Synrad Firestar TI Series, Firestar TI60, Firestar TI100 Operator's Manual

ti-Series
operator’s
manual

®

An Excel Technology Company

4600 Campus Place
Mukilteo, WA 98275

1.800.SYNRAD1

tel [phone]
fax [phone]
e-mail [e-mail]

www.synrad.com

Firestar

®

ti-Series

Operator’s Manual

ti60 version C

ti100 version B

Version 1.2

Released March 2010

Part number 900-19846-02

®

An Excel Technology Company

4600 Campus Place
Mukilteo, WA 98275

1.800.SYNRAD1

tel [phone]
fax [phone]
e-mail [e-mail]

www.synrad.com

table of contents

Laser Safety

Hazard information ....................................................................................1

Terms ..........................................................................................................................1

General hazards .........................................................................................................1

Firestar ti60 label locations ........................................................................4

Firestar ti100 label locations ......................................................................5

Agency compliance ...................................................................................6

Center for Devices and Radiological Health (CDRH) requirements .......................6

Federal Communications Commission (FCC) requirements ...................................7

European Union (EU) requirements .........................................................................8

Declaration of Conformity ........................................................................11

Getting Started 1

Introduction ...............................................................................................1-2

Firestar nomenclature ................................................................................................1-2

Unpacking ..................................................................................................1-3

Incoming inspection ..................................................................................................1-3

Packaging guidelines ..................................................................................................1-3

Inventory ....................................................................................................1-4

Contents description .................................................................................................1-5

Mounting ...................................................................................................1-6

Fasten from above ......................................................................................................1-6

Fasten from below ......................................................................................................1-7

Connecting ................................................................................................1-8

Water-cooled connections .........................................................................................1-8

ti60 air-cooled connections (SA models) .................................................................1-12

Electrical connections ...............................................................................................1-13

Control connections ..................................................................................................1-14

Operation 2

Controls and indicators .............................................................................2-2

ti-Series front panel ...................................................................................................2-2

ti-Series rear panel .....................................................................................................2-3

OEM ti60 side panel (SA models) ............................................................................2-4

Initial start-up ............................................................................................2-5

With a UC-2000 Controller ......................................................................................2-5

Without a UC-2000 Controller ................................................................................2-8

Synrad Firestar ti-Series operator’s manual

iii

table of contents

Technical Reference 3

Technical overview ....................................................................................3-2

ti-Series laser ..............................................................................................................3-2

Optical setup ..............................................................................................................3-3

Controlling laser power .............................................................................3-5

Control signals ...........................................................................................................3-5

Operating modes ........................................................................................................3-7

User I/O connections .................................................................................3-10

User I/O connection summary ..................................................................................3-10

Input/output signals ...................................................................................................3-12

Sample I/O circuits ....................................................................................................3-19

DB-9 connections (SA models) ...............................................................3-23

DB-9 pin descriptions ................................................................................................3-23

48 VDC fan speed control .........................................................................................3-24

Isolated cooling fan connections ...............................................................................3-25

Integrating Firestar safety features ............................................................3-26

Keyswitch functions ...................................................................................................3-26

Shutter functions .......................................................................................................3-27

Remote interlock functions .......................................................................................3-27

Firestar ti60 general specifications .............................................................3-28

Firestar ti100 general specifications ...........................................................3-30

Firestar ti-Series package outline drawings ................................................3-32

Firestar ti-Series packaging instructions ....................................................3-36

Maintenance/Troubleshooting 4

Maintenance ..............................................................................................4-2

Disabling Firestar .......................................................................................................4-2

Daily inspections .......................................................................................................4-2

Storage/shipping ........................................................................................................4-3

Cleaning optical components ....................................................................................4-3

Troubleshooting .........................................................................................4-6

Introduction ...............................................................................................................4-6

Operational flowchart ................................................................................................4-7

Functional block diagram ..........................................................................................4-8

Status LEDs ................................................................................................................4-9

Laser faults .................................................................................................................4-11

Resetting faults ..........................................................................................................4-11

Other laser faults ........................................................................................................4-13

Beam delivery optics ..................................................................................................4-16

Index

iv

Synrad Firestar ti-Series operator’s manual

table of contents

List of Figures

Figure 1 Firestar ti60 hazard label and CE label locations ..................4

Figure 2 Firestar ti100 hazard label locations ......................................5

Figure 3 European compliance mark ...................................................10

Figure 1-1 Firestar ti-Series shipping box contents ................................1-4

Figure 1-2 Fasten from above ..................................................................1-6

Figure 1-3 Fasten from below ..................................................................1-7

Figure 1-4 Firestar ti-Series cooling connections ...................................1-11

Figure 1-5 Recommended ti60 cooling fan locations ............................1-12

Figure 1-6 DC-48 DC power supply ........................................................1-13

Figure 2-1 ti-Series front panel controls and indicators .........................2-2

Figure 2-2 ti-Series rear panel controls and indicators ...........................2-3

Figure 2-3 OEM ti60s side panel controls and indicators .......................2-4

Figure 3-1 Firestar ti-Series beam characteristics ...................................3-3

Figure 3-2 “Flying optics” beam path ......................................................3-4

Figure 3-3 Representative Firestar ti-Series waveforms ..........................3-6

Figure 3-4 PWM Command signal waveform .........................................3-7

Figure 3-5 Representative ti-Series optical output pulse ........................3-9

Figure 3-6 User I/O connector pinouts ...................................................3-12

Figure 3-7 Auxiliary DC power supply wiring ........................................3-13

Figure 3-8 Quick Start Plug wiring diagram ...........................................3-15

Figure 3-9 Input equivalent schematic ...................................................3-16

Figure 3-10 Output equivalent schematic ................................................3-18

Figure 3-11 Customer-supplied interlock ..................................................3-19

Figure 3-12 Customer-supplied interlock, negative voltage .....................3-19

Figure 3-13 PLC driven interlock signal ...................................................3-20

Figure 3-14 Multiple PLC driven inputs ...................................................3-20

Figure 3-15 Firestar output driving warning lamp ....................................3-21

Figure 3-16 Firestar output driving relay ...................................................3-21

Figure 3-17 Firestar output driving PLC input module ............................3-22

Figure 3-18 DB-9 connector pinouts ........................................................3-23

Figure 3-19 Internal fan speed control circuitry .......................................3-24

Figure 3-20 48 VDC fan connections .......................................................3-25

Figure 3-21 Alternate fan connections .....................................................3-25

Figure 3-22 Water-cooled Firestar ti60/ti100 package outline and

mounting dimensions ............................................................3-32

Synrad Firestar ti-Series operator’s manual

v

table of contents

List of Figures (cont.)

Figure 3-23 Fan-cooled Firestar ti60 package outline and

mounting dimensions ............................................................3-33

Figure 3-24 OEM air-cooled Firestar ti60 (SA model) package

outline and mounting dimensions, sheet 1 of 2 ...................3-34

Figure 3-25 OEM air-cooled Firestar ti60 (SA model) package

outline and mounting dimensions, sheet 2 of 2 ...................3-35

Figure 3-26 Firestar ti-Series packaging instructions ...............................3-36

Figure 4-1 Operational flowchart ............................................................4-7

Figure 4-2 Firestar ti-Series functional block diagram ............................4-8

vi

Synrad Firestar ti-Series operator’s manual

table of contents

List of Tables

Table 1 Class IV safety features ..........................................................9

Table 2 European Union Directives ...................................................10

Table 1-1 Ship kit contents ....................................................................1-4

Table 1-2 Dew point temperatures .........................................................1-10

Table 3-1 Assist gas purity specifications ...............................................3-4

Table 3-2 PWM Command signal levels ...............................................3-7

Table 3-3 User I/O pin descriptions .......................................................3-10

Table 3-4 Input circuit specifications .....................................................3-16

Table 3-5 Output circuit specifications ..................................................3-18

Table 3-6 Side-mounted DB-9 pin descriptions ....................................3-23

Table 3-7 Firestar ti60 general specifications .........................................3-28

Table 3-8 Firestar ti100 general specifications .......................................3-30

Table 4-1 Required cleaning materials ..................................................4-4

Table 4-2 Status signals ..........................................................................4-9

Table 4-3 Interlock Open condition ......................................................4-10

Table 4-4 Over Temperature condition .................................................4-10

Table 4-5 Shutter Open condition ........................................................4-10

Table 4-6 Laser error codes ....................................................................4-11

Synrad Firestar ti-Series operator’s manual

vii

Trademark/copyright information

SYNRAD, Firestar, and Power Wizard are registered trademarks of SYNRAD, Inc.

All other trademarks or registered trademarks are the property of their respective owners.

© 2009, 2010 by SYNRAD, Inc.
All rights reserved.

viii

Synrad Firestar ti-Series operator’s manual

Warranty information

This is to certify that Firestar® ti-Series lasers are guaranteed by SYNRAD, Inc. to be free of all defects in
materials and workmanship for a period of one year from the date of purchase. This warranty does not ap­ply to any defect caused by negligence, misuse (including environmental factors), accident, alteration, or
improper maintenance.

If, within one year from the date of purchase, any part of the Firestar ti-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 Firestar ti-Series laser fails within the first 45 days after purchase, SYNRAD, Inc. will pay all ship­ping charges to and from SYNRAD when shipped as specified by SYNRAD Customer Service. After the
first 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 efficient operation of your Firestar
ti-Series laser, only authorized SYNRAD replacement parts can be used. This warranty is void if any parts
other than those provided by SYNRAD, Inc. are used.

SYNRAD, Inc. and SYNRAD Authorized Distributors have the sole authority to make warranty state­ments regarding SYNRAD products. SYNRAD, Inc. 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, Inc. 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 Firestar ti-Series operator’s manual

ix

Contact information

Worldwide headquarters

SYNRAD’s worldwide headquarters are located north of Seattle in Mukilteo, Washington, U.S.A. Our
mailing address is: SYNRAD, Inc.
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]
E-mail: [e-mail]

Sales and Applications

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

Technical Support

SYNRAD’s 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 [e-mail] or to [e-mail].

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 SYNRAD’s web site at http://www.synrad.com.

European headquarters

SYNRAD’s European subsidiary, Excel Technology Europe GmbH, covers Austria, Germany, Italy, and
Switzerland. Contact Excel Technology at:

Excel Technology Europe GmbH
Münchner Strasse 2a
D-82152 Planegg
Germany

Phone: [phone]
Fax: [phone]
E-mail: [e-mail]

x

Synrad Firestar ti-Series operator’s manual

laser safety

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 IV laser equipment.

Terms

Certain terms are used throughout this manual or on the equipment labels. Please familiarize yourself with
their definitions and significance.

Imminent hazards which, if not avoided, will result in death or serious injury.

Danger:

Potential hazards which, if not avoided, could result in death or serious injury.

Warning:

Potential hazards or unsafe practices which, if not avoided, may result in minor or

Caution:

moderate injury.

Caution:

Points of particular interest for more efficient or convenient equipment operation;
additional information or explanation concerning the subject under discussion.

Note:

Potential hazards or unsafe practices which, if not avoided, may result in product
damage.

General hazards

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

Danger

serious

personal

injury

This Class IV laser product emits invisible infrared laser radiation in
the 10.6 µm CO2 wavelength band.

Do not allow laser radiation to enter the eye by viewing direct or re­flected laser energy. CO2 laser radiation can be reflected from metallic
objects even though the surface is darkened. Direct or diffuse laser
radiation can inflict severe corneal injuries leading to permanent eye
damage or blindness. All personnel must wear eye protection suitable
for 10.6 µm CO2 radiation when in the same area as an exposed laser
beam. Eyewear 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 reflections from
metallic surfaces.

Enclose the beam path whenever possible. Exposure to direct or dif­fuse CO2 laser radiation can seriously burn human or animal tissue,
which may cause permanent damage.

Synrad Firestar ti-Series operator’s manual

1

laser safety

Hazard information

Danger

serious

personal

injury

Warning

serious

personal

injury

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

U.S. customers should refer to and follow the laser safety precautions
described in the American National Standards Institute (ANSI)
Z136.1-2007 document, Safe Use of Lasers. Procedures listed in this
Standard include the appointment of a Laser Safety Officer (LSO),
operation of the product in an area of limited access by trained per­sonnel, servicing of equipment only by trained and authorized person­nel, and posting of signs warning of the potential hazards.

European customers should appoint a Laser Safety Officer (LSO) who
should refer to and follow the laser safety precautions described in
EN 60825-1, 2007—Safety of Laser Products.

Warning

serious

personal

injury

Warning

serious

personal

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, filtering, and venting should be carefully
considered. Review the following references for further information
on exposure criteria:

ANSI Z136.1-2007, 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 controls or adjustments or performance of procedures
other than those specified herein may result in hazardous radiation
exposure.

injury

2

Synrad Firestar ti-Series operator’s manual

laser safety

Hazard information

Firestar® ti-Series 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 specified throughout
this manual and exercise safe operating practices per ANSI Z136.1-2007 at all times when actively lasing.

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 heat source and will ignite most materials under the proper conditions. Never
operate the laser in the presence of flammable or explosive materials, gases, liquids, or vapors.

The use of controls or adjustments or performance of procedures other than those specified herein may re­sult in exposure to hazardous invisible laser radiation, damage to, or malfunction of the laser. Severe burns
will result from exposure to the laser beam.

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 reflectors which may create a serious hazard
outside the immediate work area.

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, Inc.
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/lasersafety.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.laserinstitute.org.

Synrad Firestar ti-Series operator’s manual

3

laser safety

INVISIBLE LASER RADIATION

AVOID EYE OR SKIN EXPOSURE TO

DIRECT OR SCATTERED RADIATION

CLASS 4 LASER PRODUCT

EN-60825-1, 2007

400 WATTS MAX

10200-10800 nm

Front

Bottom

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.

INVISIBLE LASER RADIATION
AVOID EYE OR SKIN EXPOSURE TO
DIRECT OR SCATTERED RADIATION

CLASS 4 LASER PRODUCT

AVOID EXPOSURE

Invisible laser radiation

is emitted from

this aperture.

AVOID EXPOSURE

Invisible laser radiation

is emitted from
this aperture.

EN-60825-1, 2007

400 WATTS MAX
10200-10800 nm

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.

CAUTION

CONDENSATION AND
WATER DAMAGE CAN

OCCUR IF COOLING WATER

IS BELOW DEW POINT.

SEE OPERATION MANUAL.

Water-Cooled Lasers Only

CAUTION

CONDENSATION AND

WATER DAMAGE CAN

OCCUR IF COOLING WATER

IS BELOW DEW POINT.

SEE OPERATION MANUAL.

Top

ti60 Fan-Cooled Model Shown

or

OEM version

Keyswitch version

MODEL #: FSTi60KFC
SERIAL #: i060234080181
TESTED AT: 48V MFG: July 21, 2009

Complies with IEC 60825-1 (2007) and 21 CFR 1040.10 except

for deviations pursuant to Laser Notice No. 50 dated June 24, 2007.

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

MODEL #: FSTi60SFC
SERIAL #: i060234080181
TESTED AT: 48V MFG: July 21, 2009

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

MODEL #: FSTi60KFC

SERIAL #: i060234080181

TESTED AT: 48V MFG: July 21, 2009

Complies with IEC 60825-1 (2007) and 21 CFR 1040.10 except

for deviations pursuant to Laser Notice No. 50 dated June 24, 2007.

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

Firestar ti60 label locations

Figure 1 Firestar ti60 hazard label and CE label locations

4

Synrad Firestar ti-Series operator’s manual

laser safety

INVISIBLE LASER RADIATION

AVOID EYE OR SKIN EXPOSURE TO
DIRECT OR SCATTERED RADIATION

CLASS 4 LASER PRODUCT

EN-60825-1, 2007

400 WATTS MAX

10200-10800 nm

Front

Bottom

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.

INVISIBLE LASER RADIATION
AVOID EYE OR SKIN EXPOSURE TO
DIRECT OR SCATTERED RADIATION

CLASS 4 LASER PRODUCT

AVOID EXPOSURE

Invisible laser radiation

is emitted from

this aperture.

AVOID EXPOSURE

Invisible laser radiation

is emitted from
this aperture.

EN-60825-1, 2007

400 WATTS MAX
10200-10800 nm

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.

CAUTION

CONDENSATION AND
WATER DAMAGE CAN

OCCUR IF COOLING WATER

IS BELOW DEW POINT.

SEE OPERATION MANUAL.

Water-Cooled Lasers Only

CAUTION

CONDENSATION AND

WATER DAMAGE CAN

OCCUR IF COOLING WATER

IS BELOW DEW POINT.

SEE OPERATION MANUAL.

Top

ti100 Water-Cooled Model Shown

or

OEM version

Keyswitch version

MODEL #: FSTi100KFB
SERIAL #: i100234080181
TESTED AT: 48V MFG: July 21, 2009

Complies with IEC 60825-1 (2007) and 21 CFR 1040.10 except

for deviations pursuant to Laser Notice No. 50 dated June 24, 2007.

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

MODEL #: FSTi100SFB
SERIAL #: i100234080181
TESTED AT: 48V MFG: July 21, 2009

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

MODEL #: FSTi100KFB

SERIAL #: i100234080181

TESTED AT: 48V MFG: July 21, 2009

Complies with IEC 60825-1 (2007) and 21 CFR 1040.10 except

for deviations pursuant to Laser Notice No. 50 dated June 24, 2007.

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

Firestar ti100 label locations

Figure 2 Firestar ti100 hazard label locations

Synrad Firestar ti-Series operator’s manual

5

laser safety

Agency compliance

The Agency compliance section includes subsections:

■ Center for Devices and Radiological Health (CDRH) requirements

■ Federal Communications Commission (FCC) requirements

■ European Union (EU) requirements

SYNRAD lasers are designed, tested, and certified 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, scientific, and medical
(ISM) equipment. The specific provisions to which systems containing Firestar ti-Series lasers must comply
are identified 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, Inc. 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 specified by 21 CFR, Part
1040 or EN 60825-1. SYNRAD, Inc. assumes no responsibility for the compliance of the system into
which OEM laser products are integrated.

Center for Devices and Radiological Health (CDRH) requirements

Note: Firestar ti-Series lasers are available in either Keyswitch or OEM versions.

Keyswitch models

Firestar ti-Series Keyswitch model lasers comply with requirements for Class IV laser products imposed
by the Radiation Control for Health and Safety Act of 1968. Under this Act, the U.S. Food and Drug
Administration (FDA) issued a performance standard in the Code of Federal Regulations (CFR) for laser
products. This performance standard, (21 CFR, Subchapter J, Part 1040.10) was developed to protect pub­lic health and safety by imposing requirements upon manufacturers of laser products to provide an indica­tion of the presence of laser radiation, to provide the user with certain means to control radiation, and to
assure that all personnel are adequately warned of potential hazards through the use of product labels and
instructions.

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

6

Synrad Firestar ti-Series operator’s manual

laser safety

Agency compliance

OEM models

Firestar ti-Series OEM lasers are OEM products intended for incorporation as components in laser process­ing systems. As supplied by SYNRAD, these lasers do not meet the requirements of 21 CFR, Subchapter J
without additional safeguards. In the U.S., the Buyer of these OEM laser components is solely responsible
for the assurance that the laser processing system sold to an end user complies with all laser safety require­ments before the actual sale of the system. 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 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. Table 1, Class IV safety
features, indicates which features are available on ti-Series lasers, the type and description of the feature,
and if the feature is required by CDRH regulations.

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 was to prevent harmful electromagnetic interference (EMI)
from affecting authorized radio communication services. The FCC regulations that govern industrial,
scientific, and medical (ISM) equipment are fully described in 47 CFR, Part 18, Subpart C.

SYNRAD’s Firestar ti60 lasers have been tested and found to comply by demonstrating performance char­acteristics that have met or exceeded the requirements of 47 CFR, Part 18.

Firestar ti100 lasers are not yet fully tested to the requirements of 47 CFR, Part 18, Conducted and Radi­ated Emissions.

FCC information to the user

NOTE: The following FCC information to the user is provided to comply with the requirements of 47
CFR, Part 18, Section 213.

Interference Potential

In our testing, SYNRAD, Inc. has not discovered any significant electrical interference trace­able to Firestar ti-Series lasers.

System Maintenance

Ensure that all exterior covers are properly fastened in position.

Measures to Correct Interference

If you suspect that your Firestar laser interferes with other equipment, take the following steps
to minimize this interference:

1

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

lems.

2

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

equipment or system it is connected to.

Synrad Firestar ti-Series operator’s manual

7

laser safety

Agency compliance

FCC caution to the user

The Federal Communications Commission warns the user that changes or modifications of the unit not
expressly approved by the party responsible for compliance could void the user’s authority to operate the
equipment.

European Union (EU) requirements

Note: Firestar ti-Series lasers are available in either Keyswitch or OEM versions.

RoHS compliance

SYNRAD Firestar ti-Series lasers meet the requirements of the European Parliament and Council Direc­tive 2002/95/EC on the Restriction of the Use of Certain Hazardous Substances in Electrical and Elec­tronic Equipment, as amended by Decision 2005/618/EC establishing maximum concentration values for
certain hazardous substances in electrical and electronic equipment.

Laser safety standards

Under the Low Voltage Directive, 2006/95/EC, the European Norm (EN) document EN 60825-1 was de­veloped to protect persons from laser radiation by imposing requirements upon manufacturers of laser prod­ucts to provide an indication of laser radiation; to classify laser products according to the degree of hazard;
to require both user and manufacturer to establish procedures so that proper precautions are adopted; to
ensure adequate warning of the hazards associated with accessible radiation through signs, labels, and
instructions; to improve control of laser radiation through protective features; and to provide safe usage of
laser products by specifying user control measures.

Keyswitch models

Firestar ti-Series Keyswitch models are designed to comply with the requirements imposed by
EN 60825-1 for Class IV laser products. Table 1, Class IV safety features, summarizes ti-Series
product features, indicating the type and description of features and whether those features are
required by European Union regulations.

OEM models

Firestar ti-Series OEM lasers are OEM products intended for incorporation as components in
laser processing systems. As supplied by SYNRAD, these lasers do not meet the requirements
of EN 60825-1 without additional safeguards. European Union Directives state that “OEM
laser products which are sold to other manufacturers for use as components of any system for
subsequent sale are not subject to this Standard, since the final product will itself be subject
to the Standard.” 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 60204-1, Safety of Machinery; the Machinery Directive EN 98/37/EC; and/or
any other applicable Standards. 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 IV safety features, indicates which features
are available on ti-Series lasers, the type and description of the feature, and if the feature is
required by CDRH regulations.

8

Synrad Firestar ti-Series operator’s manual

laser safety

Agency compliance

Table 1 Class IV safety features

Required by:
Feature Location/Description CDRH EN60825-1

Keyswitch1 Rear panel control Yes Yes

On/Off Keyswitch controls power to laser electronics. Key can not

be removed from switch in the “On” position.

Shutter Laser control Yes Yes
function1 Functions as a beam attenuator to disable RF driver/laser output

when closed.

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

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

Lase (LASE) Rear panel indicator (Red) Yes Yes
indicator Indicates that Firestar is actively lasing. Lase LED illuminates when

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

Five second Firestar circuit element Yes No
delay Disables RF driver/laser output for five seconds after Keyswitch is

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

Power fail Firestar circuit element Yes Yes
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
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
Interlock (INT) Illuminates green when Remote Interlock circuitry is closed.
indicator Illuminates red when interlock circuitry is open.

Over Firestar circuit element No No
temperature Over temperature shutdown occurs if temperature of the
protection laser tube rises above safe operating limits.

Temp (TMP) Rear panel indicator (Green/Red) No No
indicator Illuminates green when laser temperature is within operating limits,
changing to red when thermal limits are exceeded.

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

warn personnel of potential laser hazards.

1 Keyswitch versions only

Synrad Firestar ti-Series operator’s manual

9

laser safety

Agency compliance

Electromagnetic interference standards

The European Union’s Electromagnetic Compatibility (EMC) Directive, 2004/108/EC, 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 define the emission and immunity standards
for specific product categories. For Firestar ti-Series lasers, EN 55011 and CISPR:11 define radiated and
conducted RF emission limits while the generic Standards EN 61326 and EN 50082-1 define immunity
requirements published by the International Electromechanical Commission (IEC).

SYNRAD’s Firestar ti60 lasers have been tested and found to comply by demonstrating performance char­acteristics that have met or exceeded the requirements of EMC Directive 2004/108/EC.

Firestar ti100 lasers are not yet fully tested to the requirements of EMC Directive 2004/108/EC.

When integrating SYNRAD’s Firestar ti-Series OEM lasers, the Buyer and/or integrator of the end system
is responsible for meeting all applicable Standards to obtain the CE mark. To aid this compliance process,
SYNRAD’s testing program has demonstrated that Firestar ti-Series lasers comply with the relevant re­quirements of 2004/108/EC, the Electromagnetic Compatibility Directive, as summarized in Table 2 below.

Table 2 European Union Directives

Applicable Standards / Norms

2004/108/EC Electromagnetic Compatibility Directive

2006/95/EC Low Voltage Directive

2002/95/EC RoHS Directive (amended 2005/618/EC)

EN 60825-1:2007 Safety of Laser Products (Keyswitch models only)

EN 61010-1:2001 Safety Requirements for Electrical Equipment for Measurement,
Control, and Laboratory Use - Part 1 : General Requirements

CISPR 11:2003-03 Conducted and Radiated Emissions Group 1, Class A

EN 61000-4-2:1995+A1:1998+A2:2001 Electrostatic Discharge Immunity

EN 61000-4-3:2002+A1:2002 RF Electromagnetic Fields Immunity

EN 61000-4-4:1995+A1:2001+A2:2001 Electrical Fast Transient/Burst Immunity

EN 61000-4-6:1996+A1:2001 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 official compliance mark of the European Union as shown in Figure 3 and a Declaration
of Conformity is provided for the compliant component.

Figure 3 European compliance mark

10

Synrad Firestar ti-Series operator’s manual

laser safety

Declaration of Conformity

Declaration of Conformity

in accordance with ISO / IEC 17050-2:2004

We,

Manufacturer’s Name: SYNRAD, Inc.

Manufacturer’s Address: 4600 Campus Place

Mukilteo, WA 98275
U.S.A.

hereby declare under our sole responsibility that the following equipment:

Product Name: Firestar ti60 Laser

Model Number: FSTi60KxC (Keyswitch)

FSTi60SxC (OEM

conforms to the following Directive(s) and Standard(s):

Applicable Directive(s): 2004/108/EC Electromagnetic Compatibility Directive
2002/95/EC RoHS Directive (amended by 2005/618/EC)

Applicable Standard(s): EN 61010-1:2001 Safety Requirements for Electrical Equipment
for Measurement, Control, and Laboratory
Use - Part 1: General Requirements

EN 60825-1:2007 Safety of Laser Products (Keyswitch only)

CISPR 11:2003-03 Conducted and Radiated Emissions
Group 1, Class A

EN 61000-4-2:1995
+A1:1998 +A2:2001 Electrostatic Discharge Immunity

EN 61000-4-3:2002
+A1:2002 RF Electromagnetic Fields Immunity

EN 61000-4-4:1995
+A1:2001 +A2:2001 Electrical Fast Transient/Burst Immunity

EN 61000-4-6:1996
+A1:2001 Conducted RF Disturbances Immunity

*

OEM lasers do not comply with EN 60825-1:2007, 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:

Dave Clarke, President of SYNRAD, Inc.

Dated 07 July 2009

Synrad Firestar ti-Series operator’s manual

Excel Technology Europe GmbH
Münchner Strasse 2a
D-82152 Planegg
Germany

11

laser safety

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12

Synrad Firestar ti-Series operator’s manual

getting started

Use information in this chapter to prepare your Firestar ti-Series 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 Firestar ti-Series lasers, lists important features, and de-

scribes Firestar nomenclature.

■Unpacking – provides important information about shipping your ti-Series laser.

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

■Mounting – describes how to attach the ti-Series laser to a mounting surface.

■Connecting – explains how to connect power and control cables to the laser.

1

Synrad Firestar ti-Series operator’s manual

11

getting started

Introduction

Firestar® ti-Series lasers are part of a new series of small-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 supply
or cables, our compact ti-Series lasers mount easily to flatbed cutters, robotic arms, or gantry systems mak­ing integration into your production line simple and fast.

Firestar ti-Series features include:

■Compact resonator design

■Fully integrated RF power supply

■Excellent pulsing characteristics

■ Fast rise/fall times (< 75 µs)

■Built-in “tickle” generator

■Color-coded LEDs mirror user outputs

■“Industrial-strength” ±5–24 VDC inputs and outputs

■Keyswitch fan- or water-cooled models available

■OEM (no Keyswitch/no shutter) air-, fan-, or water-cooled models available

Firestar nomenclature

Firestar ti-Series lasers are divided into two distinct functional categories: Keyswitch and OEM models. In
addition to a manual Keyswitch, all Keyswitch-equipped lasers include a manual shutter switch that allows
the laser output aperture to be blocked. OEM lasers do not incorporate either a manual keyswitch or shut­ter assembly since they 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 IV laser systems.

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 either a “K” for Keyswitch or “S”
(Switch-less) for OEM models. The next letter indicates the cooling method: “W” for water-cooled units,
“F” for fan-cooled units, and “A” for air-cooled lasers (where the customer must provide the proper cooling
via fans or blowers). The last letter in the model number indicates the current model version beginning
with “B”. For example, the model number FSTI100SFB designates that particular Firestar ti100 laser as an
OEM, fan-cooled model. FSTI60SAC indicates an OEM, air-cooled ti60 laser.

12

Synrad Firestar ti-Series operator’s manual

getting started

Unpacking

The Unpacking section includes subsections:

■ Incoming inspection

■ Packaging guidelines

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, Inc.

The shipping carrier is responsible for any damage occurring during transportation from SYNRAD, Inc. to
your receiving dock.

Packaging guidelines

■ 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 fittings; lift the laser by the mounting feet or base-

plate 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, fittings, etc.

■ Refer to the Firestar ti-Series packaging instructions drawing in the Technical Reference chapter for

details on packaging the laser using SYNRAD-supplied shipping materials.

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

open fittings to prevent debris from entering the coolant path.

Synrad Firestar ti-Series operator’s manual

13

getting started

Mounting Bolts
and Fuse

Firestar ti-Series Laser
(ti60 air-cooled version shown)

Firestar ti-Series
Operator's Manual

Firestar

ti-Series

Operator’s

Manual

Cooling Tubing
(water-cooled only)

Quick Start Plug

Inventory

Figure 1-1 Firestar ti-Series shipping box contents

Table 1-1 lists items included in the Firestar ti-Series ship kit.

Table 1-1 Ship kit contents

Shipping Box Contents Qty Shipping Box Contents Qty

SYNRAD Firestar ti-Series Laser ...............1 Mounting Bolts ........................................... 3

Firestar ti-Series Operator’s Manual ........... 1 Spare Fuse ................................................... 2

Quick Start Plug (except SA models) ........ 1 Final Test Report (not shown) ................... 1

Cooling Tubing (water-cooled only) .......... 1

14

Synrad Firestar ti-Series operator’s manual

getting started

Inventory

Contents description

Each item listed in Table 1-1 is described below.

SYNRAD Firestar ti-Series Laser – for cutting, welding, drilling, and marking a wide variety of products
and materials.

Firestar ti-Series Operator’s Manual – provides setup, operation, and maintenance information for your
Firestar ti-Series laser.

Quick Start Plug (except SA models) – connects to Firestar’s User I/O connector. Jumpers are built into
the plug to enable Firestar’s shutter and remote interlock circuits for initial start-up and testing.

Cooling Tubing (water-cooled only) – 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 – 1/4–20 × 5/8" UNC bolts fasten Firestar to your mounting surface.

Spare Fuse – fast-acting mini ATO-type fuse protects Firestar’s internal circuitry.

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

Synrad Firestar ti-Series operator’s manual

15

getting started

INVISIBLE LASER RADIATION

AVOID EYE OR SKIN EXPOSURE TO

DIRECT OR SCATTERED RADIATION

CLASS 4 LASER PRODUCT

EN-60825-1, 2007

400 WATTS MAX

10200-10800 nm

MODEL #: FSTI60SAB

SERIAL #: TI60234080181

TESTED AT: 48V MFG: January 21, 2009

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

A

A

B

Top View

(ti60 Air-Cooled Model)

Mounting

The Mounting section includes subsections:

■ Fasten from above

■ Fasten from below

Firestar’s base plate is designed so that the laser is easily mounted to either vertical or horizontal surfaces
using only three fasteners. Three ball bearing “feet” pressed into Firestar’s base plate eliminate any possible
distortion of the laser tube caused by variations in the flatness of the surface on which the laser is mount­ed. Refer to the Firestar ti-Series package outline drawings in the Technical Reference chapter for laser
mounting locations and dimensions. Read through the mounting sections below to determine which set of
mounting holes are required for your application. When mounting Firestar ti-Series lasers, you can choose
to fasten from above, into your mounting surface, or from below, into the laser’s base plate.

Note: For proper airflow, air- or fan-cooled units must have at least 2.25" (57.2 mm) of unobstructed

clearance between the outside edge of the cooling fan and any enclosure or mounting surface.

Caution

SYNRAD does not recommend mounting lasers in a vertical “head­down” or “tail-down” orientation. If you must mount your laser in

possible

equipment

this manner, please contact the factory for limitations as a vertical
orientation increases the risk of damage to the laser’s output optic.

damage

Fasten from above

To fasten your Firestar ti-Series 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

1/4–20 UNC holes into your mounting surface. These hole locations should correspond to the two
slots labeled “A” and the thru hole labeled “B” shown in Figure 1-2.

Figure 1-2 Fasten from above

16

Synrad Firestar ti-Series operator’s manual

getting started

INVISIBLE LASER RADIATION

AVOID EYE OR SKIN EXPOSURE TO

DIRECT OR SCATTERED RADIATION

CLASS 4 LASER PRODUCT

EN-60825-1, 1993

400 WATTS MAX

10200-10800 nm

MODEL #: FSTI60SAB

SERIAL #: TI60234080181

TESTED AT: 48V MFG: January 21, 2009

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

C

C

C

Top View

(ti60 Air-Cooled Model)

Mounting

2

Place Firestar on the mounting surface so that slots “A” and hole “B” on the base plate line up with

the tapped holes in the mounting surface.

3

Insert 1/4–20 × 5/8" UNC capscrews through Firestar’s base plate into the threaded holes of the

mounting surface. Turn the screws by hand until the threads engage.

4

Tighten all three capscrews to a torque of 5 ft lbf (7 N m). Do not exceed a torque of 6 ft lbf (8 N m)

as the base plate may be damaged.

Fasten from below

To fasten your Firestar ti-Series 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 0.261"

(6.6 mm) diameter holes into your mounting surface. Hole locations should correspond to the
threaded holes labeled “C” shown in Figure 1-3.

Figure 1-3 Fasten from below

2

Place Firestar on the mounting surface so that the threaded holes on the base plate (labeled “C” in

Figure 1-3) line up with the 0.261" (6.6 mm) holes drilled through the mounting surface.

3

Insert 1/4–20 × 5/8" UNC capscrews through the mounting surface into the threaded holes of

Firestar’s base plate. Turn the screws by hand until the threads engage.

4

Tighten all three capscrews to a torque of 5 ft lbf (7 N m). Do not exceed a torque of 6 ft lbf (8 N m)

as the base plate may be damaged.

Synrad Firestar ti-Series operator’s manual

17

getting started

Connecting

The Connecting section includes subsections:

■ Water-cooled connections

■ OEM air-cooled connections

■ Electrical connections

■ Control connections

Note: If your laser is fan-cooled, then skip to the Electrical connections section. For air-cooled lasers, go to

the ti60 air-cooled connections section.

Water-cooled 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. Carefully trim any burrs if the cut is “ragged”.

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

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

■Never allow the tubing to kink, since kinking severely restricts coolant flow.

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

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

■If tubing must be disconnected from a fitting, first push and hold the tubing slightly into the fitting.

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

■After disconnecting tubing from a fitting, trim 1/2" (57.2 mm) from its end before reconnecting. Trim-

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

Laser cooling fittings

If your integrated laser application uses metric cooling tubing, we recommend the installation of tubing
adaptors to convert the laser’s WATER IN and WATER OUT fittings from 1/2-inch tubing to 12-mm met-
ric tubing. These tubing adaptors are available from many tubing and fitting manufacturers.

If, for any reason, you must remove and then reinstall the threaded WATER IN and WATER OUT cooling
fittings on the laser, do not overtighten them. When installing new fittings, wrap the threads with teflon
tape and then carefully tighten the fittings until they are just snug enough to prevent water leakage.

18

Synrad Firestar ti-Series operator’s manual

getting started

Connecting

Chiller preparation guidelines

■You must provide fittings to adapt the laser’s 1/2-inch O.D. polyethylene cooling tubing to your

chiller’s Inlet and Outlet ports. These fittings can be “quick disconnect” or compression type fittings.

■Because Firestar’s cooling tubing is specified in inch sizes, the use of metric tubing fittings is discour-

aged unless you have installed the appropriate inch-to-metric tubing adaptors. Using metric fittings on
inch size tubing will lead to coolant leaks or may allow the pressurized tubing to blow-off the fitting.

Coolants

SYNRAD recommends that the laser’s cooling fluid contain at least 90% water (distilled or tap) by vol­ume. In closed-loop systems, use a corrosion inhibitor/algaecide such as Optishield® Plus or equivalent.
Avoid glycol-based additives because they reduce the coolant’s heat capacity and high concentrations may
affect power stability. For SYNRAD lasers, the minimum coolant setpoint is 18 °C (64 °F) so glycol is not
necessary unless the chiller is subjected to freezing temperatures. In applications where biocides containing
chlorides are used, concentrations should not exceed 25 parts per million (PPM). Maintain a coolant pH
level above 7.0. We recommend the installation of a filter on the chiller’s return line, especially in areas
where water hardness is a problem. Firestar ti-Series lasers incorporate the following wetted materials in
the coolant path—aluminum, brass, copper, Delrin®, PBT, polyethylene, stainless steel, and Viton®.

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 flow 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 specified 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.

■ Stop coolant flow when the laser is shut down.

■ Increase coolant flow by an additional 1.0 GPM. Do not exceed a coolant pressure of 60 PSI.

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

■ Install a dehumidifier to reduce the humidity of the enclosure containing the laser.

■ Refer to Table 1-2 and gradually increase coolant temperature until it is above the dew point tempera-

ture and condensation disappears. Do not exceed a coolant temperature of 30 °C (86 °F).

Note: Water-cooled ti-Series lasers can be operated at coolant temperatures up to 30 °C to reduce prob-

lems associated with condensation; however, this may result in decreased laser performance and/
or reduced laser lifetime.

Table 1-2 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 shown in the
chart; however, for best results and performance, use a coolant temperature in the range of 18–22 °C
(64–72 °F).

Synrad Firestar ti-Series operator’s manual

19

getting started

Connecting

Caution

possible

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

equipment

damage

Table 1-2 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 Table 1-2, look down the Air Temp column and locate an air temperature in Fahrenheit or Cel-
sius (°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 tempera-
ture. 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.

110

Synrad Firestar ti-Series operator’s manual

getting started

OUTLET

INLET

Chiller

Connecting

Cooling tubing connections

The following procedure will guide you in configuring the most efficient cooling system. Please connect
your system exactly as described below.

To connect cooling tubing to your ti-Series laser, refer to Figure 1-4 and perform the following steps:

Figure 1-4 Firestar ti-Series cooling connections

1

Cut and connect a length of tubing to fit between the chiller’s Outlet port and the upper WATER IN

port on the rear of the Firestar ti-Series laser.

2

Cut and connect a length of tubing to fit between the lower WATER OUT port on the rear of the

laser and the chiller’s Inlet port.

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

3

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

1.0–2.0 GPM (ti60) or 1.5–2.0 GPM (ti100) at less than 60 PSI (4.14 bar) of pressure.

4

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

Caution

possible

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

equipment

damage

Synrad Firestar ti-Series operator’s manual

111

getting started

Mount cooling fans so they are centered horizontally

and vertically on each side of the OEM ti60 laser

Connecting

ti60 air-cooled connections

OEM air-cooled ti60 lasers are shipped without cooling fans so customers must provide some type of air
cooling to prevent the laser from overheating. For ti60 lasers, SYNRAD recommends an airflow of at least
150 cubic feet per minute (CFM) for each of the two required fans.

Figure 1-5 illustrates the fan placement necessary to keep the ti60 heat sink temperatures below 50 °C
(122 °F). To provide proper airflow, cooling fans should have a diameter of approximately 4.5–5 inches
(114–127 mm) and have at least 2.25" (57.2 mm) of unobstructed clearance between the outside edge of
the fan housing and any mounting surface or enclosure.

(SA models)

Figure 1-5 Recommended ti60 cooling fan locations

A +48 VDC output to power customer-supplied cooling fans is available from the SA model’s side-mount­ed DB-9 connector. Internal circuitry allows the laser to control fan speed based on the laser’s output
power and chassis temperature. Refer to DB-9 connections in the Technical Reference chapter for details.

112

Synrad Firestar ti-Series operator’s manual

getting started

AC Line (Black/Brown) to ‘L’

AC Neutral (White/Blue) to ‘N’

AC Ground (Green)

Front View

Black (ground) wire from laser
to (–) Negative post

Red (power) wire
from laser to (

+)

Positive post

Rear View

Connecting

Electrical connections

The following procedures describe how to complete electrical connections to ti-Series lasers. Firestar ti­Series DC power cables are manufactured from #10 AWG wire and measure 1 meter (42 inches) in length.

DC power supply

Note: The negative (–) side of the DC input to the laser is internally connected so that the laser chas-

sis 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 film in order to electrically isolate the laser when other equipment is grounded to the

laser’s DC power supply.

Caution

possible

equipment

Do not reverse polarity when connecting DC power cables to your
DC power source. Reversed DC polarity will damage the ti-Series’s
internal RF and control board circuitry. Carefully follow the direc­tions below to ensure that DC cable leads are properly connected to
the correct DC output terminals.

damage

Firestar ti60 lasers require a DC power supply capable of supplying 48 VDC at 18 A minimum while
Firestar ti100 lasers require a 48 VDC at 35 A minimum. We recommend the SYNRAD DC-48 DC power
supply, which can provide a maximum of 40 A at 48 VDC. AC input requirements for the DC-48 supply
are 180–264 VAC, single-phase (1Ø), 9.3 A max (@ 230 VAC), 47–63 Hz. To connect the DC- 48 supply,
refer to Figure 1-6 and perform the following steps:

Figure 1-6 DC-48 DC power supply

1

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

2

Locate the 48 VDC output terminals on the power supply’s output section and connect the black (–)

DC power cable from the laser to the negative (–) output terminal.

3

Connect the red (+) DC power cable from the laser to the positive (+) 48 VDC output terminal.

Synrad Firestar ti-Series operator’s manual

113

getting started

Connecting

Note: Because AC input connections and requirements vary from facility to facility, customers must

provide the AC power cable or wiring.

4

On the front of the DC-48 power supply, connect the neutral AC wire, typically white, to the AC

neutral input terminal labeled “N”.

5

Connect the hot AC wire, typically black, to the AC input line terminal labeled “L”.

6

Connect the ground wire, typically green, to the input terminal labeled with the ground symbol.

Control connections

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

Warning

serious

personal

Always use shielded cable when connecting your PWM Command
signal source to PWM Input/PWM Return inputs. In electrically­noisy environments, long lengths of unshielded wire act like an
antenna and may generate enough voltage to trigger uncommanded
lasing.

injury

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 following steps:

1

Remove DC power from the laser.

2

Locate the Quick Start Plug in the ship kit.

Note: The Quick Start Plug is not included with SA models, but may be ordered separately.

3

Connect the Quick Start Plug to the User I/O connector on the rear of the 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 wall plug transformer cable.

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.

114

Synrad Firestar ti-Series operator’s manual

getting started

Connecting

Note: Firestar ti-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
specifications and connection details.

Quick Start Plug

Note: The Quick Start Plug is not included with SA models, but may be ordered separately.

Caution

possible

equipment

Turn off 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.

damage

In order for your Firestar ti-Series 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 fire.

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.

Caution

possible

personal

injury

The Quick Start Plug is intended solely for initial start-up and testing
of the laser. Because this plug jumpers Remote Interlock and Shutter
Open Request signals, the laser will fire 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.

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 Firestar’s keyswitch, shutter, and
remote interlock functions with automated control systems. Figure 3-8, Quick Start Plug wiring diagram, in
the Technical Reference chapter shows the Quick Start Plug wiring diagram.

Synrad Firestar ti-Series operator’s manual

115

getting started

This page intentionally left blank.

116

Synrad Firestar ti-Series operator’s manual

operation

Use information in this chapter to familiarize yourself with Firestar’s controls and indica­tors and to begin operating the laser.

This chapter contains the following information:

2

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

Firestar ti-Series lasers.

■ Initial start-up – explains how to start your Firestar ti-Series laser while verifying

proper operation.

Synrad Firestar ti-Series operator’s manual

21

operation

(Fan-Cooled ti60 Shown)

AVOID EXPOSURE

Invisible laser radiation

is emitted from

this aperture.

2

5

3

4

1

Controls and indicators

The Controls and indicators section includes subsections:

■ ti-Series front panel

■ ti-Series rear panel

■ OEM ti60 side panel (SA models)

ti-Series front panel

Figure 2-1 ti-Series front panel controls and indicators

1

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

self-adhesive label before applying power to the laser.

2

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

3

DP POWER Connector (except SA models) – provides a convenient +5 VDC, 50 mA receptacle to

power a visible red diode pointer (available from SYNRAD as an optional accessory).

4

Shutter Switch (Keyswitch models only) – activates a mechanical shutter that opens or closes the

laser aperture. Closing the shutter also interrupts RF power to the laser. There is a five-second delay
imposed from the time the shutter is opened to the time that PWM signals are accepted.

5

Optical Accessories Mounting – provides six threaded holes (8–32 UNC) for mounting optional

beam delivery components Because excessive weight may damage the laser, consult SYNRAD before
mounting components not specifically designed as Firestar options. Refer to Firestar ti-Series package
outline drawings in the Technical Reference chapter for mounting hole dimensions.

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

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

22 Synrad Firestar ti-Series operator’s manual

operation

ON

USER I/O

INT

TMP RDY SHT LASE

(Fan-Cooled ti60 Shown)

1

2

4

5

3

6

8

7

9

10

OFF

Controls and indicators

ti-Series rear panel

Figure 2-2 ti-Series rear panel controls and indicators

1

DC Power Cables – receives +48 VDC from the DC power supply. Firestar ti-Series DC power cables

are manufactured from #10 AWG wire and measure 1 meter (42 inches) in length.

2

INT (Remote Interlock) Indicator – illuminates green to indicate that a remote interlock circuit is

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

3

TMP (Temperature) Indicator – illuminates green to indicate that laser temperature is within limits

and that lasing may be enabled. The TMP indicator is red and lasing is disabled if the laser’s tem­perature rises above safe operating limits.

4

RDY (Ready) Indicator – illuminates yellow when the laser is enabled, indicating that, after a five-

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

5

SHT (Shutter) Indicator – illuminates blue to indicate that a Shutter Open Request signal is con-

nected to the User I/O port and lasing may be enabled. When a Shutter Open Request signal is
applied, there is a five-second delay until PWM inputs are recognized.

6

LASE Indicator – illuminates red to indicate that the laser is actively lasing. The LASE indicator is

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

7

Keyswitch (Keyswitch models only) – enables/disables operation of the laser. Firestar is enabled when

the Keyswitch is turned to the ON position. Turn the Keyswitch OFF to disable lasing.

8

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.

9

WATER IN Port (water-cooled models only) – labeled IN, this connection provides the cooling

10

water inlet to Firestar’s water-cooling system.

WATER OUT Port (water-cooled models only) – labeled OUT, this connection provides the cooling

water outlet from Firestar’s water-cooling system.

Synrad Firestar ti-Series operator’s manual

23

operation

(Air-Cooled ti60 OEM Shown)

1

Controls and indicators

OEM ti60 side panel

Figure 2-3 OEM ti60 side panel controls and indicators

1

DB-9 connector – provides an auxiliary +5 V power source as well as +48 VDC for powering 48 V

cooling fans. The +5 VDC output is protected by a 0.5 A self-resetting fuse while both +48 VDC
outputs are sourced directly from the user’s 48 V DC power supply and protected by internal 1.1 A
self-resetting fuses. Refer to DB-9 connections in the Technical Reference chapter for pinouts and
signal descriptions.

(SA models)

24 Synrad Firestar ti-Series operator’s manual

operation

The Initial start-up section includes subsections:

■ With a UC-2000 Controller

■ Without a UC-2000 Controller

Initial start-up

Warning

serious

personal

injury

Caution

possible

equipment

damage

On Firestar ti-Series OEM lasers, remote interlock (INT) faults are
not latched. Clearing the fault condition re-enables the RDY indica­tor and the laser will fire after the five-second delay provided that the
SHT indicator is lit and a PWM Command signal is applied. Because
exposure to 10.6 µm CO2 laser radiation can inflict 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.

Because of their smaller beam diameter, Firestar lasers have signifi­cantly higher power densities than previous SYNRAD lasers. This
means that even small amounts of contaminants 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 filtered air or nitrogen to prevent
vapor and debris from accumulating on optical surfaces.

With a UC-2000 Controller

Before your Firestar® laser is put into service for the first time, its functionality should be verified. 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.

Danger

serious

personal

injury

Synrad Firestar ti-Series operator’s manual

This Class IV laser product emits invisible infrared laser radiation in
the 10.6 µm CO2 wavelength band. Since direct or diffuse laser radia­tion can inflict 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.

25

operation

Initial start-up

Note: When performing the initial start-up sequence, you must first 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 24 inches (61 cm) from the laser aperture to prevent the beam from traveling

beyond the work area.

4

On water-cooled systems, turn on the chiller (set between 18–22 °C) and verify that it is delivering

1.0–2.0 GPM (ti60) or 1.5–2.0 GPM (ti100) at less than 60 PSI of pressure.

Caution

possible

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

equipment

damage

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

Laser Controller Operator’s Manual for setup and operation instructions before continuing.

5

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 Off.

6

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

7

Turn on the DC power supply.

If the Quick Start Plug is installed, the INT (Remote Interlock) indicator will illuminate green and
the SHT (Shutter) indicator will illuminate blue—if the manual Shutter Switch is Open. The TMP
(Temperature) indicator will illuminate green if laser temperature is within safe operating limits.

Note: On a cold start, allow for five to ten seconds of tickle before sending PWM Command signals to

the laser.

Starting your Firestar ti-Series laser

Note: Firestar RDY and SHT LEDs denote separate control functions. Although the RDY lamp may

light while the SHT LED is Off (Shutter Switch Closed or Shutter Open Request signal missing),
no power is applied to the RF boards until both RDY and SHT indicators are illuminated.

1

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

2

Place the Shutter Switch (if equipped) in the Open position. The blue SHT (Shutter) indicator on

the laser’s rear panel will illuminate.

26 Synrad Firestar ti-Series operator’s manual

operation

Initial start-up

3

Rotate the Keyswitch (if equipped) to the ON position. Verify that the RDY (Ready) indicator on the

laser’s rear panel is illuminated.

Note: Each time an OEM laser is powered up or a keyswitch version is cycled OFF/ON, a five-second

delay occurs between the time that RDY and/or SHT indicators illuminate and Firestar is permit­ted to lase.

Warning

serious

personal

Because of phase differences, external tickle pulses may combine
with the internally-generated tickle signal causing the LASE LED to
flicker during the transition from tickle to lasing. Laser output may
occur if the LASE LED flickers.

injury

Note: For remote keyswitch operation (keyswitch versions), you can set the Keyswitch to the ON posi-

tion and use the Remote Reset/Start Request input (on the User I/O connector) as a remote
keyswitch similar to other SYNRAD laser models.

4

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

5

Use the UC-2000’s PWM Adj Knob to slowly increase power. The laser’s LASE indicator illuminates

red when PWM signal pulses are long enough to produce laser output (typically 3–6 µs at 5 kHz).
The spot where the beam hits the beam block increases in brightness, to indicate increased power
output.

6

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

laser should turn off.

7

Place Firestar’s Shutter Switch (if equipped) in the Closed position.

8

On water-cooled lasers, shut off the chiller or otherwise stop coolant flow through the laser.

Caution

possible

equipment

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

damage

If your Firestar ti-Series laser fails to lase, refer to Troubleshooting in the Maintenance/Troubleshooting
chapter for troubleshooting information.

Synrad Firestar ti-Series operator’s manual

27

operation

Initial start-up

Without a UC-2000 Controller

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

Danger

serious

personal

injury

Note: When performing the initial start-up sequence, you must first 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.

This Class IV laser product emits invisible infrared laser radiation in
the 10.6 µm CO2 wavelength band. Since direct or diffuse laser radia­tion can inflict 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.

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 24 inches (61 cm) from the laser aperture to prevent the beam from traveling
beyond the work area.

4

On water-cooled systems, turn on the chiller (set between 18–22 °C) and verify that it is delivering

1.0–2.0 GPM (ti60) or 1.5–2.0 GPM (ti100) at less than 60 PSI of pressure.

Caution

possible

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

equipment

damage

5

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

tor and connect the ground or return of the Controller to PWM Return (Pin 1).

6

Set your PWM Controller to a frequency of 5 kHz @ +5 VDC and ensure that the Controller’s duty

cycle is set to zero percent output (0.0%).

7

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

28 Synrad Firestar ti-Series operator’s manual

operation

Initial start-up

8

Turn on the DC power supply.

If the Quick Start Plug is installed, the INT (Remote Interlock) indicator will illuminate green and
the SHT (Shutter) indicator will illuminate blue—if the manual Shutter Switch is Open. The TMP
(Temperature) indicator will illuminate green if laser temperature is within safe operating limits.

Note: On a cold start, allow for five to ten seconds of tickle before sending PWM Command signals to

the laser.

Starting your Firestar ti-Series laser

Note: Firestar RDY and SHT LEDs denote separate control functions. Although the RDY lamp may

light while the SHT LED is Off (Shutter Switch Closed or Shutter Open Request signal missing),
no power is applied to the RF boards until both RDY and SHT indicators are illuminated.

1

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

2

Place the Shutter Switch (if equipped) in the Open position. The blue SHT (Shutter) indicator on

the laser’s rear panel will illuminate.

3

Rotate the Keyswitch (if equipped) to the ON position. Verify that the RDY (Ready) indicator on the

laser’s rear panel is illuminated.

Note: Each time an OEM laser is powered up or a keyswitch version is cycled OFF/ON, a five-second

delay occurs between the time that RDY and/or SHT indicators illuminate and Firestar is permit­ted to lase.

Warning

serious

personal

Because of phase differences, external tickle pulses may combine
with the internally-generated tickle signal causing the LASE LED to
flicker during the transition from tickle to lasing. Laser output may
occur if the LASE LED flickers.

injury

Note: For remote keyswitch operation (keyswitch versions), you can set the Keyswitch to the ON posi-

tion and use the Remote Reset/Start Request input (on the User I/O connector) as a remote
keyswitch similar to other SYNRAD laser models.

4

Using your PWM Controller, slowly increase the duty cycle of the square wave. The LASE indicator

illuminates red when PWM pulses are long enough to produce laser output (typically between 3–6 µs
at 5 kHz). The spot where the beam hits the beam block increases in brightness, indicating increased
power output.

5

Remove the PWM Command signal from the User I/O connector. The LASE indicator on the laser

should turn off.

6

Place Firestar’s Shutter Switch (if equipped) in the Closed position.

Synrad Firestar ti-Series operator’s manual

29

operation

Initial start-up

7

On water-cooled lasers, shut off the chiller or otherwise stop coolant flow through the laser.

Caution

possible

equipment

damage

If your Firestar ti-Series laser fails to lase, refer to Troubleshooting in the Maintenance/Troubleshooting
chapter for troubleshooting information.

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

210 Synrad Firestar ti-Series operator’s manual

technical reference

Use information in this chapter as a technical reference for your Firestar ti-Series laser.

This chapter contains the following information:

■ Technical overview – briefly 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 specifications for the

laser’s User I/O connector.

■ DB-9 connections (SA models only) – describes pin configuration and specifications

for the SA model’s side-mounted DB-9 connector.

■ Integrating Firestar safety features – describes how to integrate Firestar ti-Series safety

features into your automated control system.

■ Firestar ti60 general specifications – provides specifications for Firestar ti60 lasers.

■ Firestar ti100 general specifications – provides specifications for Firestar ti100 lasers.

■ Firestar ti-Series package outline drawings – illustrates laser package and mounting

dimensions for Keyswitch and OEM ti60/ti100 lasers.

■ Firestar ti-Series packaging instructions – illustrates how to package ti-Series lasers

for shipment using SYNRAD-supplied packaging materials.

3

31Synrad Firestar ti-Series operator’s manual

technical reference

Technical overview

The Technical overview section includes subsections:

■ ti-Series laser

■ Optical setup

ti-Series laser

Laser tube

Firestar® ti-Series lasers were developed using new technology patented by SYNRAD, Inc. Firestar’s
patented “t” technology, based on a combination of free-space and waveguide resonator designs, enables
SYNRAD to economically produce a symmetrical laser beam from a small but powerful laser capable of
operating for many years with virtually no maintenance. Firestar’s unique extruded aluminum envelope
offers excellent heat transfer, long gas life, and low operating costs in contrast to other laser tube technolo­gies. In addition to 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.

Optical resonator

The optical resonator, in conjunction with the electrodes and the gas mixture, generates the laser beam.
Firestar ti-Series 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 flexible 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.

Caution

possible

equipment

damage

The output beam, roughly circular as it exits the resonator, transitions to a Gaussian-like mode in five to
ten Raleigh ranges (1.6–3.3 m). The internal structure and optics of the resonator combine to produce a
Gaussian-like mode quality (M2 factor) of < 1.2. As shown in Figure 3-1, beam waist diameter is 2.2 mm
at the output aperture and full angle divergence due to diffraction is less than 7 milliradians (a 7 mrad full
angle divergence means that beam diameter increases 7 mm over every one meter distance traveled).

Because of their smaller beam diameter, Firestar lasers have signifi­cantly higher power densities than previous SYNRAD lasers. This
means that even small amounts of contaminants 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 filtered air or nitrogen to prevent
vapor and debris from accumulating on optical surfaces.

32 Synrad Firestar ti-Series operator’s manual

technical reference

Beam Waist Diameter 2.2 mm

at Out

put Aperture

Full Angle Divergence <7 mrad

Ø

Technical overview

Figure 3-1 Firestar ti-Series beam characteristics

Internal RF power supply

The compact internal RF power supply converts DC input power into a radio frequency (RF) signal using
a crystal-controlled oscillator. The 82.5 MHz RF output from the oscillator is then amplified to obtain
the RF power required to drive the laser. From the amplifier, RF power is routed to the electrode structure
where it excites carbon dioxide (CO2) gas in the tube to produce lasing.

Control circuit

Control circuitry built into the ti-Series laser interrupts laser operation if any critical parameter is violated.
Switches and sensors monitor various conditions and parameters that, if exceeded, pose a risk of potential
damage to the laser. Additionally, laser operation is interrupted in response to the following conditions:
(1) the manual Shutter Switch is closed; (2) the Shutter Open Request signal is missing; (3) an over
temperature condition occurs; (4) the Remote Reset/Start Request signal is enabled; or (5) the Remote
Interlock signal is missing.

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.

Beam delivery optics

Divergence, or expansion, of the laser beam is important for materials processing since a larger beam
entering the focusing optic produces a smaller focused spot. Because the laser beam diverges by 7 mm over
each meter of distance traveled, the laser should be mounted a distance of 40–60 inches (1.0–1.5 m) away
from the work area and no closer than 30 inches (0.75 m) for optimum performance. Right angle turning
mirrors are often used in conjunction with the laser mounting position to obtain this distance. Figure 3-2
shows how right angle turning mirrors in a “flying optics” setup create this longer 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 laser divergence while at the same time increasing
beam diameter by a selectable magnification factor. Adding an expander/collimator to the “flying optics”
setup shown above would substantially reduce beam divergence and any variance in beam diameter caused
by the changing optical path length. In fixed-length delivery systems where the laser is positioned only one
meter away from the focusing optic and a small spot size is required, an expander/collimator is again the
best solution to provide the required beam expansion before reaching the focusing optic.

33Synrad Firestar ti-Series operator’s manual

technical reference

Technical overview

Figure 3-2 “Flying optics” beam path

Focusing optics

When selecting a focusing optic, the primary consideration should be material thickness and any vertical
tolerances that occur during final 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 field required for the material being processed.

Caution

possible

equipment

damage

Optics are fragile and must be handled carefully, preferably by the mounting ring only. Cleanliness is
another important issue affecting performance; a dirty or scratched lens will under perform and exhibit a
vastly shortened lifetime. When the application requires air (instead of nitrogen) 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 filtered to the specifications shown in Table 3-1.

Table 3-1 Assist gas purity specifications

Purge Gas Specification

Nitrogen High Purity Grade 99.9500% purity or better

Air Breathing Grade 99.9996% purity or better

Air Compressed 99.9950% purity or better, water-free; oil filtered to 5 mg/m3
or better; particulate filtered to < 1.0 micron.

Small amounts of contaminants 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 filtered air or nitrogen to prevent vapor and
debris from accumulating on optical surfaces.

34 Synrad Firestar ti-Series operator’s manual

technical reference

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 ti-Series 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

Firestar lasers incorporate a built-in tickle generator, freeing customers from the need to supply tickle
pulses between lasing commands. In cases where a 5 kHz, 1 microsecond (µs) tickle pulse is still sent to the
laser via a UC-2000 or other PWM controller, it is ignored until pulse width exceeds approximately 4 µs,
at which point lasing occurs.

Warning

serious

personal

Because of phase differences, external tickle pulses may combine
with the internally-generated tickle signal causing the LASE LED to
flicker during the transition from tickle to lasing. Laser output may
occur if the LASE LED flickers.

injury

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 off time) between applied Command signals.

Pulse Width Modulation (PWM)

Pulse Width Modulation, or PWM, controls laser power by varying the duty cycle of Firestar’s RF ampli­fiers, 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 ~75 µs; however, the laser cannot precisely follow
PWM input signals if the “On” pulse is less than 75 µs in duration. At a constant 50% duty cycle, ti-Series
lasers typically reach 90–100% of full optical output when operated at a frequency of 5 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 3-3 on the following page shows representative ti-Series
optical output waveforms at two different duty cycles with the same PWM frequency.

35Synrad Firestar ti-Series operator’s manual

technical reference

1

2.00 V M 50.0µs Ch1 1.24 V

Ch1

M3

50% PWM duty cycle at 4.8 kHz

Representative optical output pulse

T

1

2.00 V M 50.0µs Ch1 1.24 V

Ch1

M3

Representative optical output pulse

80% PWM duty cycle at 4.8 kHz

T

Controlling laser power

Figure 3-3 Representative Firestar ti-Series waveforms

Firestar ti-Series lasers are designed to operate at Command signal base frequencies up to 25 kHz; however,
the choice of PWM frequency depends on the user’s specific application. In the majority of laser applica­tions, the UC-2000’s default 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 25 kHz
maximum. At 25 kHz, the laser’s optical beam response no longer follows the Command input and is very
nearly a continuous wave (CW) value with just a small amount of ripple present.

Command signal

Warning

serious

personal

Always use shielded cable when connecting your PWM Command
signal source to PWM Input/PWM Return inputs. In electrically­noisy environments, long lengths of unshielded wire act like an
antenna and may generate enough voltage to trigger uncommanded
lasing.

injury

The modulated Command signal applied between Pin 9, PWM Input, and Pin 1, PWM Return, of the User
I/O connector on the Firestar ti-Series 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 first Command signal parameter, signal amplitude, is either logic low—corresponding to laser beam
off, or logic high—corresponding to beam on. The laser off 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 25 kHz.

36 Synrad Firestar ti-Series operator’s manual

technical reference

0 VDC

5 VDC

100 µs

200 µs

200 µs

190 µs

5 kHz Command Signal at 50% Duty Cycle

5 kHz Command Signal at 95% Duty Cycle

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
3-4 illustrates PWM Command signal parameters while Table 3-2 lists PWM signal specifications.

Figure 3-4 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 25 kHz. Table 3-2 provides mini­mum, maximum, and nominal PWM signal specifications.

Table 3-2 PWM Command signal levels

Laser State Minimum Nominal Maximum

Laser Off 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 25 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 off 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 ti-Series 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.

37Synrad Firestar ti-Series operator’s manual

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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 off) 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 off) to 20 mA (maximum power).
Software able to control your analog output card is required for either configuration.

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) sec-
tion 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 off 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 off) 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 off) mode, an asserted
logic low signal, short circuit to ground, or an open or disconnected Gate input locks the beam off.

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 configure the UC-2000’s gate
input logic to internal Pull-Down (normally off) 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 off) mode an asserted logic low signal, short circuit
to ground, or an open or disconnected Gate inputs locks the beam off.

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 efficient than a hotter one. The overshoot effect is more pronounced
at lower gating frequencies since the gas has a longer time to cool down between Command signal pulses.

38 Synrad Firestar ti-Series operator’s manual

technical reference

T

1

2.00 V M 200µs Ch1 1.24 V

Ch1

M3

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

Controlling laser power

SYNRAD’s Firestar ti-Series lasers produce an optical output pulse that is almost exactly square (see Figure
3-5), meaning that there is no leading edge overshoot and virtually no power variation across the actual
pulse. The square output pulse of the ti-Series laser coupled with its shorter rise times (~75 µs) means that
material processing is more efficient since a greater amount of laser energy is absorbed, which is especially
desirable when working with high threshold materials.

Figure 3-5 Representative ti-Series optical output pulse

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 effectively merge with a PWM signal that follows closely afterwards.
When the PWM pulse that follows is short, causing the tickle pulse to become a significant fraction of the
PWM pulse duration, then the tickle pulse effectively 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 affect 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 off time between PWM pulses exceeds 200 microseconds.

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technical reference

User I/O connections

The User I/O connections section includes subsections:

■ User I/O connection summary

■ Input/output signals

■ Sample I/O circuits

User I/O connection summary

Table 3-3 below provides a quick reference summary for Firestar ti-Series User I/O connections.

Table 3-3 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

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 pin causes the laser’s RDY indi­cator to illuminate and begins a five-second countdown after which lasing is enabled.

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 pin must be connected
to a voltage source in the range of ±5–24 VDC. Refer to Figure 3-8 for a diagram showing
how the Remote Interlock input is factory-jumpered.

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

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 Off).

7 Over Temperature

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

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User I/O connections

Pin Function Description

8 Laser Ready

This bi-directional switched output is internally connected to Pin 13, Output Common,
when the laser is enabled (RDY indicator 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 five-second delay during which lasing is inhibited. This
output is open (high impedance) when the laser is disabled (RDY indicator Off).

9 PWM Input

Connect your PWM Command signal (+5 VDC, 5 kHz nominal, 25 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.

10 Shutter Open Request

Apply a positive or negative voltage (±5–24 VDC) with respect to Pin 11, Input Com­mon to enable lasing. If your system does not supply a Shutter Open Request signal, this

pin must be connected to a voltage source in the range of ±5–24 VDC. Refer to Figure 3-8
for a diagram showing how the Shutter Open Request input is factory-jumpered. When a
voltage is initially applied to this input, there is a five-second delay during which lasing is
inhibited.

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.

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 (SHT indi­cator illuminated blue), indicating that lasing may be enabled if other operating conditions
are met. When this output is initially switched closed, there is a five-second delay during
which lasing is inhibited. This output is open (high impedance) when the laser is disabled
(SHT indicator Off).

15 Interlock Open

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

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USER I/O

INT

TMP RDYSHT LASE

Pin 8

Pin 1

Pin 15

Pin 9

ON

OFF

User I/O connections

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 section below. Figure 3-6 illustrates the pin
arrangement of the User I/O (15 pin female D-type subminiature) connector on the laser’s rear panel.

Note: See DB-9 connections later in this section for signal descriptions and pinouts of the SA model’s

side-mounted DB-9 connector.

Caution

possible

equipment

Turn off 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.

damage

Figure 3-6 User I/O connector pinouts

312 Synrad Firestar ti-Series operator’s manual

technical reference

DC POWER INPUT

+48 VDC TO RF GENERATOR

VOLTA GE REGULATORS

AND

48 V SWITCH

CHASSIS GROUND (EARTH)

0.5 A FUSE

SELF-RESETTING

0.5 A FUSE

SELF-RESETTING

USER I/O AUX DC PINS

+5 VDC TO LOGIC AND USER I/O

(12) (4)

(5)

+48 VDC (+)

DC RETURN (–)

+48 VDC (DB-9 FAN POWER)

+24 VDC TO USER I/O

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 floating with respect to chassis ground. Figure 3-7 illustrates Firestar’s
internal DC supply wiring.

Figure 3-7 Auxiliary DC power supply wiring

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

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.

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User I/O connections

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 speci­fied 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 3-4 for input
circuit specifications.

Pin 2 Remote Reset/Start Request

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

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, first 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 five-second delay after which lasing is enabled.

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 pin must be connected to a
voltage source in the range of ±5–24 VDC. Refer to Figure 3-8 for a diagram showing how the
Remote Interlock input is factory-jumpered. Because all DC power is removed from the laser’s RF
board when this input is inactive, no lasing can occur until voltage is applied to Pin 3. Refer to
Table 3-4 for input circuit specifications.

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 five-second delay during which lasing is inhibited.

On OEM lasers, the Remote Interlock input is not latched. Re-applying a signal to Pin 3 enables
the RDY indicator and lasing is possible after the five-second delay, provided that the Shutter

Open Request signal is also present (SHT indicator illuminated).

Pin 9 PWM Input

Connect your PWM Command signal (+5 VDC, 5 kHz nominal, 25 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 Table 3-4 for input circuit specifications.

314 Synrad Firestar ti-Series operator’s manual

technical reference

Pin 1 PWM Return
Pin 9 PWM Input

Pin 3 Remote Interlock
Pin 4 +5 VDC Auxiliary Power
Pin 10 Shutter Open Request

Pin 11 Input Common
Pin 12 Aux. DC Power Ground

Pin 15 Pin 9

Pin 8 Pin 1

PWM Input BNC

Rear (Solder Side)

of Male DB15
"Quick Start"

Shorting Plug

User I/O connections

Pin 10 Shutter Open Request

Apply a positive or negative voltage (±5–24 VDC) with respect to Pin 11, Input Common, to
enable lasing. If your system does not supply a Shutter Open Request signal, this pin must be
connected to a voltage source in the range of ±5–24 VDC. Refer to Figure 3-8 for a diagram
showing how the Shutter Open Request input is factory-jumpered. When a voltage is initially
applied to this input, there is a five-second delay during which lasing is inhibited. Because all DC
power is removed from the laser’s RF board when this input is inactive, no lasing can occur until
voltage is applied to Pin 10. See Table 3-4 for input circuit specifications.

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 to the Open position. Las­ing is inhibited when voltage is removed from Pin 10 or the Shutter Switch is Closed.

Note: To ensure optimum laser performance, there is a five-second delay imposed from the time

a Shutter Open Request 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 Table 3-4 for input circuit specifications.

Figure 3-8 illustrates how Remote Interlock and Shutter Open Request inputs are factory-jumpered on
the Quick Start Plug to enable lasing for initial testing and troubleshooting purposes.

Figure 3-8 Quick Start Plug wiring diagram

Figure 3-9 on the following page illustrates the input circuit’s equivalent internal schematic while Table
3-4 provides Firestar ti-Series input circuit specifications.

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USER I/O INPUT SIGNAL PINS

PWM INPUT (+) (9)

PWM RETURN (–) (1)

REMOTE RESET/START REQUEST (2)

REMOTE INTERLOCK (3)

SHUTTER OPEN REQUEST (10)

INPUT COMMON (11)

600 Ohm, 2W

600 Ohm, 2W

600 Ohm, 2W

FIRESTAR ti-SERIES

INPUT CIRCUITRY

220 Ohm, 1/8W

430 Ohm, 1/10W

User I/O connections

Figure 3-9 Input equivalent schematic

Table 3-4 Input circuit specifications

Input Signal Name Input Device Type and Specifications

PWM Input High-speed optoisolator LED, forward voltage drop (Vf) 1.5 VDC
Off state Vmax +0.8 VDC
On state Vmin +3.5 VDC @ 3 mA
On state (continuous) Vmax +6.7 VDC @ 10 mA
Frequency, max. 25 kHz

Remote Reset/Start Request Bi-directional optoisolator LED, forward voltage drop (Vf) 1.15 VDC
Remote Interlock Off 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).

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User I/O connections

Output signals

Firestar’s five user outputs correspond to the status functions described below. Outputs are optoisolated, bi­directional 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.

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

Note: Laser Ready and Shutter Open outputs indicate separate functions. The Laser Ready output

(RDY LED On) may close while the Shutter Open output is open (SHT LED Off), but RF boards
are disabled until Laser Ready and Shutter Open outputs are closed (RDY and SHT LEDs On).

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 Off). Refer to Table 3-5 for output circuit specifications.

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 (TMP indicator red). The output is open (high
impedance) when laser temperature is within operating limits (TMP indicator green). After an
over temperature fault occurs, cool the laser and then cycle DC power to reset the laser. Refer to
Table 3-5 for output circuit specifications.

Pin 8 Laser Ready

This bi-directional switched output is internally connected to Pin 13, Output Common, when
the laser is enabled (RDY indicator 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 five-second delay during which lasing is inhibited. This output is open (high impedance) when
the laser is disabled (RDY indicator Off). Refer to Table 3-5 for output circuit specifications.

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 0.3 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 (SHT indicator 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 the Shutter Open output closes (SHT indicator blue), there is a five-second delay
until PWM inputs are recognized. Refer to Table 3-5 for output circuit specifications.

Pin 15 Interlock Open

This bi-directional switched output is internally connected to Pin 13, Output Common, when
remote interlock circuitry is open (INT indicator red), indicating that lasing is disabled. The
output is open (high impedance) when lasing is enabled (INT indicator green). See Table 3-5 for
output circuit specifications.

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FIRESTAR ti-SERIES

OUTPUT CIRCUITRY

U

SER I/O OUTPUT SIGNAL PINS

SOLID
STATE
RELAY

SOLID
STATE
RELAY

SOLID
STATE
RELAY

SOLID
STATE
RELAY

SOLID
STATE
RELAY

0.3 A FUSE,

SELF-RESETTING

(6) LASER ACTIVE

(7) OVER TEMPERATURE

(8) LASER READY

(14) SHUTTER OPEN

(15) INTERLOCK OPEN

(13) OUTPUT COMMON

User I/O connections

Figure 3-10 illustrates the output circuit’s equivalent internal schematic and Table 3-5 provides Firestar
ti-Series output circuit specifications.

Figure 3-10 Output equivalent schematic

Table 3-5 Output circuit specifications

Output Device Specifications

Bi-directional MOSFET 20 Ohm Rdson
10 MOhms Off

Voltage ±24 VDC, max.

Current 50 mA, max.

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(12) AUX. DC POWER
GROUND

Close switch to

enable interlock

USER I/O PINS

(5) +24 VDC AUXILIARY

POWER

(3) REMOTE INTERLOCK

(11) INPUT COMMON

Close switch to

enable interlock

USER I/O PINS

(3) REMOTE INTERLOCK

(11) INPUT COMMON

–12 VDC

0 VDC

User I/O connections

Sample I/O circuits

Sample inputs

Figure 3-11 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 to power the circuit instead, depending on circuit voltage requirements.

Figure 3-11 Customer-supplied interlock

Figure 3-12 shows another variation for supplying a Remote Interlock signal to the laser. In this case, the
customer is using a switch and supplying a negative voltage to drive Firestar’s input circuit.

Figure 3-12 Customer-supplied interlock, negative voltage

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USER I/O PINS

(3) REMOTE INTERLOCK

(11) INPUT COMMON

PLC

DC
OUTPUT
MODULE

+V

(+5–24V)

PLC

DC
OUTPUT
MODULE

+V

(+5–24V)

USER I/O PINS

(11) INPUT COMMON

(2) REMOTE RESET/STA RT REQUEST

(3) REMOTE INTERLOCK

(10) SHUTTER OPEN REQUEST

User I/O connections

A Programmable Logic Controller (PLC) can also drive Firestar inputs. Figure 3-13 shows a typical
method for connecting to a PLC input module when only one Firestar input is used.

Figure 3-13 PLC driven interlock signal

When multiple PLC inputs are required, connect Firestar inputs to the PLC as shown in Figure 3-14. 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.

Figure 3-14 Multiple PLC driven inputs

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(5) +24 VDC AUXILIARY
POWER

(6) LASER ACTIVE

(12) AUX. DC POWER

GROUND

(13) OUTPUT COMMON

L

R1

USER I/O PINS

(5) +24 VDC AUXILIARY
POWER

(6) LASER ACTIVE

(12) AUX.DC POWER

GROUND

(13) OUTPUT COMMON

+V

L

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 3-15 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.

Figure 3-15 Firestar output driving warning lamp

Figure 3-16 illustrates a method for controlling a higher voltage, higher current load by using a 24 V 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.

Figure 3-16 Firestar output driving relay

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USER I/O PINS

PLC

DC

INPUT

MODULE

(13) OUTPUT COMMON

(6) LASER ACTIVE

(7) OVER TEMPERATURE

(8) LASER READY

(14) SHUTTER OPEN

(15) INTERLOCK OPEN

V+

(+5–24V)

User I/O connections

Figure 3-17 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.

Figure 3-17 Firestar output driving PLC input module

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Pin 5

Pin 1

Pin 6Pin 9

DB-9 connections

The DB-9 connections section includes subsections:

(SA models only)

■ DB-9 pin descriptions

■ 48 VDC fan speed control

■ Isolated cooling fan connections

DB-9 pin descriptions

The side-mounted DB-9 connector on SA model lasers provides a Shutter Switch input, auxiliary +5 V
power, and +48 VDC for powering user-supplied 48 V cooling fans. Figure 3-18 illustrates DB-9 pinouts
and Table 3-6 describes the function of each pin on the DB-9 connector.

Important Note: The pinout and functionality of the side-mounted DB-9 connector on ti-Series SA

model lasers is not the same as the connector on t-Series or t70i SA model lasers.

Figure 3-18 DB-9 connector pinouts

Table 3-6 Side-mounted DB-9 pin descriptions

Pin Function Description

1 No Connection

2 Shutter Switch

In Keyswitch models, this input connects to the physical Shutter Switch. Leave this input open to
enable lasing. Grounding this pin indicates that the shutter is Closed, which disables lasing. If
connecting an external shutter switch to Pin 2, the circuit path must be grounded to Pin 6 or Pin
7, Signal Ground. There is a five-second delay imposed from the time the shutter input is opened
to the time that PWM Command signals are accepted.

3 +5 VDC Auxiliary Power

4 Fan Power, +48 VDC

This output provides +5 V for driving external inputs or outputs (like a diode pointer). The
+5 VDC Auxiliary Power output (Pin 3) is protected by a 0.5 A self-resetting fuse. The return
(ground) path is through Pin 6 or Pin 7, Signal Ground.

This output provides +48 VDC for powering a customer-supplied cooling fan. The Fan Power,
+48 VDC output (Pin 4) is sourced directly from the user’s 48 VDC power supply and is protected
by a 1.1 A self-resetting fuse. Pin 4 and Pin 8 can only source a combined current of 1.0 A total.

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ti-Series Fan Control Output Section

(4) FAN POWER, +48 VDC

(5) FAN POWER RETURN

(8) FAN POWER, +48 VDC

(9) FAN POWER RETURN

DB-9 PINS

Q1

R1

PWM FAN
CONTROL
SIGNAL

48 VDC

1.1 A FUSE

DB-9 connections

Pin Function Description

5 Fan Power Return

This connection provides a return (ground) path for Pin 4 and Pin 8 (Fan Power, +48 VDC).
Pin 5 and Pin 9 (Fan Power Return) can only sink a combined current of 1.0 A total. Internal
circuitry allows the laser to control fan speed based on the laser’s output power and chassis tem­perature. See 48 VDC fan speed control for detailed information.

6, 7 Signal Ground

Pin 6 and Pin 7 provide a return (ground) path for Pin 2 (Shutter Switch), Pin 3 (+5 VDC Auxil­iary Power), or Pin 5/Pin 8 (Fan Power, +48 VDC) when fan speed control is not required. Pin 6

and Pin 7, Signal Ground, are the only DB-9 pins connected to chassis ground. Do not use these
pins if DC power is supplied from an external customer-supplied DC power source.

8 Fan Power, +48 VDC

This output provides +48 VDC for powering a customer-supplied cooling fan. The Fan Power,
+48 VDC output (Pin 8) is sourced directly from the user’s 48 VDC power supply and is protected

by a 1.1 A self-resetting fuse. Pin 4 and Pin 8 can only source a combined current of 1.0 A total.

9 Fan Power Return

This connection provides a return (ground) path for Pin 4 and Pin 8 (Fan Power, +48 VDC).
Pin 5 and Pin 9 (Fan Power Return) can only sink a combined current of 1.0 A total. Internal
circuitry allows the laser to control fan speed based on the laser’s output power and chassis tem­perature. See 48 VDC fan speed control for detailed information.

(SA models only)

48 VDC fan speed control

The side-mounted DB-9 connector on SA model lasers has internal circuitry that controls fan speed based
on the laser’s output power and chassis temperature. At tickle, or very low PWM duty cycles, cooling fans
run at reduced speed to minimize noise; at higher PWM duty cycles, fan speed increases to match the cool­ing rate to power output. Fan speed is controlled by pulse width modulation (PWM) of the Fan Power
Return lines (Pin 5/Pin 9) as shown in Figure 3-19.

Figure 3-19 Internal fan speed control circuitry

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(4) FAN POWER, +48 VDC

(5) FAN POWER RETURN

(8) FAN POWER, +48 VDC

(9) FAN POWER RETURN

DB-9 PINS

DC

FAN

DC

FAN

+

+

–

–

(4) FAN POWER, +48 VDC

(5) FAN POWER RETURN

DB-9 PINS

Optoisolator

Resistor

DC

FAN

+–

+ VDC

(8) FAN POWER, +48 VDC

(9) FAN POWER RETURN

Optoisolator

Resistor

DC

FAN

+

–

+ VDC

DB-9 connections

(SA models only)

Figure 3-20 illustrates the connections for fan speed control when using customer-supplied 48 VDC cool­ing fans. Connect the positive (+) fan lead to Pin 4 or Pin 8, Fan Power, +48 VDC, and connect the
negative (–) fan lead to Pin 5 or Pin 9, Fan Power Return.

If fan speed control is not desired, connect the negative (–) fan leads to Pin 6 or Pin 7, Signal Ground.

Important Note: The total current draw of both fans must not exceed 1.0 A to prevent tripping the

internal 1.1 A self-resetting fuse.

Figure 3-20 48 VDC fan connections

Note: Some types of cooling fans are not designed for PWM control and will stall at low speeds.

SYNRAD has tested Delta EFB1248SHE cooling fans with good results.

Isolated cooling fan connections

To connect cooling fans operating at voltages other than 48 VDC or with currents greater than 1.0 A,
a customer-designed isolation circuit like that shown in Figure 3-21 could power almost any type of DC
cooling fan (with a suitably sized resistor and optoisolator device) while minimizing voltage or current
spikes that might damage the laser’s control board.

Figure 3-21 Alternate fan connections

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Integrating Firestar safety features

The Integrating Firestar safety features section includes subsections:

■ Keyswitch functions

■ Shutter functions

■ 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 RDY or SHT indicators are Off (Laser Ready or Shutter Open outputs open).

Keyswitch functions

Keyswitch lasers

After DC power-up or after a remote interlock fault, the Keyswitch must be toggled OFF/ON to reset the
laser and enable the RDY LED, signaling that DC power is applied to the RF driver. Over temperature
faults are reset by removing, then reapplying DC power after the laser has cooled.

For Keyswitch-equipped lasers in automated systems, this keyswitch/reset function is available via the
Remote Reset/Start Request input on Pin 2 of the User I/O connector. To use this “remote keyswitch”
functionality, first 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, the Remote
Reset/Start Request input. Removing voltage allows DC power to reach the RF driver and begins a five­second delay after which lasing is enabled (RDY 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 3-17). The Laser
Ready output closes when the laser is enabled (RDY LED illuminated yellow), indicating that lasing is
possible. The output is open (in a high-impedance state) and the RDY LED is off when lasing is disabled.

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

OEM lasers

On OEM lasers, the RDY LED illuminates on DC power-up (provided that Shutter Open Request and
Remote Interlock inputs are enabled) and five-seconds later DC power is applied to the RF driver. Over

temperature faults are reset by removing and then reapplying DC power after the laser has cooled. Remote
interlock faults are not latched; the RDY LED illuminates yellow as soon as the interlock circuit is closed
(when the INT LED turns from red to green) and five-seconds later lasing is enabled.

Although a Remote Reset/Start Request input is not required 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 power to reach the RF driver and begins
a five-second countdown after which lasing is enabled (RDY 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 3-17).

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Integrating Firestar safety features

The Laser Ready output closes when the laser is enabled (RDY LED illuminated yellow), indicating that
lasing is possible. The output is open (in a high-impedance state) and the RDY LED is off when lasing is
disabled.

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

Shutter functions

A mechanical Shutter Switch is installed on all Keyswitch-equipped lasers. Lasing is enabled when the shut­ter is Open (SHT LED illuminated blue) and disabled when the shutter is Closed (SHT LED off). The
SHT LED illuminated blue to indicate that DC power is applied to the RF driver.

For ti-Series OEM and Keyswitch-equipped lasers in automated systems, the shutter function is provided by
the Shutter Open Request signal via Pin 10 on the User I/O connector. To use this “remote shutter”, first
place the Shutter Switch (if equipped) in the Open position and then apply a voltage in the range of ±5–24
VDC to Pin 10, Shutter Open Request. This input signal causes the SHT LED to illuminate and sends
DC power to the RF driver, enabling lasing after a five-second delay. Lasing is disabled until the manual
Shutter Switch is placed in the Open position and a Shutter Open Request signal is applied to Pin 10.

Your control system can monitor the laser’s shutter status on the User I/O connector by connecting your
system’s input between Pin 14, Shutter Open, and Pin 13, Output Common (see Figure 3-17). The Shut-
ter Open output closes when the Shutter Switch is Open and a Shutter Open Request signal is present
(SHT LED illuminated blue). The output is open (in a high-impedance state) and the SHT LED is off
when the Shutter Switch is Closed or the Shutter Open Request signal is removed.

Note: After the Shutter Open output closes, a five-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 (INT LED illuminated green), if RDY and

SHT LEDs are illuminated, and disabled when the Remote Interlock signal is removed (INT LED red,
RDY LED off). DC power is applied to the RF driver only when the INT LED is green and the RDY LED is

yellow (and the SHT LED is illuminated blue). Remote interlock functionality is provided by the Remote
Interlock input signal via Pin 3 on 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 INT LED to illuminate green and sends DC power to

the RF driver, which enables lasing after a five-second delay (provided that the RDY LED is yellow and the
SHT LED is blue). Removing the interlock signal removes DC power from the RF driver, causing the INT

LED to turn red and the RDY LED to turn off. 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 between Pin 15, Interlock Open, and Pin 13, Output Common (see Figure 3-17).
This output is closed when remote interlock circuitry is open (INT indicator illuminated red). The output
is open (in a high-impedance state) and the INT LED is green when interlock circuitry is closed.

Note: After the Interlock Open output opens, a five-second delay occurs before lasing is enabled.

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Firestar ti60 general specifications

Table 3-7 Firestar ti60 general specifications

Parameter Firestar ti60

Output Specifications

Wavelength† ..................................................10.57–10.63 microns

Power Output

Power Stability3 .............................................± 7%

Mode Quality .................................................M2 < 1.2

Beam Waist Diameter (at 1/e2)4 ....................2.2 ±0.2 mm

Beam Divergence, full angle (at 1/e2)4 ..........< 7.0 mrad

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

Polarization ...................................................Linear, vertical

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

Rise Time ......................................................< 75 µs

Modulation (Optical response) ....................up to 25 kHz

Input Specifications

Power Supply

Voltage ...................................................48 VDC

Maximum Current

1, 2

..........................................60 Watts

5, 6

.............................18 A

Command Input Signal

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

Current ..................................................10 mA @ +6.7 VDC

Frequency7 ..............................................DC–25 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

Cooling Specifications (Air-cooled) ............................. (Water-cooled)

Maximum Heat Load ....................................900 Watts ................................. 900 Watts

Minimum Flow Rate ......................................150 CFM per fan (×2) .............1.0–2.0 GPM, < 60 PSI

Coolant Temperature8 ...................................< 40 °C, ambient .....................18–22 °C

* Specifications subject to change without notice.

† Typical. Actual wavelength range may vary from 10.2–10.8 µm.

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

2 48 VDC input voltage to obtain guaranteed output power.

3 From cold start (guaranteed).

4 Measured at laser output.

5 User-supplied cooling fans on SA models may increase current load by 1.0 amperes.

6 Firestar ti-Series lasers have no appreciable in-rush current.

7 Tested at 5 kHz.

8 Water-cooled lasers can be operated at coolant temperatures up to 30 °C (86 °F) in order to reduce problems associated with

condensation; however, this may result in decreased laser performance and/or reduced laser lifetime.

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Firestar ti60 general specifications

Parameter Firestar ti60

Environmental Specifications

Operating Ambient Temperature Range9 .....15 °C–40 °C

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

Physical Specifications

ti60, water-cooled (KWC, SWC models)

Length ....................................................22.98 in (58.4 cm)

Width ..................................................... 5.62 in (14.3 cm)

Height .................................................... 5.90 in (15.0 cm)

Weight ...................................................26.2 lbs (11.9 kg)

ti60, fan-cooled (KFC, SFC models)

Length ....................................................22.46 in (57.1 cm)

Width ..................................................... 7.72 in (19.6 cm)

Height .................................................... 5.90 in (15.0 cm)

Weight ...................................................29.1 lbs (13.2 kg)

ti60, air-cooled (SAC models)

Length ....................................................22.46 in (57.1 cm)

Width ..................................................... 6.22 in (15.8 cm)

Height .................................................... 5.83 in (14.8 cm)

Weight ...................................................25.6 lbs (11.6 kg)

* Specifications subject to change without notice.

9 Published specifications guaranteed at a cooling temperature of 22 °C. For ti-Series lasers, some performance degradation may

occur when operated in ambient air or coolant temperatures above 22 °C. With air-cooled lasers, output laser power typically
decreases 0.5–1% per degree Celsius increase in ambient temperature.

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Firestar ti100 general specifications

Table 3-8 Firestar ti100 general specifications

Parameter Firestar ti100

Output Specifications

Wavelength† ..................................................10.57–10.63 microns

Power Output

Power Stability3 .............................................± 7%

Mode Quality .................................................M2 < 1.2

Beam Waist Diameter (at 1/e2)4 ....................2.2 ±0.2 mm

Beam Divergence, full angle (at 1/e2)4 ..........< 7.0 mrad

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

Polarization ...................................................Linear, vertical

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

Rise Time ......................................................< 75 µs

Modulation (Optical response) ....................up to 25 kHz

Input Specifications

Power Supply

Voltage ...................................................48 VDC

Maximum Current5 ................................35 A

1, 2

..........................................100 Watts

Command Input Signal

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

Current ..................................................10 mA @ +6.7 VDC

Frequency6 ..............................................DC–25 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

Cooling Specifications (Water-cooled)

Maximum Heat Load ....................................1700 Watts

Minimum Flow Rate ......................................1.5–2.0 GPM, < 60 PSI

Coolant Temperature7 ...................................18–22 °C

* Specifications subject to change without notice.

† Typical. Actual wavelength range may vary from 10.2–10.8 µm.

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

2 48 VDC input voltage to obtain guaranteed output power.

3 From cold start (guaranteed).

4 Measured at laser output.

5 Firestar ti-Series lasers have no appreciable in-rush current.

6 Tested at 5 kHz.

7 Water-cooled lasers can be operated at coolant temperatures up to 30 °C (86 °F) in order to reduce problems associated with

condensation; however, this may result in decreased laser performance and/or reduced laser lifetime.

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Firestar ti100 general specifications

Parameter Firestar ti100

Environmental Specifications

Operating Ambient Temperature Range8 .....15 °C–40 °C

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

Physical Specifications

ti100, water-cooled (KWB, SWB models)

Length ....................................................22.98 in (58.4 cm)

Width ..................................................... 5.62 in (14.3 cm)

Height .................................................... 5.90 in (15.0 cm)

Weight ...................................................26.2 lbs (11.9 kg)

* Specifications subject to change without notice.

8 Published specifications guaranteed at a cooling temperature of 22 °C. For ti-Series lasers, some performance degradation may

occur when operated in coolant temperatures above 22 °C.

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22.48

21.35

.25

.094

2.905

.010

5.90

4.120

1.125

.563

.500

BEAM EXIT

2.300

.800

.800

POWER

5VDC

ACCESSORY

THAN .19 INTO FA CE PLAT E

6X 8-32 UNC ACCESSORY

MOUNTING HOLES. SCREWS

SHOULD NOT EXTEND MORE

4

C

L

2X

.75

1.00

2.78

C

L

CONTROL I/O

DC POWER

INTERLOCK

(GRN/RED)

TEMP

(GRN/RED)

READY (YEL)

SHUTTER

(BLUE)

LASE

(RED)

22.98

1.500 20.975

.625

.25

20.980

5.62

2.435

4.87

.250

1/4-20 UNC

.261/4-20 UNC

1/4-20 UNC

1

1

2

2

3

3

3

C

L

4

3

2

1

NOTES:

THIS HOLE PA TTERN USED WHEN TOP ACCESS FASTENING DESIRED.

THIS HOLE PA TTERN USED WHEN BOTTOM ACCESS FASTENING DESIRED.

HARDENED BALL MOUNTING POINT (Ø.250 STEEL BALL).

BEAM PA T H MAY NOT BE CENTERED OR PERPENDICULAR TO F ACEPLA T E APERTURE.

C

DESCRIPTION:

FINISH:

MATERIAL:

REV

ECO

DATE

DESCRIPTION

DB

TOLERANCES UNLESS NOTED:

.

ANGLE = ±

.

.x = ±

.

.xx = ±

.

.xxx = ±

.

PROPRIETARY

THIS DRAWING IS PROPRIETARY TO

SYNRAD INC. AND SHALL NOT BE

USED OR DISCLOSED IN WHOLE

OR IN PA RT WITHOUT WRITTEN

PERMISSION OF SYNRAD INC.

PA RT NUMBER:

DWG/FILE NUMBER:

SHEET

ENG:

DRAWN BY:

DATE:

UNITS:

CATEGORY:

CHECKED BY:

DATE:

SIZE: B

FINISH CLASS:

APPROVED BY:

DATE:

SYNRAD INC.

4600 Campus Place

Mukilteo, WA 98275

Phone: [phone]

Fax: [phone]

OUTLINE & MOUNTING, WATER-COOLED, Ti60/Ti100

10-Mar-09

300-19847-03

1

.

.

.

300-19847-03

of

1

.

D. DUVALL

Inches

.

.

.

DMD

RELEASE TO PRODUCTION

14-May-09

4045

A

ADD NOTE 4, FA CE PLAT E INFO

B

DMD

9-Sep-09

4107

UPDATE COOLING FITTINGS LOCATION

C

.

13-Jan-10

4154

Firestar ti-Series package outline drawings

Figure 3-22 Water-cooled Firestar ti60/ti100 package outline and mounting dimensions

332 Synrad Firestar ti-Series operator’s manual

NOTES:

THIS HOLE PATTERN USED WHEN TOP ACCESS FASTENING DESIRED.

THIS HOLE PATTERN USED WHEN BOTTOM ACCESS FASTENING DESIRED.

HARDENED BALL MOUNTING POINT (Ø.250 STEEL BALL).

BEAM PATH MAY NOT BE CENTERED OR PERPENDICULAR TO FACEPLATE APERTURE.

C

C

DESCRIPTION:

FINISH:

MATERIAL:

REVECO DATE

DESCRIPTION DB

TOLERANCES UNLESS NOTED:

. °

ANGLE = ±

.

.x = ±

.

.xx = ±

.

.xxx = ±

.

PROPRIETARY

THIS DRAWING IS PROPRIETARY TO

SYNRAD INC. AND SHALL NOT BE

USED OR DISCLOSED IN WHOLE

OR IN PART WITHOUT WRITTEN

PERMISSION OF SYNRAD INC.

PART NUMBER:

DWG/FILE NUMBER:

SHEET

ENG:

DRAWN BY:

DATE:

UNITS:

CATEGORY:

CHECKED BY:

DATE:

SIZE: B

FINISH CLASS:

APPROVED BY:

DATE:

SYNRAD INC.

4600 Campus Place

Mukilteo, WA 98275

Phone: [phone]

Fax: [phone]

OUTLINE & MOUNTING, FAN-COOLED, Ti60

10-Mar-09

300-19847-02

1

.

.

300-19847-02

of

1

D. DUVALL

Inches

.

DMD

RELEASE TO PRODUCTION

14-May-09

4045A

ADD NOTE 4

B

DMD

9-Sep-09

4107

ADD DIMS FOR FANS AND CUT-OUTS

C

DMD

28-Sep-09

4118

10.66

1.38

3.18

.25

20.83

INTERLOCK

(GRN/RED)

TEMP (GRN/RED)

READY (YEL)

SHUTTER

(BLUE)

LASE

(RED)

DC POWER

CONTROL I/O

22.455

2.735

5.47

6.22

1.500

20.455

.625

20.455

Ø.250

1/4-20 UNC

1/4-20 UNC

Ø.250

1/4-20 UNC

Ø.26

3

3

3

1

2

.094

.563

1.125

2.905

±

.010

.800

.800

2.300

Ø.500

BEAM

EXIT

7.72

5.90

4.72

6X 8-32 UNC ACCESSORY

MOUNTING HOLES. SCREWS

SHOULD NOT EXTEND MORE

THAN .19 INTO FACE PLATE

5VDC

ACCESSORY

POWER

4

123

4

C

1

2

technical reference

Firestar ti-Series package outline

drawings

Figure 3-23 Fan-cooled Firestar ti60 package outline and mounting dimensions

333Synrad Firestar ti-Series operator’s manual

NOTES:

THIS MOUNTING HOLE PA TTERN USED WHEN TOP ACCESS FASTENING DESIRED.

THIS MOUNTING HOLE PA TTERN USED WHEN BOTTOM ACCESS FASTENING DESIRED.

HARDENED BALL MOUNTING POINT , 3X (Ø.250 STEEL BALL).

BEAM PA T H MAY NOT BE CENTERED OR PERPENDICULAR TO F ACEPLA T E APERTURE.

123

4

B

DESCRIPTION:

FINISH:

MATERIAL:

REVECO DATE

DESCRIPTIONDB

TOLERANCES UNLESS NOTED:

.

°

ANGLE = ±

.

.x = ±

.

.xx = ±

.

.xxx = ±

.

PROPRIETARY

THIS DRAWING IS PROPRIETARY TO

SYNRAD INC. AND SHALL NOT BE

USED OR DISCLOSED IN WHOLE

OR IN PA RT WITHOUT WRITTEN

PERMISSION OF SYNRAD INC.

PA RT NUMBER:

DWG/FILE NUMBER:

SHEET

ENG:

DRAWN BY:

DATE:

UNITS:

CATEGORY:

CHECKED BY:

DATE:

SIZE: B

FINISH CLASS:

APPROVED BY:

DATE:

SYNRAD INC.

4600 Campus Place

Mukilteo, WA 98275

Phone: [phone]

Fax: [phone]

OUTLINE & MOUNTING, AIR-COOLED, Ti60, OEM

26-Aug-08

300-19847-01

1

.

.

.

300-19847-01

of

2

D. DUVALL

Inches

.

DMDRELEASE TO PRODUCTION

14-May-09

4045

A

ADD NOTE 4

B

DMD

9-Sep-09

4107

.

.

.

.

.

20.72

.25

DC POWER

CONROL I/O

INTERLOCK

(GRN/RED)

TEMP (GRN/RED)

READY (YEL) SHUTTER

(BLUE)

LASE (RED)

2.735

5.47

6.22

1/4-20 UNC

1/4-20 UNC

Ø.26

Ø.250

1/4-20 UNC

Ø.25

.625

20.455

1.500

20.455

22.455

3

3

3 1

1

2

2

.094

2.905

±

.010

5.83

4.500

1.125

.562

.800

.800

2.300

Ø.500

BEAM

EXIT

6X 8-32 UNC ACCESSORY

MOUNTING HOLES. SCREWS

SHOULD NOT EXTEND MORE

THAN .19 INTO FA CE PLAT E

4

B

technical reference

Firestar ti-Series package outline
drawings

Figure 3-24 OEM air-cooled Firestar ti60 (SA model) package outline and mounting

334 Synrad Firestar ti-Series operator’s manual

dimensions, sheet 1 of 2

DESCRIPTION:

FINISH:

MATERIAL:

REVECO DATE

DESCRIPTION DB

TOLERANCES UNLESS NOTED:

.

°

ANGLE = ±

.x = ±

.xx = ±

.xxx = ±

.

PROPRIETARY

THIS DRAWING IS PROPRIETARY TO

SYNRAD INC. AND SHALL NOT BE

USED OR DISCLOSED IN WHOLE

OR IN PA RT WITHOUT WRITTEN

PERMISSION OF SYNRAD INC.

PA RT NUMBER:

DWG/FILE NUMBER:

SHEET

ENG:

DRAWN BY:

DATE:

UNITS:

CATEGORY:

CHECKED BY:

DATE:

SIZE: B

FINISH CLASS:

APPROVED BY:

DATE:

SYNRAD INC.

4600 Campus Place

Mukilteo, WA 98275

Phone: [phone]

Fax: [phone]

OUTLINE & MOUNTING, AIR-COOLED, Ti60, OEM

26-Aug-08

300-19847-01

2

.

.

.

300-19847-01

of

2

D. DUVALL

Inches

.

DMDRELEASE TO PRODUCTION

14-May-09

4045

A

ADD NOTE 4

B

DMD

9-Sep-09

4107

.

.

.

.

.

1.70.51

technical reference

Firestar ti-Series package outline

drawings

Figure 3-25 OEM air-cooled Firestar ti60 (SA model) package outline and mounting

dimensions, sheet 2 of 2

335Synrad Firestar ti-Series operator’s manual

technical reference

Firestar ti-Series packaging instructions

Figure 3-26 Firestar ti-Series packaging instructions

336 Synrad Firestar ti-Series operator’s manual

maintenance/

troubleshooting

Use information in this chapter to perform maintenance or troubleshoot your Firestar
ti-Series laser.

This chapter contains the following information:

■ Maintenance – describes typical ti-Series maintenance procedures.

■Troubleshooting – explains how to troubleshoot ti-Series problems.

4

Synrad Firestar ti-Series operator’s manual

41

maintenance/
troubleshooting

Maintenance

The Maintenance section includes subsections:

■Disabling Firestar

■Daily inspections

■Storage/shipping

■Cleaning optical components

Disabling Firestar

Before performing any maintenance on your Firestar® ti-Series laser, be sure to completely disable the laser
by disconnecting DC power from the laser.

Daily inspections

Perform the following steps daily to keep your Firestar ti-Series 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

1

For water-cooled lasers, inspect cooling tubing connections for signs of leakage. Check for signs of

condensation that may indicate the cooling water temperature is 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

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.

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

42

Synrad Firestar ti-Series operator’s manual

maintenance/

troubleshooting

Maintenance

3

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

to Firestar ti-Series label locations in the Laser Safety chapter for label types and locations.

Storage/shipping

When preparing a water-cooled 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 less than 29 PSI (while wearing safety
glasses!) to remove any residual water. When finished, cap all cooling 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 Firestar ti-Series packaging
instructions in the Technical Reference chapter for detailed instructions on packaging the laser for ship­ment.

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

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

Cleaning optical components

Danger

serious

personal

injury

Caution

possible

equipment

damage

Ensure that DC power to the laser is turned off 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.

Because of their smaller beam diameter, Firestar lasers have signifi­cantly higher power densities than previous SYNRAD lasers. This
means that even a small amount 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 the output window and other
beam delivery optics periodically for signs of contaminants and care­fully clean as required. In dirty environments, purge laser optics using
filtered air or nitrogen to prevent vapor and debris from accumulating
on optical surfaces.

Synrad Firestar ti-Series operator’s manual

43

maintenance/
troubleshooting

Maintenance

Debris or contaminants on the laser’s output coupler or external beam delivery components may affect 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.

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 rubber or latex finger cots or rubber gloves (powder-free) to prevent contamination of optical

surfaces by dirt and skin oils.

■ Never handle optics with tools; always use gloved hands or fingers.

■ 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 fluffed cotton swab or cotton ball instead of a lens wipe to uniformly clean

the entire surface of small-diameter mounted optics.

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

safety precautions.

Required cleaning materials

Table 4-1 lists the type and grade of materials required to properly clean optical surfaces.

Table 4-1 Required cleaning materials

Cleaning Material Requirements

Finger cots or rubber gloves Powder free

Air bulb Clean air bulb

Ethyl 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

44

Synrad Firestar ti-Series operator’s manual

maintenance/

troubleshooting

Maintenance

Cleaning optics

1

Shut off 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. Ethyl alcohol (least aggressive) is best for

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

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

surface using ethyl alcohol is required to remove any acetone residue.

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 significant amounts of water and oil that
form adsorbing films 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 final ethyl 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.

Synrad Firestar ti-Series operator’s manual

45

maintenance/
troubleshooting

Troubleshooting

The Troubleshooting section includes subsections:

■Introduction

■Operational flowchart

■Functional block diagram

■Status LEDs

■Laser faults

■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/replace­ment information. To troubleshoot the Firestar ti-Series laser, it is necessary to understand the sequence
of events that must happen before the laser can turn on and operate. Before you attempt to perform any
service, we advise you to read the entire troubleshooting guide and review both the operational flowchart
and the functional block diagram. Symptoms and possible causes are highlighted by dark print and bullet
points throughout this section. Information about each symptom and cause can be found in paragraphs
following each heading.

Danger

serious

personal

injury

This Class IV laser product emits invisible infrared laser radiation in
the 10.6 µm CO2 wavelength band. Since direct or diffuse laser radia­tion can inflict 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

damage

46

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.

Synrad Firestar ti-Series operator’s manual

Ye s

No

INT

(Remote Interlock)

indicator Green?

TMP

(Te mperature)

indicator

Green?

SHT

(Shutter) indicator

Blue?

RDY

(Ready) indicator

Ye llow?

RDY

(Ready) indicator

Yellow?

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

Quick Start Plug

Water-Cooled:

Check that cooling water

is flowing through laser

and that coolant temp

is within specified limits

Apply shutter open

signal to Shutter Open

Request input or install

factory-supplied Quick

Start Plug

Cycle Keyswitch from ON

to OFF and then

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

Ensure that manual

Shutter Switch (if

equipped) is set

to Open

Apply PWM Command

signal to laser

Tu rn Keyswitch

(if equipped)

to ON

Apply 48 VDC
power to laser

LASE indicator

illuminates Red to

indicate laser output

Laser Start Sequence

Ye s

Ye s

Ye s

No

No

No

Ye s

No

Air-Cooled:

Check that cooling fans

are clear of debris

and are providing the

specified airflow

maintenance/

troubleshooting

Troubleshooting

Operational flowchart

The flowchart in Figure 4-1 illustrates Firestar’s start-up sequence.

Figure 4-1 Operational flowchart

Synrad Firestar ti-Series operator’s manual

47

maintenance/

OVER

TEMPERATURE

DETECTOR

REMOTE

INTERLOCK

DETECTOR

STATUS INDICATORS

REMOTE

INTERLOCK

TEMP

READY

SHUTTER

LASE

SHUTTER

CONTROL

CATGEN

DELAY TIMER

48 VDC

INPUT

DB15 USER I/O

CONNECTOR

POWER

ON AND

FAULT

DETECT

OUTPUT

ISOLATION

INPUT

ISOLATION

TO RF DRIVER BOARD

TO CONTROL BOARD

PWM OUT

OVER TEMPERATURE

LASER ACTIVE

LASE

INDICATOR

INTERLOCK OPEN

REMOTE INTERLOCK

SHUTTER OPEN REQUEST

SHUTTER OPEN

VOLTAGE

REGULATOR

DC POWER

SWITCH

FAULT

PWM INPUT

REMOTE RESET/START REQUEST

READY

LASER READY

troubleshooting

Troubleshooting

Functional block diagram

Figure 4-2 is a functional block diagram illustrating ti-Series control architecture.

Synrad Firestar ti-Series operator’s manual

Figure 4-2 Firestar ti-Series functional block diagram

48

maintenance/

troubleshooting

Troubleshooting

Status LEDs

Firestar ti-Series LED indicators, also mirrored as output signals on the User I/O connector, provide status
information to the user. Table 4-2 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 4-2 Status signals

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

INT Green Red Interlock Open Open Closed

TMP Green Red Over Temperature Open Closed

RDY Yellow Off Laser Ready Closed Open

SHT Blue Off Shutter Open Closed Open

LASE Red Off Laser Active Closed Open

On ti-Series keyswitch lasers, the RDY indicator illuminates yellow only when INT and TMP indicators
are green and the Keyswitch is cycled from OFF to the ON position. After the RDY indicator illuminates,
a five-second delay occurs before Firestar is permitted to lase. The SHT LED illuminates blue when a
Shutter Open Request signal is applied and the manual Shutter Switch is set to Open. If the RDY indicator
is lit and the shutter is switched from Closed to Open, there is a five-second delay until PWM inputs are
recognized. When PWM Command pulses are applied (and are long enough to produce laser output) the
LASE LED illuminates red.

On OEM lasers, the RDY lamp illuminates on DC power-up when INT and TMP indicators illuminate
green. After the RDY indicator illuminates, a five-second delay occurs before Firestar is permitted to lase.
The SHT LED illuminates blue when a Shutter Open Request signal is applied. If the RDY indicator is
lit and then a Shutter Open Request signal is applied, there is a five-second delay until PWM inputs are
recognized. When PWM Command pulses are applied (and are long enough to produce laser output) the
LASE LED illuminates red.

Note: Firestar RDY and SHT indicators (as well as Laser Ready and Shutter Open outputs) denote

separate control functions. Although the RDY lamp may light while the SHT LED is Off (Shutter
Switch Closed or Shutter Open Request signal missing), no power is applied to the RF boards
until both RDY and SHT indicators are illuminated.

Tables 4-3 through 4-5 on the following page show how Firestar’s signal status changes when remote inter­lock, over temperature, or shutter closed conditions occur.

Synrad Firestar ti-Series operator’s manual

49

maintenance/
troubleshooting

Troubleshooting

Table 4-3 Interlock Open condition

LED Indicator LED Status Signal Name Output Signal Status

INT Red Interlock Open Closed

TMP Green Over Temperature Open

RDY Off Laser Ready Open

SHT Blue Shutter Open Closed

LASE Off Laser Active Open

Table 4-4 Over Temperature condition

LED Indicator LED Status Signal Name Output Signal Status

INT Green Interlock Open Open

TMP Red Over Temperature Closed

RDY Off Laser Ready Open

SHT Blue Shutter Open Closed

LASE Off Laser Active Open

Table 4-5 Shutter Open condition

LED Indicator LED Status Signal Name Output Signal Status

INT Green Interlock Open Open

TMP Green Over Temperature Open

RDY Yellow Laser Ready Closed

SHT Off Shutter Open Open

LASE Off Laser Active Open

410

Synrad Firestar ti-Series operator’s manual

maintenance/

troubleshooting

Troubleshooting

Laser faults

Firestar ti-Series lasers have the ability to indicate four specific fault conditions. In the event of certain
faults, the RDY LED on the laser blinks an error code, pause four seconds, and then repeat the error code.
This sequence continues until the fault is corrected and the laser is reset by cycling DC power to the laser.

Table 4-6 lists error codes, the corresponding fault condition, and describes any corrective action possible
in the field.

Table 4-6 Laser error codes

Number of Blinks
Ready (RDY) Indicator Fault Condition Corrective Action in Field

1 blink Under Voltage Fault Verify 48 VDC is measured at laser under load

2 blinks Over Voltage Fault Verify 48 VDC is measured at laser under load

3 blinks RF Drive DC Fault None

4 blinks PWM Drive Fault None

Resetting faults

Keyswitch lasers

Remote interlock fault

A remote interlock fault occurs when the Remote Interlock input opens ( the INT indicator
changes from green to red). To reset a remote interlock fault, re-establish the Remote Inter-
lock signal input (INT indicator changes from red to green) and cycle the Keyswitch from OFF
to ON (or apply a Remote Reset/Start Request pulse with the Keyswitch set to ON). When
the RDY indicator illuminates, lasing is enabled after a five-second delay.

Over temperature fault

Over temperature faults occur when thermal limits in the laser are exceeded (the TMP indica­tor changes from green to red). To reset an over temperature fault, lower coolant temperature
below 30 °C (water-cooled) or below 40 °C (air-cooled), cycle DC power to the laser, and then
cycle the Keyswitch from OFF to ON (or apply a Remote Reset/Start Request pulse with
the Keyswitch set to ON). When the RDY indicator illuminates, lasing is enabled after a five­second delay.

Note: Water-cooled ti-Series lasers can be operated at coolant temperatures up to 30 °C to

reduce problems associated with condensation; however, this may result in decreased
laser performance and/or reduced laser lifetime.

Shutter fault

A closed shutter is not considered a fault condition. When a Shutter Open Request signal is
applied and the manual Shutter Switch is set to Open, lasing is enabled after a five-second delay
provided that the RDY indicator is illuminated yellow.

Synrad Firestar ti-Series operator’s manual

411

maintenance/
troubleshooting

Troubleshooting

Under/over voltage fault

An under voltage or over voltage fault occurs when the DC input voltage is below or above
preset limits. This fault is indicated by the RDY indicator flashing 1 blink (under voltage) or
2 blinks (over voltage). To reset an under voltage or over voltage fault, ensure that 48 VDC is
applied to the laser under full-load conditions, cycle DC power, and then toggle the Keyswitch
from OFF to ON (or apply a Remote Reset/Start Request pulse with the Keyswitch set to
ON). When the RDY indicator illuminates, lasing is enabled after a five-second delay.

RF Drive DC fault

An RF Drive DC fault is indicated by the RDY indicator flashing 3 blinks. Reset the laser by
removing DC power from the laser, wait 30 seconds, reapply DC power, and then toggle the
Keyswitch from OFF to ON (or apply a Remote Reset/Start Request pulse with the Keyswitch
set to ON). If the RF Drive DC fault reappears, contact SYNRAD or a SYNRAD Authorized
Distributor.

PWM Drive fault

A PWM Drive fault is indicated by the RDY indicator flashing 4 blinks. Reset the laser by
removing DC power from the laser, wait 30 seconds, reapply DC power, and then toggle the
Keyswitch from OFF to ON (or apply a Remote Reset/Start Request pulse with the Keyswitch
set to ON). If the PWM Drive fault reappears, contact SYNRAD or a SYNRAD Authorized
Distributor.

Warning

serious

personal

injury

On Firestar ti-Series OEM lasers, remote interlock (INT) faults are
not latched. Clearing the fault condition re-enables the RDY indica­tor and the laser will fire after the five-second delay provided that the
SHT indicator is lit and a PWM Command signal is applied. Because
exposure to 10.6 µm CO2 laser radiation can inflict 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.

OEM lasers

Remote interlock fault

A remote interlock fault occurs when the Remote Interlock input opens ( the INT indicator
changes from green to red). On OEM lasers, remote interlock (INT) faults are not latched.
Re-establish the Remote Interlock signal input (INT indicator changes from red to green) to
enable the RDY indicator and begin lasing after the five-second delay.

Over temperature fault

Over temperature faults occur when thermal limits in the laser are exceeded (the TMP indica­tor changes from green to red). To reset an over temperature fault, lower coolant temperature
below 30 °C (water-cooled) or below 40 °C (air-cooled) and then cycle DC power to the laser.

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Synrad Firestar ti-Series operator’s manual

maintenance/

troubleshooting

Troubleshooting

Once the RDY lamp is illuminated, lasing is possible after the five-second delay.

Note: Water-cooled ti-Series lasers can be operated at coolant temperatures up to 30 °C to

reduce problems associated with condensation; however, this may result in decreased
laser performance and/or reduced laser lifetime.

Shutter fault

A closed shutter is not considered a fault condition. When a Shutter Open Request signal is
applied, lasing is enabled after a five-second delay provided that the RDY indicator is illumi­nated yellow.

Under/over voltage fault

An under voltage or over voltage fault occurs when the DC input voltage is below or above
preset limits. This fault is indicated by the RDY indicator flashing 1 blink (under voltage) or
2 blinks (over voltage). To reset an under voltage or over voltage fault, ensure that 48 VDC
is applied to the laser under full-load conditions and then cycle DC power. When the RDY
indicator illuminates, lasing is enabled after a five-second delay.

RF Drive DC fault

An RF Drive DC fault is indicated by the RDY indicator flashing 3 blinks. Reset the laser by
removing DC power to the laser, wait 30 seconds, and then reapply DC power. If the RF Drive
DC fault reappears, contact SYNRAD or a SYNRAD Authorized Distributor.

PWM Drive fault

A PWM Drive fault is indicated by the RDY indicator flashing 4 blinks. Reset the laser by
removing DC power to the laser, wait 30 seconds, and then reapply DC power. If the PWM
Drive fault reappears, contact SYNRAD or a SYNRAD Authorized Distributor.

Other laser faults

When a laser fault occurs, Firestar’s status LEDs and output signals will reflect a fault condition as indi­cated in Tables 4-3–4-5 or Table 4-6. Each Symptom listed below describes a particular fault. For each
Symptom, specific causes and solutions are described under Possible Causes.

Warning

serious

personal

injury

On Firestar ti-Series OEM lasers, remote interlock (INT) faults are
not latched. Clearing the fault condition re-enables the RDY indica­tor and the laser will fire after the five-second delay provided that the
SHT indicator is lit and a PWM Command signal is applied. Because
exposure to 10.6 µm CO2 laser radiation can inflict 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.

Synrad Firestar ti-Series operator’s manual

413

maintenance/
troubleshooting

Troubleshooting

Symptom:

■ A remote interlock fault is indicated.

INT LED – Red Interlock Open output – Closed
TMP LED – Green Over Temperature output – Open
RDY LED – Off Laser Ready output – Open
SHT LED – Blue Shutter Open output – Closed
LASE LED – Off Laser Active output – Open

Possible Causes:

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

On systems using remote interlocks, check to see that a positive or negative voltage (±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).

Symptom:

■ An over temperature fault is indicated.

INT LED – Green Interlock Open output – Open
TMP LED – Red Over Temperature output – Closed
RDY LED – Off Laser Ready output – Open
SHT LED – Blue Shutter Open output – Closed
LASE LED – Off Laser Active output – Open

Possible Causes:

■ Water-cooled lasers – Cooling water temperature is above 30 °C (86 °F) or there is inadequate water

flow through the laser.

Check that the chiller is maintaining a coolant temperature between 18 °C–30 °C (64 °F–86 °F) at a flow
rate of 1.0–2.0 gallons per minute (GPM) for ti60 lasers; 1.5–2.0 GPM for ti100 lasers. If coolant tempera­ture is OK, check the flow rate. If a flow meter is not available, disconnect the cooling tubing from the
chiller inlet (or the drain) and run the coolant for one minute into a five-gallon bucket; you should have
close to 1.0–2.0 gallons. If there is much less than one gallon in the bucket, check the cooling path for
kinked or pinched cooling tubes and check the chiller for a clogged or dirty filter.

Note: Water-cooled ti-Series lasers can be operated at coolant temperatures up to 30 °C to reduce prob-

lems associated with condensation; however, this may result in decreased laser performance and/
or reduced laser lifetime.

■ Fan-cooled lasers – Cooling fans are not providing adequate airflow to the laser.

Check that all cooling fans are clear of debris and are providing an airflow rate of at least 150 cubic feet
per minute (CFM) per fan for ti60 lasers. To allow for proper airflow, cooling fans must have at least 2.25
inches (57.2 mm) of unobstructed clearance between the outside edge of the cooling fan housing and any
mounting surface or enclosure.

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Synrad Firestar ti-Series operator’s manual