48 Series Operator’s Manual

4600 Campus Place

Mukilteo, WA 98275
1.800.SYNRAD1
tel 1.425.349.3500
fax 1.425.349.3667
e-mail [email protected]
web www.synrad.com
 N Version Operator’s Manual
48 Series Operator’s Manual
Model 48-1
Model 48-2

Model 48-5

Version 9.6

SYNRAD is a registered trademark of Novanta Corporation. ©Novanta Corporation 2018. All Rights Reserved. No
reproduction without written authorization.

DATE: July 2019

 Table of contents
Introduction 1

Introduction..................................................................................................................................................5
Series 48™ Trademark, Warranty & Copyright information.........................................................6
Guidelines & Content...............................................................................................................................10
Unpacking/packing, storage/shipping, mounting, connecting, cooling.............................10
Series 48 nomenclature..........................................................................................................................12
Laser Safety 2

Laser Safety..................................................................................................................................................14
Hazard Information..................................................................................................................................15
Other hazards.............................................................................................................................................18
Disposal........................................................................................................................................................18
Series 48-1 label locations......................................................................................................................19
Series 48-2 label locations......................................................................................................................20
Series 48-5 label locations......................................................................................................................21
Agency compliance .................................................................................................................................22

Operation 3
Controls and Indicators ..........................................................................................................................29
48-1/48-2 front panel...............................................................................................................................29
48-1/48-2 rear panel.................................................................................................................................30
Side panel....................................................................................................................................................31
48-5 front panel ........................................................................................................................................32
48-5 rear panel ..........................................................................................................................................33

Technical Reference 4

Technical reference summary...............................................................................................................34

Technical overview ..................................................................................................................................35
Introduction................................................................................................................................................35
Plasma section............................................................................................................................................35
Controlling Laser Power..........................................................................................................................36
Optical resonator.......................................................................................................................................36
Fault shutdown conditions....................................................................................................................37
Cooling..........................................................................................................................................................37
Cooling..........................................................................................................................................................38
Setting coolant temperature................................................................................................................38
Duo-Lase® operation (48-5)...................................................................................................................41
Optical setup...............................................................................................................................................41
Control signals............................................................................................................................................44
Operating modes......................................................................................................................................49
UC-2000 Universal Laser Controller....................................................................................................50
Continuous wave (CW) operation.......................................................................................................51
DB-9 connections......................................................................................................................................53
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 Table of contents
Technical Reference 4

User I/O connections................................................................................................................................55

Sample DB-9 Connector I/O circuits...................................................................................................58
Sample output circuits............................................................................................................................59
Integrating Series 48™ safety features ..............................................................................................61
Remote keyswitch functions.................................................................................................................61
Remote interlock functions...................................................................................................................62
Water-cooled connections.....................................................................................................................64
Water-cooled connections.....................................................................................................................65
Model 48-1 general specifications......................................................................................................67
Model 48-2 general specifications......................................................................................................69
Model 48-5 general specifications......................................................................................................71
Technical Drawings...................................................................................................................................73

Maintenance & Troubleshooting 5

Maintenance and Troubleshooting ...................................................................................................82

Introduction................................................................................................................................................82
Maintenance...............................................................................................................................................83
Disabling the Series 48™ laser..............................................................................................................83
Daily inspections.......................................................................................................................................83
Storage/shipping.......................................................................................................................................84
Coolants........................................................................................................................................................84
Cleaning guidelines..................................................................................................................................86
Cleaning optics..........................................................................................................................................87
Troubleshooting .......................................................................................................................................88
Troubleshooting Introduction..............................................................................................................88
Resetting faults..........................................................................................................................................89
Keyswitch lasers.........................................................................................................................................89
Status LEDs..................................................................................................................................................94
Beam delivery optics................................................................................................................................95

Index

Index...........................................................................................................................................................101

SYNRAD® Series 48™ Operator’s Manual Version 9.6

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 Introduction

1
Introduction
Series 48™ Trademark, Copyright & Warranty information
Series 48 guidelines and contents description
Series 48 Nomenclature

Warning Remote interlock faults are not latched on OEM lasers. Clearing the
fault condition re-enables the RDY indicator and the laser will bee
Serious enabled five seconds after the SHT indicator is lit and a PWM Com-
personal mand signal is applied.
injury
Because exposure to CO2 laser radiation in the (9-11) µm range 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.

Caution SYNRAD does not recommend vertical or head down configurations.

Possible
Equipment Please contact the factory for limitations as a vertical orientation increases the
Damage risk of damage to the lasers optics.

A risk of exposure to toxic elements 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®, or
the optics manufacturer for handling instructions.
If you operate your laser dirty or dusty environments, 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.

Important This Operation Manual explains operation activities related to Series 48™ lasers. If you cannot oper-
ate the unit using the information described in this manual, contact SYNRAD® (+1.425.349.3500) or
Note: an authorized SYNRAD Distributor.

The Quick Start Guide (QSG) Quickstart explains how to quickly unpack and assemble Series 48 lasers. Please refer-
ence the QSG along with the information within this manual.
Lift the laser only by the mounting feet or baseplate. Do not lift or support the laser by its cooling fittings.
Please reference the Quick Start Guide for unpacking, mounting, and connecting.
Failure to properly package the laser using SYNRAD shipping box and foam/cardboard inserts as shown in Pack-
aging Instructions may void the warranty. Customers may incur additional repair charges due to shipping damage
caused by improper packaging.
Before beginning any maintenance or inspections of your Series 48 laser, be sure to completely disable the laser by
disconnecting the DC Power cable (or cables) from the rear of the laser.
SYNRAD® Series 48™ Operator’s Manual Version 9.6

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 Introduction
Trademark/copyright information

Series 48™ Trademark, Warranty & Copy-

right information
SYNRAD® and Series 48™ are registered trademarks of SYNRAD.

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

2019 by SYNRAD.
All rights reserved.

SYNRAD® Series 48™ Operator’s Manual Version 9.6

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 Introduction
Warranty information

This is to certify that Series 48-1 lasers are guaranteed by SYNRAD® to be free of all defects in
materials and workmanship for three years from the date of shipment. Series 48-2 and 48-5
lasers are guaranteed to be free of all defects in materials and workmanship for a period of
one year from the date of shipment. This warranty does not apply to any defect caused by
negligence, misuse (including environmental factors), accident, alteration, or improper main-
tenance. This includes, but is not limited to, damage due to corrosion, condensation, or failing
to supply properly conditioned purge gas.
We request that you examine each shipment within 10 days of receipt and inform SYNRAD of
any shortage or damage. If no discrepancies are reported, SYNRAD shall assume the shipment
was delivered complete and defect-free.

If, within one year from the date of purchase, any part of the Series 48 laser should fail to op-
erate, 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 de-
scription of the problem. When returning a unit for service, a Return Authorization (RA) num-
ber 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 instruct-
ed.
If your Series 48 laser fails within the first 45 days after purchase, SYNRAD 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 re-
sponsible 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 Series 48 laser, only authorized SYNRAD replacement
parts can be used. This warranty is void if any parts other than those provided by SYNRAD are
used.

SYNRAD and SYNRAD Authorized Distributors have the sole authority to make warranty state-
ments regarding SYNRAD products. SYNRAD and its Authorized Distributors neither assumes
nor authorizes any representative or other person to assume for us any other warranties in
connection with the sale, service, or shipment of our products. SYNRAD reserves the right to
make changes and improvements in the design of our products at any time without incurring
any obligation to make equivalent changes in products previously manufactured or shipped.
Buyer agrees to hold SYNRAD harmless from any and all damages, costs, and expenses relat-
ing 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® Series 48™ Operator’s Manual Version 9.6

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 Introduction
Sales, Application, & Support

SYNRAD Sales & Support

SYNRAD Headquarters
SYNRAD® worldwide headquarters are located north of Seattle in Mukilteo, Washington. U.S.A.
Our mailing address is:
SYNRAD
4600 Campus Place
Mukilteo, WA 98275
U.S.A.
Phone us at: 1.800.SYNRAD1 (1.800.796.7231)
Outside the U.S.: +1.425.349.3500
Fax: +1.425.349.3667
E-mail: [email protected]

web: www.synrad.com

Sales and Applications

SYNRAD Regional Sales Managers work with customers to identify and develop the best CO2
laser solution for a given application. Because they are familiar with you and your laser appli-
cation, 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 rep-
resentative, or you can email us by sending a message to [email protected].

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

Reference materials
Your Regional Sales Manager can provide reference materials including Outline & Mounting
drawings, Operator’s Manuals, Technical Bulletins, and Application Newsletters. Most of these
materials are also available directly from SYNRAD web site at http://www.synrad.com.
SYNRAD® Series 48™ Operator’s Manual Version 9.6

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 Introduction
European headquarters
European Headquarters
For assistance in Europe, contact SYNRAD® European subsidiary, SYNRAD Europe, at:
©
Novanta Distribution (USD) GmbH
Parkring 57-59
85748 Garching bei München, Germany

Phone: +49 89 31707-0

Fax: +49 (0) 89 31707-222
E-mail: [email protected]

web: www.synrad.com

SYNRAD® Series 48™ Operator’s Manual Version 9.6

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 Introduction
Guidelines & Content Description

Guidelines & Content

See the drawings within this Operation Manual when installing and operating your Series 48™
laser.
Unpacking/Packing, Storage/Shipping, Mounting, Connecting, Cooling

Series 48 nomenclature/features

Unpacking/packing, storage/shipping, mount-

ing, connecting, cooling
SYNRAD® recommends saving all of the laser’s original packaging. It’s unique design assists in
preventing damage to your laser during storage, relocation and/or shipping.
Reference our Quick Start Guide Series at Synrad.com. Additional information can also be
found in the Technical Reference chapter within this manual.

Contents description
Each item below is also listed in tables that follow:

SYNRAD® OEM Series 48™ Laser – for cutting, welding, drilling, and marking a wide variety of
products and materials.

Customer Communication Flier Series 48– Instead of the laser manual CD, please follow the
instructions for our latest laser manual(s) located here: https://www.synrad.com/resources/
libraries/manuals

Mounting kit (Keyswitch models only) – Contains components to mount the laser and also
includes a DB-9 connector and cover to replace the factory jumper plug when integrating
Series 48 laser signals into your control system.

Spare Fuse – Fuses protect Series 48 internal circuitry. A 10 A fuse is included with 48-1 lasers,
a 20 A fuse with 48-2 lasers, and two 20 A fuses are shipped with 48-5 lasers.

Cooling Kit (water-cooled lasers only) – (48-1/48-2) includes quick-disconnect inlet and
outlet cooling manifolds, extra 1/4” union elbows, extra straight 1/8 in NPT to 1/4 in tube fit-
tings, and 20 feet of 1/4 in O.D. black polyethylene tubing. (48-5) – includes quick-disconnect
inlet and outlet cooling manifolds, extra 1/4 in union elbows, extra straight 1/4 in NPT to 3/8 in
tube fittings, and 20 feet of 3/8 in O.D. black polyethylene tubing.

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 Introduction
Guidelines & Content Description

SYNRAD® CO2
Web Flier

Spare Fuse(s)

Cooling Kit - water

cooled lasers only
(48-1/48-2 kit shown)

Series 48™ Laser

(10 W water-cooled laser shown)

AD
NR
SY

Figure 1-1 Series 48™ ship kit contents.

Table 1-1 Series 48 ship kit contents.

Shipping Box Contents Qty Shipping Box Contents Qty

Series 48 Laser.........................................1 Mounting Bolts ....................................(Not Standard)

Customer communication flier.......1 Cooling Kit ............................................(As Required)
Spare Fuses ...................(As Required)

Maximum torque (48-1) 0.41 Nm or 4 in-lb 6-32 screw, (48-2) 0.41 Nm or 4 in-lb 6-32 screw,
(48-5) 1.4 Nm or 12.1 in-lb 10-32 screw.
Minimum thread engagement should be 5 mm or 0.200 in (48-1 and 48-2 only).
Maximum thread engagement should be (48-1) 7.6 mm or 0.300 in, (48-2) 7.6 mm or 0.300 in,
(48-5) .2 mm or 0.125 in,
*Recommend using low-outgassing thread lock adhesive or locking washer.
*Refer to outline and mounting drawing for details.

SYNRAD® Series 48™ Operator’s Manual Version 9.6

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 Introduction
Guidelines & Content Description

Series 48 nomenclature
The Series 48 nomenclature section includes:
Model numbers

Series 48 laser versions

The last three characters in the Series 48 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” Standard (OEM) for OEM models. The next letter indicates the cooling
method: “W” for water-cooled units, “A” for air-cooled lasers (where the customer must pro-
vide the proper cooling via fans or blowers). The last letter in the model number indicates the
current model version “N”. For example, the model number 48-1 KAN designates the Series 48
laser as a Keyswitch, air-cooled version N.

SYNRAD® Series 48™ Operator’s Manual Version 9.6

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 Introduction
Features & Nomenclature

48 Series (Laser Family)

Power Options (Watt) Other Options

-1 10 10.6 µ
NIL
-2 25 9.3 9.3 µ
-5 50 10.2 10.2 µ
CL Closed Loop Kit

Other Customer
Specific
Options

Safety Options

S OEM Model
K Keyswitch Version
and
Shutter
Number
(A-Z)
Cooling Options

A Air
W Water

Figure 1-2 Anatomy of a model number.

SYNRAD® Series 48™ Operator’s Manual Version 9.6

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 Laser Safety

2
Laser Safety
Hazard Information – includes equipment label terms and hazards, please familiarize
yourself with all definitions and their significance.

General & Other Hazards – provides important information about the hazards and
unsafe practices that could result in death, severe injury, or product damage.

Disposal – information on your 48 series laser parts and/or components as they pertain
to disposal.

Additional safety Information – describes how to find additional information about

your 48 series laser.

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

tion information.

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

Safety Data Sheets (SDS) for materials processed should be

Warning evaluated and the adequacy of provisions for fume extraction,
Serious filtering, and venting should be carefully considered.
personal
This Class 4 CO2 laser product emits invisible infrared laser
injury radiation in the 9.3–10.6 µm wavelength band.
Because 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.
Assure you understand target material.

SYNRAD® Series 48™ Operator’s Manual Version 9.6

14
 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 4 laser equipment.

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

Parameter Description
WARNING: Alerts operator of serious dangers, hazardous radia-
tion, hazardous voltages, vapor hazard, & reflective dangers.
Potential & Imminent hazards which, if not avoided, could result in
death or serious injury.

DANGER: Alerts operator of lifting dangers.

Hazards which, if not avoided, could result in minor or moderate
Two
Person Lift injury.

CAUTION: Alerts operator of equipment dangers.

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

IMPORTANT NOTES & TIPS: Alerts operator of Content specific

Important
Note: information and/or recommendations.
If not followed may lead to inconveniences such as rail assembly
which could lead to re-work.
Note: Tip:

Figure 2-1 Labeling terms and definitions.

Warning For laser systems being used or sold within the U.S.A.,
Serious customers should refer to and follow the laser safety
precautions described American National Standards Institute
personal (ANSI) document Z136.1-2014, Safe Use of Lasers.
injury For laser systems being used or sold outside the U.S.A.,
customers should refer to and follow the laser safety
precautions described in European Normative and International
Electrotechnical Commission documents IEC/TR 60825-14:2014,
Safety of Laser Products – §14: A User’s Guide.

SYNRAD® Series 48™ Operator’s Manual Version 9.6

15
 Laser Safety
Hazard Information (Continued)
Following are descriptions of 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.

Warning Enclose the beam path whenever possible. Exposure to

Serious direct or diffuse CO2 laser radiation can seriously burn
personal human or animal tissue, which may cause permanent
injury damage.

This product is not intended for use in explosive, or po-

tentially explosive, atmospheres.

Materials processing with a laser can generate air con-

taminants such as vapors, fumes, and/or particles that
may be noxious, toxic, or even fatal.

Safety Data Sheets (SDS) for materials being processed should be thoroughly eval-
uated and the adequacy of provisions for fume extraction, filtering, and venting
should be carefully considered. Review the following references for further informa-
tion on exposure criteria:

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 Governmen-

tal Industrial Hygienists (ACGIH).

It may be necessary to consult with local governmental agencies regarding restric-

tions on the venting of processing vapors.

The use of aerosol dusters containing difluoroethane causes “blooming”, a condition

that significantly expands and scatters the laser beam. This beam expansion can ef-
fect mode quality and/or cause laser energy to extend beyond the confines of optical
elements in the system, possibly damaging acrylic safety shielding. Do not use air
dusters containing difluoroethane in any area adjacent to CO2 laser systems because
difluoroethane persists for long time periods over wide areas.

SYNRAD® Series 48™ Operator’s Manual Version 9.6

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 Laser Safety
Hazard Information (Continued)
48 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 instal-
lation 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 expo-
sure to direct or scattered laser radiation, follow all safety precautions specified throughout
this manual and exercise safe operating practices per ANSI Z136.1-2014, Safe Use of Lasers at
all times when actively lasing.
Due to the specific properties of laser light, a unique set of safety hazards that differ from oth-
er light sources must be considered. Just like light, lasers can be reflected, refracted, diffracted
or scattered.

Never use organic

Serious Light
material or metals as
Personal a beam blocker. There
Warning! are very few exceptions,
Injury e.g. black anodized
metal such as aluminum
because this is non
reflective surface.

Figure 2-2 Always wear safety glasses or protective goggles with side shields to reduce the
risk of damage to the eyes when operating the laser.
A CO2 laser is an intense energy source and will ignite most materials under the proper con-
ditions. Never operate the laser in the presence of flammable or explosive materials, gases,
liquids, or vapors.

Warning “Caution - The use of controls or adjustments or

Serious performance of procedures other than those specified herein
personal may result in hazardous radiation exposure.”
injury

Safe operation of the laser requires the use of an external beam block to safely block the
beam from traveling beyond the desired work area. Do not place your body or any combusti-
ble 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 materi-
al 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.

SYNRAD® Series 48™ Operator’s Manual Version 9.6

17
 Laser Safety
Other hazards
The following hazards are typical for this product family when incorporated for intended use:
(A) risk of injury when lifting or moving the unit; (B) risk of exposure to hazardous laser energy
through unauthorized removal of access panels, doors, or protective barriers; (C) risk of expo-
sure to hazardous laser energy and injury due to failure of personnel to use proper eye pro-
tection 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 sit-
uation occurs where the laser is rendered non-functional and cannot be repaired, it may be re-
turned to SYNRAD who, for a fee, will ensure adequate disassembly, recycling and/or disposal
of the product.

Additional laser safety information

The SYNRAD web site http://www.synrad.com/LaserFacts/safetyinfo.html contains an online
laser safety handbook that provides information on (1) Laser Safety Standards for OEM’s/Sys-
tem 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. Sec-
tion III, Chapter 6 and Appendix III are good resources for laser safety information.

Another excellent laser safety resource is the Laser Institute of America (LIA). Their compre-
hensive web site is located at http://www.lia.org.

SYNRAD® Series 48™ Operator’s Manual Version 9.6

18
 Laser Safety
Series 48-1 label locations
10.6 MICRON

DANGER-INVISIBLE LASER
RADIATION. AVOID EYE OR SKIN 30 WATTS MAX
EXPOSURE TO DIRECT OR
SCATTERED RADIATION 10200–10800 nm
CLASS 4 LASER PRODUCT
EN-60825-1, 2014

CAUTION
9.3 MICRON These RF Excited Lasers must be provided with a
pre-ionizing "Tickle" signal during standby or
laser "low" periods. This is automatically provided
with Synrad's UC Series power controller. This signal
keeps the plasma ionized during laser "low" periods
30 WATTS MAX
and facilitates breakdown and pulse to pulse fidelity.
9229–9317 nm Damage or malfunction may occur if this or
equivalent drive signals are not used. See manual
for tickle pulse specifications or contact factory.

TOP VIEW

CAUTION
CAUTION MODEL #: 48-1KWM
These RF Excited Lasers must be provided with a
CONDENSATION AND pre-ionizing "Tickle" signal during standby or SERIAL #: 0481263115066
INVISIBLE LASER RADIATION 30 WATTS MAX TESTED AT 30 Volts MFG September 20, 2011
WATER DAMAGE CAN laser "low" periods. This is automatically provided
AVOID EYE OR SKIN EXPOSURE TO Complies with IEC 60825-1 (2007) and 21 CFR 1040.10 except
DIRECT OR SCATTERED RADIATION
10200–10800 nm with Synrad's UC Series power controller. This signal
OCCUR IF COOLING WATER for deviations pursuant to Laser Notice No. 50 dated June 24, 2007.
CLASS 4 LASER PRODUCT keeps the plasma ionized during laser "low" periods
EN-60825-1, 2007
IS BELOW DEW POINT. and facilitates breakdown and pulse to pulse fidelity.
Damage or malfunction may occur if this or
SEE OPERATION MANUAL. equivalent drive signals are not used. See manual SYNRAD, Inc. 4600 Campus Place, Mukilteo WA 98275 425.349.3500

for tickle pulse specifications or contact factory.

AVOID EXPOSURE Keyswitch version

CAUTION MODEL #: MODELNUMBER
INVISIBLE LASER RADIATION
IS EMITTED FROM THIS
CONDENSATION AND SERIAL #: SERIALNUMBER
MFG October 25, 2018
APERTURE WATER DAMAGE CAN TESTED AT 48 Volts
OCCUR IF COOLING WATER Complies with IEC 60825-1 (1993) and 21 CFR 1040.10 except for deviations pursuant to
Specified by 21 CFR 1040.10 or IEC 60825-1.
IS BELOW DEW POINT.
SEE OPERATION MANUAL.
4600 Campus Place, Mukilteo WA 98275 | 425.349.3500

or
AVOID EXPOSURE

WATER-COOLED VERSION ONLY

OEM version
INVISIBLE LASER RADIATION
IS EMITTED FROM THIS
APERTURE

MODEL #: MODELNUMBER
SERIAL #: SERIALNUMBER
MFG October 25, 2018
TESTED AT 48 Volts
This laser component does not comply with standards for complete laser products as
FRONT VIEW Specified by 21 CFR 1040.10 or IEC 60825-1.

4600 Campus Place, Mukilteo WA 98275 | 425.349.3500

IMPORTANT - DB9 wiring change. Pins 3 and 4

now provide the remote interlock function and pins
This laser product is manufactured under 6 and 7 now provide the remote REMOTE INTERLOCK JUMPER

one or more of the following U.S. Patents: keyswitch function. If unused 1 2 3 4 5

6,195,379 6,198,758 6,198,759 6,603,794 these pins must be jumpered 6 7 8 9

6,614,826 7,480,323 9,031,110 9,197,028 for the laser to operate. Refer
MADE IN THE U.S.A. to manual for details. REMOTE KEYSWITCH JUMPER
Other U.S. and International Patents pending.

KEYSWITCH VERSION ONLY

IMPORTANT - DB9 wiring change. Pins 3 and 4

This laser product is manufactured under now provide the remote interlock function and pins
one or more of the following U.S. Patents:
6 and 7 now provide the remote REMOTE INTERLOCK JUMPER
5,602,865 6,195,379 6,198,758 6,198,759 keyswitch function. If unused 1 2 3 4 5
6,603,794 6,614,826 7,480,323 these pins must be jumpered 6 7 8 9
Other U.S. and International Patents pending. for the laser to operate. Refer
MADE IN THE U.S.A. to manual for details. REMOTE KEYSWITCH JUMPER

BOTTOM VIEW

Figure 2-1 Hazard label locations (48-1 example).

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 Laser Safety
Series 48-2 label locations
CAUTION
These RF Excited Lasers must be provided with a
pre-ionizing "Tickle" signal during standby or
This laser product is manufactured under laser "low" periods. This is automatically provided
DANGER-INVISIBLE LASER one or more of the following U.S. Patents: with Synrad's UC Series power controller. This signal
RADIATION. AVOID EYE OR SKIN keeps the plasma ionized during laser "low" periods
EXPOSURE TO DIRECT OR
SCATTERED RADIATION
6,195,379 6,198,758 6,198,759 6,603,794 and facilitates breakdown and pulse to pulse fidelity.
CLASS 4 LASER PRODUCT 6,614,826 7,480,323 9,031,110 9,197,028 Damage or malfunction may occur if this or
EN-60825-1, 2014 equivalent drive signals are not used. See manual
Other U.S. and International Patents pending. for tickle pulse specifications or contact factory.

TOP VIEW

CAUTION MODEL #: 48-2KWM

CAUTION These RF Excited Lasers must be provided with a SERIAL #: 0482263115066
This laser product is manufactured under
one or more of the following U.S. Patents: CONDENSATION AND pre-ionizing "Tickle" signal during standby or TESTED AT 30 Volts MFG September 20, 2011
INVISIBLE LASER RADIATION laser "low" periods. This is automatically provided
AVOID EYE OR SKIN EXPOSURE TO 75 WATTS MAX
5,602,865 6,195,379 6,198,758 6,198,759
WATER DAMAGE CAN with Synrad's UC Series power controller. This signal Complies with IEC 60825-1 (2007) and 21 CFR 1040.10 except
DIRECT OR SCATTERED RADIATION 10200–10800 nm 6,603,794 6,614,826 7,480,323 OCCUR IF COOLING WATER keeps the plasma ionized during laser "low" periods for deviations pursuant to Laser Notice No. 50 dated June 24, 2007.
CLASS 4 LASER PRODUCT
and facilitates breakdown and pulse to pulse fidelity.
Other U.S. and International Patents pending. IS BELOW DEW POINT. Damage or malfunction may occur if this or
SEE OPERATION MANUAL. equivalent drive signals are not used. See manual
for tickle pulse specifications or contact factory. SYNRAD, Inc. 4600 Campus Place, Mukilteo WA 98275 425.349.3500

Keyswitch version
CAUTION
MODEL #: MODELNUMBER
CONDENSATION AND SERIAL #: SERIALNUMBER
WATER DAMAGE CAN MFG October 25, 2018
TESTED AT 48 Volts
OCCUR IF COOLING WATER Complies with IEC 60825-1 (1993) and 21 CFR 1040.10 except for deviations pursuant to
Specified by 21 CFR 1040.10 or IEC 60825-1.
IS BELOW DEW POINT.
10.6 MICRON SEE OPERATION MANUAL.
4600 Campus Place, Mukilteo WA 98275 | 425.349.3500

WATER-COOLED VERSION ONLY or

75 WATTS MAX
10200–10800 nm OEM version
MODEL #: MODELNUMBER
AVOID EXPOSURE SERIAL #: SERIALNUMBER
MFG October 25, 2018
INVISIBLE LASER RADIATION TESTED AT 48 Volts
9.3 MICRON IS EMITTED FROM THIS This laser component does not comply with standards for complete laser products as
Specified by 21 CFR 1040.10 or IEC 60825-1.
APERTURE

4600 Campus Place, Mukilteo WA 98275 | 425.349.3500

75 WATTS MAX
9229–9317 nm

AVOID EXPOSURE

INVISIBLE LASER RADIATION

IS EMITTED FROM THIS
APERTURE

FRONT VIEW MADE IN THE U.S.A.

BOTTOM VIEW

IMPORTANT - DB9 wiring change. Pins 3 and 4

now provide the remote interlock function and pins
6 and 7 now provide the remote REMOTE INTERLOCK JUMPER
keyswitch function. If unused 1 2 3 4 5
these pins must be jumpered 6 7 8 9
for the laser to operate. Refer
to manual for details. REMOTE KEYSWITCH JUMPER
MADE IN THE U.S.A.

IMPORTANT - DB9 wiring change. Pins 3 and 4

now provide the remote interlock function and pins
6 and 7 now provide the remote REMOTE INTERLOCK JUMPER
keyswitch function. If unused 1 2 3 4 5
these pins must be jumpered 6 7 8 9
for the laser to operate. Refer
to manual for details. REMOTE KEYSWITCH JUMPER

KEYSWITCH VERSION ONLY

Figure 2-2 Hazard label locations.

SYNRAD® Series 48™ Operator’s Manual Version 9.6

20
 Laser Safety
Series 48-5 label locations
CAUTION
These RF Excited Lasers must be provided with a
pre-ionizing "Tickle" signal during standby or
This laser product is manufactured under laser "low" periods. This is automatically provided
DANGER-INVISIBLE LASER one or more of the following U.S. Patents: with Synrad's UC Series power controller. This signal
RADIATION. AVOID EYE OR SKIN keeps the plasma ionized during laser "low" periods
EXPOSURE TO DIRECT OR
SCATTERED RADIATION
6,195,379 6,198,758 6,198,759 6,603,794 and facilitates breakdown and pulse to pulse fidelity.
CLASS 4 LASER PRODUCT 6,614,826 7,480,323 9,031,110 9,197,028 Damage or malfunction may occur if this or
EN-60825-1, 2014
equivalent drive signals are not used. See manual
Other U.S. and International Patents pending.
for tickle pulse specifications or contact factory.

TOP VIEW

INVISIBLE LASER RADIATION

AVOID EYE OR SKIN EXPOSURE TO
DIRECT OR SCATTERED RADIATION CAUTION
CLASS 4 LASER PRODUCT CAUTION These RF Excited Lasers must be provided with a MODEL #: 48-5KWM
This laser product is manufactured under pre-ionizing "Tickle" signal during standby or SERIAL #: 0485263115066
one or more of the following U.S. Patents: CONDENSATION AND laser "low" periods. This is automatically provided TESTED AT 30 Volts MFG September 20, 2011
WATER DAMAGE CAN with Synrad's UC Series power controller. This signal Complies with IEC 60825-1 (2007) and 21 CFR 1040.10 except
5,602,865 6,195,379 6,198,758 6,198,759 keeps the plasma ionized during laser "low" periods for deviations pursuant to Laser Notice No. 50 dated June 24, 2007.
6,603,794 6,614,826 7,480,323 OCCUR IF COOLING WATER and facilitates breakdown and pulse to pulse fidelity.
Other U.S. and International Patents pending.
IS BELOW DEW POINT. Damage or malfunction may occur if this or
equivalent drive signals are not used. See manual SYNRAD, Inc. 4600 Campus Place, Mukilteo WA 98275 425.349.3500
150 WATTS MAX
SEE OPERATION MANUAL. for tickle pulse specifications or contact factory.
10200–10800 nm

Keyswitch version
CAUTION
MODEL #: MODELNUMBER
CONDENSATION AND SERIAL #: SERIALNUMBER
WATER DAMAGE CAN MFG October 25, 2018
TESTED AT 48 Volts
OCCUR IF COOLING WATER Complies with IEC 60825-1 (1993) and 21 CFR 1040.10 except for deviations pursuant to
Specified by 21 CFR 1040.10 or IEC 60825-1.
IS BELOW DEW POINT.
SEE OPERATION MANUAL.
4600 Campus Place, Mukilteo WA 98275 | 425.349.3500

WATER-COOLED VERSION ONLY or

150 WATTS MAX OEM version
10200–10800 nm MODEL #: MODELNUMBER
AVOID EXPOSURE SERIAL #: SERIALNUMBER
MFG October 25, 2018
INVISIBLE LASER RADIATION
TESTED AT 48 Volts
IS EMITTED FROM THIS This laser component does not comply with standards for complete laser products as
APERTURE Specified by 21 CFR 1040.10 or IEC 60825-1.

4600 Campus Place, Mukilteo WA 98275 | 425.349.3500

AVOID EXPOSURE

FRONT VIEW
INVISIBLE LASER RADIATION
IS EMITTED FROM THIS
APERTURE

KEYSWITCH VERSION ONLY

IMPORTANT - DB9 wiring change. Pins 3 and 4

now provide the remote interlock function and pins
6 and 7 now provide the remote REMOTE INTERLOCK JUMPER
keyswitch function. If unused 1 2 3 4 5
these pins must be jumpered 6 7 8 9
for the laser to operate. Refer
MADE IN THE U.S.A. to manual for details. REMOTE KEYSWITCH JUMPER

IMPORTANT - DB9 wiring change. Pins 3 and 4

now provide the remote interlock function and pins
6 and 7 now provide the remote REMOTE INTERLOCK JUMPER
keyswitch function. If unused 1 2 3 4 5
these pins must be jumpered 6 7 8 9
for the laser to operate. Refer
MADE IN THE U.S.A. to manual for details. REMOTE KEYSWITCH JUMPER

BOTTOM VIEW

Figure 2-3 Hazard label locations.

SYNRAD® Series 48™ Operator’s Manual Version 9.6

21
 Laser Safety
Agency compliance
Center for Devices and Radiological Health (CDRH) requirements.
Federal Communications Commission (FCC) requirements.
European Union (EU) requirements.

SYNRAD lasers are designed, tested, and certified to comply with certain United States (U.S.)
and European Union (EU) regulations. These regulations impose product performance re-
quirements related to electromagnetic compatibility (EMC) and product safety characteristics
for industrial, scientific, and medical (ISM) equipment. The specific provisions to which sys-
tems containing 48 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 radi-
ated emission standards fall under the jurisdiction of the U.S. Federal Communications Com-
mission (FCC). Outside the U.S., laser safety and emissions are governed by European Union
(EU) Directives and Standards.
In the matter of CE-compliant laser products, SYNRAD assumes no responsibility for the
compliance of the system into which the product is integrated, other than to supply and/or
recommend laser components that are CE marked for compliance with applicable European
Union Directives.
Because OEM laser products are intended for incorporation as components in a laser process-
ing system, they do not meet all of the Standards for complete laser processing systems as
specified by 21 CFR, §1040 or EN 60825-1. SYNRAD assumes no responsibility for the compli-
ance of the system into which OEM laser products are integrated.

Center for Devices and Radiological Health (CDRH)

requirements
Product features incorporated into the design of 48 Series lasers to comply with CDRH re-
quirements are integrated as panel controls or indicators, internal circuit elements, or input/
output signal interfaces. Specifically, these features include a 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 ver-
sion (Keyswitch or OEM). Table 1, Class 4 safety features, indicates which features are available
on p400 lasers, the type and description of the feature, and if the feature is required by CDRH
regulations.

OEM models
48 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

SYNRAD® Series 48™ Operator’s Manual Version 9.6

22
 Laser Safety
components to ensure that they meet all applicable local laser safety requirements. In cases
where the Buyer is also the end-user of the OEM laser product, the Buyer/end-user must inte-
grate the laser so that it complies with all applicable laser safety standards as set forth above.

Federal Communications Commission (FCC)

Requirements
The United States Communication Act of 1934 vested the Federal Communications Commis-
sion (FCC) with the authority to regulate equipment that emits electromagnetic radiation in
the radio frequency spectrum. The purpose of the Communication Act is to prevent harmful
electromagnetic interference (EMI) from affecting authorized radio communication services.
The FCC regulations that govern industrial, scientific, and medical (ISM) equipment are fully
described in 47 CFR, §18, §§C.
SYNRAD 48 Series lasers have been tested and found to comply by demonstrating perfor-
mance characteristics that have met or exceeded the requirements of 47 CFR, §18, §§C for
Radiated and Conducted Emissions.

Note: The following FCC information to the user is provided to comply with the re-
quirements of 47 CFR, §18, §§ 213 Information to the user.

Interference Potential
In our testing, SYNRAD has not discovered any significant electrical interference trace-
able to 48 Series lasers.

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

Measures to Correct Interference

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

1 Use shielded cables to and from the equipment that is experiencing interfer-
ence problems.
2 Ensure that the laser is properly grounded to the same electrical potential as
the equipment or system it is connected to.

FCC caution to the user

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

SYNRAD® Series 48™ Operator’s Manual Version 9.6

23
 Laser Safety
European Union (EU) requirements
RoHS compliance
SYNRAD 48 Series lasers meet the requirements of the European Parliament and Council Di-
rective 2015/863/EU on the Restriction of the Use of Certain Hazardous Substances in
Electrical and Electronic Equipment that establishes maximum concentration values for
certain hazard-ous substances in electrical and electronic equipment.

Laser safety standards

Under the Low Voltage Directive, 2014/35/EU, the European Norm (EN) document EN 60825-
1:2014 (hereafter referred to as EN 60825-1) including laser diodes and all laser devices de-
fined in ISO 11145 was developed to provide laser safety guidance and includes clauses on
Engineering Specifications, Labeling, Other Informational Requirements, Additional Require-
ments for Specific Laser Products, Classification, and Determination of the Accessible Emission
Level. To develop a risk assessment plan/laser safety program for users, see the EN 60825-
14:2004 Standard for the safety of laser products that includes clauses on Administrative
Policies, Laser Radiation Hazards, Determining the MPE, Associated Hazards, Evaluating Risk,
Control Measures, Maintenance of Safe Operation, Incident Reporting and Accident Investiga-
tion, and Medical Surveillance.

OEM models
48 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 require-
ments of EN 60825-14:2004 without additional safeguards. European Union Directives
state that “OEM laser products which are sold to other manufacturers for use as com-
ponents 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 60825-
14:2004; EN 60204-1:2016, Safety of Machinery; the Machinery Directive, 2006/42/EC;
and/or any other applicable Standards and in cases where the system is being imported
into the U.S., it must also comply with CDRH regulations.
In cases where the Buyer is also the end-user of the OEM laser product, the Buyer/end-us-
er must integrate the laser so that it complies with all applicable laser safety standards as
set forth above. Table 1, Class 4 safety features, summarizes 48 Series product features,
indicating the type and description of features and whether those features are required
by European Union regulations.

Electromagnetic interference standards

The European Union’s Electromagnetic Compatibility (EMC) Directive, 2014/30/EU, is the
sole Directive developed to address electromagnetic interference (EMI) issues in electronic
equipment. In particular, the Directive calls out European Norm (EN) documents that define
the emission and immunity standards for specific product categories. For 48 Series lasers, EN
61000-6-4:2018 defines radiated and conducted RF emission limits while EN 61000-6-2:2016
defines immunity standards for industrial environments.
SYNRAD® Series 48™ Operator’s Manual Version 9.6

24
 Laser Safety
Table 2-3 Class 4 safety features.
Required by: Available on:
Feature Location / Description CDRH EN60825-1 OEM Series 48

Keyswitch1 Rear panel control Yes Yes No

On/Off/Reset Keyswitch controls power to laser electronics. Key cannot be removed
from switch in the “On” position.
Shutter1 Laser control Yes Yes No
function Functions as a beam attenuator to disable RF driver/laser output when closed.
Shutter Rear panel indicator (Blue) No No Yes
indicator Illuminates blue to indicate shutter is open.
Ready Rear panel indicator (Yellow) Yes Yes Yes
indicator2 Indicates that laser has power applied and is capable of lasing.
Lase Rear panel indicator (Red) No No Yes
indicator Indicates that is actively lasing. Lase LED illuminates when the duty cycle of the Com-
mand signal is long enough to produce laser output.
Five second circuit element Yes No Yes
delay Disables RF driver/laser output for five seconds after Keyswitch is turned to “On” or
remote reset/start pulse is applied when Keyswitch is in “On” position.
Power fail circuit element Yes Yes No
lockout1 Disables RF driver/laser output if input power is removed then later reapplied (AC
power failure or remote interlock actuation) while Keyswitch is in “On” position.
Remote Rear panel connection Yes Yes Yes
Interlock Disables RF driver/laser output when a remote interlock switch on an equipment door
or panel is opened.
Remote Rear panel indicator (Green/Red) No No Yes
Interlock Illuminates green when Remote Interlock circuitry is closed indicator Illuminates red
when interlock circuitry is open.
Over circuit element No No Yes
temperature Temperature shutdown occurs if temperature of the laser protection tube rises above
safe operating limits.
Temp Rear panel indicator (Green/Red) No No Yes
indicator Illuminates green when laser temperature is within operating limits, changing to red
when thermal limits are exceeded.
Warning Series 48 exterior Yes Yes Yes
labels Labels attached to various external housing locations to warn personnel of potential
laser hazards.

1 Keyswitch lasers only.

2 On OEM versions, the Power indicator illuminates and the five (5) second delay begins when DC power is ap-
plied to the laser.

SYNRAD® Series 48™ Operator’s Manual Version 9.6

25
 Laser Safety
SYNRAD® Series 48 lasers have demonstrated performance characteristics that have met or
exceeded the requirements of EMC Directive 2014/30/EU. When integrating SYNRAD Series
48™ OEM lasers, the Buyer and/or integrator of the end system is responsible for meeting all
applicable Standards to obtain the CE mark. To aid this compliance process, SYNRAD testing
program has demonstrated that Series 48 lasers comply with the relevant requirements of
2014/30/EU, the Electromagnetic Compatibility Directive, as summarized in he table below.

Table 2-4 European Union Directives.

Applicable Standards / Norms

2014/30/EU Electromagnetic Compatibility Directive

2006/95/EC Low Voltage Directive
2015/863/EU RoHS Directive
EN 61010-1 Safety Requirements for Electrical Equipment for Measure-
ment, Control, and Laboratory Use - Part 1: General
Requirements
EN 61000-6-4:2007 Radiated Emissions Group 1, Class A
EN 61000-6-4:2007 Conducted Emissions Group 1, Class A
EN 61000-6-2:2005 Electrostatic Discharge Immunity
EN 61000-6-2:2005 RF Electromagnetic Field Immunity
EN 61000-6-2:2005 Electrical Fast Transient/Burst Immunity
EN 61000-6-2:2005 Conducted RF Disturbances Immunity

After a laser or laser processing system has met the requirements of all applicable EU Direc-
tives, the product can bear the official compliance mark of the European Union as a Declara-
tion of Conformity.

After a laser or laser processing system has met the requirements of all applicable EU Direc-
tives, the product can bear the official compliance mark of the European Union as shown in
the figure below and a Declaration of Conformity is provided for the compliant component.

SYNRAD® Series 48™ Operator’s Manual Version 9.6

26
 Laser Safety

Figure 2-5 48 Series Declaration Document.

SYNRAD® Series 48™ Operator’s Manual Version 9.6

27
 Operation

3
Use information in this chapter to familiarize yourself with Series 48™ controls and indicators.
Reference the Quick Start Guide for the initial startup process.

This chapter contains the following information:

Controls and indicators – displays and describes exterior controls and indicators on Series
48 Keyswitch and OEM lasers.

Initial start-up – Reference the appropriate Quick Start Guide on our website to learn how
to start your Series 48 laser while verifying proper operation.

Caution Remove the aperture seal before firing the laser. The self-adhe-
Possible sive seal is installed to prevent dust from entering the laser hous-
ing during shipment and installation and must be removed before
Equipment operation. During laser operation, use a gas purge to keep dust and
Damage vapor out of the beam path.
Applying PWM Command pulses directly to the laser without first
sending tickle pulses for at least two seconds will cause unpredict-
able laser emission, degrade optical rise time, and may lead to RF
Driver failure.
Always assure inlet water temp is maintained above dew point!

SYNRAD® Series 48™ Operator’s Manual Version 9.6

28
 Operation

APERTURE
SEAL
SHUTTER
SWITCH
ON OFF

AVOID EXPOSURE

LASER EXIT
APERTURE INVISIBLE LASER RADIATION
IS EMITTED FROM THIS
APERTURE
OPTICAL
ACCESSORY
MOUNTING (x6)
DIODE POINTER
POWER CONNECTOR
Figure 3-1 48-1/48-2 Front panel controls and indicators.
Controls and Indicators
48-1/48-2 front panel
Aperture Seal – prevents dust from damaging the output coupler during shipping. Remove
the red self-adhesive label before applying power to the laser.
Shutter Switch (Keyswitch models only) – manually closes the laser aperture and interrupts
power to the RF section(s). Do not use the shutter to partially block the beam or to control
output power.

Laser Exit Aperture – provides an opening from which the beam is emitted when lasing.

Optical Accessory Mounting – provides six threaded holes for mounting standard beam
delivery components. When considering other components not specifically designed as Series
48 options, please consult the factory for restrictions since excessive weight may cause dam-
age to the laser. To prevent damage to the laser when mounting DC opticalPOWER
components, the
8–32 mounting screws must not extend further than 4.8 mm (0.1875 in) into the laser face-
plate. CABLES
Diode Pointer Power Connector (optional) – provides a regulated +5 VDC, 100 mA output
and is internally protected against short circuits by an auto-resetting fuse. The Diode Pointer
Power connector is not installed unless the optional Diode Pointer is ordered when the laser is
manufactured.
SYNRAD® Series 48™ Operator’s Manual Version 9.6

29
 Operation

CARBON DIOXIDE LASER

POWER PWR LASE LASE LED

LED
STATUS

ON
5 SEC DELAY

FUSE
CTRL

FUSE
COMMAND
INPUT
KEYSWITCH
Figure 3-2 48-1/48-2 Rear panel controls and indicators.

48-1/48-2 rear panel

Power LED – illuminates green when the Keyswitch is turned to the ON position (or when an
OEM laser is powered up) to indicate that power is applied to internal circuitry.

Lase LED – illuminates red to indicate the lase mode of operation. If a tickle signal is present,
the LASE LED turns on after the five-second delay and becomes brighter as the PWM duty
cycle is increased.

Command (CTRL) Input – accepts tickle and PWM Command signal inputs. The output of the
UC-2000 Controller (or FH Series marking head) is attached to this connector.

Keyswitch (Keyswitch models only) – used to turn the laser on, off, and to reset faults. The
key cannot be removed when the Keyswitch is in the ON position.
DB9
Fuse – provides overcurrent protection for the internal circuitry of the laser.
CONNECTOR

AUXILIARY
SYNRAD® Series 48™ Operator’s Manual Version 9.6

POWER
30
 Operation

DB9
DC POWER CONNECTOR
CABLES

AUXILIARY
POWER

Figure 3-3 Side panel controls and indicators.

Side panel
DC Power Cables – red (+) and black (–) DC Power input cables are manufactured from #12
AWG (48-1/48-2) or #8 AWG (48-5) wire and measure 1.1 meters (3.5 feet) in length.
Auxiliary Power Connector – provides an optional 30 VDC source for powering the UC-2000
Controller. An auto-resetting solid-state fuse limits line current. Connector power is active
after 30 VDC is applied to the laser.
DB-9 Connector – provides an interconnection for message, fault shutdown, remote interlock,
remote keyswitch, and interface signals. Refer to the DB-9 connections section in the Techni-
cal Reference chapter for information on pin assignments and function.

SYNRAD® Series 48™ Operator’s Manual Version 9.6

31
 Operation
APERTURE
SEAL

LASER EXIT SHUTTER

APERTURE SWITCH

AVOID EXPOSURE
®
R

OPTICAL INVISIBLE
NVISIBLE LASER RADIATION
RADIATIO
IS EMITTED FROM THISS CARBON DIOXIDE LASER

ACCESSORY
APERTURE

MOUNTING (x6)

DIODE POINTER
POWER CONNECTOR
Figure 3-4 48-5 Front panel controls and indicators.

48-5 front panel

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

Shutter Switch (Keyswitch models only) – manually closes the aperture and interrupts power
to the RF section(s).

Diode Pointer Power Connector (optional) – provides a regulated +5 VDC, 100 mA output
and is internally protected against short circuits by an auto-resetting fuse. The Diode Pointer
Power connector is not installed unless the optional Diode Pointer is ordered when the laser is
manufactured. DC POWER
CABLES
Optical Accessory Mounting – provides six threaded holes for mounting standard beam
delivery components. When considering other components not specifically designed as Series
48 options, please consult the factory for restrictions since excessive weight may cause dam-
age to the laser. To prevent damage to the laser when mounting optical components, the
8–32 mounting screws must not extend further than 3/16” (4.8 mm) into the laser faceplate.
SYNRAD® Series 48™ Operator’s Manual Version 9.6

32
 Operation
POWER LASE LED
LED

® CARBON DIOXIDE LASER

POWER LASE POWER LASE

STATUS

KEYSWITCH ON
5 SEC DELAY

CTRL 1 CTRL 2 FUSE 1 FUSE 2

COMMAND FUSE
INPUTS
Figure 3-5 48-5 Back panel controls and indicators.

48-5 rear panel

Power LED – illuminates green when the Keyswitch is turned to the ON position (or when an
OEM laser is powered up) to indicate that power is applied to internal circuitry.

Lase LED – illuminates red to indicate the lase mode of operation. If a tickle signal is present,
the LASE LED turns on after the five-second delay and becomes brighter as the PWM duty
cycle is increased.

Keyswitch (Keyswitch models only) – used to turn the laser on, off, and to reset faults. The
key cannot be removed when the Keyswitch is in the ON position.
DB9 CONNECTOR
R Command (CTRL) Input – accepts tickle and PWM Command signal inputs. The output of the
UC-2000 Controller (or FH Series marking head) is attached to this connector. DC Power Ca-
bles – red (+) and black (–) DC Power input cables are manufactured from #12 AWG (48-1/48-
2) or #8 AWG (48-5) wire and measure 1.1 meters (3.5 feet) in length.

AUXILIARY POWER
DB-9 Connector – provides an interconnection for message, fault shutdown, remote interlock,
remote keyswitch, and interface signals. Refer to the DB-9 connections section in the Techni-
cal Reference chapter for information on pin assignments and function.

Auxiliary Power Connector – provides an optional 30 VDC @ 350 mA source for powering the
UC-2000 Controller. An auto-resetting solid-state fuse limits line current. Connector power is
active after 30 VDC is applied to the laser.
SIDE VIEW SYNRAD® Series 48™ Operator’s Manual Version 9.6

33
 Technical Reference

4
Technical reference summary
Technical overview – briefly describes Series 48 technology, design RF power supply
and basic optical setup.

Controlling laser power – explains various aspects of the Series 48 control signals.
DB-9 connections – describes input/output signals and specifications for the side
mounted DB-9 connector.

DC power/DC sense cables – provides information about DC power and voltage sense
cables.

Integrating Series 48 safety features – describes how to integrate Series 48 safety fea-
tures into your automated control system.

Series 48 general specifications – provides specifications for the Series 48 laser.

Model 48-1, 48-2, and 48-5 package outline drawing – illustrates laser package and
mounting dimensions for Keyswitch and OEM 48-1 (10, 25, and 50 watt lasers
respectively.

Series 48 packaging instructions – describes how to package Series 48 lasers for ship-
ment.

Caution Small amounts of contaminants on the laser’s output window (or on

Possible any optic in the beam path) can absorb enough energy to damage
Equipment the optic. Inspect all beam delivery optics periodically for signs of
contaminants and carefully clean as required.
Damage
In dirty environments, purge laser optics using filtered air or nitrogen
to prevent vapor and debris from accumulating on optical surfaces.

SYNRAD® Series 48™ Operator’s Manual Version 9.6

34
 Technical Reference
Technical Overview

Technical overview
Introduction

Plasma section

Optical resonator

Control circuitry

Optical setup,

Faults, cooling, and DuoLase®

Introduction
Series 48™ lasers incorporate the latest technology in sealed carbon dioxide devices, combin-
ing the best features of both waveguide and free space CO2 laser technology. The all-metal
laser tube construction features the ruggedness, stable optical support, and small size of
waveguide lasers. Its larger bore (4.8 mm) eliminates the high optical power density of wave-
guide lasers with their predisposition to optical degradation and incorporates the mode puri-
ty and easy optical alignment of free space TEM00 lasers. Low cost is achieved by using simple
extruded and welded aluminum structures packaged together with compact, state-of-the-art
RF power supplies.

48 Series lasers emit a laser beam with a wavelength of 9.3 or 10.6 microns (µm) depending
on model. The beam shape is square at the laser output aperture, changing to circular at
distances of approximately one meter or more from the laser. The laser beam diverges due to
diffraction at a full angle of 4 mrad (milliradians), with the beam waist at the output aperture
of the laser.

Power control of the laser beam is achieved by pulse width modulation (PWM) of the RF drive
circuit. Modulation control can be used to gate the laser on and off at time intervals synchro-
nized with automated processing equipment. It can also be used to control instantaneous
power by adjusting the pulse width (PWM duty cycle) at a fixed modulation frequency. Both
methods can be used simultaneously.

Plasma section
The laser consists of an RF-excited plasma tube with an adjustable mirror on each end, mount-
ed together with the RF drive assembly in a single aluminum chassis. The plasma tube is made
of two-inch square cross-section extruded aluminum tubing with pre-machined ends welded
on. RF drive power is applied between the lower electrode and the plasma tube. The internal
resonant circuit induces RF drive on the upper electrode that is 180 degrees out of phase with
that of the lower electrode. Thus the voltage between the two RF electrodes is roughly twice
that on either electrode, causing the plasma to form only in the 4.8 mm square bore region.
The two sidewalls confine the plasma but carry negligible current. Waste heat is conducted
away by all four metal sides of the bore to the outer walls of the plasma tube, where it is trans-
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Optical resonator
The optical resonator consists of a curved total reflector and a flat Zinc Selenide (ZnSe) out-
put coupler. The mirrors are held on with Viton (fluorocarbon) elastomeric o-rings for factory
adjustment by means of three screws that are secured by adhesive after alignment. The 4.8
mm bore, in conjunction with the mirror curvature selected, limits the output beam to TEM00
modes when the mirrors are properly aligned.

BEAM WAIST DIA. ~ 3.5 mm

FULL ANGLE
RF DISCHARGE REGION Ø DIVERGENCE ~ 4 mrad

OUTPUT COUPLER
TOTAL REFLECTOR

Figure 4-1 Beam characteristics.

Controlling Laser Power

Electrical description
Control of laser operation and power output levels is essentially performed using a single PCB.
The Control PCB connects the modulated signal to the RF amplifier. It also provides electron-
ics to monitor performance of RF control, output circuitry, input power, temperature, PWM
accuracy, provides outputs to an externally accessible connector, and incorporates reverse
polarity protection.

Functional differences between model types generally relate to the number of RF channels.
Model 48-1 lasers use a single RF electrode requiring a single modulated RF drive input from
the Control PCB. The 48-2 uses 2 RF electrodes and requires 2 RF channels, while the 48-5 uses
4 electrodes and 4 RF channels (2 Control PCB’s). For the purpose of this description, a single
channel will be described. Model specific details relating to differences in electrical character-
istics are individually discussed.

The modulated input Command signal is generated externally to the laser and connected to
the panel-mounted BNC connector labeled CTRL. This signal is connected to an optoisolator,
the output of which is applied to the PWM switch control circuit. The PWM switch control
circuit gates the PWM switch off and on at the frequency and duty cycle controlled by the
modulation source. When the PWM switch closes, a potential of +30 VDC is applied to the RF
Driver. The PWM control circuit provides on/off gating of the PWM switch unless disabled by
the five-second delay, Shutter Switch, or the fault shutdown circuits.

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The five-second delay disables PWM output to the RF amplifier for a period of approximately
five seconds after the panel-mounted Keyswitch and Remote Keyswitch link are closed (power
ON). On OEM models, the five-second delay period begins on DC power up of the laser.

The Shutter Switch allows the operator to temporarily interrupt laser output during active lase
modes. A mechanical lever physically blocks the exit aperture and at the same time actuates
independent micro-switches that electrically interrupt power to the RF module by disabling
the PWM input optoisolator, forcing an “off” state.

Fault shutdown conditions

The output of the Keyswitch is connected to the control board through the DB-9 Connector
user port. Note that the supplied DB-9 jumper plug can be removed to allow the user to insert
a remotely located relay or switch in series with the Keyswitch. If the Keyswitch is left on or is
electrically bypassed, the user can turn the laser on and off, and reset fault shutdowns from a
remote location.

The temperature warning message output (Pin 5 of the DB-9 connector) goes low when the
laser tube temperature reaches 54 °C ±2 °C and remains low until tube temperature falls 2 °C
below the trigger temperature. The warning message output does not shut down the laser.
Over temperature fault shutdown occurs when laser tube temperature reaches 60 °C ±2 °C.

Control board operation begins when the supply voltage rises above +18 VDC and remains
below +36 VDC. After start-up, the control board will shut the laser down if supply voltage
falls below +15 VDC or rises above +36 VDC.

If an electronics failure causes the control board to output PWM power to the RF Drivers in
excess of 20% of the commanded PWM input, a fault shutdown will occur.

To reset after any fault shutdown, correct the problem(s) then cycle the Keyswitch (or Remote
Keyswitch
if one is present) or remove power to the laser for 30 seconds. During any fault shutdown, the
fault shutdown output (Pin 1 of the DB-9 connector) will latch to low state until a keyswitched
reset occurs.

The Power-On Reset feature will not allow lasing to restart after a power failure or shutdown
has occurred until the Keyswitch or Remote Keyswitch is first cycled off (open circuit condi-
tion) and then back on (closed circuit). Power-On Reset is defeated on all OEM versions. OEM
customers must provide this required safety feature elsewhere as part of their equipment
integration.

Cooling
Coolants
SYNRAD recommends that the laser’s cooling fluid contain at least 90% distilled water by vol-
ume. In closed-loop systems, use a corrosion inhibitor/algaecide such as Optishield® Plus or

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equivalent as required. 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. If tap water is used, chloride levels should not exceed a concentration
of 25 parts per million (PPM) and total hardness should be below 100 PPM. Install a filter on
the chiller’s return line and inspect frequently.

Cooling
Series 48 electronics are mounted opposite the laser tube in the smaller section of the “H” bay
and share the same cooling removal as the plasma tube. Typical efficiency of CO2 laser plasma
tubes operating in a TEM00 mode is 10% to 12% (radiation out to RF power in). Factor in the
conversion efficiency of AC input to RF output and the overall “wall plug” efficiency of these
lasers drops to about 6% to 8%, resulting in a considerable amount of heat removal, even at
10 W and 25 W output power levels; therefore, external cooling in the form of forced air- or
water-cooling is required.

Since Series 48-1, 48-2 lasers are OEM products, they do not include cooling fans. Customers
must provide some type of air cooling to prevent the laser from overheating. See the cooling
requirements at the end of this chapter.

Note: DO NOT use de-ionized (DI) water as a coolant. DI water is unusually corrosive
and is not recommend for mixed material cooling systems.

Setting coolant temperature

Choosing the correct coolant temperature is important to the proper operation and longev-
ity 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 water-cooled lasers are run in a high
heat/high humidity environment and the chiller’s coolant temperature is colder than the dew
point temperature of the surrounding air or when the system is shut down, but coolant con-
tinues 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 3.8 LPM (1.0 GPM). Do not exceed a coolant pres
sure of 414 kPa (60 PSI).

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Table 4.2 Dew Point Table °F temperatures.

Dew Point Table °F
Relative Humidity (%)
Air Temp

20% 25% 30% 35% 40% 45% 50% 55% 60% 65% 70% 75% 80% 85% 90% 95%
(°F)

60 °F - - - 32 36 39 41 44 46 48 50 52 54 55 57 59

65 °F - - 33 37 40 43 46 48 51 53 55 57 59 60 62 64

70 °F - 33 37 41 45 48 51 53 56 58 60 62 64 65 67 69

75 °F - 37 42 46 49 52 55 58 60 62 65 67 68 70 72 73

80 °F 35 41 46 50 54 57 60 62 65 67 69 71 73 75 77 78

85 °F 40 45 50 54 58 61 64 67 70 72 74 76 78 80 82 83

90 °F 44 50 54 59 62 66 69 72 74 77 79 81 83 85 87 88

95 °F 48 54 59 63 67 70 73 76 79 81 84 86 88 90 92 93

100 °F 52 58 63 68 71 75 78 81 84 86 88 91 93 95 97 98

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Table 4.2 Dew point temperatures °C (Continued).
Dew Point Table °C
Relative Humidity (%)
Air Temp

20% 25% 30% 35% 40% 45% 50% 55% 60% 65% 70% 75% 80% 85% 90% 95%
(°C)

16 °C - - - 0 2 4 5 7 8 9 10 11 12 13 14 15

18 °C - - 1 3 4 6 8 9 11 12 13 14 15 16 17 18

21 °C - 1 3 5 7 9 11 12 13 14 16 17 18 18 19 21

24 °C - 3 6 8 9 11 13 14 16 17 18 19 20 21 22 23

27 °C 2 5 8 10 12 14 16 17 18 19 21 22 23 24 25 26

29 °C 4 7 10 12 14 16 18 19 21 22 23 24 26 27 28 28

32 °C 7 10 12 15 17 19 21 22 23 25 26 27 28 29 31 31

35 °C 9 12 15 17 19 21 23 24 26 27 29 30 31 32 33 34

38 °C 11 14 17 20 22 24 26 27 29 30 31 33 34 35 36 37

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

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

The prior table provides dew point temperatures for a range of air temperature and relative
humidity values. Remember that the laser’s coolant temperature must be set above the dew
point temperatures shown in the chart; refer to the cooling specifications at the end of this
chapter.

Duo-Lase® operation (48-5)

The 48-5 laser combines two laser tubes for twice the output of a standard laser. The outputs
from two 25 W sealed CO2 tubes are combined optically to provide a single diffraction-limited
beam at 50 W. This optical combining technique is based on the fact that each laser is linearly
polarized, allowing the use of a polarization sensitive beam combiner to achieve 98% effi-
ciency in combining the two beams. The two components of the resulting beam are spatially
parallel and collinear, reducing the normal temporal and spatial variations of a single laser.
Output polarization is random and therefore superior for many cutting applications.

Important 48-5 (50 W) lasers must be water-cooled to prevent damage to the laser. See
Note: the water-cooled connections section for more details.

The 48-5 laser uses two control boards and four RF drivers. The control boards are tied togeth-
er electronically so that if a failure mode shuts down either board, both laser tubes are turned
off. The control boards are equipped with individual fuses for each RF driver PWM output. In
the event of an RF driver failure, only that fuse will open, allowing other RF drivers in the sys-
tem to continue operating. Unless both fuses are open on a given control board, no shutdown
will occur, nor is there a fault output signal.

In general, the two Command inputs (CTRL1 and CTRL2) should always be driven identically
with a “Y” or “T” connector. For special applications in redundant or ultra-wide dynamic range
systems, it is permissible to drive only one Command input; however, the beam’s random
polarization is compromised.

Optical setup
After selecting a CO2 laser for your processing system, the two most important elements to
consider are: (1) 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 reliable laser-based material processing system and each element should
be approached with same careful attention to detail.

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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 slowly, increasing 4 mm in diameter over every meter, Series 48 lasers should
be mounted a distance of 1.0–1.5 m (40–60 in) away from the work area. Right angle turning
mirrors are often used in conjunction with the laser mounting position to obtain this distance.
Figure below shows how right angle turning mirrors in a “flying optics” setup create this lon-
ger beam path.

Expander/collimators are optical devices that reduce beam divergence while at the same time
increasing beam diameter by a selectable magnification factor. Adding an expander/collima-
tor 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.

Figure 4-2 “Flying optics” beam path.

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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 to be processed.Op-
tics are fragile and must be handled carefully, preferably by the mounting ring only. Be careful
to select optics that are thick enough to withstand the maximum assist gas pressure available
for the process. This is especially important in metal cutting applications using high-pressure
assist gases.

Cleanliness is another important issue affecting performance and becomes increasingly im-
portant as laser power increases. Dirty or scratched lenses will under perform, exhibit a vastly
shortened lifetime, and may fail catastrophically.

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 con-
tains minute particles of oil and other contaminants that will damage optical surfaces. If com-
pressed shop air is the only choice available, it must be filtered and dried to ISO 8573-1:2010
Class 1, 2, 1 specifications shown in the table below.
Table 4-2 Assist gas purity specifications.
Assist Gas Typical Purpose Specification

Air Cutting/Drilling Breathing Grade > 99.9996% purity; filtered to ISO Class 1
particulate level
Air Cutting/Drilling Compressed Instrument-grade air filtered and dried to
ISO 8573-1:2010 Class 1, 2, 1 (< 10 1.0–
5.0 µm particles/m3; < –40 °F dew point;
< 0.01 mg/m3 oil vapor)
Argon Welding High Purity Grade > 99.998% purity; filtered to ISO Class 1
particulate level
Helium Welding High Purity Grade > 99.997% purity; filtered to ISO Class 1
particulate level
Nitrogen Cutting/Drilling High Purity Grade > 99.9500% purity; filtered to ISO Class 1
particulate level
Oxygen Cutting/Drilling Ultra Pure Grade > 99.9998% purity; filtered to ISO Class 1
particulate level

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Control signals
Control signals

Operating modes

Much of the information provided in this section describes the use of a SYNRAD UC-2000
Universal Laser Controller to provide tickle and PWM Command signals to the laser. If you are
using an alternate method of laser control, thoroughly review this section for an understand-
ing of the signal requirements necessary to control SYNRAD® Series 48™ lasers. Table below
lists input voltage and current specifications for 48 Series control (CTRL) inputs. Tables above
and below provide specific tickle pulse and PWM Command signal parameters.
Table 4-3 Input signal specifications.
Parameter Specification
Logic Low (Off State) 0.0 V to + 0.5 VDC; 0.0 VDC nominal
Logic High (On State) +3.5 V to +10.0 VDC; + 5.0 VDC nominal
Maximum Current Load 6 mA (48-1 / 48-2); 12 mA (48-5)

Tickle pulse
Series 48 lasers require a 1 µs tickle pulse delivered at a nominal 5 kHz clock frequency from
the Controller. Tickle pulses pre-ionize the laser gas to just below the lasing threshold so that
any further increase in pulse width adds enough energy to the plasma to cause laser emission.
This tickle signal causes 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. The lase threshold is preset for 3 µs ± 0.5 µs based on a PWM and tickle
frequency input of 5 kHz. See the following table for tickle specifications.

Caution
Applying PWM Command pulses directly to the laser without first
Possible sending tickle pulses, for at least two seconds, will cause unpredict-
Equipment able laser emission, degrade optical rise time, and may lead to RF
Damage Driver failure.

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Table 4-4 Tickle pulse specifications.

Parameter Specification
Tickle Frequency 5 kHz
Pulse Length 1.0 µs ± 0.2 µs
Pulse Rise/Fall Time < 100 ns between +0.5 V to +3.5 VDC

The UC-2000 (or FH Series marking head) does not produce tickle pulses continuously, but
generates them only when the PWM Command signal is low. Tickle pulses are sent one tickle
period, 200 µs, after the falling edge of a PWM Command signal pulse. Figure 3-3 illustrates
tickle pulse parameters.

200 µs 1 µs
5 VDC

0 VDC

Figure 4-3 Tickle pulse waveform.

Series 48™ lasers are designed to operate at a tickle frequency of 5 kHz, which allows the laser
to meet published specifications. Tickle frequencies lower than 4.5 kHz may compromise laser
performance, particularly optical rise times, and stress the RF electronics thereby reducing
long term reliability while tickle frequencies greater than 5 kHz may cause unintended lasing.
Special care must be taken to maintain plasma ionization without lasing at tickle frequencies
greater than 5 kHz. When sending 1 µs tickle pulses at 5 kHz, PWM signals can be sent at an
independent, higher frequency but must go to near zero (< 1%) duty cycle to ensure laser
turn-off.

Pulse width modulation (PWM)

Pulse Width Modulation, or PWM, controls laser power by varying the duty cycle of the laser’s
RF amplifiers, which in turn control the time-averaged RF power applied to the laser. Because
laser output follows PWM input with a rise and fall time constant of ~100 µs, the laser cannot
precisely follow Command signal frequencies over 5 kHz with duty cycles greater than 50%.
Typically, the depth of modulation for a 50% duty cycle is 90 to 100% at 2 kHz and 60 to 80%
at 5 kHz. Figure 3-4 shows Series 48 optical waveforms at two different modulation frequen-
cies.

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79 Acqs
Tek step 500kS/s T

Ch2 Freq
2.008kHz
Low signal
amplitude

Ch2 +Duty
T
49.4%
1
Low signal
amplitude

Ch 1 100mV Ch 2 1V M 100 µS Ch 2 / 740m V

2 kHz Modulation
Figure 4-4 Series 48-2 kHz waveform. The upper waveform is laser output, the lower wave
form is PWM input.

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34 Acqs
Tek step 500kS/s T

Ch2 Freq
4.906kHz
Low signal
amplitude

Ch2 +Duty
50%
1 Low signal
amplitude

Ch 1 100mV Ch 2 2V M 100 µS Ch 2 / 720m V

5 kHz Modulation
Figure 4-5 Series 48-5 kHz waveform. The upper waveform is laser output, the lower wave
form is PWM input.

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Series 48™ lasers are designed to operate at Command signal base frequencies up to 20 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 re-
view Marking/engraving operation later in this chapter.

For high-speed motion applications that cannot tolerate any ripple in the optical beam re-
sponse but still need adjustable power levels, we recommend the use of higher PWM frequen-
cies, up to 20 kHz maximum. At 20 kHz, the laser’s optical beam response no longer follows
the Command input and is very nearly a DC value with just a small amount of ripple present.

Warning Always use shielded cable when connecting your PWM Com-
Serious mand signal source to the laser’s CTRL connections.
personal In electrically-noisy environments, long lengths of unshielded
injury wire act like an antenna and may generate enough voltage to
trigger uncommanded lasing.

Command signal
The modulated Command signal applied to Series 48 lasers has three parameters: signal am-
plitude, base frequency, and PWM duty cycle. By changing these parameters, you can com-
mand 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 +0.5 VDC while the laser on voltage, typically 5 V, can range from +3.5
V to 10.0 VDC.

Base frequency, the second parameter, is the rate at which the amplitude is switched between
its low and high logic states. The standard base frequency is 5 kHz, which has a period of 200
µs. Maximum PWM frequency is 20 kHz.

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. The following figure illustrates Command signal parameters while
the following table lists PWM Command signal specifications.

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Table 4-5 PWM Command signal specifications.

Laser State Minimum Nominal Maximum

Laser Off Voltage 0.0 VDC 0.0 VDC +0.5 VDC
Laser On Voltage +3.5 V +5.0 VDC +10.0 VDC
Current (@ 5 VDC) —— —— 6 mA (48-1/48-2)
12 mA (48-5)
Frequency Range 0 Hz (DC) 5 kHz 20 kHz
Duty Cycle 0% —— 100%

200 µs 200 µs
100 µs 190 µs
5 VDC

0 VDC
5kHz Command Signal at 50% Duty Cycle 5kHz Command Signal at 95% Duty Cycle

Figure 4-6 PWM Command signal waveform.

Operating modes
External control
In addition to controlling your Series 48 laser using a UC-2000 Controller, controlling the laser
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 a function generator capable
of sending PWM pulses at the proper time (gating) and with the proper duty cycle (power).

Analog voltage or analog current control

Although Series 48™ 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 con-
nector then control both gating and power.

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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 in-
stalled. 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 both configurations.

UC-2000 Universal Laser Controller

SYNRAD recommends using a UC-2000 Universal Laser Controller to generate tickle pulses
and Pulse Width Modulated (PWM) Command signals to control the laser’s output power. The
UC-2000 requires 15–50 VDC @ 35 mA, supplied from either its wall plug transformer or from
the Auxiliary Power connector on the side of Series 48 lasers. Refer to the UC-2000 Laser Con-
troller Operator’s Manual for information about UC-2000 operation.

To connect a UC-2000 Controller (available separately from SYNRAD), perform the following
steps:

1 Remove DC power from the laser Fabricate a suitable DB-9 plug so Pin 1, PWM Positive,
connects to the center pin of the Power/Control cable’s BNC connector and Pin 6, PWM
Negative, connects to the shield.
2 If your system does not provide an enable input to the DB-9 plug, then jumper Pin 9,
Laser Enable, to Pin 5, DC Out.
3 Connect the DB-9 plug to the DB-9 I/O connector on the rear of the laser.
4 Connect the miniature DC power plug on the UC-2000’s Power/Control cable to the min-
iature connector on the wall plug transformer cable.
5 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.

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Continuous wave (CW) operation

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 occur-
ring. To operate the laser in CW mode, a constant +5 VDC signal is applied to the CTRL input(s)
of the laser. This constant voltage source forces the internal switching electronics to remain
on, providing continuous and uninterrupted laser output power.

For pure CW operation, a steady +5 V signal can be applied through this connector (a tickle
signal must be applied during laser-off periods). This input is optically-isolated from the chas-
sis and power supply ground circuit, but must not be subjected to common mode voltages
greater than ±50 VDC from chassis ground. The 48-5 laser has two Command inputs, CTRL1
and CTRL2, that should always be driven identically from the signal source by using a “Y” cable
or “T” BNC connector.

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 gen-
erator 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 lev-
el (+3.5 V to +5.0 VDC) signal is applied to the Gate input connector. In the pull-down (normal-
ly off ) mode an asserted logic low state, short circuit to ground, or an open or disconnected
Gate input locks the beam off.

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

Note: When operating in CW mode, laser power output cannot be adjusted. If you require
an adjustable output power level, refer to the Pulse width modulation (PWM) sec-
tion for information regarding high frequency operation.

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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. This
overshoot is more pronounced at lower gating frequencies since the gas has a longer time to
cool down between Command signal pulses.

Caution Do not ground Remote Keyswitch or Remote Interlock inputs to an

Possible external circuit—this will damage laser circuitry. Any external cir-
cuit(s) connected to these terminals must be floating with respect to
Equipment
ground. We recommend using “dry circuit” (zero voltage) switches or
Damage relay circuitry.

Do not apply a voltage to the Remote Interlock Input on DB-9 Con-

nector Pin 3 as this will damage internal laser circuitry. The Remote
Interlock Input on Pin 3 is a “dry-circuit” (zero voltage) input and
must connect only to Pin 2 or Pin 4 to complete the interlock circuit.

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), ’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 deter-
mining factor but rather this behavior happens only when the off time between PWM pulses
exceeds 200 microseconds.

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DB-9 I/O Connections

DB-9 connections
Series 48™ lasers are equipped with a female DB-9 connector mounted to the sidewall of the
laser. The DB-9 Connector provides the user with a convenient method for monitoring fault
conditions (over temperature, control/RF circuitry failure, etc.) and adds remote interlock, re-
mote keyswitch (relay or switch), message output, and remote LED indicator capability. These
signals allow you to connect remote keyswitch, LASE, and ready (PWR) indicators to a remote
operator’s station or connect a remote interlock safety switch to interlock equipment doors or
panels.

A factory-installed jumper plug is attached to the DB-9 Connector on each laser to enable
normal operation on initial start-up. Two jumpers are wired into the plug as shown in the
figure below. The jumper between Pin 6 and Pin 7 closes the Remote Keyswitch Input and
the jumper between Pin 3 and Pin 4 closes the Remote Interlock Input. If the jumper plug is
removed, then you must connect the appropriate external remote interlock or remote key-
switch circuitry in order to enable lasing. To take advantage of the DB-9 functions described
in the following table, ‘DB-9 pin assignments’, you must manufacture a connecting cable that
properly integrates the DB-9 signals into your automated system. A spare DB-9 male connec-
tor and cover is included with each laser (Keyswitch only) to facilitate cable manufacture.

For OEM lasers, a plug is installed in place of the Keyswitch and the remote keyswitch pins of
the DB-9 Connector then become the external power on/off/reset control means.

Note: On lasers manufactured as OEM (-S) version lasers, i.e. without a Key switch, the
Remote Interlock function is bypassed internally; however, the Remote Keyswitch
function on Pin 6 and Pin 7 provides a similar functionality.

REMOTE INTERLOCK
JUMPER
1 2 3 4 5
6 7 8 9
REMOTE
KEYSWITCH JUMPER
Figure 4-7 Factory-installed DB-9 jumper plug wiring.

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DB-9 I/O Connections

Note: You can control Series 48™ lasers from an alternate user-supplied PWM Command
signal source. See Controlling laser power in the Technical Reference chapter for
control signal descriptions.

Series 48 lasers are equipped with a female DB-9 connector mounted to the sidewall of the
laser that provides a means of monitoring fault conditions (over-temperature, control/RF cir-
cuitry failure) and adds remote interlock, remote keyswitch (relay or switch), message output,
and remote LED indicator capability. For a complete description of DB-9 pin assignments and
functions, see the DB-9 connections section in the Technical Reference chapter.

A factory-installed jumper plug is attached to the DB-9 Connector to enable normal laser
operation (see Figure 3-6). If the jumper plug is removed, you must (1) jumper Pin 3 to Pin 4
(or Pin 2) or connect to external “remote interlock” circuitry and (2) you must jumper Pin 6 to
Pin 7 or connect to external “remote keyswitch” circuitry as described in the DB-9 connections
section in the Technical Reference chapter.

Note: On lasers manufactured as OEM (-S) version lasers, i.e. without a Keyswitch, the
Remote Interlock function is bypassed internally; however, the Remote Keyswitch
function on Pin 6 and Pin 7 provides a similar functionality.

1 Connect the mini-DIN connector on the end of the UC-2000 Controller’s Power/Control
cable to the Laser connector on the rear panel of the UC-2000.
2 Connect the miniature DC power plug on the UC-2000’s Power/Control cable to the laser’s
side-mounted Auxiliary Power connector.
To use the UC-2000’s wall plug transformer instead, connect the miniature DC power plug
on the UC-2000’s Power/Control cable to the miniature connector on the wall plug trans
former cable
3 On 48-1 and 48-2 lasers, attach the BNC connector on the end of the UC-2000’s Power/
Control cable to the BNC connector labeled CTRL on the rear of the laser.
On 48-5 lasers, attach the long “leg” of the BNC “Y” control cable to the BNC connector on
the UC-2000’s Power/Control cable. Attach the short “legs” of the “Y” cable to the laser’s
CTRL1 and CTRL2 connectors located on the rear of the laser.
4 If your application uses external gating signals to command On/Off switching of the laser,
attach a BNC cable between your gate signal source and the UC-2000’s Gate connector.
5 If your application uses external analog voltage or current signals to control the PWM
duty cycle of the laser, attach a BNC cable between your analog voltage or current source
and the UC-2000’s ANV/ANC connector.

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User I/O Connections
User I/O connections
User I/O connection summary

Input/output signals

Sample I/O circuits

The PWM Command signal and all input/output (I/O) control signals are connected to the
User I/O port. Please refer to the figure below for the 15 pin female D-type sub-miniature
connector on the rear panel. The figure below illustrates the pin arrangement of the User I/O
connector.
Table 4-6 DB-9 pin assignments.

Pin # Function & Description

1 Fault Shutdown Output

Indicates failure of internal circuitry or existence of over temperature (> 60 °C ±2 °C),
over voltage, or under voltage fault. This active low signal (referenced to Pin 2 or Pin 4)
transitions from +15 V (normal operation) to 0 VDC when a fault occurs. Use this out-
put signal to disable external processes during a fault1. See the two following table(s)
for output signal specifications.
2 Signal Ground
Signal ground/chassis ground for Pins 1, 3, 5, 8, and 9.
3 Remote Interlock Input
Disables the laser when an interlock switch wired to this input from an equipment
door or panel is opened. Ground this input to Pin 2 or Pin 4 only. Do not apply a
voltage to this pin2 See the two following table(s) for input signal specifications. As
shipped, Pins 3 and 4 are connected by the factory-installed jumper plug to enable the
Remote Interlock function.
4 Signal Ground
Signal ground/chassis ground for Pins 1, 3, 5, 8, and 9.
5 Message Output
This active low signal (referenced to Pin 2 or Pin 4) transitions from +15 V (normal
operation) to 0 VDC when a pre-shutdown temperature warning occurs (when laser
temperature reaches 54 °C ±2 °C) and remains low until temperature falls 2 °C. Use this
output to notify user of need to increase laser cooling or risk shutdown1. See the two
following table(s) for output signal specifications.
6 Remote Keyswitch Input
Connect a remote relay or switch in series with the laser Keyswitch to control laser On /
Off / Reset functions. Connect Pin 6 to Pin 7 to run; open this connection to halt lasing
or reset faults. As shipped, Pins 6 and 7 are connected by the factory-installed jumper
plug to enable the Remote Keyswitch function2,3. See the two following table(s) for
input signal specifications.

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User I/O Connections
Pin # Function & Description
7 Remote Keyswitch Output
Connect Pin 7 to Pin 6 to enable the Remote Keyswitch function (see Pin 6 description
above). Pin 7 is at DC line potential (+30 VDC) only when the Keyswitch is set to ON.
As shipped, Pins 6 and 7 are connected by the factory-installed jumper plug3,4. See the
two following table(s) for output signal specifications.
8 Remote Lase LED Output
Connect an LED or LED-optoisolator between Pin 8 and Signal Ground for a remote
LASE indication5,6. See the two following table(s) for output signal specifications.
9 Remote Ready LED Output
Connect an LED or LED-optoisolator between Pin 9 and Signal Ground for a remote
Ready (PWR) indication5. See the two following table(s) for output signal specifications.

1 Pin 1 and Pin 5 are active low outputs. Specifications: OFF: +15 VDC, 5 mA into 3 kOhm. ON: < 1 VDC, sinking 100 mA.
2 “Dry-circuit” (zero voltage) external switches are required since current into remote interlock and debounced remote keyswitch pins is
negligible.
3 Connecting an LED to Pins 6 or 7 to indicate keyswitch status requires an external current-limiting resistor.
4 The remote keyswitch output pin is not current-limited or fused.
5 Pins 8 and 9 can be directly connected to the anodes of LEDs or LED-input optoisolators without external current limiting devices. Con-
nect LED cathodes to Pin 2 or 4. Current is limited internally to 20 mA at 3.3 V maximum.
6 The output of Pin 8, the Remote Lase LED Output, is a Pulse Width Modulated (PWM) signal based on the PWM Command input signal. It
is not a steady state (on/off ) output.

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User I/O Connections
DB-9 connections
The figure below shows the physical layout and pin identification of the Series 48™ DB-9 Con-
nector. Refer to the following tables in the next section describing input/output signal specifi-
cations.

DB-9 Connector
PIN 5 PIN 1

PIN 9 PIN 6
Figure 4-8 Physical layout of Series 48 DB-9 Connector.
Table 4-7 DB-9 Connector input signal specifications.

Pin # Input Signal Name Input Specifications

3 Remote Interlock Input 50 mA maximum @ 30 VDC. Important Note: Use “dry

6 Remote Keyswitch Input circuit” (zero-voltage) external switches to prevent inter-
nal circuit damage.

Table 4-8 DB-9 Connector output signal specifications.

Pin # Output Signal Name Output Specifications

1 Fault Shutdown Output Active Low output signal: Off: + 15 VDC, 5 mA into 3
kOhm;
5 Message Output On: < 1 VDC, sinking 100 mA.
7 Remote Keyswitch Output 50 mA maximum @ 30 VDC. Output active (+30 VDC)
when Keyswitch ON or bypassed (OEM models).
8 Remote Lase LED Output Current-limited to 11 mA @ 2.4 VDC maximum. Voltage
output is pulse width modulated at input PWM
Command signal frequency, not a steady state on/
off signal.
9 Remote Ready LED Output Current-limited to 11 mA @ 2.4 VDC maximum.

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User I/O Connections
Sample DB-9 Connector I/O circuits
Sample input circuits
The figure below illustrates a method of connecting a relay contact or limit switch to act as a
remote keyswitch. Remember that Remote Keyswitch and Remote Interlock inputs are “dry
circuit” or zero-voltage inputs.

DB-9 CONNECTOR PINS

(7) REMOTE KEYSWITCH

RELAY CONTACT OR OUTPUT
LIMIT SWITCH
(6) REMOTE KEYSWITCH
INPUT

Figure 4-9 Remote Keyswitch circuit.

The figure below shows how to connect the laser’s Remote Interlock input in series with one
or more door safety switches or relay contacts.

DB-9 CONNECTOR PINS

(2) SIGNAL GROUND

DOOR SAFETY SWITCHES
OR RELAY CONTACTS

(3) REMOTE INTERLOCK

INPUT
Figure 4-10 Remote Interlock circuit.

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User I/O Connections
Sample output circuits
Figures below illustrate how to connect the laser’s Remote Ready LED Output to a Program-
mable Logic Controller (PLC) DC input module using current sourcing, current sinking, and
resistive pull-up methods.

Note: You can use these same circuits to monitor the laser’s Remote Lase LED Output
(DB-9, Pin 8); however, the Remote Lase LED Output is not a steady state (on/off )
output. It is a Pulse Width Modulated (PWM) signal based on the PWM Command
input signal to the laser.

PLC
DB-9 CONNECTOR PINS
4N29 OPTOISOLATOR
+24 VDC
1 6
(9) REMOTE READY NC INPUT
LED OUTPUT 5
RTN

2
(2) SIGNAL GROUND
4
NC 3

24 VDC GND

Figure 4-11 Remote Ready output to PLC input (PLC sourcing).

The following figure shows how to connect the Message Output signal on the DB-9 Connec-
tor to a PLC. The Message Output function provides a pre-shutdown temperature indication
when laser tube temperature reaches 54 °C ±2 °C, signaling the need to increase laser cooling
or risk laser shutdown if laser temperature rises to > 60 °C ±2 °C.

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User I/O Connections
PLC
DB-9 CONNECTOR PINS

(5) MESSAGE OUTPUT INPUT

(2) SIGNAL GROUND RTN

Figure 4-12 Message Output to PLC input.

The following figure illustrates how to connect the Fault Shutdown Output signal to a PLC.
The Fault Shutdown Output function signals a laser shutdown due to an under/over voltage
condition, an over temperature condition, or failure of internal circuitry.

PLC
DB-9 CONNECTOR PINS

(1) FAULT SHUTDOWN INPUT

OUTPUT

(2) SIGNAL GROUND RTN

Figure 4-13 Fault Shutdown Output to PLC input.

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 Technical Reference
Integrating Safety Features
Integrating Series 48™ safety features
The Integrating Series 48 safety features section includes subsections:

Remote Keyswitch functions

Remote interlock functions

The Series 48 DB-9 Connector allows system integrators or end-users to integrate Series 48 la-
ser safety features into their control system. In particular, the Series 48 Remote Keyswitch and
Remote Interlock functions serve to disable DC power to the laser’s RF driver. Without power,
the RF driver cannot supply PWM Command or tickle signals to the resonator, causing the CO2
gas to remain in a zero-energy state.

Remote keyswitch functions

Keyswitch lasers
After DC power-up, or after a fault or open interlock condition, the Keyswitch must be toggled
to reset the laser, which enables the PWR LED and signals 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 lasers in automated control systems, this reset function is provided by the Re-
mote Key-switch signal via pins 6 and 7 on the DB-9 Connector. To use this “remote keyswitch”
functionality, first place the Keyswitch in the ON position. To reset a fault condition, open and
then close a “dry-circuit” (zero voltage) switch or relay contact between Pin 6, Remote Key-
switch Input, and Pin 7, Remote Keyswitch Output. Reconnecting Pin 6 to Pin 7 applies power
to the RF driver and begins a five-second delay after which lasing is enabled. The RF driver is
disabled when the remote keyswitch circuit is open.

Your control system can monitor the laser’s power-on status through the DB-9 Connector by
connecting your system’s input between Pin 9, Remote Ready LED Output, and Pin 2 or Pin
4, Signal Ground. The Remote Ready LED Output goes active when the laser is enabled (PWR
LED turns On), indicating that lasing is possible after the five-second delay. The output is inac-
tive (PWR LED off ) when lasing is disabled. Refer back to Table 3-6, DB-9 pin assignments for
specific details.
Important

Note: Pin 9, the Remote Ready LED Output, is a current- and voltage-limited output
meant only for direct connection to an LED or LED-input optoisolator.

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Integrating Safety Features
OEM lasers
On OEM lasers, the PWR LED illuminates on DC power-up and five seconds later DC power is
applied to the RF driver. To reset a fault condition, remove DC power for 30 seconds and then
reapply power to the laser or toggle (open, then close) the Remote Keyswitch signal via pins
6 and 7 on the DB-9 Connector. To use this “remote reset” functionality, open and then close
a “dry-circuit” (zero voltage) switch or relay contact between Pin 6, Remote Keyswitch Input,
and Pin 7, Remote Keyswitch Output. Reconnecting Pin 6 to Pin 7 applies power to the RF
driver and begins a five-second delay after which lasing is enabled.

Your control system can monitor the laser’s power-on status through the DB-9 Connector by
connecting your system’s input between Pin 9, Remote Ready LED Output, and Pin 2 or Pin
4, Signal Ground. The Remote Ready LED Output goes active when the laser is enabled (PWR
LED turns On), indicating that lasing is possible after the five-second delay. The output is inac-
tive (PWR LED off ) when lasing is disabled. Refer back to Table 3-6, DB-9 pin assignments for
specific details.

Remote interlock functions

Keyswitch lasers
Interlock circuits are often used to disable machinery when a shield, panel, or door is opened.
The Series 48™ remote interlock connects directly into an external, zero-voltage remote inter-
lock circuit to prevent lasing by removing DC power from the laser’s RF driver boards when
the circuit is electrically “open”.

Remote interlock functionality is provided by the Remote Interlock Connection via Pin 3 on
the DB-9 Connector. Lasing is enabled when the Remote Interlock Connection signal is closed
and disabled when the Remote Interlock Connection signal is electrically “open”. DC power is
applied to the RF driver only when the Remote Interlock Connection signal is closed (PWR LED
is illuminated). When the Remote Interlock Connection is opened and then closed, you must
toggle the Keyswitch or Remote Keyswitch Input to reset the laser.

To use the Series 48 remote interlock feature, connect Pin 3, Remote Interlock Connection, to
your “dry-circuit” (zero-voltage) interlock circuit and then ground the circuit to Pin 2 or Pin 4,
Signal Ground.

Caution Do not apply a voltage to Pin 3, Remote Interlock Connection on the

Possible DB-9 Connector—the laser will be damaged. This input is a “dry-cir-
Equipment cuit” (zero voltage) input and must be grounded to either Pin 2 or Pin
4 to complete the interlock circuit.
Damage

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Integrating Safety Features
Lasing is enabled when Pin 3 is grounded (when the external interlock circuit is closed). If
the external interlock circuit opens, then Pin 3 opens and lasing is disabled. To enable lasing
again, you must close the interlock circuit and toggle the Keyswitch or Remote Keyswitch
Input. This resets the laser and begins a five-second delay after which lasing is enabled.

Your control system can monitor the laser’s power-on status through the DB-9 Connector by
connecting your system’s input between Pin 9, Remote Ready LED Output, and Pin 2 or Pin
4, Signal Ground. The Remote Ready LED Output goes active when the laser is enabled (PWR
LED turns On), indicating that lasing is possible after the five-second delay. The output is inac-
tive (PWR LED off ) when lasing is disabled. Refer back to Table 3-6, DB-9 pin assignments for
specific details.

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 Technical Reference
Cooling Fittings

Caution Read guidelines for cutting and installing tubing before installation.
Possible Assure you understand the guidelines before proceeding to the next
step.
Equipment
Make sure to connect the cooling system exactly as described for your
Damage particular laser.

Water-cooled connections
Setting coolant temperature
Choosing the correct coolant temperature is important to the proper operation and longev-
ity 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 hu-
midity 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. Refer to the dewpoint table in the Maintenance and Trou-
bleshooting chapter within this manual.

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

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

Stop coolant flow when the laser is shut down.

See the coolant pressure specifications within this chapter.

Note: Refer to the Series 48 Water Cooled Quick Start Guide and the drawings within this
chapter. Also see the cooling specifications within this chapter.

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 Technical Reference
Cooling Fittings
Water-cooled connections
Coolant fitting guidelines
Cut tubing lengths generously to allow for trimming.

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

Avoid excessive stress on fittings by creating a gentle radius when bends in the tubing
are close to fittings. Bending tubing too sharply will compromise the sealing proper-
ties 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.

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 12.7 mm (0.5 in) from its end before re
connecting. Trimming the end of the tubing before reconnecting provides an undis-
turbed sealing surface.

You must provide fittings that will adapt the laser’s 1/4” or 3/8” O.D. polyethylene cool-
ing tubing to your chiller’s Inlet and Outlet ports. These fittings can be either
“quick disconnect” or compression type fittings.

Note: Because Series 48 cooling tubing is specified in inch sizes, the use of metric tube
fittings is discouraged unless you have installed the appropriate inch-to-metric
tubing adaptors. The use of metric fittings on inch size tubing will lead to cool-
ant leaks and/or pressurized tubing blowing-off the fitting(s).

If your integrated laser application uses metric cooling tubing, we recommend

the installation of tubing adaptors to convert 48-1/48-2 cooling kit fittings from
1/4” tubing to 6 mm metric tubing. For 48-5 cooling kits, convert the 3/8” tubing
to 8 mm metric tubing. These tubing adaptors are available from many tubing
and fitting manufacturers.

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Cooling Fittings
48-1/48-2 and 48-5 cooling tubing connec-
tions
If water cooling is desired with the 48-1/48-2, see the appropriate Series 48 Quick Start Guide
located on our website. Also reference the drawings at the end of this chapter as necessary.

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 Technical Reference
Series 48 General Specifications
Model 48-1 general specifications
Table 4-9 Model 48-1 general specifications.
Parameter
Output Specifications 10.6 µm 9.3 µm
Wavelength (microns) ....................... 10.57–10.63 ................................ 9.23–9.31
†

Power Output1, 2 ................................... 10 W................................................ 8 W

Power Stability3 .................................... ±10%.............................................. ±15%
Mode Quality......................................... M2 < 1.2......................................... M2 < 1.2
Beam Waist Diameter (at 1/e2)4 ...... 3.5 mm........................................... 3.5 mm
Beam Divergence, full angle ........... 4 mrad............................................ 4 mrad
Ellipticity ................................................. < 1.2................................................ < 1.2
Polarization ............................................ Linear, vertical............................. Linear, vertical
Extinction ratio...................................... 50:1 minimum............................. 50:1 minimum
Rise Time ................................................. < 150 µs......................................... < 150 µs

Electrical Specifications
Power Supply Output
Voltage.............................................. 30 VDC
Maximum Current ........................ 7 A

Control (CTRL) Input

Logic Low (Off State) ................... 0.0 V to +0.5 VDC; 0.0 V nominal
Logic High (On State)................... +3.5 V to +10.0 VDC; +5.0 V nominal
Maximum Current Load.............. 6 mA @ +5.0 VDC

Tickle Pulse Signal

Tickle Frequency5.......................... 5 kHz
Pulse Length................................... 1.0 µs ± 0.2 µs
Pulse Rise/Fall Time...................... < 100 ns between +0.5 V to +3.5 VDC

PWM Command Input Signal

PWM Frequency6 .......................... DC to 20 kHz
PWM Duty Cycle ........................... 0% to 100%

* 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 Minimum 30 VDC input voltage to obtain guaranteed output power.
3 From cold start (guaranteed) at 95% duty cycle.
4 Measured at laser output.
5 48 Series lasers are designed to operate at a tickle frequency of 5 kHz, which allows the laser to meet published specifications.
Tickle frequencies lower than 4.5 kHz may compromise laser performance, particularly optical rise times, and stress the RF
electronics thereby reducing long term reliability while tickle frequencies greater than 5 kHz may cause laser emission.
6 FCC and CE tested at 5 kHz.
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Series 48 General Specifications
Model 48-1 general specifications

Parameter
Cooling Specifications7 (Air-cooled) (Water-cooled)
Maximum Heat Load, laser .............. 300 W............................................. 300 W
Minimum Flow Rate ........................... 250 CFM × 2 fans....................... 0.5 GPM, < 60 PSI
Coolant Temperature ......................... < 40 °C, ambient........................ 18 °C to 22 °C

Environmental Specifications
Operating Temperature8 ................... 15 °C to 40 °C
Humidity.................................................. 0% to 95%, non-condensing

Physical Specifications
Length ..................................................... 16.9 in (42.9 cm)
(incl. cooling tubes)...................... 18.1 in (46.0 cm)
Width ....................................................... 2.8 in (7.1 cm)
Height ...................................................... 4.2 in (10.7 cm)
Weight ..................................................... 9.0 lbs (4.1 kg)

* Specifications subject to change without notice.

7 Inlet cooling water temperature should always be maintained above the dew point to avoid condensation and water damage
to the laser.
8 Published specifications guaranteed at a cooling temperature of 22 °C. Some performance degradation may occur when operated in
ambient air or coolant temperatures above 22 °C.

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Series 48 General Specifications
Model 48-2 general specifications
Table 4-10 Model 48-2 general specifications.

Parameter
Output Specifications 10.6 µm 9.3 µm
Wavelength (microns) ....................... 10.57–10.63 ................................ 9.23–9.31
†

Power Output1, 2 .................................. 25 W................................................ 18 W

Power Stability3 .................................... ±5%................................................ ±7%
Mode Quality......................................... M2 < 1.2......................................... M2 < 1.2
Beam Waist Diameter (at 1/e2)4 ...... 3.5 mm........................................... 3.5 mm
Beam Divergence, full angle ........... 4 mrad............................................ 4 mrad
Ellipticity ................................................. < 1.2................................................ < 1.2
Polarization ............................................ Linear, vertical............................. Linear, vertical
Extinction ratio...................................... 50:1 minimum............................. 50:1 minimum
Rise Time ................................................. < 150 µs......................................... < 150 µs

Electrical Specifications
Power Supply Output
Voltage.............................................. 30 VDC
Maximum Current ........................ 14 A

Control (CTRL) Input

Logic Low (Off State) ................... 0.0 V to +0.5 VDC; 0.0 V nominal
Logic High (On State)................... +3.5 V to +10.0 VDC; +5.0 V nominal
Maximum Current Load.............. 6 mA @ +5.0 VDC

Tickle Pulse Signal

Tickle Frequency5.......................... 5 kHz
Pulse Length.................................... 1.0 µs ± 0.2 µs
Pulse Rise/Fall Time....................... < 100 ns between +0.5 V to +3.5 VDC

PWM Command Input Signal

PWM Frequency6 .......................... DC to 20 kHz
PWM Duty Cycle ............................ 0% to 100%

* 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 Minimum 30 VDC input voltage to obtain guaranteed output power.
3 From cold start (guaranteed) at 95% duty cycle.
4 Measured at laser output.
5 48 Series lasers are designed to operate at a tickle frequency of 5 kHz, which allows the laser to meet published specifications.
Tickle frequencies lower than 4.5 kHz may compromise laser performance, particularly optical rise times, and stress the RF
electronics thereby reducing long term reliability while tickle frequencies greater than 5 kHz may cause laser emission.
6 FCC and CE tested at 5 kHz. SYNRAD® Series 48™ Operator’s Manual Version 9.6

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 Technical Reference
Series 48 General Specifications
Model 48-2 general specifications

Parameter
Cooling Specifications7 (Air-cooled) (Water-cooled)
Maximum Heat Load, laser .............. 500 W............................................. 500 W
Minimum Flow Rate ........................... 250 CFM × 4 fans....................... 0.8 GPM, < 60 PSI
Coolant Temperature ......................... < 40 °C, ambient........................ 18 °C to 22 °C

Environmental Specifications
Operating Temperature8 ................... 15 °C to 40 °C
Humidity.................................................. 0% to 95%, non-condensing

Physical Specifications
Length ..................................................... 31.9 in (81.0 cm)
(incl. cooling tubes)...................... 33.1 in (84.1 cm)
Width ....................................................... 2.8 in (7.1 cm)
Height ...................................................... 4.2 in (10.7 cm)
Weight ..................................................... 18.0 lbs (8.2 kg)

* Specifications subject to change without notice.

7 Inlet cooling water temperature should always be maintained above the dew point to avoid condensation and water damage
to the laser.
8 Published specifications guaranteed at a cooling temperature of 22 °C. Some performance degradation may occur when operated in
ambient air or coolant temperatures above 22 °C.

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 Technical Reference
Series 48 General Specifications
Model 48-5 general specifications
Table 4-11 Model 48-5 general specifications.

Parameter
Output Specifications 10.6 µm
Wavelength (microns) ....................... 10.57–10.63†
Power Output1, 2 .................................. 50 W
Power Stability3 .................................... ±5%
Mode Quality......................................... M2 < 1.2
Beam Waist Diameter (at 1/e2)4 ...... 3.5 mm
Beam Divergence, full angle ........... 4 mrad
Ellipticity ................................................. < 1.2
Polarization ............................................ Random
Extinction ratio...................................... N/A
Rise Time ................................................. < 150 µs

Electrical Specifications
Power Supply Output
Voltage.............................................. 30 VDC
Maximum Current ........................ 28 A

Control (CTRL) Input

Logic Low (Off State) ................... 0.0 V to +0.5 VDC; 0.0 V nominal
Logic High (On State)................... +3.5 V to +10.0 VDC; +5.0 V nominal
Maximum Current Load.............. 12 mA @ +5.0 VDC

Tickle Pulse Signal

Tickle Frequency5.......................... 5 kHz
Pulse Length................................... 1.0 µs ± 0.2 µs
Pulse Rise/Fall Time...................... < 100 ns between +0.5 V to +3.5 VDC

PWM Command Input Signal

PWM Frequency6 .......................... DC to 20 kHz
PWM Duty Cycle ........................... 0% to 100%

* 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 Minimum 30 VDC input voltage to obtain guaranteed output power.
3 From cold start (guaranteed) at 95% duty cycle.
4 Measured at laser output.
5 48 Series lasers are designed to operate at a tickle frequency of 5 kHz, which allows the laser to meet published specifications.
Tickle frequencies lower than 4.5 kHz may compromise laser performance, particularly optical rise times, and stress the RF
electronics thereby reducing long term reliability while tickle frequencies greater than 5 kHz may cause laser emission.
6 FCC and CE tested at 5 kHz. SYNRAD® Series 48™ Operator’s Manual Version 9.6

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 Technical Reference
Series 48 General Specifications
Model 48-5 general specifications

Parameter
Cooling Specifications7, 8 (Water-cooled)
Maximum Heat Load, laser .............. 800 W
Minimum Flow Rate ........................... 1.5 GPM, < 60 PSI
Coolant Temperature ......................... 18 °C to 22 °C

Environmental Specifications
Operating Temperature9 ................... 15 °C to 40 °C
Humidity.................................................. 0% to 95%, non-condensing

Physical Specifications
Length ..................................................... 34.9 in (88.6 cm)
(incl. cooling tubes)...................... 36.4 in (92.5 cm)
Width ....................................................... 5.3 in (13.5 cm)
Height ...................................................... 4.5 in (11.4 cm)
Weight ..................................................... 44.0 lbs (20.0 kg)

* Specifications subject to change without notice.

7 Lasers with output power > 50 W must be water-cooled. Lasers with output < 50 W can be water- or air-cooled although
water-cooling is strongly recommended for duty cycles > 50%. Water-cooling improves power stability at any duty cycle.
8 Inlet cooling water temperature should always be maintained above the dew point to avoid condensation and water damage
to the laser.
9 Published specifications guaranteed at a cooling temperature of 22 °C. Some performance degradation may occur when operated in
ambient air or coolant temperatures above 22 °C.

Note: Series 48™ lasers are tested to meet published specifications at an input voltage of
30.0 VDC.

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 Technical Reference
48 Series Drawings

Technical Drawings
Note: Series 48 lasers may be hard-mounted to equipment by removing several of the
bottom panel screws and replacing these with longer screws to secure the laser
to optical assemblies. This mounting method is only recommended as long as the
screws do not support the weight of the laser. For a sturdier attachment, the laser
may be clamped to optical assemblies by applying clamping forces between top
and bottom cover screws. Do not apply clamping forces on the longitudinal cen-
terline.

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 Technical Reference
48 Series Drawings

Figure 4-14 Model 48-1 package outline and mounting dimensions, 1 of 2.

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 Technical Reference
48 Series Drawings

Figure 4-15 Model 48-2 package outline and mounting dimensions, 2 of 2.

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 Technical Reference
48 Series Drawings

Figure 4-16 Model 48-5 package outline and mounting dimensions.

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 Technical Reference
48 Series Drawings

Figure 4-17 Model 48-1 packaging instructions.

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 Technical Reference
48 Series Drawings

Figure 4-18 Model 48-2 packaging instructions.

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 Technical Reference
48 Series Drawings

Figure 4-19 Model 48-5 packaging instructions.

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 Technical Reference
48 Series Drawings

Figure 4-20 FLMK-1A (10W fan shroud) packaging instructions.

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 Technical Reference
48 Series Drawings

Figure 4-21 FLMK-2A (25W fan shroud) packaging instructions.

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 Maintenance/
Troubleshooting
Maintenance

5
Maintenance and Troubleshooting

Introduction
Maintenance – describes typical 48 series maintenance procedures.

Troubleshooting – explains how to troubleshoot common 48 series problems.

Important This section of the Operation Manual explains how to conduct regular main-
Note: tenance and/or basic troubleshooting to series 48 lasers. If you cannot attend
to the unit using the information described in this manual, contact SYNRAD®,
(+.425.349.3500) or an authorized SYNRAD Distributor.

Warning All Class 4 laser product that emit invisible infrared laser radiation
Serious in the 9.3–10.6 µm CO2 wavelength band are capable of seriously
personal burning human tissue.
Because direct or diffuse laser radiation can inflict severe corneal
injury
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 seri-
ously burning human tissue.
Always be aware of the beam’s path and always use a beam block while testing.
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 the laser or beam delivery optics, contact SYNRAD or the
optics manufacturer for handling instructions.
The use of aerosol dusters containing difluoroethane causes “blooming”, a condition
that significantly expands and scatters the laser beam. This beam expansion can affect
mode quality and/or cause laser energy to extend beyond the confines of optical ele-
ments in the system, possibly damaging acrylic safety shielding. Do not use air dusters
containing difluoroethane in any area adjacent to CO2 laser systems because difluo-
roethane persists for long time periods over wide areas.

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Maintenance

Maintenance
Disabling the series 48 laser
Daily inspections
Storage/shipping
Cleaning optical components

Disabling the Series 48™ laser

Before performing any maintenance on your 48 series laser, be sure to completely disable the
laser by disconnecting the DC Power Cables from the DC power supply.

Daily inspections
Perform the following steps daily to keep your 48 series laser in optimum operating condition.
Except for the procedures described below, no other service is required or should be attempt-
ed.

Caution Even small amounts of contamination on optics in the beam

Possible path can absorb enough energy to damage the optic. Inspect
beam delivery optics periodically for signs of contaminants and
Equipment carefully clean as required. In dirty environments, purge laser optics
Damage using filtered air or nitrogen to prevent vapor and debris from accu-
mulating on optical surfaces.

If you operate the laser in dirty or dusty environments, contact SYNRAD® about the risks of
doing so and precautions you can take to increase the longevity for the laser system and
associated optical components.

1 Inspect all cooling tubing connections for signs of leakage. Check for signs of condensa-
tion that may indicate the cooling water temperature has been set below the dew point
temperature. Condensation will damage electrical and optical components inside the la-
ser. See the Setting coolant temperature section in the Getting Started chapter for details
on preventing condensation.
2 When using compressed air as a purge gas on your series 48 laser, empty water traps
and oil separators on each filter and/or dryer between the laser and your compressed
air source. Compressed air purity must meet the purge gas specifications shown in the
Getting Started chapter.

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Maintenance
3 Inspect beam delivery components for signs of dust or debris and clean as required.
When cleaning the optical surfaces of beam delivery components, carefully follow the
manufacturer’s instructions.
4 Visually inspect the exterior housing of the laser to ensure that all warning labels are
present. Refer to the Laser Safety chapter for 48 series label types and locations.

Storage/shipping
Refer to Packaging instructions in the Technical Reference chapter and/or appropriate quick
start guide for detailed instructions on properly packaging the laser for shipment.
In cold climates, any water left in the cooling system may freeze, which could damage internal
components. After draining thoroughly, use compressed shop air at no more than 200 kPa (29
PSI)—Wear safety glasses!—to remove any residual water. When finished, cap all connectors
to prevent debris from entering the cooling system.
If you no longer have the original shipping box and inserts, contact SYNRAD Customer Service
about purchasing replacement packaging.

Important Failure to properly package the laser using SYNRAD-supplied shipping boxes
Note: and foam/cardboard inserts as shown in the Packaging instructions may void
the warranty. Customers may incur additional repair charges for shipping dam-
age caused by improper packaging.

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

Coolants
SYNRAD® recommends that the laser’s cooling fluid contain at least 90% distilled water by
volume. In closed-loop systems, use a corrosion inhibitor/algaecide such as Optishield® Plus
or equivalent as required. Avoid glycol-based additives because they reduce the coolant’s
heat capacity and high concentrations may affect power stability. Refer to the cooling spec-
ifications and the dew point table located in the Technical Reference chapter of this manual.
Glycol is not necessary unless the chiller is subjected to freezing temperatures. If tap water
is used, chloride levels should not exceed a concentration of 25 parts per million (PPM) and
total hardness should be below 100 PPM. Install a filter on the chiller’s return line and inspect
frequently.
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Maintenance

Caution DO NOT use de-ionized (DI) water as a coolant!

Possible DI water is unusually corrosive and is not recommend for mixed ma-
Equipment terial cooling systems.
Damage Operating the laser at coolant temperatures above 22 °C (72 °F) may
result in decreased performance and/or premature failure of elec-
tronic components.

Do not exceed coolant pressure of 414 kPa (60 PSI)!

Inlet cooling water temperature must always be maintained above the dew point tem-
perature to prevent condensation and water damage to your laser.
Even small amounts of contamination on optics in the beam path can absorb enough
energy to damage the optic.
Inspect 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.

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

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

Refer to the dew point temperature table within the prior chapter for a range of air tempera-
ture and relative humidity values. Remember that the laser’s coolant temperature must be
set above the dew point temperatures shown in the chart, but should not exceed the envi-
ronmental specifications located in the Series 48 General Specifications within the Technical
References chapter of this manual.

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 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. Care-
fully 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 Exercise great care when handling infrared optics; they are much more fragile
Note: than common glass materials. Optical surfaces and coatings are easily dam-
aged by rough handling and improper cleaning methods.

Cleaning guidelines
Wear latex gloves or finger cots (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 lens on a tissue or suitable equivalent material for protection;
never place optics on hard or rough surfaces.

It may be necessary to use a cotton ball or fluffed cotton swab instead of a lens wipe
to uniformly clean the entire surface of small-diameter mounted optics.

Before using any cleaning agents, read Material Safety Data Sheets (MSDS) and ob
serve all necessary safety precautions.

Required cleaning materials

The table below lists the type and grade of materials required to properly clean optical surfac-
es.

Table 5-1 Required cleaning materials.

Cleaning Material Requirements
Latex gloves or finger cots Powder free
Air bulb Clean air bulb
Ethyl or isopropyl alcohol Spectroscopic or reagent grade
Acetone Spectroscopic or reagent grade
Lens wipe (preferred) Optical (cleanroom) quality
Cotton balls or cotton swabs High-quality surgical cotton/high-quality paper-bodied

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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 for contaminants.

3 Remove loose contaminants from the optic by holding a clean air bulb at an angle to
the optic and blow a stream of air at a glancing angle across the lens surface. Repeat
as necessary.

4 Dampen a lens wipe with the selected cleaning agent. Alcohol (least aggressive) is
best for initial surface cleaning. Acetone (moderately aggressive) is best for oily resi
due or minor baked-on vapors and debris.

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.

6 Carefully examine the optic under suitable lighting. 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 depos-

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

Note: optical surface using alcohol is required to remove any acetone residue.
Use a clean lens wipe on each pass. The wipe will pick up and carry surface
contaminants that may scratch optical surfaces or coatings if reused.

Caution Do not allow the nozzle of the air bulb to touch the optical sur-
face. Any contact may damage the optic by scratching coatings on
Possible
the optical surface.
Equipment
Damage 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 con-
taminants.
Use a new lens wipe on each pass as contaminants picked up by
the wipe may scratch the optical surface.

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 Maintenance/
Troubleshooting
Troubleshooting

Troubleshooting
Introduction

Resetting faults

Laser faults

Beam delivery optics

Troubleshooting Introduction
This section is designed to help isolate problems to the module level only. Problems on circuit
boards or the laser tube are not within the scope of this guide because they are not user-ser-
viceable assemblies; do not attempt to repair them. Contact SYNRAD® or a SYNRAD Autho-
rized Distributor for repair or replacement information.
To troubleshoot the Series 48™ 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 the relevant
schematic diagrams. 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
the paragraphs following each heading.

Caution Attempting repair of a SYNRAD laser without the express authoriza-

tion of SYNRAD, will void the product warranty. If troubleshooting
Possible
or service assistance is required, please contact SYNRAD Customer
Equipment Service.
Damage
Operating the laser at coolant temperatures above 22 °C (72 °F) may
result in decreased performance and/or premature failure of elec-
tronic components.
Do not exceed coolant pressure of 414 kPa (60 PSI)!

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Troubleshooting
Troubleshooting
Resetting faults
Keyswitch lasers
On Keyswitch lasers, the PWR indicator illuminates green only when the Remote Interlock
input is closed and the Keyswitch is cycled from OFF to the ON position (or the Remote Key-
switch input is opened and then closed). After the PWR indicator illuminates, a five-second
delay occurs before the laser is permitted to lase. The LASE LED illuminates dimly when tickle
pulses are applied to the laser and when PWM Command pulses are applied (and are long
enough to produce laser output) the LASE LED illuminates and appears to brighten in relation
to an increasing PWM duty cycle.
To reset a remote interlock fault after the fault condition has been cleared, the Keyswitch must
be cycled from OFF to ON (or with the Keyswitch ON, cycle the Remote Keyswitch input open
and then closed). When the PWR indicator illuminates, lasing is enabled after the five-second
delay.
To reset an over temperature fault, lower coolant temperature below 22 °C (water-cooled) or
below
40 °C (air-cooled). When the laser cools sufficiently, remove DC power for 30 seconds and then
reapply power to the laser or cycle the Keyswitch from OFF to ON (or with the Keyswitch ON,
cycle the Remote Keyswitch input open and then closed). When the PWR indicator illumi-
nates, lasing is enabled after the five-second delay.
A closed shutter is not considered a fault condition; when the shutter is opened, lasing is en-
abled provided the PWR indicator is illuminated green.
After a power failure or shutdown has occurred, the Power-On Reset feature will not allow
lasing to restart until the Keyswitch or Remote Keyswitch is first cycled off (open circuit condi-
tion) and then back on (closed circuit).
During any fault shutdown, the Fault Shutdown Output (Pin 1 on the DB-9 Connector), which
is normally at +15 VDC, latches to a low state (0 VDC) until a keyswitched reset occurs.

OEM lasers
On OEM lasers, the PWR lamp illuminates on DC power-up. After the PWR indicator illumi-
nates, a five-second delay occurs before the laser is permitted to lase. The LASE LED illumi-
nates dimly when tickle pulses are applied to the laser and when PWM Command pulses are
applied (and are long enough to produce laser output) the LASE LED illuminates and appears
to brighten in relation to an increasing PWM duty cycle.
To reset an over temperature fault, the coolant temperature must be lowered below 22 °C
(water-cooled) or below 40 °C (air-cooled). When the laser cools sufficiently, remove DC power
for 30 seconds and then reapply power to the laser or toggle (open, then close) the Remote
Keyswitch signal via Pin 6 and Pin 7 on the DB-9 Connector. When the PWR indicator illumi-

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Troubleshooting
Troubleshooting
Operational flowchart

Laser Start Sequence

Apply 30 VDC
power to the
laser

Open the shutter,

Refer to Keyswitch
laser? Yes cycle the keyswitch
troubleshooting to OFF then ON
guide

Yes

PWR
indicator
Green?

Yes

Apply tickle signal or PWM

command to the laser

Yes

LASE indicator
illuminates Red to
indicate laser output

Figure 5-1 48 series™ operational flowchart.

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Troubleshooting
Troubleshooting

nates, lasing is enabled after the five-second delay.

The Power-On Reset feature is not available on OEM models; OEM customers must provide
this required safety feature as part of their equipment integration.
During any fault shutdown, the Fault Shutdown Output (Pin 1 on the DB-9 Connector), which
is normally at +15 VDC, latches to a low state (0 VDC) until the laser is reset by removing DC
power for 30 seconds and then reapplying power to the laser.
Each Symptom listed below describes a particular fault condition. For each Symptom, specific
causes and solutions are described in the Possible Causes section.

Symptom:
There is no output laser beam; PWR and LASE indicators are off.

Possible Causes & Solutions:

No DC voltage is applied or the voltage level is out of specification.
Check that +30 VDC is available on the power supply output terminals and ensure that DC
Power cable terminal connections are tight.
Check the fuse(s) on the rear of the laser. Replace with fast-blow 10 Amp (48-1) or 20 Amp (48-
2/48-5) AGC/3AG fuses (rated at 32 V minimum) as required.

A reverse DC voltage was applied to the laser.

Replace the fuse(s) with a fast-blow 10 Amp (48-1) or 20 Amp (48-2/48-5) AGC/3AG fuse (rated
at 32 V minimum) as required.

The laser’s DB-9 Connector is not configured correctly.

Ensure that the factory-wired DB-9 jumper plug is firmly plugged into the laser’s DB-9 Con-
nector.
If the laser is connected through the DB-9 Connector to external circuits, check that field wir-
ing is correct. The remote interlock connection (Pin 3) must be grounded through your exter-
nal interlock circuit to Pin 2 or Pin 4. Pin 6 must be connected to Pin 7 through your external
keyswitch circuitry. Refer to Connecting in the Getting Started chapter and DB-9 connections
in the Technical Reference chapter for details. A quick method to isolate the problem to either
the laser or the field wiring is to disconnect field wiring and plug in the factory-wired jumper
plug; if the lasers operates normally with the jumper plug installed, verify external wiring and
circuit devices.

The laser’s Keyswitch is not set properly.

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Troubleshooting

Cycle the Keyswitch to the OFF position for a few seconds, then cycle back to ON.

The laser is in an over temperature condition.

Allow the laser to cool. Verify that the laser is receiving the proper air or water flow per the fol-
lowing table. On air-cooled lasers, verify fan operation and check for at least 57.2 mm (2.25 in)
of unobstructed clearance around the fan housing. To restart the laser, disconnect DC power,
wait 30 seconds, and then reapply DC power.

Table 5-2 Series 48™ cooling specifications.

Model Air-cooled Water-cooled
48-1 7.1 m3/min × 2 fans (1 per side) 1.9 LPM at < 414 kPa
250 CFM × 2 fans (1 per side) 0.5 GPM at < 60 PSI

48-2 7.1 m3/min × 4 fans (2 per side) 3.0 LPM at < 414 kPa
250 CFM × 4 fans (2 per side) 0.8 GPM at < 60 PSI

48-5 N/A 5.7 LPM at < 414 kPa

N/A 1.5 GPM at < 60 PSI

Symptom:
No output beam and the PWR and LASE LEDs are Off, but +30 VDC is applied.

Possible Causes:
A fault shutdown has occurred. Pin 1 on the DB-9 Connector is at 0 VDC in reference to
Pin 2 or Pin 4 (Pin 1 is at +15 VDC during normal operation).
An over temperature, overvoltage/undervoltage, or RF circuitry failure has occurred.
Correct the problem(s), then remove power from the laser for 30 seconds. Re-apply power (on
Keyswitch lasers, cycle the Keyswitch or Remote Keyswitch).

Symptom:
No output beam, the PWR LED is On, but the LASE indicator is off.

Possible Causes:
The Shutter Switch is closed or not fully open.

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Troubleshooting

Close and then re-open the Shutter Switch.

Symptom:
No output beam, but the PWR LED is On. The LASE indicator is dim and does not
brighten.

Possible Causes:
A PWM Command input signal is not present.
Verify that a PWM Command signal is present on the CTRL input. On 48-5 dual-tube lasers, a
Command signal must be applied to both CTRL1 and CTRL2 inputs simultaneously. See Con-
trolling laser power in the Technical Reference chapter for PWM Command signal details.

Symptom:
Laser power varies or responds intermittently to input PWM Command pulses.

Possible Causes:
Verify that your UC-2000 or equivalent PWM controller is delivering tickle pulses of the
proper duration. See Controlling laser power in the Technical Reference chapter for
tickle pulse details.

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 LED and I/O States, 48 Series Lasers

94
INPUT STATUS OUTPUT STATUS

LASER CONDITION /
LED STATUS COMMENTS
FAULT

PWM
Message

Remote Key
Remote Lase

Remote Ready

Fault Shutdown

Remote Interlock
DB-9 DB-9 DB-9 DB-9
Connector & pins DB-9: 6 to 7 DB-9: 3 to 4 BNC Outputs ref'd to pins 2,4 of DB-9
pin 1 pin 5 pin 9 pin 8
Status LEDs

DC Power Off X X X No RF to tube

DC Power Applied Laser O X X

H H ON No RF to tube
Not Enabled X O X
Laser enabled, no tickle
C C None ON H H ON RF enabled
or PWM

Tickle Applied C C Tickle ON ON* H H ON Tickle RF enabled

SYNRAD® Series 48™ Operator’s Manual Version 9.6

Laser Firing C C ON ON* H H ON LASING!

Shutter Closed* C C X ON H H ON No RF to tube

Keyswitch in OFF
X X X H H No RF to tube
position*

Tube nearing overtemp C C ON H L Internal temp > 54°C

Troubleshooting

Over Temp Fault X X X L L Internal temp > 60°C

Under Voltage Fault X X X L Voltage below 28VDC

Maintenance/

Over Voltage Fault X X X L Voltage above 32VDC

Troubleshooting

TABLE KEY: C = circuit closed Brightness of Lase L = output low

*Keyswitch lasers only O = circuit open LED = PWM duty H = output high/open
x = Does not matter cycle

Table 5.3 48 series™ Input/Output & LED Status Signals. 3/24/2017

 Maintenance/
Troubleshooting
Troubleshooting
Beam delivery optics
Symptom:
The laser appears to slowly lose power over time; laser output power must be in
creased to maintain previous performance.

Possible Causes:
Beam delivery optics are coated by vapor residue or debris.

Symptom:
The laser appears to slowly lose power over time; laser output power must be in-
creased to maintain previous performance.

Possible Causes:
Beam delivery optics are coated by vapor residue or debris.
Shut down the laser and carefully inspect each optic in the beam delivery path, including the
laser’s output coupler. Remember that optics are fragile and must be handled carefully; pref-
erably by the mounting ring only. If the optic requires cleaning, refer to the required cleaning
materials table earlier in this chapter, then refer back to Maintenance for cleaning instructions.
Use only recommended cleaning materials to prevent scratching delicate optical surfaces.
If the focusing optic is pitted, it must be replaced immediately. The laser’s high power density
will cause pits or debris on the lens to absorb enough energy that the lens may crack. If this
happens, other optics in the beam path may be contaminated or damaged as well.
When the application requires air (instead of nitrogen or argon) as an assist gas, we recom-
mend the use of breathing quality air available in cylinders from a welding supply company.
Because compressed shop air contains minute particles of oil and other contaminants that
will damage optical surfaces, it must be carefully filtered and dried before use as a purge or
assist gas. Refer to Assist gas purity specifications, in the Technical Reference chapter for filter-
ing specifications.

Caution If you operate your laser or marking head in a dirty or dusty environ-
Possible ment, contact SYNRAD® about the risks of doing so and the precau-
tions you can take to increase the longevity of your laser.
Equipment
Damage

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 Index
Chapter Index
A M
American National Standards Institute (ANSI) 17 Maintenance
Assist gas purity daily inspections, 83
specifications, 36, 42, 43 disabling Firestar, 83
storage/shipping, 84
C MSDS 86

Caution O
condensation, 5, 28, 44, 52, 61, 62, 63, 64, 83, 85, 87, 95
CDRH , 22 Occupational Safety and Health Administration (OSHA) 18
Chiller
temperature setpoint, 38 R
Class IV safety features 25
Code of Federal Regulations (CFR) , 22, 23 Reference materials 8
Command signal 52 RoHS 24
Condensation damage 83
Customer Service 8 S
D Sales and Applications 8
Specifications
Daily inspections 83 assist gas purity, 36, 42, 43
Danger Storage/shipping 84
laser radiation, 14, 15, 17, 82
DC Power cable 83 T
Dew point
chart, 55 Technical Support 8
Disabling Firestar 83 Trademark information 6
Troubleshooting 86
F operational flowchart, 90

Flowchart U
laser start-up, 90
Food and Drug Administration (FDA) , 22 User I/O
connection summary, 55
H User I/O connections
input/output signals 55
Hazard information 15, 16, 17
label locations, 19, 20, 21 W
terminology, 15
Warning
I air contaminants, 5
Warranty information 7
Inspections
daily, 83

L
Label locations 19, 20, 21
Laser Institute of America (LIA) 18

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 Index

Tables and Figures Tables and Figures

Figure 1-1 Series 48™ ship kit contents.................. 11 ing dimensions. ........................................................ 76
Table 1-1 Series 48 ship kit contents........................ 11 Figure 4-17 Model 48-1 packaging instructions.. 77
Figure 1-2 Anatomy of a model number................. 13 Figure 4-18 Model 48-2 packaging instructions.. 78
Figure 2-1 Labeling terms and definitions............. 15 Figure 4-19 Model 48-5 packaging instructions.. 79
Figure 2-2 Always wear safety glasses. .................. 17 Figure 4-20 FLMK-1A (10W fan shroud) packaging in-
Figure 2-1 48-1 Hazard label locations.................... 19 structions. ................................................................... 80
Figure 2-2 48.2 Hazard label locations..................... 20 Figure 4-21 FLMK-2A (25W fan shroud) packaging in-
Figure 2-3 48-5 Hazard label locations.................... 21 structions. ................................................................... 81
Table 2-3 Class 4 safety features................................. 25 Table 5-1 Required cleaning materials.................... 85
Table 2-4 European Union Directives....................... 26 Figure 5-1 48 series™ flowchart.................................. 89
Figure 2-4 European compliance mark................... 26 Table 5-2 Series 48™ cooling specifications........... 91
Figure 2-5 48 Series Declaration Document. ......... 27 Table 5.3 48 series™ Input/Output & LED Status. .93
Figure 3-1 48-1/48-2 Front panel............................... 29 Figure A-1 Typical closed loop setup........................ 97
Figure 3-2 48-1/48-2 Rear panel. ............................... 30 Figure A-2 Duty cycle vs. pwr output before/after C.L. kit
Figure 3-3 Side panel controls and indicators. .... 31 installed........................................................................ 98
Figure 3-4 48-5 Front panel.......................................... 32 Table A-1 C.L general specifications......................... 99
Figure 3-5 48-5 Back panel............................................ 33
Figure 4-1 Beam characteristics. ................................ 36
Figure 4-2 “Flying optics” beam path. .................... 42
Table 4-2 Assist gas purity specifications............... 43
Table 4-3 Input signal specifications........................ 44
Table 4-4 Tickle pulse specifications......................... 45
Figure 4-3 Tickle pulse waveform.............................. 45
Figure 4-4 Series 48-2 kHz waveform. .................. 46
Figure 4-5 Series 48-5 kHz waveform.................... 47
Table 4-5 PWM Command signal specifications.. 49
Figure 4-6 PWM Command signal waveform....... 49
Figure 4-7 Factory-installed DB-9............................... 53
Table 4-6 DB-9 pin assignments................................. 55
Figure 4-8 Physical layout of Series 48 DB-9.......... 57
Table 4-7 DB-9 Connector input signal specs....... 57
Table 4-8 DB-9 Connector output signal specs..... 57
Figure 4-9 Remote Keyswitch circuit........................ 58
Figure 4-10 Remote Interlock circuit........................ 58
Figure 4-11 Remote Ready output to PLC input.. 59
Figure 4-12 Message Output to PLC input............. 60
Figure 4-13 Fault Shutdown Output to PLC input..60
Table 4-9 Model 48-1 general specifications......... 67
Table 4-10 Model 48-2 general specifications...... 69
Table 4-11 Model 48-5 general specifications...... 71
Figure 4-14 Model 48-1 package outline and mount-
ing dimensions, 1 of 2............................................. 74
Figure 4-15 Model 48-2 package outline and mount-
ing dimensions, 2 of 2............................................. 75
Figure 4-16 Model 48-5 package outline and mount-
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