operator s manual 4600 Campus Place Mukilteo, WA SYNRAD1 tel fax web

Transcription

1 operator s manual 4600 Campus Place Mukilteo, WA SYNRAD1 tel fax synrad@synrad.com web

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3 UC-2000 Universal Laser Controller Operator s Manual Version 3.0 December 2010 Part number Campus Place Mukilteo, WA SYNRAD1 tel fax synrad@synrad.com web

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5 table of contents Laser Safety Hazard information...1 Terms...1 General hazards...1 Label locations...4 Agency compliance...5 Federal Communications Commission requirements...5 European Union requirements...5 Declaration of Conformity...8 Getting Started 1 Inventory Contents description Introduction Features Mounting Standard model Panel mount model Connecting Power cable Control cable Operation 2 Controls and indicators Control panel Rear panel LCD display Initial start-up Setup Setting PWM frequency Setting gate logic Setting max PWM percentage Setting lase on power-up Setting REMOTE (RS-232) protocol Setting option Save and exit Factory default settings iii

6 table of contents Operation 2 (cont.) UC-2000 control Local control REMOTE (RS-232) control Laser control Operating modes Gate input Technical Reference 3 Control signals Tickle pulse Pulse Width Modulation (PWM) Command signal External control Gate input Analog control Closed loop control REMOTE control Serial Port connector Host serial port configuration REMOTE checksum commands Connector pinouts Laser connector Closed loop (C/L) connector General specifications UC-2000 package outlines Troubleshooting 4 Troubleshooting iv

7 table of contents Appendix A Closed Loop Stabilization Kit...A-2 Introduction...A-2 Safety precautions...a-2 Connecting...A-3 Operation...A-4 Closed loop specifications...a-4 Appendix B Non-checksum commands...b-2 REMOTE non-checksum commands...b-2 Index v

8 table of contents Figure 1 Figure 2 List of Figures UC-2000 CE label location...4 European compliance mark...6 Figure 2-1 Control panel Figure 2-2 Rear panel Figure 2-3 Firmware screen Figure 2-4 Start-up screen Figure 2-5 Setup screens Figure 2-6 REMOTE mode Figure 2-7 MANUAL mode Figure 2-8 ANC mode Figure 2-9 ANV mode Figure 2-10 MAN. CLOSED mode Figure 2-11 ANV CLOSED mode Figure 3-1 Tickle pulse parameters Figure 3-2 Representative optical output waveforms Figure 3-3 Command signal parameters Figure 3-4 UC-2000 input/output signal relationships Figure 3-5 Physical layout of RS-232 Serial Port connector Figure 3-6 RS-232 cable wiring diagram Figure 3-7 UC-2000 package outline dimensions Figure 3-8 UC-2000 panel mount package outline dimensions Figure A-1 Typical closed loop setup...a-3 vi

9 table of contents List of Tables Table 1 European Union Directives...6 Table 1-1 Shipping box contents Table 2-1 Factory default settings Table 3-1 Command signal output specifications Table 3-2 Gate input specifications Table 3-3 Analog current specifications Table 3-4 Analog voltage specifications Table 3-5 Analog voltage closed loop specifications Table 3-6 UC-2000 RS-232 pin assignments Table 3-7 Host serial port configuration Table 3-8 Laser connector pinouts Table 3-9 C/L connector pinouts Table 3-10 UC-2000 general specifications Table A-1 Closed loop general specifications...a-4 Table B-1 REMOTE Mode commands...b-3 Table B-2 REMOTE Lase commands...b-3 Table B-3 REMOTE Setup commands...b-3 Table B-4 REMOTE PWM (or SET) percentage command...b-4 Table B-5 REMOTE Status Request command...b-5 vii

10 Trademark/copyright information SYNRAD, Firestar, and Power Wizard are registered trademarks of SYNRAD, Inc. Evolution is a trademark of SYNRAD, Inc. All other trademarks or registered trademarks are the property of their respective owners. 2005, 2009, 2010 by SYNRAD, Inc. All rights reserved. viii

11 Warranty information This is to certify that UC-2000 Universal Laser Controllers are guaranteed by SYNRAD, Inc. to be free of all defects in materials and workmanship for a period of one year from the date of purchase. This warranty does not apply to any defect caused by negligence, misuse (including environmental factors), accident, alteration, or improper maintenance. We request that you examine each shipment within 10 days of receipt and inform SYNRAD, Inc. 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 UC-2000 Universal Laser Controller should fail to operate, contact the SYNRAD Customer Service department at SYNRAD1 (outside the U.S. call ) and report the problem. When calling for support, please be prepared to provide the date of purchase, model number and serial number of the unit, and a brief description of the problem. When returning a unit for service, a Return Authorization (RA) number is required; this number must be clearly marked on the outside of the shipping container in order for the unit to be properly processed. If replacement parts are sent to you, then you are required to send the failed parts back to SYNRAD for evaluation unless otherwise instructed. If the UC-2000 Universal Laser Controller fails within the first 45 days after purchase, SYN- RAD, Inc. will pay all shipping charges to and from SYNRAD when shipped as specified by SYNRAD Customer Service. After the first 45 days, SYNRAD will continue to pay for the costs of shipping the repaired unit or replacement parts back to the customer from SYNRAD. The customer, however, will be responsible for shipping charges incurred when sending the failed unit or parts back to SYNRAD or a SYNRAD Authorized Distributor. In order to maintain your product warranty and to ensure the safe and efficient operation of your UC-2000 Universal Laser Controller, only authorized SYNRAD replacement parts can be used. This warranty is void if any parts other than those provided by SYNRAD, Inc. are used. SYNRAD, Inc. and SYNRAD Authorized Distributors have the sole authority to make warranty statements regarding SYNRAD products. SYNRAD, Inc. and its Authorized Distributors neither assumes nor authorizes any representative or other person to assume for us any other warranties in connection with the sale, service, or shipment of our products. SYNRAD, Inc. reserves the right to make changes and improvements in the design of our products at any time without incurring any obligation to make equivalent changes in products previously manufactured or shipped. Buyer agrees to hold SYNRAD harmless from any and all damages, costs, and expenses relating to any claim arising from the design, manufacture, or use of the product, or arising from a claim that such product furnished Buyer by SYNRAD, or the use thereof, infringes upon any Patent, foreign or domestic. ix

12 Contact information Worldwide headquarters SYNRAD s worldwide headquarters are located in Mukilteo, Washington, U.S.A. Our mailing address is: SYNRAD, Inc Campus Place Mukilteo, WA U.S.A. Phone us at: SYNRAD1 ( ) Outside the U.S.: Fax: synrad@synrad.com Sales and Applications SYNRAD s Regional Sales Managers work with customers to identify and develop the best CO 2 laser solution for a given application. Because they are familiar with you and your laser application, use them as a first point of contact when questions arise. Our Regional Sales Managers also answer technical support questions regarding the installation, use, troubleshooting, and maintenance of our products and can provide reference materials including Outline & Mounting drawings, Operator s Manuals, Technical Bulletins, and Application Newsletters. In addition, your Regional Sales Manager serves 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 SYNRAD1. Customer Service For assistance with order or delivery status, or to obtain a Return Authorization (RA) number, contact SYNRAD at SYNRAD1 and ask to speak to a Customer Service representative. European headquarters SYNRAD s European subsidiary, Excel Technology Europe GmbH, covers Austria, Germany, Italy, and Switzerland. Contact Excel Technology at: Excel Technology Europe GmbH Münchner Strasse 2a D Planegg Germany Phone: +49 (0) Fax: +49 (0) synrad@excel-europe.com x

13 laser safety Hazard information Hazard information includes terms, symbols, and instructions used in this manual or on the equipment to alert both operating and service personnel to the recommended precautions in the care, use, and handling of Class IV laser equipment. Terms Certain terms are used throughout this manual or on the equipment labels. Please familiarize yourself with their definitions and significance. Danger: Warning: Caution: Caution: Note: Imminent hazards which, if not avoided, will result in death or serious injury. Potential hazards which, if not avoided, could result in death or serious injury. Potential hazards or unsafe practices which, if not avoided, may result in minor or moderate injury. Potential hazards or unsafe practices which, if not avoided, may result in product damage. Points of particular interest for more efficient or convenient equipment operation; additional information or explanation concerning the subject under discussion. General hazards Following are descriptions of general hazards and unsafe practices that could result in death, severe injury, or product damage when working with or around CO 2 lasers. Specific warning and cautions not appearing in this section are found in your laser s Operator s Manual. Danger serious personal injury Direct or diffuse laser radiation can inflict severe corneal injuries. Always wear eye protection when in the same area as an exposed laser beam. Eyewear protects against scattered energy and is not intended to protect against direct viewing of the beam or reflections from metallic surfaces. Protective eyewear that blocks 10.6 µm wavelength CO 2 laser radiation is available from SYNRAD. 1

14 laser safety Hazard information Warning serious personal injury Enclose the beam path whenever possible. Direct or diffuse laser radiation can seriously burn human or animal tissue, which may cause permanent damage. U.S. customers should refer to and follow laser safety precautions in ANSI Z , Safe Use of Lasers. Procedures listed in this Standard include the appointment of a Laser Safety Officer (LSO), operation of the product in an area of limited access by trained personnel, servicing of equipment only by trained and authorized personnel, and posting of signs warning of the potential hazards. European customers should appoint a Laser Safety Officer (LSO) who should refer to and follow laser safety precautions described in EN , 2007 Safety of Laser Products. Materials processing with a laser can generate air contaminants such as vapors, fumes, and/or particles that may be noxious, toxic, or even fatal. Material Safety Data Sheets (MSDS) for materials being processed should be thoroughly evaluated and the adequacy of provisions for fume extraction, filtering, and venting should be carefully considered. Review the following references for further information on exposure criteria: ANSI Z , Safe Use of Lasers, section 7.3. U.S. Government s Code of Federal Regulations: 29 CFR 1910, Subpart Z. Threshold Limit Values (TLV s) published by the American Conference of Governmental Industrial Hygienists (ACGIH). It may be necessary to consult with local governmental agencies regarding restrictions on the venting of processing vapors. 2

15 laser safety Hazard information Warning serious personal injury The use of controls or adjustments or performance of procedures other than those specified herein may result in hazardous radiation exposure. Other hazards The following hazards are typical for this product family when incorporated for intended use: (A) risk of injury when lifting or moving the unit; (B) risk of exposure to hazardous laser energy through unauthorized removal of access panels, doors, or protective barriers; (C) risk of exposure to hazardous laser energy and injury due to failure of personnel to use proper eye protection or failure to adhere to applicable laser safety procedures; (D) risk of exposure to hazardous or lethal voltages through unauthorized removal of covers, doors, or access panels; (E) generation of hazardous air contaminants that may be noxious, toxic, or even fatal. Disposal This product contains components that are considered hazardous industrial waste. If a situation occurs where the unit is rendered non-functional and cannot be repaired, it may be returned to SYNRAD, Inc. who, for a fee, will ensure adequate disassembly, recycling, and/or disposal of the product. Additional laser safety information The SYNRAD web site ( contains an online laser safety handbook that provides information on (1) Laser Safety Standards for OEM s/ System Integrators; (2) Laser Safety Standards for End Users; (3) References and Sources; and (4) Assistance with Requirements. In addition, the Occupational Safety and Health Administration (OSHA) has an online Technical Manual located at Section III, Chapter 6 and Appendix III are good resources for laser safety information. Another excellent laser safety resource is the Laser Institute of America (LIA). Their comprehensive web site is located at 3

16 laser safety Label locations MODEL: UC VDC, 35mA MFG: December 01, Campus Place, Mukilteo, WA (425) Ser#: UC MODEL: UC VDC, 35mA MFG: December 01, Campus Place, Mukilteo, WA (425) Ser#: UC Figure 1 UC-2000 CE label location 4

17 laser safety Agency compliance The UC-2000 Universal Laser Controller has been tested and certified to comply with certain United States and European Union (EU) Directives. These Directives impose product performance requirements related to electromagnetic compatibility (EMC) and product safety characteristics for laser products. The associated Directives and specific provisions to which systems containing the UC-2000 Universal Laser Controller must comply are identified and described in the following paragraphs. Federal Communications Commission requirements The United States Communication Act of 1934 vested the Federal Communications Commission (FCC) with the authority to regulate equipment that emits electromagnetic radiation in the radio frequency spectrum. The purpose of the Communication Act is to prevent harmful electromagnetic interference from affecting radio communication services. FCC information to the user NOTE: This equipment has been tested and found to comply with the limits for a Class A digital device pursuant to Part 15 of the FCC Rules. These limits are designed to provide reasonable protection against harmful interference when the equipment is operated in a commercial environment. This equipment generates, uses, and can radiate radio frequency energy and, if not installed and used in accordance with the instruction manual, may cause harmful interference to radio communications. Operation of this equipment in a residential area is likely to cause harmful interference in which case the user will be required to correct the interference at his own expense. FCC caution to the user The Federal Communications Commission warns the user that changes or modifications of the unit not expressly approved by the party responsible for compliance could void the user s authority to operate the equipment. European Union requirements Electromagnetic interference standards The European Union s Electromagnetic Compatibility (EMC) Directive 2004/1086/EC is the sole Directive developed to address electromagnetic interference (EMI) issues in electronic equipment. In particular, the Directive calls out European Norm (EN) documents that define the emission and immunity standards for specific product categories. For the UC-2000 Universal Laser Controller, EN defines radiated RF emission limits while the generic Standard EN defines immunity requirements published by the International Electromechanical Commission (IEC). 5

18 laser safety Agency compliance UC-2000 Universal Laser Controllers have demonstrated performance characteristics that have met or exceeded the requirements of the EMC directive 2004/108/EC. Table 1 contains a summary of EU performance requirements pertaining to the UC-2000 Universal Laser Controller. Table 1 European Union Directives Applicable Standards/Norms 2004/108/EC EN 55011:1998 EN :1997 ENV 50204:1995 EN :1995+A1:1998 EN :1999 EN :1995 EN :1996 Electromagnetic Compatibility Directive Radiated and Conducted Emissions RF Electromagnetic Immunity RF Electromagnetic Fields Immunity Electrostatic Discharge Immunity RF Electromagnetic Fields Immunity Electrical Fast Transient/Burst Immunity Conducted RF Disturbances Immunity After a product has met the requirements of all applicable EU directives, the product can bear the official compliance mark of the European Union as shown in Figure 2. Figure 2 European compliance mark 6

19 laser safety Agency compliance RoHS compliance UC-2000 Universal Laser Controllers meet the requirements of the European Parliament and Council Directive 2002/95/EC on the Restriction of the Use of Certain Hazardous Substances in Electrical and Electronic Equipment, as amended by Decision 2005/618/EC establishing maximum concentration values for certain hazardous substances in electrical and electronic equipment. 7

20 laser safety Declaration of Conformity We, Declaration of Conformity in accordance with ISO / IEC :2004 Manufacturer s Name: SYNRAD, Inc. Manufacturer s Address: 4600 Campus Place Mukilteo, WA U.S.A. hereby declare under our sole responsibility that the following equipment: Product Name: Model Number: UC-2000 Universal Laser Controller UC-2000 conforms to the following Directive(s) and Standard(s): Applicable Directive(s): 2004/108/EC Electromagnetic Compatibility Directive 2002/95/EC RoHS Directive (amended by 2005/618/EC) Applicable Standard(s): EN 55011:1998 Conducted and Radiated Emissions EN :1997 RF Electromagnetic Immunity ENV 50204:1995 RF Electromagnetic Fields Immunity EN :1995 +A1:1998 Electrostatic Discharge Immunity EN :1999 RF Electromagnetic Fields Immunity EN :1995 Electrical Fast Transient/Burst Immunity EN :1996 Conducted RF Disturbances Immunity Corporate Officer: European Contact: Dave Clarke, President of SYNRAD, Inc. Excel Technology Europe GmbH Münchner Str. 2a D Planegg Germany Dated 01 July

21 getting started 1 Use information in this section to prepare your UC-2000 Universal Laser Controller for operation. The order of information presented in this section is the same as the order of tasks that you will need to perform. The best way to get the UC-2000 ready for operation is to start at Inventory and work your way through Connecting. This section contains the following information: Inventory lists all components shipped with your UC-2000 Controller. Introduction describes the history of the UC Mounting describes UC-2000 mounting methods. Connecting explains how to connect the UC-2000 to your laser. 11

22 getting started Inventory Table 1-1 lists all items packaged with your UC-2000 Controller. Table 1-1 Shipping box contents Shipping Box Contents Qty SYNRAD UC-2000 Universal Laser Controller...1 UC-2000 Operator s Manual...1 Power/Control Cable...1 Wall Plug Transformer...1 BNC to BNC Control Cable...1 BNC Tee...1 Contents description A description of each item listed in Table 1-1 follows: SYNRAD UC-2000 Universal Laser Controller outputs laser Command signals and accepts external control and gating signals. UC-2000 Laser Controller Operator s Manual presents setup, operation, and technical information. Power/Control Cable provides DC power to the UC-2000 and outputs tickle/command signals to the laser. Wall Plug Transformer provides 24 VDC to the UC-2000 Controller from a VAC, Hz wall plug outlet. BNC to BNC Control Cable use with BNC Tee to connect Power/Control Cable to dualtube lasers. BNC Tee for connecting control cables to dual-tube lasers with two PWM control inputs. 12

23 getting started Introduction The UC-2000 Universal Laser Controller is SYNRAD s third-generation laser controller, a product which has evolved from years of experience with hundreds of SYNRAD laser controllers currently being used in applications at customer sites throughout the world. Features UC-2000 features include: Real-time LCD display of operating mode and PWM power settings Control knob sets laser power in 0.5% or 5% increments Built-in Lase indicator Remote analog voltage or analog current power control DB-9 serial connection allows UC-2000 control through an RS-232 serial port from a host computer or PLC New REMOTE (RS-232) checksum communications protocol to eliminate transmission line errors. Real-time display of power setpoint and actual closed loop power regulation Available in an optional panel mount design 13

24 getting started Mounting Standard model The UC-2000 Universal Laser Controller s rubber feet are designed for shelf or table-top mounting. If your application requires the UC-2000 to be securely fastened to a shelf or rack, perform the following steps: 1 Remove at least two of the four 6 32 Phillips head screws holding the UC-2000 s rubber feet to the chassis. 2 Drill holes into your mounting surface so that hole positions correspond to the UC s feet locations. Refer UC-2000 package outlines in the Technical Reference chapter for dimensions. 3 Position the UC-2000 and its rubber feet over the mounting holes and replace the 6 32 screws removed in Step 1. Note: If you must replace the standard mounting screws, the screw s additional length must be no longer than the thickness of the mount to prevent damage to the UC-2000 s case or internal components. Panel mount model To mount the UC-2000 panel mount version, perform the following steps: 1 Refer UC-2000 package outlines in the Technical Reference chapter for dimensions and then cut out a rectangle, measuring approximately 7.13" 3.25" (18.1 cm 8.3 cm), on your rack mount filler panel or cabinet housing. 2 Use the mounting hole dimensions shown in the UC-2000 package outlines panel mount drawing to drill and tap four 6 32 (M ) screw holes in the rack mount panel or cabinet housing. 3 Insert the panel mount UC-2000 Controller into the rectangular cutout and secure with four 6 32 or M3.5 screws. 14

25 getting started Connecting Refer to Controls and indicators in the Operation chapter for illustrations showing the placement and function of connections to the UC-2000 Controller. Power cable To connect power to the UC-2000, perform the following steps: 1 Locate the Power/Control cable in the shipping kit. 2 Connect the 4-pin mini-din connector to the Laser connector on the rear of the UC For Series 48 lasers, connect the miniature DC power plug on the other end of the Power/Control cable to the laser s side-mounted auxiliary power connector. For Evolution or Firestar lasers, connect the miniature DC power plug on the end of the Power/Control cable to the miniature connector on the cable from the Wall Plug Transformer. Plug the compact transformer into any VAC, Hz outlet. For other laser types, power the UC-2000 from any VDC source capable of supplying 35 milliamperes (ma) of current. If you choose to supply DC voltage from an alternate power source, ensure that connector polarity to the miniature DC power plug is correct: the tip or inner sleeve polarity is positive (+); the ring or outer sleeve polarity is negative ( ). Control cable Attach the Power/Control cable to your laser according to its type: Series 48-1, 48-2 laser: Attach the BNC connector from the Power/Control cable to the laser s control input, labeled CTRL, located on the rear of the laser. Series 48-5 laser: Attach one end of the BNC BNC coaxial control cable to the BNC connector from the Power/Control cable using the supplied BNC Tee. Attach the open end of the BNC Tee to one of the control inputs, CTRL1 or CTRL2, located on the rear of the laser. Connect the other end of the BNC BNC cable to the other control input. 15

26 getting started Connecting Firestar v30, v40, t70i, ti-series, f100, or f201 laser: Attach the BNC connector from the Power/Control cable to the BNC connector on the Quick Start Plug (or customer-supplied DB-15 connector) attached to the User I/O port on the rear panel of the laser. Firestar t-series laser: Attach the BNC connector from the Power/Control cable to the BNC connector on the Quick Start Plug (or customer-supplied DB-15 connector) attached to the User I/O port on the rear panel of the RF power supply. Firestar f200/f400 laser: Attach one end of the BNC BNC coaxial control cable to the BNC connector from the Power/Control cable using the supplied BNC Tee. Attach the open end of the BNC Tee to one of the Quick Start Plugs (or customer-supplied DB-15 connector) attached to the User I/O port on the rear panel of the laser. Connect the other end of the BNC BNC cable to the other Quick Start Plug (or customer-supplied DB-15 connector). Evolution 100/125 laser: Attach the BNC connector from the Power/Control cable to the control input, labeled Control In, located on the front or rear panel of the RF-3000 RF power supply. Evolution 200/240 laser: Attach the BNC connector from the Power/Control cable to the BNC Tee connecting the Set 1 and Set 2 control inputs, labeled Control In, located on the front or rear panel of the RF RF power supplies. The connections you have just completed are sufficient for manual operation and testing of the UC-2000 Controller. Refer to Initial start-up in the Operation chapter for start-up procedures. See UC-2000 control and Laser control in the Operation chapter for detailed information regarding UC-2000 operation and the various options for PWM laser control. External control in the Technical Reference chapter describes how to connect externally-generated control signals to the UC-2000 Controller. 16

27 operation 2 Use information in this section to familiarize yourself with UC-2000 controls and indicators and to begin operation. This section contains the following information: Controls and indicators displays and describes UC-2000 controls, indicators, and connections. Initial start-up explains how to operate the UC-2000 Controller. Setup describes how to set UC-2000 operating parameters. UC-2000 control describes local and REMOTE control of the UC Laser control describes each of the UC-2000 s PWM control methods and explains the gating function. 21

28 operation Controls and indicators Control panel 1 6 UC-2000 LASER CONTROLLER 2 SELECT ENTER LASE ON / OFF 5 Figure 2-1 Control panel LCD Display displays UC-2000 operating and setup parameters. 2 Select Pushbutton scrolls through menu selections. 3 Enter Pushbutton selects a menu item. 4 Lase On/Off Pushbutton press to toggle the laser On or Off using the current operating parameters. 5 Lase Indicator illuminates red to indicate that PWM Command pulses are being sent to the laser (if the Gate input is active). 6 PWM Adj Knob rotate to change PWM duty cycle. When setting PWM duty cycle manually, rotate the PWM Adj Knob to change output in 0.5% increments or press down and turn to increase or decrease laser PWM duty cycle in 5% increments. 22

29 operation Controls and indicators Rear panel ANV/ANC LASER SERIAL PORT C/L GATE Figure 2-2 Rear panel ANV/ANC Connector input BNC connector for applications using external analog voltage or current control signals. 2 Laser Connector 4-pin mini-din connection for the Power/Control cable, which provides DC power to the Controller and sends tickle/pwm signals out to the laser. 3 Serial Port Connector DB-9 connector allows a computer or programmable logic controller (PLC) to control the UC-2000 via an RS-232 serial port. 4 C/L Connector 8-pin mini-din connector allows closed loop power control of lasers equipped with a SYNRAD closed loop kit. 5 Gate Connector input BNC connector for applications using external gating signals to gate the laser beam on and off. Note: All BNC connectors on the UC-2000 Controller are wired so that the signal is connected to the center pin and the signal return, or ground, is connected to the BNC shell. 23

30 operation Controls and indicators LCD display When power is first applied to the UC-2000 Controller, the firmware screen (shown in Figure 2-3) appears and displays the current firmware version. ********** **** ** * S Y N R A D * * UC V2. 4 * ***** * ****** *** * Figure 2-3 Firmware screen After a few moments, the display changes to the start-up screen shown in Figure 2-4. MODE : M ANUAL PWM : % PUSH F OR COARS E Figure 2-4 Start-up screen Note: On subsequent start-ups, the UC-2000 recalls the last saved operating parameters. During normal operation, the UC-2000 s LCD display contains four lines that display the following information: Line 1 displays MODE: and the currently selected operating mode. Line 2 displays PWM:. % or SET:. %, the currently commanded PWM duty cycle in one-half percent increments. In manual closed loop or ANV closed loop mode, Line 3 displays POWER:. %, the actual regulated closed loop output power percentage. Line 4 displays information about the currently displayed control mode. 24

31 operation Initial start-up To initially test your UC-2000 Universal Laser Controller, perform the following steps: Warning possible personal injury Ensure that all personnel in the area are wearing protective eyewear. Read and follow all safety precautions described in your laser s Operator s Manual before beginning operation. 1 Place a beam block in front of the laser s output aperture to prevent the beam from traveling beyond the work area. 2 Ensure that all personnel in the area are wearing protective eyewear, then apply power to both the laser and the UC Press the Select pushbutton and scroll through the menu until Line 4 in the LCD display reads FUNC: MANUAL. 4 Press the Enter pushbutton to choose the MANUAL mode of operation. 5 If your laser is equipped with a keyswitch, turn it On (clockwise). The laser s green PWR indicator (Series 48 laser) or yellow Ready indicator (Evolution or Firestar laser) illuminates and, after a five-second delay, the laser is ready to lase. 6 Press the Lase On/Off pushbutton. The red Lase indicator on the UC-2000 and the laser s LASE indicator will both illuminate. 7 Rotate the PWM Adj Knob to set laser power in 0.5% increments or press down and rotate to change power in 5% increments. Laser output should increase and decrease correspondingly. If the laser fails to fire, refer to the Troubleshooting chapter. Note: Although the ratio of laser output to its power input is nonlinear, laser output is approximately proportional to PWM duty cycle. The curve of laser output versus PWM duty cycle also varies slightly when different PWM frequencies are used. 8 Press the Lase On/Off pushbutton to halt lasing. The red Lase indicator on the UC-2000 and the laser s LASE indicator will both turn off. 25

32 operation Setup Setup mode allows you to select operating parameters such as PWM frequency, gate logic, and maximum PWM percentage. To enter Setup mode when power is first applied, press and hold the Enter pushbutton while the firmware screen is displayed. Enter Setup mode at any time by pressing Enter and Select buttons simultaneously. After a few seconds the first setup screen (Figure 2-5) appears with the top line, FREQUENCY: KHZ, flashing. FREQU E N CY : 5 K HZ C H E CKS U M ( ON ) GAT E P U L L UP O P T I O N 2 MAX I MUM P WM : 9 5 % O P T I O N 3 LAS E ON PWR - U P N S A V E A N D E X I T Figure 2-5 Setup screens Press the Select pushbutton to scroll through setup parameters. When SAVE AND EXIT is flashing, press Enter to exit Setup mode and write current parameters to memory. Each parameter is described in further detail below. Setting PWM frequency The UC-2000 sends Pulse Width Modulation (PWM) signals to the laser at user-selectable frequencies of 5, 10, or 20 khz. The standard modulation frequency of 5 khz works well in most laser applications and provides the greatest depth of modulation (Figure 3-2 in the Technical Reference chapter). For applications that cannot tolerate the on/off nature of optical beam response but still require adjustable power levels, use a PWM frequency of 10 or 20 khz. To change the PWM frequency, perform the following steps: 1 Enter Setup mode and press the Select pushbutton until FREQUENCY: KHZ is flashing. 2 Press the Enter pushbutton. The current PWM frequency flashes. 3 Press Select to scroll through PWM frequency choices: 5, 10, or When the desired frequency is flashing, press Enter to choose that frequency as the current PWM frequency. 5 Press Select to go to the next parameter or press Select until SAVE AND EXIT flashes then push Enter to exit Setup mode and write operating parameters to memory. 26

33 operation Setup Setting gate logic A gate signal is available in all operating modes to gate, or switch, the laser. Connecting an external pulse train to the Gate connector (laser output enabled when gate input is active) causes the UC-2000 to rapidly switch the laser on and off. The laser s on power level is set by the UC-2000 s PWM Adj Knob or by external ANC, ANV, or REMOTE inputs. When laser off time exceeds 200 µs, a tickle signal is generated to maintain plasma ionization. A gate signal by itself does not fire the laser; instead the gate input is logically ANDed with the state of the Lase On/Off pushbutton. The pushbutton must be On (Lase indicator illuminated) and the appropriate active gate signal must be applied to the Gate connector in order to fire the laser. The default gate logic is pull up or normally on. Pull up logic means that the laser will fire without a gate signal present when the Lase On/Off pushbutton is pressed On. Users who intend to use a gating signal should set the UC-2000 s gate input logic to pull down or normally off. When set to pull down mode, a high-level signal in the range of +2.8 V to +5.0 VDC must be present at the Gate input connector in order to fire the laser. Pull down (normally off) logic ensures that the laser is always off in the event the gate signal is open or disconnected, or a tri-state (electrically floating) condition exists. Note: PWM output pulses are NOT synchronized with the Gate input signal. Set input gate logic to pull up (normally on) only if a gate signal is not used in your laser application or during laser setup. When the gate function is set to pull up (normally on), the laser will fire when the Lase On/Off pushbutton is pressed unless the Gate input connector is held in a logic low state or is short-circuited through a set of dry relay contacts. To change input gate logic, perform the following steps: 1 In Setup mode, press the Select pushbutton until GATE PULL flashes. 2 Press the Enter pushbutton. The current gate mode flashes. 3 Press Select to scroll through gate logic choices: Up or Down. 4 When the desired input logic is flashing, press Enter to choose that mode as the current gate input mode. 5 Press Select to go to the next parameter or press Select until SAVE AND EXIT flashes then push Enter to exit Setup mode and write operating parameters to memory. 27

34 operation Setup Setting max PWM percentage The UC-2000 s maximum PWM percentage (maximum allowable duty cycle) is adjustable to either 95 or 99%. The default maximum PWM percentage, 95%, allows the laser s plasma to cool slightly, increasing laser efficiency. A 99% PWM duty cycle should be used only when absolutely necessary and then only in applications where a gating signal limits long-term average power such as in a marking application. Note: SYNRAD lasers are designed for maximum performance using a 95% duty cycle. Increasing the maximum PWM percentage beyond 95% greatly increases the laser s heat load with little or no corresponding increase in laser output power. Continuous operation at 99% duty cycle may lead to thermal instability and optical degradation. To change the maximum PWM percentage, perform the following steps: 1 Press the Select pushbutton until MAXIMUM PWM: % is flashing. 2 Press the Enter pushbutton. The current PWM percentage flashes. 3 Press Select to scroll through maximum PWM choices: 95 or When the desired percentage is flashing, press Enter to choose that percentage as the current maximum PWM percentage. 5 Press Select to go to the next parameter or press Select until SAVE AND EXIT flashes then push Enter to exit Setup mode and write operating parameters to memory. Setting lase on power-up Normal operation of the UC-2000 Controller requires an operator to press the Lase On/Off pushbutton to enable lasing after Controller power-up. This safety feature prevents inadvertent laser operation in the event that power is cycled off and then on again such as during a power failure. In integrated applications where the UC-2000 is mounted inside a control cabinet and is not readily accessible to equipment operators, the UC-2000 Controller can be programmed to start lasing immediately upon power-up. To enable lasing on power-up, perform the following steps: 1 Press the Select pushbutton until LASE ON PWR-UP is flashing. 2 Press the Enter pushbutton. The current lase on power-up setting flashes. 28

35 3 Press Select to scroll through power-up settings: N or Y. operation Setup The UC-2000 s default setting is N (No), lasing on power-up is disabled. Choose Y (Yes) to enable laser output immediately after power is applied to the UC When the Y setting is flashing, press Enter to choose that setting as the current lase on power-up command. 5 Press Select to go to the next parameter or press Select until SAVE AND EXIT flashes then push Enter to exit Setup mode and write operating parameters to memory. 6 Follow all procedures to ensure that the laser is safe to fire (or disconnect the Power/ Control cable to prevent firing) and then press the Lase On/Off pushbutton. 7 When the red Lase indicator illuminates, wait six seconds until the UC-2000 beeps twice. This indicates that the new Lase On Power-Up setting is saved into memory. 8 Power down the UC-2000 Controller. The next time the UC-2000 is powered up, the Lase indicator will illuminate and the laser will begin firing immediately at the commanded power setting (provided that the Gate input is active). Warning possible personal injury When LASE ON PWR-UP is enabled, the system integrator is responsible for providing additional safe-guards to prevent accidental or unintended operation of the laser when power is applied to the UC-2000 Universal Laser Controller. Setting REMOTE (RS-232) protocol By default, UC-2000 Controllers running firmware version 2.4 use a new RS-232 transmission protocol that includes a checksum byte to provide a more robust communication link between the UC-2000 Controller and the host by better handling any errors introduced by the transmission line. No other configuration is required except to implement the new command string structure as described in the REMOTE control section of the Technical Reference chapter. 29

36 operation Setup If you plan to use the previous non-checksum single-byte command protocol, you must disable the checksum protocol as described below: 1 Enter Setup mode and press the Select pushbutton until CHECKSUM (ON) is flashing. 2 Press the Enter pushbutton once to disable the checksum protocol. The display will show CHECKSUM, without the (ON), to indicate the checksum is disabled. Note: The checksum mode (On or Off) is immediately saved to memory. 3 Press Select until SAVE AND EXIT flashes then push Enter to exit Setup mode and write operating parameters to memory. Setting option 2 3 This functions are reserved for future use and are not currently available. Save and exit Press Select to loop back around to the first setup parameter or push Enter to exit Setup mode and write operating parameters to memory. On exit, the Controller beeps twice to indicate that operating parameters were successfully saved to non-volatile memory. Factory default settings Table 2-1 lists factory default settings for the UC-2000 Controller. Table 2-1 Factory default settings Parameter Default Setting Frequency... 5 khz Gate... Pull Up Maximum PWM Duty Cycle... 95% Lase on Power-Up... N (No) Checksum... ON 210

37 operation UC-2000 control You can control the UC-2000 using either of two methods: local control, using panel knobs and buttons; or REMOTE control, using RS-232 serial port commands. Both methods allow you to control laser operation including output power adjustment and On/Off status. Local control PWM Adj Knob Use the PWM Adj Knob (Item 6 in Figure 2-1) to manually set the laser s output power by varying the duty cycle of the PWM Command signal. Rotate the knob clockwise or counterclockwise to increase or decrease the PWM duty cycle in 0.5% increments. To make larger changes, press the PWM Adj Knob down while turning to make changes in 5% increments. See Control signals in the Technical Reference chapter for descriptions of control signals generated by the UC-2000 Controller. Select/Enter pushbuttons Press the Select pushbutton (Item 2 in Figure 2-1) to scroll through selections in the current menu. Press the Enter pushbutton (Item 3) to choose the currently displayed operating mode in the main menu or to choose the flashing option in the Setup menu. Press and hold Enter when power is first applied (while the firmware screen is displayed) to enter Setup mode. To enter Setup mode at any time, press and hold both Select and Enter buttons simultaneously. Lase On/Off pushbutton The Lase On/Off pushbutton acts like a toggle switch to enable/disable lasing. Press the Lase On/Off pushbutton once to begin lasing; press it again to halt lasing. The red Lase LED above the Lase On/Off pushbutton illuminates when PWM Commands are being sent to the laser. Note: For safety reasons, lasing is automatically disabled and the Lase indicator is turned off if a new operating mode is selected while the laser is being commanded to lase. When the red Lase LED is off (with power applied to the Controller), the UC-2000 operates in Standby mode sending only tickle pulses to maintain plasma ionization in the laser. See Control signals in the Technical Reference chapter for a description of control signals generated by the UC-2000 Controller. The UC-2000 can be set to begin lasing automatically on power-up. To choose this option, Lase on Power-Up, refer back to the Setup section earlier in this chapter. 211

38 operation UC-2000 control Autosave feature Six seconds after the last pushbutton or PWM Adj Knob operation (in local UC-2000 control), the Controller automatically saves the current mode settings and PWM power percentage into non-volatile memory. After saving operational settings, the Controller beeps twice to indicate success. If power is removed and later reapplied, the UC-2000 Controller will powerup with the last saved operating mode and power settings. Note: All REMOTE (RS-232) commands received by the UC-2000 are immediately saved to non-volatile memory. REMOTE (RS-232) control Warning possible personal injury To prevent accidental exposure to laser radiation while operating using REMOTE control, it is the responsibility of the user to ensure that the computer is properly configured and that suitable software is available to control the UC Choosing REMOTE control, Figure 2-6, allows a host computer or programmable logic controller (PLC) to control the laser s desired output and operation through an RS-232 serial link. Immediately on entry to REMOTE operation, the UC-2000 saves current local control settings and then recalls the last saved REMOTE control settings. Once in REMOTE, the PWM Adj Knob and Laser On/Off pushbutton are disabled but the LCD display and Select/Enter pushbuttons continue to operate normally. When exiting REMOTE operation, the UC-2000 saves current REMOTE control settings and then recalls the last saved local control settings. See REMOTE control in the Technical Reference chapter for a complete list and description of REMOTE (RS-232) commands. 212

39 Note: operation UC-2000 control In response to a status request, the UC-2000 can report status data to the RS-232 link while it is in any local control or REMOTE control mode. MODE : SET : REMOTE X X. X % U S E R S23 2 P O RT Figure 2-6 REMOTE mode 213

40 operation Laser control Laser output power is controlled by choosing one of five UC-2000 operating modes: MANU- AL, ANC, ANV, MAN. CLOSED, and ANV CLOSED. When none of these modes is active, the Controller operates in Standby mode. Each operating mode is described in detail below. When operating the Controller using local control, choose one of the UC-2000 s five operating modes by pressing the Select pushbutton. Line 1 in the LCD display shows the various modes as you scroll through them. When the desired operating mode is displayed, press the Enter Pushbutton. Pressing Enter causes the displayed mode to become the active mode of operation. When operating the UC-2000 via REMOTE (RS-232) control, choose an operating mode by sending the appropriate command byte to the Controller s Serial Port connector. Line 1 in the LCD display changes to indicate the newly selected REMOTE control operating mode, which you control by sending REMOTE (RS-232) commands. If your REMOTE control application does not use ANC, ANV or closed loop inputs, then you will operate in MANUAL REMOTE mode and adjust laser power manually by sending the appropriate command and data bytes to the RS-232 serial port. Note: For safety reasons, lasing is automatically disabled and the Lase indicator is turned off if a new operating mode is selected while the laser is being commanded to lase (Lase indicator is illuminated). Operating modes Standby During standby operation (power applied to the UC-2000 Controller with the Lase indicator off), the UC-2000 sends 5 khz tickle pulses to pre-ionize laser gas to just below the lasing threshold. Tickle allows the laser to respond almost instantaneously to Command signals as the beam is switched off and on during laser operations. See Control signals in the Technical Reference chapter for descriptions of tickle and PWM Command signals. 214

41 MANUAL operation Laser control When operating the UC-2000 using local control, Figure 2-7, adjust laser power using the PWM Adj Knob. Rotating the knob changes laser output power from zero to maximum by varying the UC-2000 s PWM output from 0 to 95 (or 99) percent in 0.5% steps. When operating the UC-2000 using REMOTE control, adjust laser power manually by sending the appropriate command and data bytes via the RS-232 serial port. Line 2 in the LCD display shows PWM:. %, where. is the commanded PWM duty cycle percentage. An external Gate signal is the only active input allowed in MANUAL mode. MODE : M ANUAL PWM : X X. X % PUSH F OR COARS E Figure 2-7 MANUAL mode ANC In analog current (ANC) mode, Figure 2-8, control laser power using an external 4 20 ma current loop, which is the standard interface for industrial control loop supervision. The PWM duty cycle is continuously variable and changes proportionally to the applied current zero at 4 ma increasing to maximum power at 20 ma. Line 2 in the LCD display shows PWM:. %, where. is the commanded PWM duty cycle percentage. See External control in the Technical Reference chapter for ANC signal connections and specifications. MODE : ANC PWM : X X. X % 4 ma <CURRENT< 2 0mA Figure 2-8 ANC mode 215

42 operation Laser control ANV In analog voltage (ANV) mode, Figure 2-9, control laser power using an external analog 0 10 V source. The PWM duty cycle is continuously variable and changes proportionally to the applied voltage zero at 0 V increasing to maximum power at 10 VDC. Line 2 in the display shows PWM:. %, where. is the commanded PWM duty cycle percentage. See External control in the Technical Reference chapter for ANV signal connections and specifications. MODE : ANV PWM : X X. X % 0 V < VOLTAGE< 1 0V Figure 2-9 ANV mode MAN. CLOSED Closed loop power control is available for SYNRAD lasers with a factory installed Closed Loop Stabilization Kit. See Appendix A for details. When operating the UC-2000 using local control, Figure 2-10, adjust the laser s desired output power (regulated setpoint) using the PWM Adj Knob. When operating the UC-2000 using REMOTE control, adjust the laser s desired output power (regulated setpoint) manually by sending the appropriate command and data bytes to the RS-232 serial port. In either case, closed loop sensor feedback regulates power stability within ±2% of the setpoint. Closed loop settling time is typically two milliseconds (ms) after a change in setpoint. Line 2 in the display shows SET:. %, where. is the commanded power setpoint. Line 3 displays POWER:. %, where. is the actual regulated output power percentage. See External control in the Technical Reference chapter for closed loop signal connections and specifications. Note: If SET:. % and POWER:. % values do not match, then closed loop control is set out of range (the SET:. % value is outside the recommended upper or lower control limit range of 20 80% of rated output laser power). 216