 shipment. This warranty does not apply
to any defect caused by negligence, misuse (including environmental factors), accident, alteration,
or improper maintenance. We request that you examine each shipment within 10 days of receipt and
inform SYNRAD of any shortage or damage. If no discrepancies are reported, SYNRAD shall assume the
shipment was delivered complete and defect-free.

If, within one year from the date of shipment, any part of the f-Series laser should fail to operate, contact
the SYNRAD Customer Service department at 1.800.SYNRAD1 (outside the U.S. call 1.425.349.3500)
and report the problem. When calling for support, please be prepared to provide the date of purchase,
model number and serial number of the unit, and a brief description of the problem. When returning a
unit for service, a Return Authorization (RA) number is required; this number must be clearly marked on
the outside of the shipping container in order for the unit to be properly processed. If replacement parts
are sent to you, then you are required to send the failed parts back to SYNRAD for evaluation unless
otherwise instructed.

If your f-Series laser fails within the rst 45 days after shipment, SYNRAD will pay all shipping charges
to and from SYNRAD when shipped as specied by SYNRAD Customer Service. After the rst 45 days,
SYNRAD will continue to pay for the costs of shipping the repaired unit or replacement parts back to
the customer from SYNRAD. The customer, however, will be responsible for shipping charges incurred
when sending the failed unit or parts back to SYNRAD or a SYNRAD Authorized Distributor. In order to
maintain your product warranty and to ensure the safe and ecient operation of your f-Series laser, only
authorized SYNRAD replacement parts can be used. This warranty is void if any parts other than those
provided by SYNRAD are used.

SYNRAD and SYNRAD Authorized Distributors have the sole authority to make warranty statements
regarding SYNRAD products. SYNRAD and its Authorized Distributors neither assumes nor authorizes
any representative or other person to assume for us any other warranties in connection with the sale,
service, or shipment of our products. SYNRAD reserves the right to make changes and improvements
in the design of our products at any time without incurring any obligation to make equivalent changes
in products previously manufactured or shipped. Buyer agrees to hold SYNRAD harmless from any and
all damages, costs, and expenses relating to any claim arising from the design, manufacture, or use of
the product, or arising from a claim that such product furnished Buyer by SYNRAD, or the use thereof,
infringes upon any Patent, foreign or domestic.

SYNRAD f201 Operator’s Manual Version 3.2

vii

Service & support information

SYNRAD worldwide headquarters are located north of Seattle in Mukilteo, Washington. U.S.A.
Our mailing address is:

SYNRAD©
4600 Campus Place
Mukilteo, WA 98275
U.S.A.

Phone us at: 1.800.SYNRAD1 (1.800.796.7231)
Outside the U.S.: +1.425.349.3500
Fax: [phone]
web: www.synrad.com
E-mail: [e-mail]

Sales and Applications

SYNRAD 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 rst 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 specications. To speak to the Regional Sales Manager in your area, call SYNRAD at 1.800.
SYNRAD1.

Customer Service

For assistance with order or delivery status, service status, or to obtain a Return Authorization
(RA) number, contact SYNRAD at 1.800.SYNRAD1 and ask to speak to a Customer Service rep-

resentative, or you can email us by sending a message to [e-mail].

Technical Support

SYNRAD Regional Sales Managers are able to answer many technical questions regarding the
installation, use, troubleshooting, and maintenance of our products. In some cases, they may
transfer your call to a Laser, Marking Head, or Software Support Specialist. You may also e-mail

questions to the Technical Support Group by sending your message to customercare@synrad.

com.

Reference materials

Your Regional Sales Manager can provide reference materials including Outline & Mounting
drawings, Operator’s Manuals, Technical Bulletins, and Application Newsletters. Most of these
materials are also available directly from the SYNRAD web site at http://www.synrad.com.

SYNRAD f201 Operator’s Manual Version 3.2

viii

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: [phone]
Web: www.synrad.com
E-mail: [e-mail]

SYNRAD f201 Operator’s Manual Version 3.2

ix

Laser Safety

1

This chapter contains safety information that you will need to know prior to getting started.

yourself with all denitions and their signicance.

Hazard Information – includes equipment label terms and hazards, please familiarize

unsafe practices that could result in death, severe injury, or product damage.

pertain to disposal.

your f201 laser.

tion information.

General & Other Hazards – provides important information about the hazards and

Disposal – information on your f201 laser parts and/or components as they

Additional Safety Information – describes how to nd additional information about

Compliance – explains in the subsections therein applicable and appropriate regula-

Note: Read the entire safety section. This will ensure you are familiar with the hazards
and warnings prior to starting.

Warning

Serious
personal
injury

is Class 4 CO laser product emits invisible infrared laser
radiation in the 9.3–10.6 µm wavelength band.

Because direct or diuse laser radiation can inict severe
corneal injuries, always wear eye protection when in the same
area as an exposed laser beam.

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 f201 Operator’s Manual Version 3.2

10

Laser Safety

Person Lift

Hazard Information

Hazard information includes terms, symbols, and instructions used in this manual or on the
equipment to alert both operating and service personnel to the recommended precautions in
the care, use, and handling of Class 4 laser equipment.

Terms
Certain terms are used throughout this manual or on the equipment labels. Please familiarize

yourself with their denitions and signicance.

Parameter Description

WARNING: Potential & Imminent hazards which, if not avoided,

could result in death or serious injury.

Alerts operator of serious dangers, hazardous radiation, hazardous voltages,
vapor hazard, & reective dangers.

DANGER: Hazards which, if not avoided, could result in minor or

moderate injury.

Two

Alerts operator of liing dangers.

CAUTION: Potential hazards or unsafe practices which, if not avoided,

may result in product damage.

Alerts operator of equipment dangers.

IMPORTANT NOTES & TIPS:

Important

Note:

Note:

Tip:

Content specic information and/or recommendations.

Figure 1-1 Labeling terms and denitions.

Warning

Serious
personal
injury

For laser systems being used or sold within the U.S.A., cus­tomers should refer to and follow the laser safety precautions
described American National Standards Institute (ANSI) docu­ment Z136.1-2014, Safe Use of Lasers.

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 f201 Operator’s Manual Version 3.2

11

Laser Safety

General hazards

Following are descriptions of general hazards and unsafe practices that could result in death,
severe injury, or product damage. Specic warnings and cautions not appearing in this sec­tion are found throughout the manual.

Danger

Serious
personal
injury

mal tissue, which may cause permanent damage.

This product is not intended for use in explosive, or potentially explosive, atmospheres!

Materials processing with a laser can generate air contaminants such as vapors, fumes,
and/or particles that may be noxious, toxic, or even fatal. Material Safety Data Sheets
(MSDS) for materials being processed should be thoroughly evaluated and the adequa­cy of provisions for fume extraction, ltering, and venting should be carefully consid­ered. Review the following references for further information on exposure criteria:

Do not allow laser radiation to enter the eye by viewing direct
or reected laser energy.

CO laser radiation can be reected from metallic objects even
though the surface is darkened. Direct or diuse laser radiation
can inict severe corneal injuries leading to permanent eye
damage or blindness. All personnel must wear eye protection
suitable for CO radiation, e.g. 9.3–10.6 µm when in the same
area as an exposed laser beam.

Eye wear protects against scattered energy but is not intend­ed to protect against direct viewing of the beam—never look
directly into the laser output aperture or view scattered laser
reections from metallic surfaces.

Enclose the beam path whenever possible. Exposure to direct
or diuse CO laser radiation can seriously burn human or ani-

ANSI Z136.1-2014, Safe Use of Lasers, section 7.3.

U.S. Government’s Code of Federal Regulations: 29 CFR 1910, Subpart Z.

Threshold Limit Values (TLV’s) published by the American Conference of Governmental
Industrial Hygienists (ACGIH).

It may be necessary to consult with local governmental agencies regarding restrictions
on the venting of processing vapors.

The use of aerosol dusters containing diuoroethane causes “blooming”, a condition
that signicantly expands and scatters the laser beam. This beam expansion can eect
mode quality and/or cause laser energy to extend beyond the connes of optical ele­ments in the system, possibly damaging acrylic safety shielding. Do not use air dusters
containing diuoroethane in any area adjacent to CO laser systems because diuo­roethane persists for long time periods over wide areas.

SYNRAD f201 Operator’s Manual Version 3.2

12

Laser Safety

Light

Warning!

General hazards
F201 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. To prevent expo­sure to direct or scattered laser radiation, follow all safety precautions specied throughout
this manual and exercise safe operating practices per ANSI Z136.1-2014, Safe Use of Lasers at
all times when actively lasing.

Due to the specic properties of laser light, a unique set of safety hazards that dier from oth­er light sources must be considered. Just like light, lasers can be reected, refracted, diracted
or scattered.

Never use organic

Serious
Personal
Injury

material or metals as
a beam blocker. There
are very few exceptions,
e.g. black anodized
metal such as aluminum
because this is non
reective surface.

Figure 1-2 Always wear safety glasses or protective goggles with side shields to reduce the
risk of damage to the eyes when operating the laser.

A CO2 laser is an intense energy source and will ignite most materials under the proper con­ditions. Never operate the laser in the presence of ammable or explosive materials, gases,
liquids, or vapors.

Warning

Serious
personal
injury

Safe operation of the laser requires the use of an external beam block to safely block the
beam from traveling beyond the desired work area. Do not place your body or any combusti­ble object in the path of the laser beam. Use a water-cooled beam dump or power meter, or
similar non-scattering, noncombustible material as the beam block. Never use organic materi­al or metals as the beam blocker; organic materials, in general, are apt to combust or melt and
metals act as specular reectors which may create a serious hazard outside the immediate
work area.

“Caution - The use of controls or adjustments or performance
of procedures other than those specied herein may result in
hazardous radiation exposure.”

SYNRAD f201 Operator’s Manual Version 3.2

13

Laser Safety

Other hazards

The following hazards are typical for this product family when incorporated for intended use:
(A) risk of injury when lifting or moving the unit; (B) risk of exposure to hazardous laser energy
through unauthorized removal of access panels, doors, or protective barriers; (C) risk of expo­sure to hazardous laser energy and injury due to failure of personnel to use proper eye pro­tection and/or failure to adhere to applicable laser safety procedures; (D) risk of exposure to
hazardous or lethal voltages through unauthorized removal of covers, doors, or access panels;
(E) generation of hazardous air contaminants that may be noxious, toxic, or even fatal.

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 SYNRAD who, for a fee, will ensure adequate disassembly, recycling and/or disposal
of the product.

Additional laser safety information
The SYNRAD web site http://www.synrad.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.

In addition, the Occupational Safety and Health Administration (OSHA) provides an online
Technical Manual located at http://www.osha.gov/dts/osta/otm/otm_iii/otm_iii_6.html. Sec­tion 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 compre­hensive web site is located at http://www.lia.org.

SYNRAD f201 Operator’s Manual Version 3.2

14

Laser Safety

F201 label locations

400 WATTS MAX

10200-10800 nm

MADE IN THE U.S.A.MADE IN THE U.S.A.

DANGER-INVISIBLE LASER

RADIATION. AVOID EYE OR SKIN

EXPOSURE TO DIRECT OR

SCATTERED RADIATION

CLASS 4 LASER PRODUCT

EN-60825-1, 2014

Keyswitch version

MODEL #: MODELNUMBER
SERIAL #: SERIALNUMBER

MFG Month DD, YYYY

Complies with IEC 60825-1 (1993) and 21 CFR 1040.10 except for deviations pursuant to

TESTED AT XX Volts

Specified by 21 CFR 1040.10 or IEC 60825-1

4600 Campus Place, Mukilteo WA 98275 | 425.349.3500

.

or

OEM version

MODEL #: MODELNUMBER
SERIAL #: SERIALNUMBER

MFG Month DD, YYYY

This laser component does not comply with standards for complete laser products as

TESTED AT XX Volts

Specified by 21 CFR 1040.10 or IEC 60825-1

4600 Campus Place, Mukilteo WA 98275 | 425.349.3500

AVOID EXPOSURE

Invisible laser radiation

is emitted from
this aperture.

.

Front

AVOID EXPOSURE

INVISIBLE LASER RADIATION

IS EMITTED FROM THIS

APERTURE

with Synrad's UC Series power controller. This signal

and facilitates breakdown and pulse to pulse fidelity.

keeps the plasma ionized during laser "low" periods

laser "low" periods. This is automatically provided

These RF Excited Lasers must be provided with a

equivalent drive signals are not used. See manual

for tickle pulse specifications or contact factory.

pre-ionizing "Tickle" signal during standby or

Damage or malfunction may occur if this or

This laser component does not comply with standards for complete
laser products as specified by 21 CFR 1040.10 or IEC 60825-1.

SYNRAD, Inc. 4600 Campus Place, Mukilteo WA 98275 425.349.3500

OCCUR IF COOLING WATER

SEE OPERATION MANUAL.

IS BELOW DEW POINT.

WATER DAMAGE CAN

CONDENSATION AN D

MODEL #: FSF100SD

SERIAL #: F100204082943

TESTED AT: 96V MFG: July 22, 2008

CAUTION

CAUTION

CAUTION

CONDENSATION AND

WATER DAMAGE CAN

OCCUR IF COOLING WATER

IS BELOW DEW POINT.

SEE OPERATION MANUAL.

WATER-COOLED VERSION ONLY

WARNING

Do not remove water fittings!

Do not lift or pull on water fittings!

This may cause misalignment or water leaks.

If a water leak is discovered, please contact

Synrad customer service immediately.

Top

10200-10800 NANOMETERS

400 WATTS MAX

EN-60825-1, 2007

DIRECT OR SCATTERED RADI ATION
AVOID EYE OR SKIN EXPOSURE TO

INVISIBLE LASER RADI ATION

CLASS 4 LASER PRODUCT

CAUTION

These RF Excited Lasers must be provided with a

pre-ionizing "Tickle" signal during standby or

laser "low" periods. This is automatically provided

with Synrad's UC Series power controller. This signal

keeps the plasma ionized during laser "low" periods

and facilitates breakdown and pulse to pulse fidelity.

Damage or malfunction may occur if this or

equivalent drive signals are not used. See manual

for tickle pulse specifications or contact factory.

Rear

WARNING

Do not remove water fittings!

Do not lift or pull on water fittings!

This may cause misalignment or water leaks.
If a water leak is discovered, please contact

Synrad customer service immediately.

This laser product is manufactured under
one or more of the following U.S. Patents:

4,805,182 5,065,405 6,195,379 6,603,794
4,837,772 5,215,864 6,198,758 6,614,826
5,008,894 5,602,865 6,198,759

Other U.S. and International Patents pending.

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 1-3 F 100 hazard label locations.

SYNRAD f201 Operator’s Manual Version 3.2

15

Laser Safety

F201 label locations (continued)

700 WATTS MA X

10200-10800 nm

Keyswitch version

MODEL #: MODELNUMBER
SERIAL #: SERIALNUMBER

MFG Month DD, YYYY

Complies with IEC 60825-1 (1993) and 21 CFR 1040.10 except for deviations pursuant to

TESTED AT XX Volts

Specified by 21 CFR 1040.10 or IEC 60825-1

4600 Campus Place, Mukilteo WA 98275 | 425.349.3500

.

or

OEM version

MODEL #: MODELNUMBER
SERIAL #: SERIALNUMBER

MFG Month DD, YYYY

This laser component does not comply with standards for complete laser products as

TESTED AT XX Volts

Specified by 21 CFR 1040.10 or IEC 60825-1

4600 Campus Place, Mukilteo WA 98275 | 425.349.3500

.

CAUTION

CONDENSATION AND

WATER DAMAGE CAN

OCCUR IF COOLING WATER

IS BELOW DEW POINT.

SEE OPERATION MANUAL.

WATER-COOLED VERSION ONLY

This laser component does not comply with standards for complete
laser products as specified by 21 CFR 1040.10 or IEC 60825-1.

SYNRAD, Inc. 4600 Campus Place, Mukilteo WA 98275 425.349.3500

with Synrad's UC Series power controller. This signal

and facilitates breakdown and pulse to pulse fidelity.

keeps the plasma ionized during laser "low" periods

laser "low" periods. This is automatically provided

equivalent drive signals are not used. See manual

for tickle pulse specifications or contact factory.

pre-ionizing "Tickle" signal during standby or

Damage or malfunction may occur if this or

OCCUR IF COOLING WATER

SEE OPER ATION MANUAL.

IS BEL OW DEW POIN T.

WATER DAMAGE CA N

CONDENSATION AN D

CAUTION

MODEL #: FS200SD

SERIAL #: F200204082943

TESTED AT: 96V MFG: July 22, 2008

DANGER-INVISIBLE LASER

RADIATION. AVOID EYE OR SKIN

EXPOSURE TO DIRECT OR

SCATTERED RADIATION

CLASS 4 LASER PRODUCT

These RF Excited Lasers must be provided with a

CAUTION

EN-60825-1, 2014

Top

10200-10800 NANOMETERS

700 WATTS MAX

EN-60825-1, 2007

DIRECT OR SC ATTERED RADI ATION
AVOID EYE OR SKIN EXPOSURE TO

INVISIBLE LASER RADI ATION

CLASS 4 LASER PRODUCT

CAUTION

These RF Excited Lasers must be provided with a

pre-ionizing "Tickle" signal during standby or

laser "low" periods. This is automatically provided

with Synrad's UC Series power controller. This signal

keeps the plasma ionized during laser "low" periods

and facilitates breakdown and pulse to pulse fidelity.

Damage or malfunction may occur if this or

equivalent drive signals are not used. See manual

for tickle pulse specifications or contact factory.

AVOID EXPOSURE

Invisible laser radiation

is emitted from
this aperture.

Front

AVOID EXPOSURE

INVISIBLE LASER RADIATION

IS EMITTED FROM THIS

APERTURE

WARNING

Do not remove water fittings!

Do not lift or pull on water fittings!

This may cause misalignment or water leaks.

If a water leak is discovered, please contact

Synrad customer service immediately.

Bottom

Figure 1-4 F 200 hazard label locations.

WARNING

Do not remove water fittings!
Do not lift or pull on water fittings!

This may cause misalignment or water leaks.
If a water leak is discovered, please contact
Synrad customer service immediately.

Other U.S. and International Patents pending.

4,805,182 5,065,405 6,195,379 6,603,794

4,837,772 5,215,864 6,198,758 6,614,826

5,008,894 5,602,865 6,198,759

one or more of the following U.S. Patents:

Rear

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.

This laser product is manufa ctured unde r

SYNRAD f201 Operator’s Manual Version 3.2

16

Laser Safety

F201 label locations (continued)

700 WATTS MAX

10200–10800 nm

CAUTION

CONDENSATION AND

WATER DAMAGE CAN

OCCUR IF COOLING WATER

MADE IN THE U.S.A.

OEM version

MODEL #: MODELNUMBER
SERIAL #: SERIALNUMBER

MFG Month DD, YYYY
TESTED AT XX Volts

This laser component does not comply with standards for complete laser products as

Specified by 21 CFR 1040.10 or IEC 60825-1

4600 Campus Place, Mukilteo WA 98275 | 425.349.3500

.

IS BELOW DEW POINT.

SEE OPERATION MANUAL.

WATER-COOLED VERSION ONLY

washer set into threaded

Insert metric or UNC
mount and spherical
fastener thru laser

mounting plate

OCCUR IF COOLING WATER
SEE OPERATION MANUAL.
IS BELOW DEW POIN T.

WATER DAMAGE CAN
CONDENSATION AN D

OR

CAUTION

plate and spherical washer

or UNC hole in laser mount

set into threaded metric

fastener thru mounting
Insert metric or UNC

This laser component does not comply with standards for complete
laser products as specified by 21 CFR 1040.10 or IEC 60825-1.

SYNRAD, Inc. 4600 Campus Place, Mukilteo WA 98275 425.349.3500

one fastener per mount-

ing foot. Doing so will

Do not use more than

damage the laser

TESTED AT: 96V MFG: July 22, 2008

MODEL #: FSF201SC

SERIAL #: F201204082943

with Synrad's UC Series power controller. This signal

and facilitates breakdown and pulse to pulse fidelity.

keeps the plasma ionized during laser "low" periods

laser "low" periods. This is automatically provided

These RF Excited Lasers must be provided with a
equivalent drive signals are not used. See manual
for tickle pulse specifications or contact factory.

pre-ionizing "Tickle" signal during standby or

Damage or malfunction may occur if this or

CAUTION

DANGER-INVISIBLE LASER

RADIATION. AVOID EYE OR SKIN

EXPOSURE TO DIRECT OR

SCATTERED RADIATION

CLASS 4 LASER PRODUCT

Top

EN-60825-1, 2014

10200-10800 NANOMETERS

700 WATTS MAX

EN-60825-1, 2007

DIRECT OR SCATTERED RADI ATION
AVOID EYE OR SKIN EXPOSURE TO

INVISIBLE LASER RADIATIO N

CLASS 4 LASER PRODUCT

Insert metric or UNC

fastener thru laser

mount and spherical

washer set into threaded

mounting plate

AVOID EXPOSURE

Invisible laser radiation

is emitted from
this aperture.

Front

Insert metric or UNC

fastener thru mounting

plate and spherical washer

set into threaded metric

or UNC hole in laser mount

Rear

This laser product is manufactured under
one or more of the following U.S. Patents:

4,805,182 5,065,405 6,195,379 6,603,794
4,837,772 5,215,864 6,198,758 6,614,826
5,008,894 5,602,865 6,198,759

Other U.S. and International Patents pending.

AVOID EXPOSURE

Invisible laser radiation

is emitted from

this aperture.

Figure 1-5 F 201 hazard label locations.

OR

This may cause misalignment or water leaks.
If a water leak is discovered, please contact

Do not remove water fittings!
Do not lift or pull on water fittings!

Synrad customer service immediately.

WARNING

Do not use more than

one fastener per mount-

ing foot. Doing so will

damage the laser

CAUTION

These RF Excited Lasers must be provided with a

pre-ionizing "Tickle" signal during standby or

laser "low" periods. This is automatically provided

with Synrad's UC Series power controller. This signal

keeps the plasma ionized during laser "low" periods

and facilitates breakdown and pulse to pulse fidelity.

Damage or malfunction may occur if this or

equivalent drive signals are not used. See manual

for tickle pulse specifications or contact factory.

WARNING

Do not remove water fittings!

Do not lift or pull on water fittings!

This may cause misalignment or water leaks.

If a water leak is discovered, please contact

Synrad customer service immediately.

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.

SYNRAD f201 Operator’s Manual Version 3.2

17

Laser Safety

Agency compliance

Center for Devices and Radiological Health (CDRH) requirements.

Federal Communications Commission (FCC) requirements.

European Union (EU) requirements.

SYNRAD lasers are designed, tested, and certied to comply with certain United States (U.S.)
and European Union (EU) regulations. These regulations impose product performance re­quirements related to electromagnetic compatibility (EMC) and product safety characteris­tics for industrial, scientic, and medical (ISM) equipment. The specic provisions to which
systems containing f201 lasers must comply are identied and described in the following
paragraphs. Note that compliance to CDRH, FCC, and EU requirements depends in part on the
laser version selected—Keyswitch or OEM.

In the U.S., laser safety requirements are governed by the Center for Devices and Radiological
Health (CDRH) under the auspices of the U.S. Food and Drug Administration (FDA) while radi­ated emission standards fall under the jurisdiction of the U.S. Federal Communications Com­mission (FCC). Outside the U.S., laser safety and emissions are governed by European Union
(EU) Directives and Standards.

In the matter of CE-compliant laser products, SYNRAD assumes no responsibility for the
compliance of the system into which the product is integrated, other than to supply and/or
recommend laser components that are CE marked for compliance with applicable European
Union Directives.

Because OEM laser products are intended for incorporation as components in a laser process­ing system, they do not meet all of the Standards for complete laser processing systems as
specied by 21 CFR, §1040 or IEC 60825-1. SYNRAD assumes no responsibility for the compli­ance of the system into which OEM laser products are integrated.

Center for Devices and Radiological Health (CDRH)
requirements

Product features incorporated into the design of f201 lasers to comply with CDRH require­ments are integrated as panel controls or indicators, internal circuit elements, or input/output
signal interfaces. Specically, these features include a lase and laser ready indicators, remote
interlock for power on/o, a laser aperture shutter switch, and a ve-second delay between
power on and lasing. Incorporation of certain features is dependent on the laser version (Key­switch or OEM). Table 1, Class 4 safety features, indicates which features are available on f201
lasers, the type and description of the feature, and if the feature is required by CDRH regula­tions.

OEM models
F201 OEM lasers are OEM products intended for incorporation as components in laser pro-

cessing 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.
Under CDRH regulations, the Buyer must submit a report to the CDRH prior to shipping the
system. In jurisdictions outside the U.S., it is the sole responsibility of the Buyer of these OEM

SYNRAD f201 Operator’s Manual Version 3.2

18

Laser Safety

components to ensure that they meet all applicable local laser safety requirements. In cases
where the Buyer is also the end-user of the OEM laser product, the Buyer/end-user must inte­grate the laser so that it complies with all applicable laser safety standards as set forth above.

Federal Communications Commission (FCC)
Requirements

The United States Communication Act of 1934 vested the Federal Communications Commis­sion (FCC) with the authority to regulate equipment that emits electromagnetic radiation in
the radio frequency spectrum. The purpose of the Communication Act is to prevent harmful
electromagnetic interference (EMI) from aecting authorized radio communication services.
The FCC regulations that govern industrial, scientic, and medical (ISM) equipment are fully
described in 47 CFR, §18, §§C.

SYNRAD f201 lasers have been tested and found to comply by demonstrating performance
characteristics that have met or exceeded the requirements of 47 CFR, §18, §§C for Radiated
and Conducted Emissions.

FCC information to the user

Interference Potential

Note:

In our testing, SYNRAD has not discovered any signicant electrical interference trace­able to f201 lasers.

System Maintenance
Ensure that all exterior covers are properly fastened in position.

Measures to Correct Interference
If you suspect that your laser interferes with other equipment, take the following steps to

minimize this interference:

1

2

The following FCC information to the user is provided to comply with the requirements
of 47 CFR, §18, §§ 213 Information to the user.

Use shielded cables to and from the equipment that is experiencing interfer-

ence problems.

Ensure that the laser is properly grounded to the same electrical potential as

the equipment or system it is connected to.

FCC caution to the user
The Federal Communications Commission warns the user that changes or modications of

the unit not expressly approved by the party responsible for compliance could void the user’s
authority to operate the equipment.

SYNRAD f201 Operator’s Manual Version 3.2

19

Laser Safety

European Union (EU) requirements

RoHS compliance
SYNRAD f201 lasers meet the requirements of the European Parliament and Council Directive

2014/35/EU on the Restriction of the Use of Certain Hazardous Substances in Electrical and
Electronic Equipment that establishes maximum concentration values for certain hazardous
substances in electrical and electronic equipment.

Laser safety standards
Under the Low Voltage Directive, 2014/35/EU, the International Standard species the min-

imum documentation, marking and labeling for all laser products classied in accordance
with IEC 60825-1:2014 (hereafter referred to as EN 60825-1) including laser diodes and all laser
devices dened in ISO 11145 was developed to provide laser safety guidance and includes
clauses on Engineering Specications, Labeling, Other Informational Requirements, Addition­al Requirements for Specic Laser Products, Classication, and Determination of the Accessi­ble Emission Level. To develop a risk assessment plan/laser safety program for users, see the
EN 60825-14:2004 Standard for the safety of laser products that includes clauses on Adminis­trative Policies, Laser Radiation Hazards, Determining the MPE, Associated Hazards, Evaluat­ing Risk, Control Measures, Maintenance of Safe Operation, Incident Reporting and Accident
Investigation, and Medical Surveillance.

OEM models
F201 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 nal product will
itself be subject to the Standard.” This means that Buyers of OEM laser components are
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. Note
that when an OEM laser component is incorporated into another device or system, the
entire machinery installation may be required to conform to EN 60825-1:2004, EN 60204­1:2016, Safety of Machinery; the Machinery Directive, 2006/42/EC; and/or any other ap­plicable Standards and in cases where the system is being imported into the U.S., it must
also comply with CDRH regulations.

In cases where the Buyer is also the end-user of the OEM laser product, the Buyer/end-us­er must integrate the laser so that it complies with all applicable laser safety standards as
set forth above. Table 1, Class 4 safety features, summarizes f201 product features, indi­cating the type and description of features and whether those features are required by
European Union regulations.

Electromagnetic interference standards

SYNRAD f201 lasers have demonstrated performance characteristics that have met or exceed­ed the requirements of EMC Directive 2014/30/EU.

The European Union’s Electromagnetic Compatibility (EMC) Directive, 2014/30/EU, is the sole
Directive developed to address electromagnetic interference (EMI) issues in electronic equip­ment. In particular, the Directive calls out European Norm (EN) documents that dene the
emission and immunity standards for specic product categories. For f201 lasers, EN 61000­6-4:2018 denes radiated and conducted RF emission limits while EN 61000-6-2:2016 denes
immunity standards for industrial environments.

SYNRAD f201 Operator’s Manual Version 3.2

20

Laser Safety

Table 1-1 Class 4 safety features.

Required by: Available on:
Feature Location / Description CDRH EN60825-1 OEM f201

Keyswitch1 Rear panel control Yes Yes No

On/O/Reset Keyswitch controls power to laser electronics.

Key cannot be removed from switch in the “On” position.

Shutter Laser control Yes Yes Yes
function Functions as a beam attenuator to disable RF driver/

laser output when closed.

Shutter Rear panel indicator (Blue) No No Yes
indicator Illuminates blue to indicate shutter is open.

Ready Rear panel indicator (Yellow) Yes Yes Yes
indicator Indicates that laser has power applied and is capable

of lasing.

Lase Rear panel indicator (Red) No No Yes
indicator Indicates that the laser is actively lasing. Lase LED

illuminates when the duty cycle of the Command signal
is long enough to produce laser output.

Five second Circuit element Yes No Yes
delay Disables RF driver/laser output for ve seconds after

Keyswitch is turned to “On” or remote reset/start pulse is
applied when Keyswitch is in “On” position.

Power fail Circuit element Yes Yes No
lockout1 Disables RF driver/laser output if input power is removed

then later reapplied (AC power failure or remote interlock
actuation) while Keyswitch is in “On” position.

Remote Rear panel connection Yes Yes Yes
Interlock Disables RF driver/laser output when a remote interlock

switch on an equipment door or panel is opened.

Remote Rear panel indicator (Green/Red) No No Yes
Interlock Illuminates green when Remote Interlock circuitry is closed.
Indicator Illuminates red when interlock circuitry is open.

Over Circuit element No No Yes
temperature Temperature shutdown occurs if temperature of the laser
protection tube rises above safe operating limits.

Temp Rear panel indicator (Green/Red) No No Yes
indicator Illuminates green when laser temperature is within

operating limits, changing to red when thermal limits

are exceeded.

Warning Laser exterior Yes Yes Yes
labels Labels attached to various external housing locations to

warn personnel of potential laser hazards.

1 Not available on f201 OEM lasers

SYNRAD f201 Operator’s Manual Version 3.2

21

Laser Safety

When integrating SYNRAD f201 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 testing program has demonstrated that f201 lasers comply with the relevant
requirements of 2014/30/EU, the Electromagnetic Compatibility Directive, as summarized in
the table below.

Table 1-2 European Union Directives.

Applicable Standards / Norms

2014/30/EU Electromagnetic Compatibility Directive

2014/35/EU Low Voltage Directive

2011/65/EU RoHS Directive

EN 61010-1:2010 Safety Requirements for Electrical Equipment for Measure-
ment, Control, and Laboratory Use - Part 1: General

Requirements

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 Electromagnetic Field Immunity

EN 61000-6-2:2005 Electrical Fast Transient/Burst Immunity

EN 61000-6-2:2005 Conducted RF Disturbances Immunity

After a laser or laser processing system has met the requirements of all applicable EU Direc­tives, the product can bear the ocial compliance mark of the European Union as a Declara­tion of Conformity.

SYNRAD f201 Operator’s Manual Version 3.2

22

Laser Safety

3/4/19

We,

Manufacturer’sName: SYNRAD®A

Manufacturer’sAddress: 4600CampusPlace

DeclarationofConformity

inaccordancewithISO/IEC17050‐2:2004

©

Mukilteo,WA98275U.S.A.





NovantaCompany



Herebydeclareunderoursoleresponsibilitythatthefollowingequipment:

ProductName: Firestar™f100Laser

ModelNumber: FSf100KD(Keyswitch)

FSf100KD(*OEM)



ConformstothefollowingDirective(s)andStandard(s):

ApplicableDirective(s): 2014/30/EU ElectromagneticCompatibilityDirective

2014/35/EU LowVoltageDirective
2011/65/EU RoHSDirective

ApplicableStandard(s):

EN61010‐1:2010 SafetyRequirementsforElectricalEquipmentforMeasurement,Control,

andLaboratoryUse‐Part1:GeneralRequirements

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

TimFreni,QualityManagerofSYNRAD

85748GarchingbeiMünchen,Germany





Dated:

Figure 1-6 F100 declaration of conformity.

MADEINTHEU.S.A.

900‐20976‐19RevB

SYNRAD f201 Operator’s Manual Version 3.2

23

Laser Safety

3/4/19

We,

Manufacturer’sName: SYNRAD®A

Manufacturer’sAddress: 4600CampusPlace

DeclarationofConformity

inaccordancewithISO/IEC17050‐2:2004

©

NovantaCompany

Mukilteo,WA98275U.S.A.







Herebydeclareunderoursoleresponsibilitythatthefollowingequipment:

ProductName: Firestar™f201Laser

ModelNumber: FSf201SD(*OEM)



ConformstothefollowingDirective(s)andStandard(s):

ApplicableDirective(s): 2014/30/EU ElectromagneticCompatibilityDirective

2014/35/EU LowVoltageDirective
2011/65/EU RoHSDirective

ApplicableStandard(s):

EN61010‐1:2010 SafetyRequirementsforElectricalEquipmentforMeasurement,Control,and

LaboratoryUse‐Part1:GeneralRequirements
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



Date:

Figure 1-7 F201 declaration of conformity.

SYNRAD f201 Operator’s Manual Version 3.2

24

MADEINTHEU.S.A.

900‐20976‐14RevB

getting started

2

Use information in this chapter to prepare your Firestar f201 laser for operation. The
order of information presented in this chapter is the same as the order of tasks that
you will need to perform. The best way to get your laser ready for operation is to start
at Unpacking and work your way through Connecting.

This chapter contains the following information:

■Introduction – introduces the f201 laser, lists important features, and describes

Firestar nomenclature.

■Unpacking – provides important information about unpacking your f201 laser.

■Inventory – displays and describes all components shipped with your f201 laser.

■Mounting – describes how to attach your f201 laser to a mounting surface.

■Connecting – explains how to connect cooling tubing, power, and control cabling.

Caution

possible

equipment

damage

Caution

possible

equipment

damage

Operating the laser at coolant temperatures above 22 °C (72 °F)
may result in decreased performance and/or premature failure of
electronic components.

Operating the laser at coolant temperatures above 22 °C (72 °F)
may result in decreased performance and/or premature failure of
electronic components.

SYNRAD f201 Operator’s Manual Version 3.2

25

getting started

Introduction

F201 lasers are part of a smaller-footprint lasers 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 atbed cutters, robotic arms, or gantry systems making integration into your
production line simple and fast.

f201 features include:

■ Compact resonator design ■ Color-coded LEDs mirror user outputs

■ Integrated RF power supply ■ “Industrial-strength” ±5 V to 24 VDC I/O

■ Built-in “tick le” generator ■ Keyswitch and OEM models available

Firestar nomenclature

Firestar f201 lasers are available only as OEM lasers; they do not include either a keyswitch or manual
shutter assembly. SYNRAD’s OEM lasers are primarily designed as components for integration into larger
processing systems by the Original Equipment Manufacturer (OEM) or System Integrator who bears the
responsibility for meeting the appropriate laser safety requirements for Class 4 laser systems.

Single tube

Firestar f201 lasers contain a single tube (optical resonator) within the laser chassis. These lasers incor­porate a single set of controls and indicators as well as a single set of cooling ports.

Model numbers

The last three characters in the Firestar model number serve to designate the functional category,
cooling method, and model version. The functional category is indicated by an “S” (Switch-less) for OEM
models. The next letter indicates the cooling method: “W” for water-cooled units, “W” is omitted on f201
lasers since they are all water-cooled). The last letter in the model number indicates the current model
version beginning with “B”. For example, the model number. FSF201SC indicates a “C” version OEM
water-cooled f201 laser.

Important Note: All Firestar f201 lasers are water-cooled because of the integrated RF section’s heat

removal requirements. F201 lasers cannot be fan-cooled. Damage to your laser will
void your warranty.

SYNRAD f201 Operator’s Manual Version 3.2

26

getting started

Unpacking

The Unpacking section includes subsections:

■ Incoming inspection

■ Packaging guidelines

■ Unpacking the laser

■ Removing the lifting handles

Incoming inspection

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 to
your receiving dock.

Packaging guidelines

Warning

possible

personal

Lifting or moving f201 lasers 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.

injury

■ To prevent equipment damage or loss of small components, use care when removing packaging materi-

als.

■ After unpacking, review the Inventory section and verify that all components are on hand.

■ Do not lift or support the laser using the cooling ttings; lift the laser by the mounting feet or

baseplate only.

■ Save all shipping containers and packaging materials, including covers and plugs. Use these special-

ized packing materials when shipping the laser to another location.

■ When packing a laser for shipment, be sure to remove all accessory items not originally attached to

the laser including beam delivery components, cooling tubing, etc.

■ Refer to Packaging instructions drawings in the Technical Reference chapter for details on packag-

ing f201 lasers using SYNRAD-supplied shipping materials.

■ When shipping water-cooled lasers, remember to drain all cooling water from the laser and then cap

the open ttings to prevent debris from entering the coolant path.

■ F201 lasers and power supplies are heavy and awkward to move. Use appropriate lifting techniques,

additional personnel, and/or hoisting equipment to prevent a risk of injury when rigging this equip­ment.

SYNRAD f201 Operator’s Manual Version 3.2

27

getting started

1

Unpacking

Unpacking the laser

To unbox the laser, refer to the gure below and perform the following steps:

5

2

6

FRAGILE

FRAGILE

FRAGILE

SAVE

THIS BO

X

6

3

4

Figure 2-1 Unpacking the laser.

1

Carefully cut the shipping strap wrapped around the container. This strap secures the upper lid to

the shipping crate.

2

Remove the upper lid and set it aside.

3

Remove the four polyurethane foam blocks that center the inner box within the outer crate.

4

Open the four aps of the inner box.

5

Remove the three foam blocks cradling the top of the laser. To remove the center block, rst slide

it forward several inches and then lift.

6

The laser is shipped with three lifting handles bolted to the mounting feet. Use these handle grips

to hoist or lift the laser from its shipping container. To prevent injury to personnel or damage to
the laser, always use a minimum of three people to handle the laser.

Note: Do not lift or support the laser using the cooling ttings. Lift the laser using the lifting handles,

mounting feet or baseplate only.

7

After removing the laser, pull out all the accessory items packaged with the laser.

SYNRAD f201 Operator’s Manual Version 3.2

28

getting started

Remove these
bolts

Unpacking

Removing the lifting handles

Once you have placed the laser in its nal mounting location, refer to the gure below and perform the
following steps to remove the lifting attachments.

10200-10800 NANOMETERS

1400 WATTS MAX

EN-60825-1, 1993

AVOID EYE OR SKIN EXPOSURE TO

INVISIBLE LASER RADIATION

DIRECT OR SCATTERED RADIATION

CLASS 4 LASER PRODUCT

CONDENSATION AND

CAUTION

OCCUR IF COOLING WATER

WATER DAMAGE CAN

IS BELOW DEW POINT.

SEE OPERATION MANUAL.

This laser component does not comply with standards for complete
laser products as specified by 21 CFR 1040.10 or IEC 60825-1.

MODEL #: FSF400SC

SERIAL #: F400204082943

TESTED AT: 96V MFG: July 22, 2008

SYNRAD, Inc. 4600 Campus Place, Mukilteo WA 98275 425.349.3500

Figure 2-2 Removing lifting handles.

1

Locate the 8 mm hex wrench included with the accessory items.

2

Remove the M10 × 1.5 metric capscrews from the three locations shown in the above gure.

3

Retain the three M10 × 1.5 capscrews. Use these bolts for mounting if metric fasteners are required.

4

Store the lifting attachments so that they can be reinstalled if the laser is moved to another loca-

tion.

SYNRAD f201 Operator’s Manual Version 3.2

29

getting started

Chiller Fittings and
Mounting Bolts

Cooling Tubing

DC Power Cable

Quick Start Plug

SYNRAD CO
Welcome flier

Inventory

f201 lasers

2

Firestar f-Series Laser

(f100 shown)

Figure 2-3 F201 shipping box contents.

SYNRAD f201 Operator’s Manual Version 3.2

30

getting started

Inventory

Table 2-1 f201 ship kit contents.

Shipping Box Contents Qty Shipping Box Contents Qty

DC Power Cable ............................................1 Spare 20 Ampere Fuses (not shown) ..... 1/2

Quick Start Plug ............................................1 Chiller Fittings ............................................... 2

BNC Control Cable (f201 only) ..................1 Spherical Washer Sets (f201 only) ........... 3

Cooling Tubing ...............................................1 Cooling Kit ...................................................... 1

Mounting Bolts ..............................................3/6 Final Test Report (not shown) .................. 1

SYNRAD CO2 Welcome Flier ...................... 1

f201 contents description

Each item listed in the table above is described below:

DC Power Cable – carries DC power from the DC power supply to your Firestar laser.

Quick Start Plug – 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.

BNC Control Cable (f201 only) – Coaxial cable carries the PWM Command signal from the UC-2000
Controller to the laser’s Quick Start Plug.

Cooling Tubing – Carries cooling water from the chiller to the laser and back. This black polyethylene
tubing is 1/2-inch O.D. by 30 feet and must be cut to length.

Mounting Bolts –Fasten our laser to your mounting surface. Firestar f201 lasers include three metric (M8
× 1.25 × 30 mm) and three standard (5/16–18 × 1.25" UNC) capscrews.

SYNRAD CO2 Welcome Flier – Contains an f201 customer welcome that provides where to nd, opera­tion, and maintenance information for your f201 single-tube laser on our website.

Spare 20 Ampere Fuses (not shown) – fast-blow fuses protects Firestar’s internal circuitry.

Chiller Fittings – Adapt 1/2-inch O.D. tubing to 3/8" NPT threads for connection to a chiller. The chiller’s
inlet and outlet ports must be equipped with, or be adapted to, 3/8" NPT female threads.

Spherical Washer Sets (not shown) – used in conjunction with Firestar f201 mounting bolts to align the
laser to your mounting surface. Shipped with f201 lasers only.

Cooling Kit – adapts the laser’s straight 1/2-inch coolant ttings to 90° adaptor ttings for either 1/2-inch
standard or 12-mm metric cooling tubing.

Final Test Report (not shown) – contains data collected during the laser’s nal pre-shipment test.

SYNRAD f201 Operator’s Manual Version 3.2

31

getting started

A

A

-

Mounting

f201 mounting

F201 mounting brackets are threaded to accept either metric or standard fasteners.

Important Note: As shown in the gure below, DO NOT use more than one fastener per mounting

location. Using two or more fasteners per mounting tab will cause damage to the
laser; use only one fastener per location to mount your f201 laser.

Do not use more than

one fastener per mount

ing foot. Doing so will

damage the laser

Fastening f201 lasers from above

To fasten your f201 laser to a mounting surface from above, perform the following steps:

1

Refer to the appropriate outline and mounting drawing for dimensions and then drill and tap

three mounting holes into your mounting surface. For SAE installations, drill and tap three 5/16–18
(f201).

These hole locations (referenced by Note 2 on the O & M drawings) should correspond to the thru

holes labeled “A” as shown in the gure below.

2

Assemble three spherical washer sets as detailed in the Outline and Mounting drawing.

3

Place the spherical washer sets over the threaded holes in your mounting surface.

4

Carefully position the laser so that each thru hole in the baseplate aligns with a spherical washer

and threaded mounting hole.

5

Insert the appropriate metric or standard capscrews, included in the laser’s ship kit, through the

baseplate, through the spherical washers, and into the threaded holes of the mounting surface
(see gure below). Turn the screws by hand until the threads engage.

6

Evenly tighten all three capscrews. For M8 capscrews, torque to 12 N m; for M10 screws, torque to

24 N m. When using 5/16" screws, torque to 13 ft lb; for 3/8" capscrews, tighten to 23 ft lb.

damage the laser

Do not use more than

ing foot. Doing so will

CAUTION

CONDENS ATION AN D

WATER DAMAGE CA N

IS BELOW DEW POIN T.

OCCUR IF COOLING WATER

sense fault conditions that could potentially

damage the laser’s electronic circuit boards.

The RF Drive circuit in this laser is designed to

On rare occasions, the laser may shutdown during

one fastener per mount-

Insert metric or UNC

fastener thru mounting

set into threaded metric

or UNC hole in laser mount

plate and spherical washer

OR

mounting plate

fastener thru laser

mount and spherical

Insert metric or UNC

washer set into threaded

MODEL #: FSF400SD

SERIAL #: F400204082943

TESTED AT: 96V MFG: July 22, 2008

SYNRAD, Inc. 4600 Campus Place, Mukilteo WA 98275 425.349.3500

laser products as specified by 21 CFR 1040.10 or IEC 60825-1.

This laser component does not comply with standards for complete

SEE OPER ATION MA NUAL.

re-apply DC power.

problem in the laser’s control circuit.

SYNRAD, Inc. as this may indicate a serious

the start-up sequence. When this happens, the

power from the laser, wait 30 seconds, and then

If the Ready indicator continues to flash, contact

Ready indicator will flash a series of three blinks,

pause, and then repeat. If this occurs, remove DC

CLASS 4 LASER PRODUCT

INVISIBLE LASER RADI AT IO N

AVOID EYE OR SKIN EXPOSURE TO

DIRECT OR SC ATTERED RADI ATION

EN-60825-1, 2007

1400 WATTS MA X

10200-10800 NANOMETERS

Top View

A

Figure 2-4 Fastening the f201 from below.

SYNRAD f201 Operator’s Manual Version 3.2

32

Cooling ttings
removed for clarity

getting started

washer set into threaded

M

M

M

S

S

Mounting

f201 mounting

Insert metric or SAE

fastener thru laser

mount and spherical

mounting plate

Figure 2-5 Detail of fastening into mounting surface.

Fastening f201 lasers from below

To fasten your f201 laser to a mounting surface from below, perform the following steps:

1

Refer to the appropriate outline and mounting drawing for dimensions and then drill three 8.5

mm (f201) holes into your mounting surface. For SAE installations, drill three 0.332" (f201) holes
into your mounting surface.

These hole locations (referenced by Note 1 or Note 3 on the O & M drawings) should correspond

to the threaded holes labeled “M”, for metric, or “S”, for standard, as shown in the following gure.

damage the laser

Do not use more than

ing foot. Doing so will

one fastener per mount-

C A UTION

CONDENS A TION AN D

W A TER D AM A GE CA N

The RF Drive circuit in this laser is designed to

OCCUR IF COOLING W A TE R

sense fault conditions that could potentially

damage the laser’s electronic circuit boards.

S

Insert metric or UNC

fastener thru mounting

plate and spherical washer

OR

fastener thru laser

mount and spherical

Insert metric or UNC

MODEL #: FSF400SD

SERIAL #: F400204082943

TESTED AT: 96V MFG: July 22, 2008

SYNRAD, Inc. 4600 Campus Place, Mukilteo WA 98275 425.349.3500

laser products as specified by 21 CFR 1040.10 or IEC 60825-1.

This laser component does not comply with standards for complete

IS BEL O W DEW POIN T .

SEE OPER A TION MAN U AL .

re-apply DC power.

problem in the laser’s control circuit.

SYNRAD, Inc. as this may indicate a serious

the start-up sequence. When this happens, the

power from the laser, wait 30 seconds, and then

If the Ready indicator continues to flash, contact

Ready indicator will flash a series of three blinks,

pause, and then repeat. If this occurs, remove DC

On rare occasions, the laser may shutdown during

set into threaded metric

washer set into threaded

or UNC hole in laser mount

mounting plate

Top View

CLASS 4 LASER P R ODUC T

INVISIBLE LASER RADI A TIO N

A V OID EYE OR SKIN EXPOSURE T O

DIRECT OR SC A TTERED RADI A TIO N

EN-60825-1, 2007

1400 W A TTS MA X

10200-10800 NANOMETERS

(f400 model shown)

Cooling fittings
removed for clarity

Figure 2-6 Fastening f201 from below.

2

Assemble three spherical washer sets as detailed in the outline and mounting drawing.

3

Place the spherical washer sets over the thru holes in your mounting surface.

4

Carefully position the laser so that each threaded hole in the baseplate (labeled “M” or “S” in the

prior gure) aligns with a spherical washer and thru hole in the mounting surface.

5

Insert the appropriate metric or standard capscrews, included in the laser’s ship kit, through the

mounting surface and spherical washers into the threaded holes of Firestar’s baseplate (see Figure
1-11). Turn the screws by hand until the threads engage.

6

Evenly tighten all three capscrews. For M8 capscrews, torque to 12 N m; for M10 capscrews,

tighten to 24 N m. When using 5/16" capscrews, torque to a value of 13 ft lb; for 3/8" capscrews,
tighten to 23 ft lb.

SYNRAD f201 Operator’s Manual Version 3.2

33

getting started

Connecting

The Connecting section includes subsections:

■ Cooling connections

■ PS-96 power supply connections

■ Control connections

■ Other connections

Cooling connections

Read Guidelines for cutting and installing tubing before installing any cooling tubing and then make sure to
connect the cooling system exactly as described for your particular laser.

Guidelines for cutting and installing tubing

■ Cut tubing lengths generously to allow for trimming.

■ Cut tubing squarely; diagonal cuts may not seal properly. Trim away burrs if the cut is “ragged”.

■ Avoid excessive stress on ttings; create gentle bends when routing tubing close to connectors. Exces-

sive stress from sharp bends will compromise the sealing properties of the tting.

■ Never allow the tubing to kink, since kinking severely restricts coolant ow.

■ Push tubing completely into the tting, then pull the tubing to verify that it is locked into place. Tub-

ing extends into the tting approximately 7/8 of an inch.

■ If tubing must be disconnected from a tting, rst push and hold the tubing slightly into the tting.

Next push the white tting ring evenly towards the tting, and then pull the tubing free.

■ After disconnecting tubing from a tting, trim 12.7 mm (1/2") from its end before reconnecting. Trim-

ming the end of the tubing before reconnecting the tting provides an undisturbed sealing surface.

Laser cooling ttings

If your integrated laser application uses metric cooling tubing, we recommend the installation of tubing
adaptors to convert the laser’s existing WATER IN/WATER OUT ttings from 1/2-inch standard to 12-mm
metric tubing. The ship kit sent with your f201 laser includes a cooling kit containing two each 1/2-inch
male to 1/2-inch female 90° adaptors and two each 1/2-inch male to 12-mm female 90° adaptors. If
required, many tubing and tting manufacturers can supply 1/2-inch to 12-mm straight ttings.

Connecting

Caution

Firestar f201 lasers incorporate special ttings that accept only stan­dard 1/2" O.D. cooling tubing.

possible

equipment

DO NOT REMOVE OR ADJUST THESE FITTINGS!

damage

Each laser is shipped with a cooling kit that includes 90° push-on
tubing connectors to adapt the brass ttings to your choice of stan­dard (1/2-inch) or metric (12-mm) cooling tubing.

SYNRAD f201 Operator’s Manual Version 3.2

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getting started

Mounting

Chiller preparation guidelines

■The ship kit includes chiller ttings with 3/8" NPT male threads. If these ttings will not connect to

your chiller then you must provide ttings that will adapt the laser’s 1/2" O.D. polyethylene cooling
tubing to your chiller’s Inlet and Outlet ports.

■Because Firestar’s cooling tubing is supplied in inch sizes, do not use metric tubing ttings unless you

have installed the appropriate inch-to-metric tubing adaptors. The use of metric ttings on inch size
tubing will lead to coolant leaks or may allow the pressurized tubing to blow o the tting.

Coolants

SYNRAD recommends the laser’s cooling uid contain at least 90% distilled water by volume. In closed­loop systems, use a corrosion inhibitor/algaecide such as Optishield® Plus or equivalent as required.
Avoid glycol-based additives because they reduce the coolant’s heat capacity and high concentrations
may aect 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. 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. Install a lter on the chiller’s return line and inspect frequently. f201 lasers use the following wet­ted materials in the coolant path—aluminum, brass, copper, Delrin®, PBT, polyethylene, stainless steel,
and Viton®.

Note: DO NOT use de-ionized (DI) water as a coolant. DI water is unusually corrosive and is not recom-

mended for mixed material cooling systems.

Setting coolant temperature

Choosing the correct coolant temperature is important to the proper operation and longevity of your laser.
When coolant temperature is lower than the dew point (the temperature at which moisture condenses out
of the surrounding air), condensation forms inside the laser housing leading to failure of laser electronics as
well as damage to optical surfaces.

The greatest risk of condensation damage occurs when the laser is in a high heat/high humidity environ­ment and the chiller’s coolant temperature is colder than the dew point of the surrounding air or when the
system is shut down, but coolant continues to ow through the laser for extended periods of time.

The chiller’s temperature setpoint must always be set above the dew point temperature. In cases where this
is not possible within the specied coolant temperature range of 18 °C to 22 °C (64 °F to 72 °F), then the
following steps MUST be taken to reduce the risk of condensation damage.

■ Use the Gas Purge port (f201) to introduce nitrogen or dry, ltered air into the laser housing.

■ Air-condition or dehumidify the room or the enclosure containing the laser.

■ Increase coolant ow by an additional 3.8 lpm (1.0 GPM). Do not exceed a coolant pressure of 414

kPa (60 PSI).

Note: To reduce problems associated with condensation, Firestar f201asers can operate up to 28 °C.

However, these elevated cooling temperatures may result in decreased laser performance and/
or reduced laser lifetime.

SYNRAD f201 Operator’s Manual Version 3.2

35

getting started

The following table provides dew point temperatures for a range of air temperature and relative humid­ity values. Remember that the laser’s coolant temperature must be set above the dew point tempera­tures given in the chart; however, for best results and performance, use a coolant temperature in the
range of 18–22 °C (64–72 °F) when possible.

Connecting

Table 2-3 Dew point temperatures.

Dew Point Temperature Chart °F (°C)

Relative Humidity (%)

20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95

Air Temp
°F (°C)

60 (16) — — — 32 36 39 41 44 46 48 50 52 54 55 57 59

(0) (2) (4) (5) (7) (8) (9) (10) (11) (12) (13) (14) (15)

65 (18) — — 33 37 40 43 46 48 51 53 55 57 59 60 62 64

(1) (3) (4) (6) (8) (9) (11) (12) (13) (14) (15) (16) (17) (18)

70 (21) — 33 37 41 45 48 51 53 56 58 60 62 64 65 67 69

(1) (3) (5) (7) (9) (11) (12) (13) (14) (16) (17) (18) (18) (19) (21)

75 (24) — 37 42 46 49 52 55 58 60 62 65 67 68 70 72 73

(3) (6) (8) (9) (11) (13) (14) (16) (17) (18) (19) (20) (21) (22) (23)

80 (27) 35 41 46 50 54 57 60 62 65 67 69 71 73 75 77 78

(2) (5) (8) (10) (12) (14) (16) (17) (18) (19) (21) (22) (23) (24) (25) (26)

85 (29) 40 45 50 54 58 61 64 67 70 72 74 76 78 80 82 83

(4) (7) (10) (12) (14) (16) (18) (19) (21) (22) (23) (24) (26) (27) (28) (28)

90 (32) 44 50 54 59 62 66 69 72 74 77 79 81 83 85 87 88

(7) (10) (12) (15) (17) (19) (21) (22) (23) (25) (26) (27) (28) (29) (31) (31)

95 (35) 48 54 59 63 67 70 73 76 79 81 84 86 88 90 92 93

(9) (12) (15) (17) (19) (21) (23) (24) (26) (27) (29) (30) (31) (32) (33) (34)

100 (38) 52 58 63 68 71 75 78 81 84 86 88 91 93 95 97 98

(11) (14) (17) (20) (22) (24) (26) (27) (29) (30) (31) (33) (34) (35) (36) (37)

To use the table above, look down the Air Temp column and locate an air temperature in Fahrenheit or
Celsius (°C values are shown in parentheses) that corresponds to the air temperature in the area where
your laser is operating. Follow this row across until you reach a column matching the relative humid­ity in your location. The value at the intersection of the Air Temp and Relative Humidity columns is the
Dew Point Temperature in °F (or °C). The chiller’s temperature setpoint must be set above the dew point
temperature. 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 forming inside the laser.

SYNRAD f201 Operator’s Manual Version 3.2

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getting started

Connecting

f201 cooling tubing connections

To connect cooling tubing to your f201 laser, refer to the gure below and perform the following steps.
The numbered items that follow correspond to the step numbers in the following procedure.

Chiller

OUTLET

INLET

20A FAST

FUSE

DC POWER

96 VDC 18A MAX

WATER OUT

Remote
Interlock

WATER IN

OFF/RESET

Lase

Shutter

Ready

Temp

ON

USER I/O

Figure 2-7 F201 ooling connections.

1

Cut and connect a length of cooling tubing to t between the chiller’s Outlet port and the

WATER IN port on the rear of your f201 laser.

2

Cut and connect a length of cooling tubing to t between the WATER OUT port on the rear of the

laser and the chiller’s Inlet port.

3

Turn on the chiller and adjust the temperature setpoint to 18 °C to 22 °C. Regulate coolant ow to

9.5 lpm (2.5 GPM) for f201 lasers at less than 414 kPa (60 PSI) of pressure.

4

Closely examine all cooling connections and verify that there are no leaks.

1

Locate the 1/2-inch O.D. cooling tubing in the Ship Kit and cut four lengths (12–18 inches long) to

t partway between your chiller and the rear of the laser.

2

Select two lengths of tubing and connect one end of each piece to the laser’s WATER IN ports.

3

Connect the other end of each length of tubing to the “Y” tting (included in the Ship Kit).

Caution

possible

equipment

damage

Inlet cooling water temperature must always be maintained above
the dew point to prevent condensation and water damage to your
Firestar laser.

SYNRAD f201 Operator’s Manual Version 3.2

37

getting started

4

Cut and connect a length of tubing to t between the chiller’s Outlet port and the center of the “Y”

tting.

5

Select the other two lengths of previously cut 1/2-inch cooling tubing and connect one end of

each piece to the laser’s WATER OUT ports.

6

Connect the other end of each length of tubing to the other “Y” tting.

7

Cut and connect a length of tubing to t between the chiller Inlet and the center of the “Y” tting.

8

Turn on the chiller and adjust the temperature setpoint to 18 °C to 22 °C. Regulate coolant ow to

15.1 lpm (4.0 GPM) of pressure.

9

Closely examine all cooling connections, assure there are no leaks.

Connecting

PS-96 power supply connections

The following procedures describe how to connect the PS-96 DC power supply to your f201 laser.

When connecting other types of DC power sources, remember to follow proper Lockout/Tagout pro­cedures to ensure that AC power is de-energized, and then connect input AC power per the manufac­turer’s instructions. Firestar f201 lasers require a DC power source capable of supplying 96 VDC.

Note: The negative (–) side of the DC input to the laser is internally connected so that the laser chassis
serves as DC power ground. You should isolate the laser’s DC power supply so that the only grounded
connection is at the laser. Alternatively, you can mount the laser chassis on an insulating pad or lm in
order to electrically isolate the laser when other equipment is grounded to the laser’s DC power supply.

Warning

serious

personal

injury

Caution

possible

equipment

Hazardous DC voltages exist on DC power supply output termi­nals when the power supply is energized. Contacting energized
terminals may result in serious personal injury or death. Protect all
96 VDC connections from incidental contact in accordance with
National, State, and Local requirements for electrical insulation and
labeling.

Do not reverse polarity when connecting the DC Power cable 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 cable leads are properly connected to the
correct DC output terminals.

damage

Caution

possible

equipment

Do not plug and unplug the DC Power cable on the rear of the laser
to switch DC power to the laser. Switching power under load causes
arcing that will damage the connector and control board. To prop­erly cycle power to the laser, switch the AC power source control­ling the PS-96 DC power supply.

damage

SYNRAD f201 Operator’s Manual Version 3.2

38

getting started

DC Power cable

To connect the DC Power cable to your f201 laser, refer to the following gure and perform the steps
described below.

DC Power cable—f201 lasers

1 Verify that input AC voltage to the DC power supply is physically locked out or disconnected.

2 Locate the f201 DC Power cable. The DC Power cable is 5 meters (16 feet) long with a plug on one

end and ve (5) connection lugs on the other. This cable has a minimum bend radius of 87.4 mm
(3.44").

3 Carefully remove the plastic terminal guard from the output terminal block.

Important Note: Always re-install the terminal guard to protect users against inadvertent contact with

hazardous DC voltages on the connection lugs and DC output terminals.

4 On the lug end of the cable, attach the two black wires with the “0 VDC” marker to the negative (–)

96 VDC output terminal on the DC power supply. Tighten the terminal nut to a maximum torque
of 4.0 N m (35 in lb).

PS-96 AC input section

Three-phase operation

SYNRAD’s PS-96 DC power supply is capable of supplying 96 VDC at 47 amperes maximum.
Three-phase AC input power requirements for the PS-96 supply are 105–264 VAC, 3Ø (three
phase with ground phase to phase), 23 A maximum per phase, 47–63 Hz. The following table
provides recommendations for three-phase input wiring and fusing.

Caution

possible

personal

injury

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.

(recommended)

Table 2-4 Three-phase AC electrical recommendations.

Parameter Recommendation

Input voltage 105–264 VAC, 3Ø

Input current, max. 23 Amperes (per phase)

Wire gauge 10 AWG

Fuse/circuit breaker 30 Amps

To connect three-phase AC input power to the PS-96 power supply, refer back to the prior gure and
perform the following steps:

SYNRAD f201 Operator’s Manual Version 3.2

39

getting started

+96 VDC Output

Connecting

Caution

possible

equipment

damage

Caution

possible

personal

injury

VAC

Do not plug and unplug the DC Power cable on the rear of the laser
to switch DC power to the laser. Switching power under load causes
arcing that will damage the connector and control board. To prop­erly cycle power to the laser, switch the AC power source control­ling the PS-96 DC power supply.

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.

Chassis Ground

– DC Output

Figure 2-8 PS-96 interface.

Note: Because AC input connections and requirements vary from facility to facility, cus-

tomers must provide the AC power cable or wiring.

1 Follow your facility’s Lockout/Tagout procedures and verify that input AC power to the DC power

supply is physically locked out or disconnected.

2 Connect the safety ground (earth) wire, typically green, to the input terminal labeled “GND”.

3 Connect the rst AC three-phase hot wire, typically black, to the input terminal labeled “L1/L”.

4 Connect the second three-phase hot wire, typically red, to the input terminal labeled “L2/L”.

5 Connect a jumper wire (the same wire gauge as the other AC wires) between the terminals labeled

“L2/L” and “L2/N”.

6 Connect the third AC hot wire, typically blue, to the input terminal labeled “L3/N”.

Single-phase input power requirements for SYNRAD PS-96 DC power supply are 208–264 VAC, 1Ø
(single phase), 20 A maximum, 47–63 Hz. Table below provides recommendations for single-phase input
wiring and fusing.

SYNRAD f201 Operator’s Manual Version 3.2

40

getting started

Connecting

Single-phase operation

Table 2-5 Single-phase AC electrical recommendations.

Parameter Recommendation

Input voltage 208–264 VAC, 1Ø

Input current, max. 20 Amperes

Wire gauge 10 AWG

Fuse/circuit breaker 30 Amps

There are two possible circuit congurations for single-phase connections: (1) one circuit where the
voltage between hot conductors measures 208–264 VAC (recommended), or (2) an alternate case using
two individual circuits where the voltage between the hot and neutral conductors from each individual
circuit measures 120–264 VAC. To connect single-phase AC input power to the PS-96 power supply, refer
back to prior gures and perform the following steps:

Note: Because AC input connections and requirements vary from facility to facility, cus-

tomers must provide the AC power cable or wiring.

One single-phase circuit (208–264 VAC)

1 Follow your facility’s Lockout/Tagout procedures and verify that input AC power to the DC power

supply is physically locked out or disconnected.

2 Connect the safety ground (earth) wire, typically green, to the input terminal labeled “GND”.

3 Connect one AC hot wire, typically black, to the input terminal labeled “L1/L”.

4 Connect a jumper wire (the same wire gauge as the other AC wires) between the terminals labeled

“L1/L” and “L2/L”.

5

Connect the other hot wire, typically black, to the input terminal labeled “L2/N.

6

Connect a jumper wire (the same wire gauge as the other AC wires) between the terminals labeled

“L2/N” and “L3/N”.

Note: The neutral white, typically white, is not used in this wiring scheme.

Two individual single-phase circuits (120–264 VAC)

1 Follow your facility’s Lockout/Tagout procedures and verify that input AC power to the DC power

supply is physically locked out or disconnected.

2 Connect the safety ground (earth) wires from both circuit 1 and circuit 2, typically green, to the

input terminal labeled “GND”.

3 Connect the AC hot wire from circuit 1, typically black, to the input terminal labeled “L1/L”.

4 Connect the return (neutral) wire from circuit 1, typically white, to the input terminal labeled

“L2/N”.

5 Connect the hot wire from circuit 2, typically black, to the input terminal labeled “L2/L”.

6 Connect the return (neutral) wire from circuit 2, typically white, to the input terminal labeled

“L3/N”.

SYNRAD f201 Operator’s Manual Version 3.2

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getting started

Control connections

All control connections to Firestar f201 lasers are made through the 15-pin User I/O connector on
the rear panel. The User I/O port receives power commands from SYNRAD’s UC-2000 Universal Laser
Controller or FH Series Marking Head and also serves as the connection point for auxiliary signals be­tween the laser and any parts handling, automation, or monitoring equipment.

UC-2000 Universal Laser Controller

SYNRAD recommends the use of a UC-2000 Universal Laser Controller to generate pulse width modu­lated (PWM) Command signals that control the laser’s output power. To connect a UC-2000 Controller
(available separately), perform the steps described in the appropriate f201 laser section below:

Note: F -Series lasers can also be controlled from an alternate user-supplied Command signal source.

Refer to Controlling laser power in the Technical Reference chapter for control signal descrip­tions and refer to User I/O connections, also in the Technical Reference chapter, for signal speci­cations and connection details.

f201 lasers

1 Disconnect DC power from the laser.

2 Locate the Quick Start Plug in the ship kit.

3 Connect the Quick Start Plug to the User I/O connector on the rear of the f201 laser.

4 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.

5 Connect the miniature DC power plug on the UC-2000’s Power/Control cable to the miniature con-

nector on the cable from the UC-2000’s wall plug transformer.

6 Connect the mini-DIN connector on the other end of the UC-2000’s Power/Control cable to the

Laser connector on the UC-2000’s rear panel.

7 Plug the compact transformer into any 100–240 VAC, 50–60 Hz outlet.

Connecting

Quick Start Plug

In order for your f201 laser to properly operate, several input signals must be applied to the DB-15 User
I/O connector before lasing is enabled. Voltage must be applied to Remote Interlock (Pin 3) and Shutter
Open Request (Pin 10) inputs before the laser will re. In applications where Firestar is integrated into
an automated system and safety interlocks are required, these input signals must be provided by the
customer’s control system. The Quick Start Plug included in the ship kit has factory-installed shorting
jumpers wired into it to enable these inputs. Connect the Quick Start Plug to the User I/O connector
when performing initial start-up and testing of your Firestar laser.

For further information about the User I/O connector, see User I/O connections in the Technical Refer­ence chapter for User I/O pinouts and signal descriptions. See Integrating Firestar safety features, also in
the Technical Reference chapter, for detailed instructions on integrating your lasers keyswitch, shutter,
and remote interlock functions with automated control systems.

SYNRAD f201 Operator’s Manual Version 3.2

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getting started

Other connections

Connecting

Warning

serious

personal

injury

Caution

possible

equipment

damage

The use of the Quick Start Plug bypasses the laser’s safety interlock
function, potentially exposing personnel in the area to invisible
infrared laser radiation.

Because this plug jumpers Remote Interlock and Shutter Open
Request signals, the laser will re immediately on application of
a PWM Command signal. Your integrated control system should
provide interlock and shutter signals directly to the DB-15 User I/O
connector only after safe operating conditions are established.

The Quick Start Plug is intended only for initial testing and trouble­shooting by qualied personnel. In normal operation, the laser’s
Remote Interlock input should be connected to the machine’s
safety interlock circuitry.

Turn o DC power before installing or removing any plug or cable
from the User I/O connector. Ensure that user connections are made
to the appropriate pins and that the appropriate signal levels are
applied. Failure to do so may damage the laser.

Gas Purge connector

A gas purge is highly recommended when operating the laser in dirty or dusty environments. Purging the
laser creates a positive pressure inside the laser housing that prevents dirt and debris from accumulating on
optical surfaces including beam combiner, telescope, and turning optics. In condensing atmospheres, a gas
purge helps to reduce the potential for condensation damage.

To connect the f201 gas purge port, perform the steps described below:

1

Connect nitrogen or breathing-grade air to the Gas Purge connector using 1/4-inch plastic tubing.

2

Push the tubing completely into the tting and then pull the tubing lightly to ensure that it is locked

into place.

Note: To disconnect gas purge tubing, rst push and hold the tubing slightly into the tting. Next push

the white tting ring evenly towards the tting, and then pull the tubing free.

3

Set a purge pressure between 13.8–34.5 kPa (2–5 PSI). This provides just enough positive airow

to prevent dust from entering the laser. If a owmeter is available, set a ow rate of 0.85–1.7 m3/hr
(30–60 SCFH, Standard Cubic Feet per Hour) at a pressure not to exceed 34.5 kPa (5 PSI).

The Gas Purge connector on your f201 laser must be connected to a source of nitrogen or clean, dry air
only; do not use any other gases for purging. Purge gas specications are listed in the table below.

SYNRAD f201 Operator’s Manual Version 3.2

43

getting started

Gas Purge connector

Table 2-6 Purge gas specications.

Purge Gas Specication

Nitrogen High Purity Grade > 99.9500% purity; ltered to ISO Class 1 particulate level

Air Breathing Grade > 99.9996% purity; ltered to ISO Class 1 particulate level

Air Compressed Instrument-grade air ltered and dried to ISO 8573-1:2010
Class 1, 2, 1 (< 10 1.0–5.0 µm particles/m3; < –40 °F dew
point; < 0.01 mg/m3 oil vapor)

Caution

possible

equipment

damage

Do not exceed a gas purge pressure of 34.5 kPa (5 PSI). Excessive
pressure may damage the purge assembly or other internal laser
components.

Do not use argon as a purge gas. Use only nitrogen or clean, dry air
as described in Table 1-6, Purge gas specications.

SYNRAD f201 Operator’s Manual Version 3.2

44

operation

operation

3

Use information in this chapter to familiarize yourself with your lasers controls and
indicators and to begin operating the laser.

This chapter contains the following information:

■ Controls and indicators – displays and describes exterior controls and indicators on

f201 lasers.

■ Initial start-up – explains how to start your f201 laser while verifying proper opera-

tion.

Danger

serious

personal

injury

Warning

serious

personal

injury

Warning

serious

personal

injury

This Class 4 laser product emits invisible infrared laser radiation
in the 10.6 µm CO2 wavelength band. Since direct or diuse laser
radiation can inict severe corneal injuries, always wear eye protec­tion when in the same area as an exposed laser beam. 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.

On Firestar f201 OEM lasers, remote interlock faults are not latched.
Clearing the fault condition re-enables the Ready indicator and the
laser will re after the ve-second delay provided that the Shut­ter indicator is lit and a PWM Command signal is applied. Because
exposure to 10.6 µm CO2 laser radiation can inict severe corneal in­juries and seriously burn human tissue, the OEM or System Integra­tor must ensure that appropriate safeguards are in place to prevent
unintended lasing.

The use of the Quick Start Plug bypasses the laser’s safety interlock
function, potentially exposing personnel in the area to invisible
infrared laser radiation.

The Quick Start Plug is intended only for initial testing and trouble­shooting by qualied personnel. In normal operation, the laser’s
Remote Interlock input should be connected to the machine’s
safety interlock circuitry.

SYNRAD f201 Operator’s Manual Version 3.2

45

operation

Controls and indicators

The Controls and indicators section includes subsections:

■ f201 lasers

f201 lasers

2

3

1

AVOID EXPOSURE

Invisible laser radiation

is emitted from

this aperture.

Figure 3-1 F201 controls and indicators (front).

1

Laser Aperture – provides an opening in Firestar’s front panel from which the beam exits.

2

Aperture Seal – prevents dust from damaging the output coupler during shipping. Remove the

red self-adhesive label before applying power to the laser.

3

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 specically designed as Firestar op­tions. Refer to Firestar package outline drawings in the Technical Reference chapter for mounting
dimensions.

Note: When mounting optical components to f201 lasers, the 8–32 UNC fasteners must extend no

further than 4.8 mm (0.19") into the laser’s faceplate.

SYNRAD f201 Operator’s Manual Version 3.2

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operation

10

9

8

76

5

FUSE

Remote
Interlock

LaseShutterReadyTemp

5

WATER OUT

USER I/O

GAS PURGE

Clean and dry
air or N2 only

11

DC POWER

20A FAST

96 VDC 36A MAX

4

12

WATER IN

Figure 3-2 F201 controls and indicators (rear).

4

WATER OUT and WATER IN Ports – provides connection points for Firestar’s cooling system using

non-removable straight 1/2-inch ttings. A cooling kit contains 90° tubing adaptors for both 1/2­inch and 12-mm cooling tubing.

5

FUSE Holder – protects laser circuitry with a 20 A, 125 V fast-acting fuse.

6

DC POWER Connector – receives 96 VDC from the DC power supply through the DC Power cables.

7

Remote Interlock Indicator – illuminates green to indicate that a remote interlock circuit is closed

and that lasing may be enabled. The Remote Interlock indicator is red and lasing is disabled if the
interlock input is open.

8

Temp Indicator – illuminates green to indicate that coolant temperature and ow is within limits

and that lasing may be enabled. The Temp indicator is red and lasing is disabled if the coolant tem­perature rises above safe operating limits.

9

Ready Indicator – illuminates yellow when the laser is enabled, indicating that, after a ve-second

delay, lasing will begin when a PWM Command signal is applied.

10

Lase Indicator – illuminates red to indicate that the laser is actively lasing. The Lase indicator is o

when tickle pulses are being generated and illuminates red when PWM Command signal pulses
are long enough to produce laser output.

11

User I/O Connector – provides a connection point for auxiliary output power, as well as input and

output signals. Refer to User I/O connections in the Technical Reference chapter for pinouts and
signal descriptions.

12

Gas Purge Connector (f201 only) – provides a low pressure nitrogen (or pure air) purge gas con-

nection to prevent dust and debris from entering the laser housing and damaging electronic or
optical components.

SYNRAD f201 Operator’s Manual Version 3.2

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operation

Initial start-up

The Initial start-up section includes subsections:

■ With a UC-2000 Controller

■ Without a UC-2000 Controller

With a UC-2000 Controller

Before your laser is put into service for the rst time, its functionality should be veried. Follow this
procedure to verify the laser system is operating at optimum performance. For this procedure, use the
UC-2000 as a stand-alone controller; do not attempt to control the laser or UC-2000 externally.

Note: When performing the initial start-up sequence, you must rst connect the Quick Start Plug or you

must 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 chapter for User I/O pinouts and
signal descriptions.

Starting auxiliary equipment

1

Ensure that all personnel in the area are wearing protective eyewear.

2

Remove the red self-adhesive aperture seal from the laser faceplate.

3

Place a beam block 61 cm (24 in) from the laser aperture to prevent the beam from traveling beyond

the work area.

4

Turn on the chiller and set the temperature setpoint between 18 °C–22 °C. Verify that the chiller is

delivering the recommended ow rate for your laser at less than 414 kPa (60 PSI) of pressure. Exam­ine all cooling connections carefully and ensure that they do not leak.

5

Start purge gas ow at a rate of 0.85–1.7 m3/hr (30–60 SCFH, Standard Cubic Feet per Hour) at a

pressure not to exceed 34.5 kPa (5 PSI). If a owmeter is not available, set a purge pressure between

13.8–34.5 kPa (2–5 PSI).

Note: If you have not yet operated your UC-2000 Universal Laser Controller, refer to the UC-2000 Laser

Controller Operator’s Manual and quick start guide for setup and operation instructions before
continuing.

6

Set the UC-2000 to MANUAL mode, and then set the PWM Adj Knob to provide zero percent

output (0.0%). The UC-2000’s Lase indicator should be O.

7

Verify that the laser’s Keyswitch (if equipped) is in the OFF/RESET position.

8

Turn on the +96 VDC power supply.

If the factory-wired Quick Start Plug is installed, the Remote Interlock indicator will illuminate green

and the Shutter indicator will illuminate blue—if the manual Shutter Switch is Open. The Temp indi­cator will illuminate green if laser temperature is within safe operating limits.

SYNRAD f201 Operator’s Manual Version 3.2

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operation

Starting your f201 laser

Note: Ready LEDs denote separate control functions. Although the Ready lamp may light, no power is

applied to the RF boards until both Ready and Shutter indicators are illuminated.

1

If the laser has a Diode Pointer installed, remove its aperture dust cover.

Note: Assure the red self-adhesive aperture seal is removed from the laser faceplate.

2

Press the UC-2000’s Lase On/O button. The Lase indicator on the UC-2000 should illuminate.

3

Use the PWM Adj Knob on the UC-2000 to slowly increase power. The Lase LED turns red when

PWM Command pulses are long enough to produce laser output (typically 7–10 µs at 5 kHz). The
spot where the beam hits the beam block increases in brightness to indicate increased power
output.

4

Press the UC-2000’s Lase On/O button to stop lasing. Lase indicators on the UC-2000 and the

laser should both turn o.

5

Shut o the chiller or otherwise stop coolant ow through the laser.

6

Shut o gas purge ow to the laser. In dirty or dusty environments; however, it may be necessary

to purge the laser continuously to prevent contamination of internal optics.

Warning

serious

personal

Because of phase dierences, external tickle pulses may combine
with the internally-generated tickle signal causing the Lase LED to
icker during the transition from tickle to lasing. Laser output may
occur if the Lase LED ickers.

injury

If your f201 laser fails to lase, refer to Troubleshooting in the Maintenance/Troubleshooting chapter for
troubleshooting information.

Without a UC-2000 Controller

If you are not using a UC-2000 to control the laser, follow the procedure below to verify laser operation.
Although a tickle signal is not required, you will need to provide PWM Command signals to User I/O
connector. Refer to User I/O connections in the Technical Reference chapter for connector pinouts and
refer to Controlling laser power in the Technical Reference chapter for Command signal descriptions.

Note: When performing the initial start-up sequence, you must rst connect the Quick Start Plug or

you must provide the required Remote Interlock Request signals to the User I/O connector. See
User I/O connections in the Technical Reference chapter for User I/O pinouts and signal descrip­tions.

Caution

possible

equipment

Do not ow coolant through the laser for an extended period of
time when the laser is shutdown. This causes condensation to form
inside the laser which may result in catastrophic damage to internal
optics and electronic circuits.

damage

SYNRAD f201 Operator’s Manual Version 3.2

49

operation

Initial start-up

Starting auxiliary equipment

1

Ensure that all personnel in the area are wearing protective eyewear.

2

Remove the red self-adhesive aperture seal from the laser faceplate.

3

Place a beam block 61 cm (24 in) from the laser aperture to prevent the beam from traveling beyond

the work area.

4

Connect the output of your PWM controller to PWM Input (Pin 9) on the laser’s User I/O connector

and connect the ground or return of the controller to PWM Return (Pin 1). On f200 lasers, parallel
this PWM signal between both User I/O connectors.

5

Turn on the chiller and set the temperature setpoint between 18 °C–22 °C. Verify that the chiller is

delivering the recommended ow rate for your laser at less than 414 kPa (60 PSI) of pressure. Exam­ine all cooling connections carefully and ensure that they do not leak.

6

Start purge gas ow at a rate of 0.85–1.7 m3/hr (30–60 SCFH, Standard Cubic Feet per Hour) at a

pressure not to exceed 34.5 kPa (5 PSI). If a owmeter is not available, set a purge pressure be­tween 13.8–34.5 kPa (2–5 PSI).

Caution

possible

Inlet cooling water temperature must always be maintained above the
dew point to prevent condensation and water damage to your Firestar
laser.

equipment

damage

7

Verify that the laser’s Keyswitch (if equipped) is in the OFF/RESET position.

8

Turn on the +96 VDC power supply.

Note: If the factory-wired Quick Start Plug is installed, the Remote Interlock indicator will illuminate

green and the Shutter indicator will illuminate blue—if the manual Shutter Switch is open. The
Temp indicator will illuminate green if laser temperature is within safe operating limits.

Caution

possible

equipment

damage

Do not exceed a gas purge pressure of 34.5 kPa (5 PSI). Excessive
pressure may damage the purge assembly or other internal laser
components.

Do not use argon as a purge gas. Use only nitrogen or clean, dry air
as described in the following table, Purge gas specications.

SYNRAD f201 Operator’s Manual Version 3.2

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operation

This page intentionally left blank.

SYNRAD f201 Operator’s Manual Version 3.2

51

technical reference

4

Use information in this chapter as a technical reference for your Firestar f201 laser.

This chapter contains the following information:

■ Technical overview – briey describes Firestar’s technology and basic optical setup.

■ Controlling laser power – explains various aspects of Firestar control signals.

■ User I/O (Input/Output) connections – describes signals and specications for the

15-pin User I/O connector.

■ DC Power cables – provides information about f201 power cables including con-

nectors and pinouts.

■ Integrating Firestar safety features – describes how to integrate Firestar f201 safety

features into your automated control system.

■ f201 general specications – provides specications for the Firestar f201 laser.

■ Firestar f201 package outline drawing – illustrates laser package outline and

mounting dimensions for f201 lasers.

■ Packaging instructions – illustrates how to package Firestar f201 lasers for ship-

ment.

SYNRAD f201 Operator’s Manual Version 3.2

52

technical reference

Technical overview

The Technical overview section includes subsections:

■ Laser tube

■ Optical resonator

■ Internal RF power supply

■ Optical setup

Laser tube

Firestar® f201 lasers were developed using new technology patented by SYNRAD. Firestar’s patented “f”
technology, based on an unstable free-space resonator design, 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. Firestar’s unique extruded aluminum envelope oers excellent heat transfer,
long gas life, and low operating costs in contrast to other laser tube technologies. Besides being the
vessel that maintains the lasing environment, the aluminum tube is also the structural platform that
integrates the laser’s optical, electrical, and cooling components.

Duo-Lase

Firestar lasers consist of two standard, sealed tubes (f201 tubes respectively) that are combined using
SYNRAD’s Duo-Lase® technology to provide a single diraction-limited beam at twice the output power.
All power and control functions between the two laser sections are totally independent, essentially
achieving fail-safe operation for applications that can be served with the power of a single laser tube.
Any one electronic or laser tube failure will aect only that section, leaving the second section unaf­fected and available for temporary use.

The Duo-Lase optical combining technique is based on the fact that each tube is linearly polarized,
which allows the use of a polarization-sensitive beam combiner to achieve a 98 percent eciency in
combining the two beams. Both components of the resulting output beam are spatially parallel and
collinear. The normal temporal and spatial variations inherent in a single tube laser are reduced by com­bining the output of two lasers.

®

operation

Cooling

Heat generated by excited CO2 molecules is transferred to the bore walls by diusion. Collected heat is
transferred to the water in the cooling tubes by conduction of the electrodes and aluminum envelope.
The coolant path is directed through corrosion-resistant copper alloy tubing to regulate laser tempera­ture for maximum stability.

Optical resonator

The optical resonator, in conjunction with the electrodes and the gas mixture, generates the laser beam.
Firestar f201 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. O-rings are sandwiched between optical elements and the end
cap to form a gas seal and to provide a exible cushion that allows the slight movement necessary for
alignment. All optical elements are aligned and locked into place by factory technicians before the laser
is shipped.

SYNRAD f201 Operator’s Manual Version 3.2

53

technical reference

Full Angle Divergence 4 mrad

Technical overview

Caution

possible

equipment

damage

On f201 lasers, a small telescope just before the output coupler corrects a slight ellipticity in the beam
generated by the resonator. The output beam, roughly square as it exits the telescope, transitions to
Gaussian-like in mid and far elds three meters and beyond. The internal structure and optics of the
resonator combine to produce a Gaussian-like mode quality (M2 factor) of 1.2 ±0.1. As shown in the g­ure below, beam diameter (beam waist) is 3.5 mm at the output aperture and full angle divergence due
to diraction is 4 milliradians (a 4 mrad full angle divergence means that beam diameter increases 4 mm
over every one meter distance traveled).

Because of their smaller beam diameter, Firestar lasers have signi­cantly higher power densities than previous SYNRAD lasers. This
means that any contamination on the laser’s output coupler (or on
any beam delivery optic) can absorb enough energy to damage one or
more optics in the beam path. Periodically inspect the laser’s output
coupler and all other beam delivery optics for signs of contaminants
and then carefully clean as required. In dirty environments, purge
laser optics using ltered air or nitrogen to prevent vapor and debris
from accumulating on optical surfaces.

Ø

Beam Diameter 3.5 mm

at Output Aperture

Figure 4-1 beam characteristics.

On f201 lasers, the beam waist is located one meter before the output aperture due to the addition of
internal beam conditioning optics that improve beam quality and strip any side lobes present to pro­duce a Gaussian-like mode quality (M2 factor) of 1.2 ±0.1. Beam diameter at the output aperture is 4.5
mm with a full angle divergence of 4 milliradians.

Internal RF power supply

The compact, self-contained RF power supply converts 96 VDC input power into a high-power radio
frequency (RF) signal. The 40.68 MHz RF output from the RF power supply is then routed to the electrode
structure in the laser tube where it excites carbon dioxide (CO2) gas in the tube to produce lasing.

Control circuit

Switches and sensors built into the f201 control board monitor the laser for various conditions like
under/over voltage, over temperature, and VSWR faults that pose a risk of damage to the laser. Addition­ally, laser operation is controlled by the following: a manual Shutter Switch; a Keyswitch (on Keyswitch­equipped lasers); the Shutter Open Request input; the Remote Interlock input; and the Remote Reset/
Start Request input.

SYNRAD f201 Operator’s Manual Version 3.2

54

technical reference

Technical overview

Optical setup

After selecting a laser for a CO2 laser processing system, the two most important elements to consider are:
(1) beam delivery optics to transmit the beam to the work area; and (2) focusing optics to focus the beam
onto the part or material to be processed. Each element is crucial in the development of a laser-based ma­terial processing system and each element should be approached with the same careful attention to detail.

Delivery optics

Divergence, or expansion, of the laser beam is important in materials processing since a larger beam
entering the focusing optic produces a smaller focused spot. Because the laser beam diverges slowly,
increasing by two or three diameters over several meters, Firestar lasers should be mounted a distance
of 1.3–1.8 meters (50–70 inches) away from the work area and no closer than one meter (40 inches) for
optimum performance. Right angle turning mirrors are often used in conjunction with the laser mount­ing position to obtain this distance. Figure below shows how right angle turning mirrors in a “ying
optics” setup help create this longer beam path.

Firestar f201 lasers, with their internal one-meter beam path and conditioning optics, can be mounted
right at the work area.

Figure 4-2 “Flying optics” beam path.

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.

Expander/collimators are optical devices that reduce beam divergence while at the same time increasing
beam diameter by a selectable magnication factor. Adding an expander/collimator to the “ying optics”
setup shown above would substantially reduce beam divergence and any variance in beam diameter caused
by the changing optical path length. In xed-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 f201 Operator’s Manual Version 3.2

55

technical reference

Technical overview

Focusing optics

When selecting a focusing optic, the primary consideration should be material thickness and any vertical
tolerances that occur during nal part positioning rather than making a selection based only on minimum
spot size. The chosen focal length should create the smallest possible focused spot while providing the
depth of eld required for the material to be processed.

Caution

possible

equipment

damage

Optics are fragile and must be handled carefully, preferably by the mounting ring only. Be careful to select
optics that are thick enough to withstand the maximum assist gas pressure available for the process. This
is especially important in metal cutting applications using high-pressure assist gases. Cleanliness is another
important issue aecting performance and becomes increasingly important as laser power increases. Dirty
or scratched lenses will under perform, exhibit a vastly shortened lifetime, and may fail catastrophically.

When the laser application requires air as an assist gas, use only breathing quality air available in cylin­ders from a welding supply company. Compressed shop air contains minute particles of oil and other
contaminants that will damage optical surfaces. If compressed shop air is the only choice available, it
must be ltered to the specications shown in the following table.

Trace amounts of contamination on the laser’s output window (or
on any optic in the beam path) can absorb enough energy to damage
the optic. Inspect all beam delivery optics periodically for signs of
contaminants and carefully clean as required. In dirty environments,
purge laser optics using ltered air or nitrogen to prevent vapor and
debris from accumulating on optical surfaces.

Table 4-1 Assist gas purity specications.

Assist Gas Typical Purpose Specication

Air Cutting/Drilling Breathing Grade > 99.9996% purity; ltered to ISO Class 1
particulate level

Air Cutting/Drilling Compressed Instrument-grade air ltered and dried to
ISO 8573-1:2010 Class 1, 2, 1 (< 10 1.0–

5.0 µm particles/m3; < –40 °F dew point;

< 0.01 mg/m3 oil vapor)

Argon Welding High Purity Grade > 99.998% purity; ltered to ISO Class 1
particulate level

Helium Welding High Purity Grade > 99.997% purity; ltered to ISO Class 1
particulate level

Nitrogen Cutting/Drilling High Purity Grade > 99.9500% purity; ltered to ISO Class 1
particulate level

Oxygen Cutting/Drilling Ultra Pure Grade > 99.9998% purity; ltered to ISO Class 1
particulate level

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Controlling laser power

The Controlling laser power section includes subsections:

■ Control signals

■ 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 f201 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. For
more information about the UC-2000, please consult the UC-2000 Laser Controller Operator’s Manual.

Tickle pulse

Tickle pulses pre-ionize the laser gas to just below the lasing threshold so that a further increase in pulse
width adds enough energy to the plasma to cause laser emission. Tickle pulses cause the laser to re­spond predictably and almost instantaneously to PWM Command signals, even when there is consider­able delay (laser o time) between applied Command signals. All Firestar f201 lasers incorporate a built­in tickle generator, freeing customers from the need to supply tickle pulses between lasing commands.

Internal circuitry monitors the incoming PWM signal and determines the amount of time the laser was
on (lasing) during the last 200 microsecond (µs) interval. If the laser’s on time was greater than the preset
tickle value, then no tickle pulse is generated because the PWM signal was sucient to maintain a plasma
state. If no PWM signal was applied during the 200-µs measurement period (or was shorter than the preset
tickle value), internal circuitry generates a tickle pulse such that the laser always receives a pre-set amount
of RF drive averaged over any 200-µs interval.

Warning

serious

personal

Because of phase dierences, external tickle pulses may combine with
the internally-generated tickle signal causing the Lase LED to icker
during the transition from tickle to lasing. Laser output may occur if
the Lase LED ickers.

injury

Pulse Width Modulation (PWM)

Pulse Width Modulation, or PWM, controls laser power by varying the duty cycle of Firestar’s RF ampli­ers, which in turn control the time-averaged RF power applied to the laser. Typically, laser output follows
the PWM input with a rise and fall time constant of ~150 µs; however, the laser cannot precisely follow
PWM input signals if the “On” pulse is less than 150 µs in duration. At a constant 50% duty cycle, f201
lasers typically reach 90–100% of full optical output when operated at a frequency of 3 kHz.

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). Figure on the following page shows representative
f201 optical output waveforms at two dierent duty cycles and frequencies.

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22

1

Optical output pulse (10% duty cycle at 100 Hz)

Optical output pulse (50% duty cycle at 5 kHz)

Controlling laser power

1

T

T

T

100mV Ch2 5 V M 250µs Ch2 1.6 V

Ch1

22

Ch1

T

50mV Ch2 5 V M 100µs Ch2 1 V

Figure 4-3 Typical Firestar f201 waveforms.

Firestar f201 lasers are designed to operate at Command signal base frequencies up to 100 kHz; how­ever, the choice of PWM frequency depends on the user’s specic application. In the majority of laser
applications, the UC-2000’s default Command signal frequency of 5 kHz has proven to work well. When
considering Command frequencies at 5 kHz or below, please review Marking/engraving operation later
in this section. For high-speed motion applications that cannot tolerate any ripple in the optical beam
response but still need adjustable power levels, we recommend the use of higher PWM frequencies, up
to 100 kHz maximum. At 100 kHz, the laser’s optical beam response no longer follows the Command
input and is very nearly a DC value with just a small amount of ripple present.

Command signal

The modulated Command signal applied between Pin 9, PWM Input, and Pin 1, PWM Return, of the User

Warning

Always use shielded cable when connecting your PWM Command
signal source to PWM Input/PWM Return inputs. In electrically-

serious

personal

noisy environments, long lengths of unshielded wire act like an
antenna and may generate enough voltage to trigger uncommanded
lasing.

injury

I/O connector on the Firestar f201 laser has three basic parameters: signal amplitude, base frequency,
and PWM duty cycle. By changing these parameters, you can command the beam to perform a variety
of marking, cutting, welding, or drilling operations.

The rst Command signal parameter, signal amplitude, is either logic low—corresponding to laser beam

o, or logic high—corresponding to beam on. The laser o voltage, typically 0 V, can range from 0.0 V to
+0.8 VDC while the laser on voltage, typically 5 V, can range from +3.5 V to +6.7 VDC.

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 µs. Maximum PWM frequency is 100 kHz.

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0

5

200 µs

200 µs

Controlling laser power

The third Command signal parameter, PWM duty cycle, is the percentage of the period that the Com­mand signal is high. If the Command signal’s amplitude (at 5 kHz) is high for 100 µs and low for 100 µs, it
has a 50% duty cycle; if the amplitude is high for 190 µs and low for 10 µs, it has a 95% duty cycle. Figure
below illustrates PWM Command signal parameters while the table below lists PWM signal specica­tions.

100 µs

VDC

VDC

5 kHz Command Signal at 50% Duty Cycle

190 µs

5 kHz Command Signal at 95% Duty Cycle

Figure 4-4 PWM Command signal waveform.

Firestar’s User I/O PWM input consists of a high-speed optoisolator 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 below provides mini­mum, maximum, and nominal PWM signal specications.

Table 4-2 PWM Command signal specications.

Laser State Minimum Nominal Maximum

Laser O 0.0 VDC 0.0 VDC +0.8 VDC

Laser On +3.5 VDC (3 mA) +5.0 VDC (6 mA) +6.7 VDC (10 mA), continuous

Frequency Range 0 Hz (DC) 5 kHz 100 kHz

Duty Cycle 0% — — 100%

Operating modes

External control

In addition to controlling the Firestar laser using a UC-2000 Controller, control of Firestar externally,
without a UC-2000, is also possible. The two primary elements of laser control are gating, the ability to
turn the laser on and o at the appropriate times, and power, the ability to control the laser’s output en­ergy. Both gating and power can be handled by a device such as a personal computer, Programmable Logic
Controller (PLC), or function generator capable of sending PWM pulses at the proper time (gating) and
with the proper duty cycle (power).

Analog voltage or current control

Although Firestar f201 lasers cannot be controlled directly by analog voltage or current signals, this type
of control is possible when using the 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
laser gating and power.

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Controlling laser power

To generate the correct analog voltage from a computer or PLC, a Digital-to-Analog (D/A or DAC) card
capable of generating 0 V (laser o) to 10 V (maximum laser power) must be installed. To generate the
proper analog current, install a D/A card that can generate 4 mA (laser o) to 20 mA (maximum power).
Software able to control your analog output card is required for either conguration.

Continuous wave (CW)

In some applications, such as high speed marking or cutting, the time constant of the laser and the PWM
modulation causes a series of dots that may be visible on the marking surface instead of a “clean” line.
Operating the laser in CW mode will prevent this behavior from occurring.

To operate the laser in CW mode, apply a constant +5 VDC signal to Pin 9, PWM Input, and Pin 1, PWM
Return, on the User I/O connector. This constant voltage source forces the internal switching electronics
to remain on, providing continuous and uninterrupted laser output power. During CW operation, output
power cannot be changed. To adjust output power, refer back to the Pulse Width Modulation (PWM) sec­tion for information regarding high frequency operation.

Note: SYNRAD 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.

Gated operation

In many marking and cutting applications, the laser is required to pulse, or gate, on and o in synchroni­zation with an external control signal (typically from a computer or function generator operating in the
range from DC to 1 kHz). To pulse or gate the laser, connect a signal providing +5.0 VDC pulses to the
Gate connector on the rear panel of the UC-2000.

Users who intend to use a gating signal should set the UC-2000’s gate input logic to internal Pull-Down
(normally o) mode. This prevents the beam from being enabled unless a high level (+3.5 V to +5.0
VDC) signal is applied to the Gate input connector. In the pull-down (normally o) mode an asserted
logic low state, short circuit to ground, or an open or disconnected Gate input locks the beam o.

Warning

serious

personal

injury

The UC-2000’s default gate logic is factory set to internal Pull-Up
(normally on) mode so that an open (disconnected) Gate input
causes the laser to turn on. This functionality allows the user to easily
test and verify laser operation prior to integration.

In an integrated system, you should congure the UC-2000’s gate
input logic to internal Pull-Down (normally o) mode. This prevents
the beam from being enabled unless a high level (+3.5 V to +5.0
VDC) signal is applied to the Gate input connector. In the Pull­Down (normally o) mode an asserted logic low signal, short circuit
to ground, or an open or disconnected Gate input locks the beam o.

Many CO2 lasers operating in applications requiring short gating pulses at repetition rates below 500 Hz
will exhibit some leading edge overshoot regardless of the PWM frequency. This occurs because a cooler
lasing medium (the CO2 gas) is more ecient than a hotter one. This overshoot eect is more pronounced
at lower gating frequencies since the gas has a longer time to cool down between Command signal pulses.

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Controlling laser power

Marking/engraving operation

When the delay between the end of one PWM Command signal pulse and the beginning of the next
PWM pulse exceeds 200 microseconds (less than or equal to 5 kHz), Firestar’s on-board tickle generator
sends a tickle pulse to maintain plasma ionization in the tube. Because the on-board tickle generator can
not anticipate when the next PWM Command pulse will arrive; the tickle pulse (which typically lasts for
2–6 µs depending on the laser) can eectively merge with a PWM signal that follows closely afterwards.
When the PWM pulse that follows is short, causing the tickle pulse to become a signicant fraction of the
PWM pulse duration, then the tickle pulse eectively substantially increases the length of the PWM pulse
it has merged with. For subtle marking applications on sensitive, low threshold materials this lengthened
PWM pulse may aect mark quality.

While this situation can occur when using PWM Command signal frequencies of 5 kHz and less, it is im­portant to note that it isn’t the Command signal frequency itself that is the determining factor but rather
this behavior happens only when the o time between PWM pulses exceeds 200 microseconds.

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User I/O connections

The User I/O connections section includes subsections:

■ User I/O connection summary

■ Input/output signals

■ Sample I/O circuits

■ I/O connections

User I/O connection summary

Table below provides a quick reference summary to Firestar f201 User I/O connections.

Table 4-3 User I/O pin descriptions.

Pin Function Description

1 PWM Return

Use this input pin as the return side of the PWM Command signal.

2 Remote Reset/Start Request input

Apply a positive or negative voltage (±5–24 VDC) with respect to Pin 11, Input Common,
to reset or remote keyswitch the laser. The laser remains disabled while voltage is applied.
Removing voltage from the Remote Reset/Start Request input causes the laser’s Ready
indicator to illuminate and begins a ve-second countdown after which lasing is enabled.

3 Remote Interlock input

Apply a positive or negative voltage (±5–24 VDC) with respect to Pin 11, Input Common,
to enable lasing. If your system does not use a remote interlock, this input must be con­nected to a voltage source in the range of ±5–24 VDC. Refer to Figure 3-7 for a diagram
showing how the Remote Interlock input is factory-jumpered on the Quick Start Plug.

4 + 5 VDC Auxiliary Power

This connection provides +5 VDC for driving external inputs or outputs. The +5 VDC
Auxiliary Power output can source up to 0.5 A and is protected by a 0.5 A self-resetting
fuse. The return (ground) path must be through Pin 12, Auxiliary DC Power Ground.

5 + 24 VDC Auxiliary Power

This connection provides +24 VDC for driving external inputs or outputs. The +24 VDC
Auxiliary Power output can source up to 0.5 A and is protected by a 0.5 A self-resetting
fuse. The return (ground) path must be through Pin 12, Auxiliary DC Power Ground.

6 Laser Active output

This bi-directional switched output is internally connected to Pin 13, Output Common,
when the laser is actively lasing (Lase indicator illuminated red). This output is open (high
impedance) when no beam is being emitted (Lase indicator O).

7 Over Temperature output

This bi-directional switched output is internally connected to Pin 13, Output Common,
when laser temperature is above safe operating limits (Temp LED illuminated red). The
output is open (high impedance) when laser temperature is within limits (Temp LED green).

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User I/O connections

Table 4-3 User I/O pin descriptions (continued).

Pin Function Description

8 Laser Ready output

This bi-directional switched output is internally connected to Pin 13, Output Common,
when the laser is enabled (Ready LED illuminated yellow), indicating that lasing will occur
when a PWM Command signal is applied to Pin 9 and Pin 1. When this output is initially
switched closed, there is a ve-second delay during which lasing is inhibited. This output is
open (high impedance) when the laser is disabled (Ready LED O).

9 PWM Input

Connect your PWM Command signal (+5 VDC, 5 kHz nominal, 100 kHz max, pulse width
modulated) to this input pin to control laser output power. Refer back to Controlling laser
power for further information on laser control signals.

11 Input Common

Use this input pin to connect return lines for Remote Interlock, Shutter Open Request,
and Remote Reset/Start Request lines.

12 Auxiliary DC Power Ground

This connection provides a ground (earth) connection for +5 and +24 VDC auxiliary
power outputs. This pin is the only User I/O pin that is connected to chassis ground. Do not
use this pin for grounding if DC power to external I/O circuits is supplied from an external
customer-supplied DC power source.

13 Output Common

Use this pin to complete the return path for output connections (Pin 6, 7, 8, 14, or 15).
The Output Common line is protected by a 0.25 A self-resetting fuse.

15 Interlock Open output

This bi-directional switched output is internally connected to Pin 13, Output Common,
when remote interlock circuitry is open (Remote Interlock indicator illuminated red), indi­cating that lasing is disabled. The output is open (high impedance) when lasing is enabled
(Remote Interlock indicator green).

Input/output signals

Firestar’s input/output signals are divided into three categories: auxiliary DC power, input signals, and
output signals. Signals in each category are fully described in the sections below. Following gure illus­trates the pin arrangement of the User I/O (15 pin female D-type subminiature) connector on Firestar’s
rear panel.

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User I/O connections

Auxiliary DC power

Firestar’s User I/O connector provides auxiliary DC power for driving external inputs or outputs connected
to the 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 oating with respect to chassis ground. Figure 3-6 illustrates Firestar’s
internal DC supply wiring.

Caution

Turn o DC power before installing or removing any plug or cable
from the User I/O connector. Ensure that user connections are made

possible

equipment

to the appropriate pins and that the appropriate signal levels are ap­plied. Failure to do so may damage the laser.

damage

Pin 8

FUSE

20A FAST

DC POWER

96 VDC 18A MAX

Figure 4-5 User I/O connector pinouts.

Remote

Interlock

USER I/O

Pin 1

OFF/RESET

LaseShutterReadyTemp

ON

Pin 9Pin 15

Pin 4 + 5 VDC Auxiliary Power

This connection provides +5 VDC for driving external inputs or outputs. The +5 VDC Auxiliary
Power output can source up to 0.5 A and is protected by a 0.5 A self-resetting fuse. The return
(ground) path must be through Pin 12, Auxiliary DC Power Ground.

Pin 5 + 24 VDC Auxiliary Power

This connection provides +24 VDC for driving external inputs or outputs. The +24 VDC Aux­iliary Power output can source up to 0.5 A and is protected by a 0.5 A self-resetting fuse. The
return (ground) path must be through Pin 12, Auxiliary DC Power Ground.

Pin 12 Auxiliary DC Power Ground

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This connection provides a ground (earth) connection for +5 and +24 VDC auxiliary power out­puts. 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.

Figure 4-6 Auxiliary power supply wiring.

Input signals

A total of four user inputs allow control of Firestar 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. The
fourth input, PWM Input, is optoisolated and has a separate return, PWM Return, to fully isolate PWM
signals from the other three user inputs. Note that throughout this manual, input voltage levels are speci­ed with respect to their corresponding return line.

Pin 1 PWM Return

Connect the return side of your PWM Command signal to this pin. Refer to Table 4-4 for input
circuit specications.

Pin 2 Remote Reset/Start Request

Apply a positive or negative voltage (±5–24 VDC) with respect to Pin 11, Input Common, to re­set or remote keyswitch the laser. The laser remains disabled while voltage is applied to this input.
Removing voltage from the Remote Reset/Start Request input causes the laser’s Ready lamp
to illuminate and begins a ve-second countdown after which lasing is enabled. Because all DC
power is removed from the laser’s RF driver when this input is active, no lasing can occur until
voltage is removed from Pin 2. Refer to Table 3-4 for input circuit specications.

For Keyswitch-equipped lasers in automated systems, the Remote Reset/Start Request input
can operate as a remote keyswitch. To use this “remote keyswitch” functionality, rst place the
Keyswitch in the ON position. Then after each DC power-up cycle (or to reset a fault condition),
apply a momentary voltage pulse in the range of ±5–24 VDC to Pin 2. This reset action initiates
a ve-second delay after which lasing is enabled. To prevent operator injury when using Key­switch-equipped lasers, the Remote Reset/Start Request signal is ignored when the Keyswitch is
set to the OFF/RESET position. The manually-operated Keyswitch must be set to the ON position
before the laser can be reset from a remote location.

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User I/O connections

Pin 3 Remote Interlock

Apply a positive or negative voltage (±5–24 VDC) with respect to Pin 11, Input Common, to
enable lasing. If your system does not use a remote interlock, this input must be connected to a
voltage source in the range of ±5–24 VDC. Refer to following gure for a diagram showing how
the Remote Interlock input is factory-jumpered on the Quick Start Plug. Because all DC power is
removed from the laser’s RF driver when this input is inactive, no lasing can occur until voltage
is applied to Pin 3. Refer to Table 4-4 for input circuit specications.

After voltage is removed and then re-applied to the Remote Interlock input on Keyswitch­equipped lasers, the Keyswitch or the Remote Reset/Start Request input must be toggled to
restart the laser This action initiates a ve-second delay during which lasing is inhibited.

On OEM lasers, the Remote Interlock input is not latched. Re-applying a voltage to Pin 3
enables the Ready indicator and lasing is possible after the ve-second delay, provided that the
Shutter Open Request signal is also present (Shutter indicator illuminated).

Pin 9 PWM Input

Connect your PWM Command signal (+5 VDC, 5 kHz nominal, 100 kHz max) to Pin 9. This pulse
width modulated Command signal controls laser output so that a duty cycle of 50% corre­sponds to a laser output of approximately one-half rated output power and a duty cycle of
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 following table for input circuit specications.

Pin 10 Shutter Open Request

Apply a positive or negative voltage (±5–24 VDC) with respect to Pin 11, Input Common, to
enable lasing, in conjunction with the manual Shutter Switch (if equipped). If your system does
not supply a Shutter Open Request signal, this input must be connected to a voltage source
in the range of ±5–24 VDC. Refer to Figure 3-7 for a diagram showing how the Shutter Open
Request input is factory-jumpered on the Quick Start Plug. When a voltage is initially applied to
this input, there is a ve-second delay during which lasing is inhibited. Because all DC power is
removed from the laser’s RF driver when this input is inactive, no lasing can occur until voltage is
applied to Pin 10. See Table 3-4 for input circuit specications.

To enable Keyswitch-equipped lasers, you must apply a voltage (in the range of ±5–24 VDC) to
the Shutter Open Request input and move the manual Shutter Switch (if equipped) to the Open
position. Lasing is inhibited when voltage is removed from Pin 10 or the Shutter Switch is Closed.

Note: To ensure optimum performance, a ve-second delay is imposed from the time a Shutter

Open Request input occurs to the time that PWM Command signals are accepted.

Pin 11 Input Common

Use this pin to connect return lines for Remote Interlock, Shutter Open Request, and Remote
Reset/Start Request lines. Refer to the following table for input circuit specications.

Figure below illustrates how Remote Interlock inputs are factory-jumpered on the Quick Start Plug to
enable lasing for initial testing and troubleshooting purposes.

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Pin 15 Pin 9

User I/O connections

Figure below illustrates the input circuit’s equivalent internal schematic while following table provides
Firestar f201 input circuit specications.

Table 4-4 Input circuit specications.

Input Signal Name Input Device Type and Specications

PWM Input High-speed optoisolator LED, forward voltage drop (Vf) 1.5 VDC

O state Vmax +0.8 VDC
On state Vmin +3.5 VDC @ 3 mA
On state (continuous) Vmax +6.7 VDC @ 10 mA
Frequency, max. 100 kHz

Remote Reset/Start Request Bi-directional optoisolator LED, forward voltage drop (Vf) 1.15 VDC
Remote Interlock O state Vmax < 1.0 VDC
Shutter Open Request On state Vmin ±5.0 VDC @ 7 mA
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).

Warning

The use of the Quick Start Plug bypasses the laser’s safety interlock
function, potentially exposing personnel in the area to invisible

serious

personal

injury

infrared laser radiation.

The Quick Start Plug is intended only for initial testing and trouble­shooting by qualied personnel. In normal operation, the laser’s
Remote Interlock input should be connected to the machine’s safety
interlock circuitry.

Pin 1 PWM Return
Pin 9 PWM Input

Pin 3 Remote Interlock
Pin 4 +5 VDC

Pin 11 Input Common
Pin 12 Aux. DC Power Ground

Figure 4-8 Input equivalent schematic.

Rear (Solder Side)

of Male DB15
"Quick Start"

Shorting Plug

Pin 8 Pin 1

PWM Input BNC

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REMO

INPUT COMMON (11)

User I/O connections

Output signals

Firestar’s ve user outputs correspond to the status functions described below. Outputs are optoisolated,
bi-directional analog switches that allow for high-side or low-side switching. The shared connection,
Output Common, is separate from the laser’s chassis ground to allow high-side or low-side switching and
to isolate control signals for optimum EMI performance.

USER I/O INPUT SIGNAL PINS

PWM INPUT (+) (9)

PWM RETURN (–) (1)

220 Ohm, 1/8W

430 Ohm, 1/10W

TE RESET/START REQUEST (2)

REMOTE INTERLOCK (3)

SHUTTER OPEN REQUEST (10)

600 Ohm, 2W

600 Ohm, 2W

600 Ohm, 2W

FIRESTAR f-SERIES

INPUT CIRCUITRY

Figure 4-7 Quick Start Plug wiring diagram.

Firestar’s optically-isolated outputs are useful for sending laser status to a Programmable Logic Controller
(PLC) or computerized control system. Each of the ve outputs can source 50 mA at ±24 VDC maximum
for a total load of 250 mA. For controlling larger loads, use these outputs to drive a control relay.

Note: Laser Ready and Shutter Open outputs denote separate control functions. The Laser Ready

output (Ready LED On) may close while the Shutter Open output is open (Shutter LED O), but
the RF driver is disabled until both Laser Ready and Shutter Open outputs are closed (Ready
and Shutter indicators illuminated).

Pin 6 Laser Active

This bi-directional switched output is internally connected to Pin 13, Output Common, when
the laser is actively lasing (Lase indicator red). This output is open (high impedance) when no
beam is being emitted (Lase indicator O). Refer to the following table for output circuit speci­cations.

Pin 7 Over Temperature

This bi-directional switched output is internally connected to Pin 13, Output Common, when
laser temperature is above safe operating limits (Temp indicator red). The output is open (high
impedance) when laser temperature is within operating limits (Temp LED green). After an over
temperature fault occurs, cool the laser and then cycle DC power to reset the laser. Refer to he
following table for output circuit specications.

SYNRAD f201 Operator’s Manual Version 3.2

68

Pin 8 Laser Ready

This bi-directional switched output is internally connected to Pin 13, Output Common, when
the laser is enabled (Ready indicator On), indicating that lasing will occur when a PWM Com­mand signal is applied to Pin 9 and Pin 1. When this output is initially switched closed, there is a
ve-second delay during which lasing is inhibited. This output is open (high impedance) when
the laser is disabled (Ready LED O ). Refer to Table below for output circuit specications.

Pin 13 Output Common

Use this pin to complete the return (ground) path for any output connection (Pin 6, 7, 8, 14, or

15). The Output Common line is protected by a 0.25 A self-resetting fuse.

Pin 14 Shutter Open

This bi-directional switched output is internally connected to Pin 13, Output Common, when
the Shutter Switch is Open and a Shutter Open Request signal is present (Shutter LED blue),
indicating that lasing may be enabled if other operating conditions are met. The output is open
(high impedance) when the Shutter Switch is Closed or the Shutter Open Request signal is
removed. When Shutter Open output closes (Shutter LED O), there is a ve-second delay until
PWM inputs are recognized. Refer to the below table for output circuit specications.

Pin 15 Interlock Open

This bi-directional switched output is internally connected to Pin 13, Output Common, when
remote interlock input circuitry is open (Remote Interlock LED red), indicating that lasing is
disabled. This output is open (high impedance) when the laser is enabled (Remote Interlock
indicator green). When this output is initially switched open, there is a ve-second delay during
which lasing is inhibited. See the following tables for output circuit specications.

technical reference

User I/O connections

Following gure illustrates the output circuit’s equivalent internal schematic and the following provides
Firestar
f201 output circuit specications.

Table 4-5 Output circuit specications.

Output Device Specications

Bi-directional MOSFET 2.5 Ohms Rdson
10 MOhms O

Voltage ±24 VDC, max.

Current 50 mA, max.

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GROUND

enab

USER I/O PINS

TE INTERLOCK

Close switch to

USER I/O PINS

TE INTERLOCK

(11) INPUT COMMON

–12

User I/O connections

Sample I/O circuits

Sample inputs

Figure below illustrates one method of supplying a Remote Interlock signal using a customer-supplied
limit switch. Firestar’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.

(5) +24 VDC AUXILIARY

Close switch to

le interlock

POWER

(3) REMO

(11) INPUT COMMON

(12) AUX. DC POWER

Figure 4-10 Customer-supplied interlock.

Figure below shows another variation for supplying a Remote Interlock signal to the laser. In this case,
the customer is using a limit switch and supplying a negative voltage to drive Firestar’s input circuit.

enable interlock

VDC

0 VDC

(3) REMO

Figure 4-11 Customer-supplied interlock, negative voltage.

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technical reference

K

User I/O connections

A Programmable Logic Controller (PLC) can also drive Firestar inputs. Figure below shows a typical
method for connecting to a PLC output module when only one Firestar input is used.

PLC

DC

OUTPUT

MODULE

+V

(+5–24V)

Figure 4-12 PLC driven interlock signal.

When multiple PLC outputs are used, connect Firestar inputs to the PLC as shown in Figure below. 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.

USER I/O PINS

(3) REMOTE INTERLOC

(11) INPUT COMMON

PLC

DC

OUTPUT

MODULE

+V

(+5–24V)

Figure 4-13 Multiple PLC driven inputs.

USER I/O PINS

(11) INPUT COMMON

(2) REMOTE RESET/STA RT REQUEST

(3) REMOTE INTERLOCK

(10) SHUTTER OPEN REQUEST

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technical reference

(5)

PO

(6)

(12)

GR

(13) OUTPUT COMMON

USER I/O PINS

(5)

PO

(6)

(12)

GR

(13) OUTPUT COMMON

+V

USER I/O PINS

User I/O connections

Sample outputs

Firestar’s optoisolated, bi-directional switched outputs can drive small loads (50 mA max), PLC inputs, or
relays that can control higher current loads. Figure below illustrates one method of controlling a remote
warning lamp using power supplied by Firestar’s +24 VDC Auxiliary Power output. Remember to size
current-limiting resistor, R1, so that the current draw does not exceed 50 mA.

+24 VDC AUXILIARY

WER

LASER ACTIVE

AUX. DC POWER

OUND

R1

L

Figure 4-14 Firestar output driving warning lamp.

Figure below illustrates a method for controlling a higher voltage, higher current load by using a 24V
control relay. Ensure that the relay coil’s pull-in current does not exceed 50 mA. A diode or surge sup­pressor must be installed across the relay coil to prevent voltage spikes from damaging Firestar outputs.

+24 VDC AUXILIARY

WER

LASER ACTIVE

AUX.DC POWER

OUND

Figure 4-15 Firestar output driving relay.

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L

technical reference

(13)

(6)

(7)

(8)

(14)

(15)

User I/O connections

Figure below illustrates how Firestar’s outputs can drive the DC Input Module of a Programmable Logic
Controller (PLC). By supplying voltage (+VDC) to Pin 13, Output Common, each Firestar output is inde­pendently switched to activate individual PLC inputs.

PLC

DC

USER I/O PINS

OUTPUT COMMON

LASER ACTIVE

OVER TEMPERATURE

LASER READY

INPUT

MODULE

V+

(+5–24V)

SHUTTER OPEN

INTERLOCK OPEN

Figure 4-16 Firestar output driving PLC input module.

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technical reference

DC Power cables

The DC Power cables section includes subsections:

■ f201 DC Power cables

Note: If you lengthen the DC Power cable, you must calculate and measure the additional voltage drop

to ensure that 96 VDC is available at the laser’s DC POWER connector under full-load conditions.
Depending on the additional length required, you may need to use larger gauge wire.

f201 DC Power cables

DC Power cables for f201 lasers are manufactured with #12 AWG wire; however, DC input current is split
between two positive (+) and two negative (–) conductors. Firestar f201 DC Power cables are available in
5 meter (16.4 ft) and 7 m (23 ft) lengths. The standard length is 5 meters. The minimum bend radius for
f201 DC Power cables must be greater than 124.5 mm (4.9 in).

F201 DC Power cables are wired into a Canon-type ME3476L14-4S plug that connects with a matching
receptacle on the laser’s rear panel. Table below provides pinout information for f201 DC Power cable
connectors.

Table 4-7 f201 DC Power connector pinouts.

Function Wire Color Code Terminal Designation

+96 VDC Red A

– VDC Black B

+96 VDC Red C

– VDC Black D

Ground Green Shell

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technical reference

Integrating Firestar safety features

The Integrating Firestar safety features section includes subsections:

■ Remote Interlock functions

Firestar’s DB-15 User I/O connector allows system integrators or end-users to integrate Firestar safety
features into their control system. Firestar’s keyswitch, shutter, and remote interlock functions serve
to enable or disable DC power to Firestar’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. Firestar status indicators
provide users with a quick visual indication of the laser’s operational status. All power to the laser’s RF
board is removed whenever Ready or Shutter indicators are O (Laser Ready or Shutter Open outputs
open).

OEM lasers

On OEM lasers, the Ready LED illuminates on DC power-up (provided that Shutter Open Request and
Remote Interlock inputs are enabled) and ve seconds later, DC power is applied to the RF driver. Over
temperature faults are reset by removing and then re-applying DC power after the laser has cooled. Re­mote interlock faults are not latched; the Ready LED illuminates yellow as soon as the interlock circuit is
closed (when the Remote Interlock LED turns from red to green) and ve seconds later lasing is enabled.

Although a Remote Reset/Start Request input is not needed to reset OEM faults, it can be used to inhibit
(disable) lasing. Disable the laser by applying a voltage in the range of ±5–24 VDC to Pin 2, the Remote
Reset/Start Request input. Removing voltage allows DC power to reach the RF driver and begins a
ve-second countdown after which lasing is enabled (Ready LED illuminates yellow). The RF driver is
disabled as long as voltage is applied to Pin 2.

Your control system can monitor the laser’s ready status on the User I/O connector by connecting your
system’s input between Pin 8, Laser Ready, and Pin 13, Output Common (see Figure 4-16).

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technical reference

Integrating Firestar safety features

The Laser Ready output closes when the laser is enabled (Ready LED illuminated yellow), indicating that
lasing is possible. The output is open (Ready LED o) when lasing is disabled.

Note: After the Laser Ready output closes, a ve-second delay occurs before lasing is enabled.

Remote interlock functions

Interlock circuits are often used to disable machinery when a shield, panel, or door is opened. Firestar’s
remote interlock function allows you to connect into an external remote interlock circuit and prevent
lasing by removing DC power from the laser’s RF driver boards when the circuit is electrically “open”.

Lasing is enabled when a Remote Interlock signal is present (Remote Interlock LED illuminated green),
if Ready and Shutter LEDs are illuminated, and disabled when the Remote Interlock signal is removed
(Remote Interlock LED red, Ready LED o). DC power is applied to the RF driver only when the Remote
Interlock LED is green and the Ready LED is yellow (and the Shutter LED is illuminated blue). Remote in­terlock functionality is provided by the Remote Interlock input signal on Pin 3 of the User I/O connector.

To use Firestar’s remote interlock feature, apply a voltage in the range of ±5–24 VDC to Pin 3, Remote In­terlock. Applying an interlock signal causes the Remote Interlock LED to illuminate green and sends DC
power to the RF driver, which enables lasing after a ve-second delay (provided that the Ready LED is
yellow and the Shutter LED is blue). Removing the interlock signal removes DC power from the RF driver,
causing the Remote Interlock LED to turn red and the Ready LED to turn o. Lasing remains disabled
until a Remote Interlock signal is reapplied to Pin 3.

Your control system can monitor the laser’s remote interlock status on the User I/O connector by con­necting your system’s input to Pin 15, Interlock Open, and Pin 13, Output Common (see Figure 3-16).
This output is closed when remote interlock circuitry is open (Remote Interlock LED illuminated red).
The output is open (in a high-impedance state) and the Remote Interlock LED is green when interlock
circuitry is closed.

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technical reference

Figure 4-16 F201 packaging diagram.

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technical reference

f201 general specications

Table 4-10 Firestar f201 general specications.

Parameter Firestar f201

Output Specications

Wavelength .............................................................10.2–10.7 microns

Power Output

Continuous .....................................................200 Watts

Pulsed3 ..............................................................250 Watts

Power Stability4 ......................................................± 7%

Power Stability5 ......................................................± 5%

Mode Quality ..........................................................M2 = 1.2 ±0.1

Beam Waist Diameter (at 1/e2)6 ........................4.5 ±0.1 mm

Beam Divergence, full angle, (at 1/e2) ............4.0 ±0.2 mrad

Ellipticity ...................................................................< 1.2

Polarization ..............................................................Linear, horizontal

Extinction Ratio .......................................................> 100:1

Rise Time ...................................................................< 150 µs

1, 2

Input Specications
Power Supply

Voltage .............................................................96 ±2.0 VDC

Maximum Current ........................................36 A

Command Input Signal

Voltage ......................................................................+3.5 to +6.7 VDC

Current (max., continuous) ................................10 mA @ +6.7 VDC

Frequency7 ...............................................................DC–100 kHz

Duty Cycle ................................................................0–100%

Logic Low State (Vmin–Vmax.) .........................0.0 to +0.8 VDC

Logic High State (Vmin–Vmax.) ........................+3.5 to +6.7 VDC

* Specications subject to change without notice.

1 This power level is guaranteed for 12 months regardless of operating hours.

2 Minimum 96 VDC input voltage to obtain guaranteed output power.

3 100 Hz, 10% duty cycle, average power as read by laser power meter, then multiplied by 10.

4 From cold start (guaranteed) at 95% duty cycle.

5 After two minutes (typical) at 95% duty cycle.

6 Measured at laser output.

7 FCC and CE tested at 5 kHz.

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technical reference

f201 general specications

Table 4-10 Firestar f201 general specications (continued).

Parameter Firestar f201

Cooling Specications

Maximum Heat Load ............................................4000 Watts (13.7 kBtu/hr)

Flow Rate (minimum) .........................................2.0 GPM at < 60 PSI (7.6 lpm at < 414 kPa)

(recommended) ................................2.5 GPM at < 60 PSI (9.5 lpm at < 414 kPa)

Pressure Drop ..........................................................1 PSI at 2 GPM (6.9 kPa at 7.6 lpm)

Coolant Temperature8 ..........................................18 °C to 22 °C

Environmental Specications

Operating Temperature9 .....................................15 °C to 40 °C

Humidity ...................................................................0–95%, non-condensing

Physical Specications

Length .......................................................................48.4 in (122.9 cm)

Width .........................................................................11.0 in (27.9 cm)

Height ........................................................................6.48 in (16.5 cm)

Weight .......................................................................96 lbs (43.5 kg)

* Specications subject to change without notice.

8 Firestar f201 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.

9 Published specications guaranteed at a cooling temperature of 22 °C.

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technical reference

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maintenance/

troubleshooting

5

Use information in this chapter to perform maintenance or troubleshoot your f201
laser.

This chapter contains the following information:

■ Maintenance – describes typical f201 maintenance procedures.

■ Troubleshooting – explains how to troubleshoot common f201 problems.

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maintenance/
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Maintenance

The Maintenance section includes subsections:

■ Disabling f201 lasers

■ Daily inspections

■ Storage/shipping

■ Cleaning optical components

Disabling f201 lasers

Before performing any maintenance on your Firestar® f201 laser, be sure to completely disable the laser
by disconnecting the DC Power cable (or cables) from the rear of the laser.

Daily inspections

Perform the following steps daily to keep your Firestar f201 laser in optimum operating condition. Ex­cept for the procedures described below, no other service is required or should be attempted.

Caution

possible

equipment

If you operate your laser or marking head in a dirty or dusty environ­ment, contact SYNRAD about the risks of doing so and precautions
you can take to increase the longevity of your laser, marking head,
and associated optical components.

damage

Warning

serious

personal

A risk of exposure to toxic elements, like zinc selenide, may result
when certain optical or beam delivery components are damaged. In
the event of damage to laser, marking head, or beam delivery optics,
contact SYNRAD, Inc. or the optics manufacturer for handling
instructions.

injury

1

Inspect all cooling tubing connections for signs of leakage. Check for signs of condensation that may

indicate the cooling water temperature has been set below the dew point temperature. Condensation
will damage electrical and optical components inside the laser. See Setting coolant temperature in the
Getting Started chapter for details on preventing condensation.

2

When using compressed air as a purge gas on your f201 laser, empty water traps and oil separa-

tors on each lter and/or dryer between the laser and your compressed air source. Compressed air
purity must meet the purge gas specications shown in Table 1-6 in the Getting Started chapter.

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maintenance/

troubleshooting

Maintenance

3

Inspect beam delivery components for signs of dust or debris and clean as required. When cleaning

the optical surfaces of beam delivery components, carefully follow the manufacturer’s instructions.

4

Visually inspect the exterior housing of the laser to ensure that all warning labels are present. Refer

to the Laser Safety chapter for f201 label types and locations.

Storage/shipping

When preparing the laser for storage or shipping, remember to drain cooling water from the laser. In cold
climates, any water left in the cooling system may freeze, which could damage internal components. After
draining thoroughly, use compressed shop air at no more than 29 PSI (wear safety glasses!) to remove any
residual water. When nished, 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. Refer to Packaging instructions in
the Technical Reference chapter for detailed instructions on properly packaging the laser for shipment.

Important Note: Failure to properly package the laser using SYNRAD-supplied shipping boxes and

foam/cardboard inserts as shown in the Packaging instructions may void the war­ranty. Customers may incur additional repair charges for shipping damage caused by
improper packaging.

Cleaning optical components

Debris or contaminants on the laser’s output coupler or external beam delivery components may aect la­ser processing and lead to damage or failure of the optics and/or the laser. Carefully follow the steps below
to inspect and clean the optical components in the beam path. Before beginning the cleaning process,
read this entire section thoroughly to ensure that all cleaning materials are available and that each step is
completely understood.

Caution

possible

equipment

damage

Because of their smaller beam diameter, Firestar lasers have signi­cantly higher power densities than previous SYNRAD lasers. This
means that any contamination on the laser’s output coupler (or on
any beam delivery optic) can absorb enough energy to damage one or
more optics in the beam path. Periodically inspect the laser’s output
coupler and all other beam delivery optics for signs of contaminants
and then carefully clean as required. In dirty environments, purge
laser optics using ltered air or nitrogen to prevent vapor and debris
from accumulating on optical surfaces.

Important – Firestar f201 and lasers do not have output windows
located inside the faceplate. NEVER disassemble the laser housing
to inspect f201 optics. Instead, always connect nitrogen or ltered
air to the laser’s Gas Purge port to prevent vapor and debris from
contaminating internal optical surfaces.

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Maintenance

Danger

serious

personal

Ensure that DC power to the laser is turned o and locked out before
inspecting optical components in the beam path. Invisible CO2 laser
radiation is emitted through the aperture. Corneal damage or blind­ness may result from exposure to laser radiation.

injury

Important Note: Exercise great care when handling infrared optics; they are much more fragile than

common glass materials. Optical surfaces and coatings are easily damaged by rough
handling and improper cleaning methods.

Cleaning guidelines

■ Wear latex gloves or nger cots (powder-free) to prevent contamination of optical surfaces by dirt and

skin oils.

■ Never handle optics with tools; always use gloved hands or ngers.

■ Hold optics by the outer edge; never touch the coated surface.

■ Always place optics on lens tissue for protection; never place optics on hard or rough surfaces.

■ It may be necessary to use a cotton ball or ued cotton swab instead of a lens wipe to uniformly clean

the entire surface of small-diameter mounted optics.

■ Before using any cleaning agents, read Material Safety Data Sheets (MSDS) and observe all necessary

safety precautions.

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 nger cots Powder-free

Air bulb Clean air bulb

Ethyl or isopropyl alcohol Spectroscopic or reagent grade

Acetone Spectroscopic or reagent grade

Lens wipe (preferred) Optical (cleanroom) quality

Cotton balls or cotton swabs High-quality surgical cotton/high-quality paper-bodied

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troubleshooting

Maintenance

Cleaning optics

1

Shut o and lock out all power to the laser. You must verify that the laser is OFF (in a zero-energy

state) before continuing with the optical inspection!

2

Visually inspect all optical surfaces in the beam path, including the laser’s output coupler, for con-

taminants.

Caution

possible

lens

damage

3

Remove loose contaminants from the optic by holding a clean air bulb at an angle to the optic and

blow a stream of air at a glancing angle across the lens surface. Repeat as necessary.

4

Dampen a lens wipe with the selected cleaning agent. Alcohol (least aggressive) is best for initial

surface cleaning. Acetone (moderately aggressive) is best for oily residue or minor baked-on vapors
and debris.

Important Note: If acetone is used as a cleaning solvent, a second follow-up cleaning of the optical

surface using alcohol is required.

Do not allow the nozzle of the air bulb to touch the optical surface.
Any contact may damage the optic by scratching coatings on the
optical surface.

Do not use compressed shop air to blow contamination from the op­tic. Compressed air contains signicant amounts of water and oil that
form adsorbing lms on the optical surface.

Do not exert pressure on the surface of the optic during cleaning.
Optical surfaces and coatings are easily scratched by dislodged con­taminants.

Use a new lens wipe on each pass as contaminants picked up by the
wipe may scratch the optical surface.

5

Gently, and without applying pressure, drag the damp lens wipe across the optical surface in a single

pass. Do not rub or apply any pressure, especially when using a cotton swab. Drag the wipe without
applying any downward pressure.

Note: Use a clean lens wipe on each pass. The wipe will pick up and carry surface contaminants that

may scratch optical surfaces or coatings.

To prevent streaking during the nal alcohol cleaning, drag the lens wipe slowly across the surface
so that the cleaning liquid evaporates right behind the wipe

6

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.

7

Repeat Steps 4 through 6 as required, removing all traces of contaminants and deposits.

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Troubleshooting

The Troubleshooting section includes subsections:

■ Introduction

■ Operational owchart

■ Functional block diagram

■ Status LEDs

■ Laser fault indications

■ Resetting faults

■ Other laser faults

■ Beam delivery optics

Introduction

This 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 SYNRAD or a SYNRAD Authorized Distributor for repair or replace­ment information.

To troubleshoot Firestar f201 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 owchart and the functional block diagram.

Danger

serious

personal

injury

This Class 4 laser product emits invisible infrared laser radiation in
the 10.6 µm CO2 wavelength band. Because exposure to direct or dif­fuse laser radiation can inict severe corneal injuries, always wear eye
protection when in the same area as an exposed laser beam. 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.

Caution

possible

equipment

Attempting repair of a SYNRAD Firestar laser without the express
authorization of SYNRAD, Inc. will void the product warranty.
If troubleshooting or service assistance is required, please contact
SYNRAD Customer Service.

damage

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Troubleshooting

Operational owchart

The owchart in the gure below illustrates Firestar’s start-up sequence.

Laser Start Sequence

Apply 96 VDC
power to laser

Remote Interlock
indicator Green?

Ye s

Temp indicator

Green?

Ye s

Shutter indicator

Blue?

Ye s

Turn Keyswitch

to ON

(if equipped)

Ready indicator

Yellow?

No

No

No

No

Apply interlock signal
to Remote Interlock input
or install factory-supplied

Quick Start Plug

Check that cooling water

is flowing through laser

and that coolant temp

is below 22˚ C

Apply shutter open

signal to Shutter Open

Request input or install

factory-supplied Quick

Start Plug

Cycle Keyswitch from ON

to OFF/RESET and then

back to ON
(on OEM lasers, 
cycle DC power)

Cycle DC power 

(remove DC power, 

wait 15 seconds,

reapply DC power)

Ensure that manual

Shutter Switch is set

to Open

Ready indicator

Yellow?

No

Figure 5-1 Operational owchart.

Ye s

Apply PWM Command

signal to laser

Lase indicator

illuminates Red to

indicate laser output

Ye s

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Troubleshooting

Functional block diagram

Figure below is a functional block diagram illustrating the f201’s control architecture.

STATUS INDICATORS

LASE

SHUTTER

READY

TEMP

OVER

DETECTOR

TEMPERATURE

REMOTE

DETECTOR

INTERLOCK

REMOTE INTERLOCK

SHUTTER

CONTROL

LASE

INDICATOR

SHUTTER OPEN REQUEST

PWM INPUT



ISOLATION

INPUT

PWM OUT

CATGEN

DELAY TIMER

REMOTE RESET/START REQUEST

FAULT

TO RF DRIVER BOARD

TO CONTROL BOARD

REMOTE

INTERLOCK

LASER ACTIVE

INTERLOCK OPEN

SHUTTER OPEN

ISOLATION

OUTPUT

OVER TEMPERATURE

Figure 5-2 f201 functional block diagram.

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88

LASER READY

CONNECTOR

DB15 USER I/O

POWER

SWITCH

INPUT

VOLTAGE

REGULATOR

DC POWER

READY

FAULT

DETECT

ON AND 

96 VDC

maintenance/

troubleshooting

Troubleshooting

Status LEDs

Firestar f201 LED indicators, also mirrored as output signals on the User I/O connector, provide status in­formation to the user. Table below shows Firestar output signal and LED indicator states during normal
and fault conditions. User I/O outputs are Closed when the state indicated by the signal name is True.

Table 5-2 Status signals.

LED Status Output Signal Name User I/O Signal Status
LED Indicator Normal Fault Normal Fault

Remote Interlock Green – – Interlock Open Open – –
– – Red – – Closed

Temp Green – – Over Temperature Open – –
– – Red – – Closed

Ready Yellow – – Laser Ready Closed – –
– – O – – Open

Shutter Blue – – Shutter Open Closed – –
– – O – – Open

Lase Red – – Laser Active Closed – –
– – O – – Open

When PWM Command pulses are applied (and are long enough to produce laser output) the Lase LED
illuminates red.

On OEM lasers, the Ready lamp illuminates on DC power-up when Remote Interlock and Temp indica­tors illuminate green. After the Ready indicator illuminates, a ve-second delay occurs before Firestar is
permitted to lase.

Note: Firestar Ready and Shutter indicators (as well as Laser Ready and Shutter Open outputs) denote
separate control functions. Although the Ready lamp may light while the Shutter LED is O (Shutter
Switch Closed or Shutter Open Request signal missing), no power is applied to the RF boards until both
Ready and Shutter indicators are illuminated.

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troubleshooting

Troubleshooting

Tables below show how 201 signal status changes when remote interlock, over-temperature, or shutter
closed conditions occur (fault conditions are shown in bold type).

Table 5-3 Normal operating condition.

LED Indicator LED Status Output Signal Output Status

Remote Interlock Green Interlock Open Open

Temp Green Over Temperature Open

Ready Yellow Laser Ready Closed

Lase (tickle active) O Laser Active Open
Lase (if PWM applied) Red Laser Active Closed

Table 5-4 Quick Start Plug or interlock/shutter inputs not connected.

LED Indicator LED Status Output Signal Output Status

Remote Interlock Red Interlock Open Closed

Temp Green Over Temperature Open

Ready O Laser Ready Open

Lase (tickle inactive) O Laser Active Open
Lase (if PWM applied) O Laser Active Open

Table 5-5 Interlock open condition.

LED Indicator LED Status Output Signal Output Status

Remote Interlock Red Interlock Open Closed

Temp Green Over Temperature Open

Ready O Laser Ready Open

Lase (tickle inactive) O Laser Active Open
Lase (if PWM applied) O Laser Active Open

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Table 5-6 Over Temperature fault.

LED Indicator LED Status Output Signal Output Status

Remote Interlock Green Interlock Open Open

Temp Red Over Temperature Closed

Ready O Laser Ready Open

Lase (tickle inactive) O Laser Active Open
Lase (if PWM applied) O Laser Active Open

Table 5-7 Shutter closed condition.

LED Indicator LED Status Output Signal Output Status

Remote Interlock Green Interlock Open Open

Temp Green Over Temperature Open

Ready Yellow Laser Ready Closed

Lase (tickle inactive) O Laser Active Open
Lase (if PWM applied) O Laser Active Open

Table 5-8 VSWR fault.

LED Indicator LED Status Output Signal Output Status

Remote Interlock Green Interlock Open Open

Temp Green Over Temperature Open

Ready Yellow Laser Ready Closed

Shutter Blue (Flashing) Shutter Open Closed

Lase (tickle active) O Laser Active Open
Lase (if PWM applied)* Red Laser Active Closed

* A continuously ashing Shutter LED indicates a VSWR fault and the laser is limited to a maximum pulse length of 12 µs (ap-

proximately 6% duty cycle at 5 kHz) until the fault clears.

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Laser fault indications

On f201 lasers manufactured after November 2007, Ready (RDY) and Shutter (SHT) LED’s ash to annun­ciate one of four laser faults. The following table lists error codes, the corresponding fault, and describes
basic corrective action. See the following section, Resetting faults, for detailed corrective actions.

Table 5-9 Laser error codes.

LED # of Blinks Fault Condition Corrective Action

RDY 1 blink Under Voltage Fault Verify 96 VDC (measured under load)/cycle power

RDY 2 blinks Over Voltage Fault Verify 96 VDC (measured under load)/cycle power

RDY 3 blinks RF Drive Switch Fault Remove DC power to the laser, wait 30 seconds, and
then reapply DC power

Resetting faults

Remote interlock condition

A remote interlock condition occurs when the Remote Interlock input opens (the Remote Interlock LED
changes from green to red).

To reset a remote interlock condition on Keyswitch-equipped lasers, re-establish the Remote Interlock
signal input (Remote Interlock LED changes from red to green) and cycle the Keyswitch from OFF/RESET
to ON (or apply a ±5–24 VDC Remote Reset/Start Request pulse with the Keyswitch set to ON). When
the Ready indicator illuminates, lasing is enabled after a ve-second delay.

Warning

serious

personal

injury

On Firestar f201 OEM lasers, remote interlock faults are not latched.
Clearing the fault condition re-enables the Ready indicator and the
laser will re after the ve-second delay provided that the Shut­ter indicator is lit and a PWM Command signal is applied. Because
exposure to 10.6 µm CO2 laser radiation can inict severe corneal in­juries and seriously burn human tissue, the OEM or System Integra­tor must ensure that appropriate safeguards are in place to prevent
unintended lasing.

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On OEM lasers, remote interlock conditions are not latched. Re-establish the Remote Interlock signal
input (Remote Interlock LED changes from red to green) to enable the Ready indicator and begin lasing
after the ve-second delay.

Over temperature fault

Over temperature faults occur when thermal limits in the laser are exceeded (the Temp LED changes from
green to red).

To reset an over-temperature fault on Keyswitch-equipped lasers, lower coolant temperature below
°C (f201), cycle DC power to the laser, and then cycle the Keyswitch from OFF/RESET to ON (or apply a
±5–24 VDC Remote Reset/Start Request pulse with the Keyswitch set to ON). When the Ready indicator
illuminates, lasing is enabled after a ve-second delay.

Note: Because of the over-temperature latch circuit, the Temp indicator remains red prior to cycling

power even after the laser has cooled suciently to begin operation. If the Temp indicator remains
red after cycling power, the laser is not suciently cooled—cool the laser for several more min­utes, cycle power, and then cycle the Keyswitch.

Over-temperature faults are now latched. To reset an over-temperature fault, lower coolant temperature
below 28 °C (f201) to cool the laser and then cycle DC power to the laser. Once the Temp indicator is
green and the Ready lamp is lit, lasing is possible after the ve-second delay.

Under voltage fault

An under voltage fault occurs when the DC input voltage falls below preset limits. This fault is indicated
by the Ready LED ashing 1 blink. To reset an under voltage fault, rst correct the voltage problem and
ensure that 96 VDC is measured at the laser under full-load conditions. Next, cycle DC power o and then
on again. On Keyswitch-equipped lasers, you must also toggle the Keyswitch from OFF/RESET to ON (or
apply a ±5–24 VDC Remote Reset/Start Request pulse with the Keyswitch set to ON). When the Ready
LED illuminates, lasing is enabled after a ve-second delay.

Over voltage fault

An over voltage fault occurs when the DC input voltage rises above preset limits. This fault is indicated by
the Ready LED ashing 2 blinks. To reset an over voltage fault, rst correct the voltage problem and ensure
that 96 VDC is measured at the laser under full-load conditions. Next, cycle DC power o and then on
again. On Keyswitch-equipped lasers, you must also toggle the Keyswitch from OFF/RESET to ON (or apply
a ±5–24 VDC Remote Reset/Start Request pulse with the Keyswitch set to ON). When the Ready LED
illuminates, lasing is enabled after a ve-second delay.

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RF Drive Switch fault

An RF Drive DC fault occurs on power-up when the tube fails to breakdown or a fault occurs in the RF
Driver’s 96-volt switching circuitry. In this case, the Ready LED ashes 3 blinks. If an RF Drive DC fault
occurs, reset the laser by removing DC power to the laser, wait 30 seconds, and then reapply power. On
Keyswitch-equipped lasers, you must also toggle the Keyswitch from OFF/RESET to ON (or apply a ±5–24
VDC Remote Reset/Start Request pulse with the Keyswitch set to ON) When the Ready LED illumi­nates, lasing is enabled after a ve-second delay. If the RF Drive DC fault reappears, contact SYNRAD or
a SYNRAD Authorized Distributor.

PWM Drive/RF Oscillation faults

New circuitry on the f201 RF board has eliminated PWM Drive and RF Oscillation faults. The 4-blink fault
indication no longer exists.

VSWR fault

A VSWR fault indicates an impedance mismatch between the tube and RF Driver and occurs when a
PWM Command signal is rst applied. This fault is annunciated by the Shutter LED ashing continuously
until the fault disappears. If a VSWR fault occurs, the VSWR circuit limits the maximum PWM pulse
length to 12 microseconds (µs). This equates to a 6% maximum duty cycle at a 5 kHz frequency or a 24%
maximum duty cycle at a 20 kHz PWM frequency. When the VSWR fault clears, the laser resumes normal
operation without cycling DC power. If the VSWR fault fails to clear or reappears, contact SYNRAD or a
SYNRAD Authorized Distributor.

The leading causes of VSWR failures are environmental conditions, like cold overnight temperatures
while the laser is o. In cases like this, it may take as long as 60 seconds for tickle to breakdown the tube
and begin normal daily operation.

Other laser faults

Each Symptom listed below describes a particular fault condition. For each Symptom, specic causes and
solutions are described in the Possible Causes section.

Symptom:

■ A remote interlock condition is indicated by the following status LEDs and I/O states:

Remote Interlock LED – Red Interlock Open output – Closed
Temp LED – Green Over Temperature output – Open
Ready LED – O Laser Ready output – Open
Lase LED – O Laser Active output – Open

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Possible Causes:

■ No voltage is applied to Pin 3 (Remote Interlock) of the User I/O connector.

Warning

serious

personal

injury

On systems using remote interlocks, check to see that a positive or negative voltage in the range of ±5–24
VDC is applied to Pin 3, Remote Interlock, with respect to Pin 11, Input Common, on the User I/O con­nector (refer to User I/O connections in the Technical Reference chapter for details). For systems not using
interlocks, connect the factory-supplied Quick Start Plug to the User I/O connector on the laser’s rear panel
or wire your male DB-15 connector so that Pin 11 (Input Common) is jumpered to Pin 12 (Auxiliary DC
Power Ground) and Pin 3 (Remote Interlock) is jumpered to Pin 4 (+5 VDC Auxiliary Power).

On Firestar f201 OEM lasers, remote interlock faults are not latched.
Clearing the fault condition re-enables the Ready indicator and the
laser will re after the ve-second delay provided that the Shut­ter indicator is lit and a PWM Command signal is applied. Because
exposure to 10.6 µm CO2 laser radiation can inict severe corneal in­juries and seriously burn human tissue, the OEM or System Integra­tor must ensure that appropriate safeguards are in place to prevent
unintended lasing.

Symptom:

■ An over-temperature fault is indicated by the following status LEDs and I/O states:

Remote Interlock LED – Green Interlock Open output – Open
Temp LED – Red Over Temperature output – Closed
Ready LED – O Laser Ready output – Open
Lase LED – O Laser Active output – Open

Possible Causes:

■ Coolant temperature is above 28 °C (f201) or there is inadequate coolant ow through the laser.

Check that your chiller is maintaining a water temperature between 18 °C–28 °C (64 °F–82 °F) at a ow
rate of 9.5 lpm (2.5 GPM) for f201.

If water temperature is OK, check the ow rate. The simplest way to do this, if a ow meter is not avail­able, is to disconnect the cooling tubing from the chiller inlet (or the drain) and run the cooling water for
one minute into a ve-gallon bucket; you should have close to the number of gallons listed above. If there
is much less than the recommend ow, check the cooling path for kinked or pinched cooling tubes or
check the chiller for a clogged or dirty lter.

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On f201 lasers, the over-temperature fault (indicated by the Temp indicator turning red) is latched. This
means that if an over-temperature condition occurs the Temp indicator will turn red, the Over Tempera­ture output will Close, the Ready light goes out, and lasing is disabled. Because of its latched condition,
the Temp indicator will remain red even after the laser has cooled suciently to begin operation.

To reset an over-temperature fault, lower coolant temperature below 28 °C (f201) and then cycle DC
power (remove DC power, wait 30 seconds, reapply DC power). On Keyswitch-equipped f100/f200 lasers
you must also cycle the Keyswitch from OFF/RESET to ON (or with the Keyswitch ON, apply a positive or
negative voltage in the range of ±5–24 VDC to Pin 2, Remote Reset/Start Request) after re-applying DC
power. When the Ready indicator illuminates, lasing is enabled after the ve-second delay. If the Temp
indicator remains red after cycling power, continue to ow cooling water through the laser for a few
more minutes and then cycle DC power again.

Symptom:

■ Your OEM laser has quit lasing or lasing halted and then restarted. The Lase LED may be O or On

depending on whether PWM Command signals are being applied, but no fault is indicated.

Remote Interlock LED – Green Interlock Open output – Open
Temp LED – Green Over Temperature output – Open
Ready LED – Yellow Laser Ready output – Closed
Lase LED – O or On Laser Active output – Open or Closed

■ The remote interlock circuit momentarily opened.

Remote interlock faults are not latched on OEM lasers. This means that if an interlock open fault occurs,
the Remote Interlock indicator will turn red, the Interlock Open output will Close, the Ready light goes out,
and lasing is disabled. However, if the interlock circuit closes, the Remote Interlock indicator will change
from red to green, the Ready light illuminates, and ve seconds later lasing is enabled.

Symptom:

■ There is no output laser beam and all LED status indicators are O

Possible Causes:

■ The 20 A fast-acting fuse has blown.

Remove DC power from the laser and then check each fuse on the rear panel. Replace as required using
only a Bussman ABC-20 or equivalent.

Symptom:

■ There is no output laser beam from your f201 laser, but status indicators appear as:

Remote Interlock LED – Green Interlock Open output – Open
Temp LED – Green Over Temperature output – Open
Ready LED – O Laser Ready output – Open
Lase LED – O Laser Active output – Open

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Possible Causes:

■ One of the two 20 A fast-acting fuses has blown.

On f201 lasers, a single blown 20 A fuse on the laser’s rear panel may cause the Ready lamp to remain
O while other LEDs indicate normal status. Remove DC power from the laser and then check each fuse
on the rear panel. Replace as required using only a Bussman ABC-20 or equivalent.

Beam delivery optics

Troubleshooting

Symptom:

■ The laser loses power over time; laser output power must be increased to maintain performance.

Possible Causes:

■ Beam delivery optics are coated by vapor residue or debris.

Shut down the laser and carefully inspect each optic in the beam delivery path, including the laser’s out­put coupler. Remember that optics are fragile and must be handled carefully; preferably by the mount­ing ring only. If the optic requires cleaning, refer back to Maintenance for cleaning instructions. Use only
recommended cleaning materials (see Table 5-1) 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 Firestar lasers, pits or debris on the lens surface may absorb enough energy from the focused beam to
crack the lens. If this happens, other optics in the beam path may be contaminated or damaged as well.

Warning

serious

personal

injury

The use of aerosol dusters containing dioroethane causes “bloom­ing”, a condition that signicantly expands and scatters the laser
beam. This beam expansion can eect mode quality and/or cause
laser energy to extend beyond the connes of optical elements in
the system, possibly damaging acrylic safety shielding. Do not use air
dusters containing dioroethane in any area adjacent to CO2 laser
systems because dioroethane persists for long time periods over wide
areas.

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Caution

possible

equipment

If you operate your laser or marking head in a dirty or dusty environ­ment, contact SYNRAD about the risks of doing so and precautions
you can take to increase the longevity of your laser, marking head,
and associated optical components.

damage

When operating f201 lasers, connect nitrogen or breathing-grade air to the Gas Purge connector.
Purging the laser creates a positive pressure inside the laser housing that prevents dirt and debris from
accumulating on optical surfaces including beam combiner, telescope, and turning optics. In condens­ing atmospheres, a gas purge helps to reduce the potential for condensation damage. See Connecting
in the Getting Started chapter for information on using a gas purge. Table 2-6 in the Getting Started
chapter provides ltering and drying specications for recommended purge gases.

Danger

serious

personal

Ensure that DC power to the laser is turned o and locked out before
inspecting optical components in the beam path. Invisible CO2 laser
radiation is emitted through the aperture. Corneal damage or blind­ness may result from exposure to laser radiation.

injury

In addition to a gas purge for the laser housing, many laser processing applications like cutting, weld­ing, and drilling require an assist gas for the focusing/gas jet assembly. When the application requires
air (instead of nitrogen) as an assist gas, we recommend the use of breathing quality air available in
cylinders from a welding supply company. Because compressed shop air contains minute particles of oil
and other contaminants that will damage optical surfaces, it must be carefully ltered and dried before
use as a purge or assist gas. Refer to Table 4-1, Assist gas purity specications, in the Technical Reference
chapter for a list of common assist gases and their corresponding ltering and drying specications.

Warning

serious

personal

A risk of exposure to toxic elements, like zinc selenide, may result
when certain optical or beam delivery components are damaged. In
the event of damage to laser, marking head, or beam delivery optics,
contact SYNRAD, Inc. or the optics manufacturer for handling
instructions.

injury

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