Firestar vi30/40 Dual Cooled Laser Quick Start Guide

Transcription

1 Important See the Firestar vi30/40 Operators Manual for complete installation details and instructions. A PDF version is available online at: Read all Danger, Warning, Caution terms, symbols, and instructions located in the (Laser Safety Hazard information) sections in the Firestar vi30/40 Laser Operation Manual. Unpacking: 1. Unseat the wiring by sliding the harness out of the notch, then down and out of the foam as shown below. 2. Remove the laser from the box and locate the mounting hardware kit at the bottom of the box under the laser. Carefully push the wire harness through the notch in the top foam piece, and save with packaging. Important Re-packaging Assure the (2) H2O ports are nested inside the foam notches, & all residual water drained from the system. There is only one way the laser fits into the foam! Hint: If laser does not reseat easily, try flipping it around so the ports sit into the foam as shown. Important Caution! Unpacking the laser incorrectly can lead to damage. Keep All specially designed Foam and Packaging, you will need to re-use it when moving your laser. Refer to this guide and the Technical Reference chapters in the laser s Operation Manual when re-packaging for shipping and/or relocation. Mounting feet and/or rails are optional, for complete details, refer to the vi30/40 Operator s Manual and drawings on our website: Caution! When re-packing the laser for relocation or shipment, use compressed shop air (less than 29 PSI) to blow out excess water from the cooling systems. Wear safety goggles! Nothing can be on the sides of the laser at any time as damage will occur. The skin on the sides of the laser is fragile! All box components must be stowed under the laser. The wire harness &/or ports can be damaged in shipping if not re-packaged as shown above. 1 vi30/40 Dual Cooled QSG Version 2.0

2 Readying your Laser for use: Remove the laser aperture self-adhesive film before mounting your laser into final position. 3. Failure to remove the aperture seal can damage your system! Failure to remove seal can damage the laser. AVOID EXPOSURE Invisible laser radiation is emitted from this aperture. (Fan-Cooled ti60 Shown) Important Mounting feet and/or rails are optional. See the vi30/40 Operator s Manual and drawings on our website: SYNRAD does not recommend mounting lasers in a vertical, (head and/or tail down) position. Please contact the factory for limitations as a vertical orientation increases the risk of damage to the lasers optics. Consult the factory for further mounting angle guidance outside >75% from the horizontal. When mounting the laser to a baseplate, use only one metric or SAE fastener per mounting tab on the baseplate. Do not use any type of jackscrew arrangement as this will twist the baseplate and may distort the tube. 2 vi30/40 Dual Cooled QSG Version 2.0

3 Mounting: 4. Locate the Mounting Hardware ( ). Three ball bearing feet pressed into Firestar s base plate eliminate any possible distortion of the laser tube caused by variations in the flatness of the mounting surface. Front Back 4.1 Standard Mounting Dual cooled with fans shown (vi30 shown). 5. Choose your mounting type. A. Standard Mounting (smallest footprint): B. Tall Mounting (matches v30 height-for upgrading from v30 to vi30/40 for mounting from below): The Tall mounting kit (SYNRAD P/N ). C. Tall/Wide Mounting (matches v30 height-for upgrading from v30 to vi30/40 for mounting from above): The Tall/Wide mounting kit (SYNRAD P/N ). 6. Standard Mounting: Drill three thru holes in the final mounting surface that correspond to either the ISO (metric) or UNC fastener pattern shown in the O&M drawing: 7. Insert the three M6 1 ISO or 1/4 20 UNC fasteners through the mounting surface into the corresponding threaded holes Evenly tighten all capscrews to a maximum torque of 6.1 N m (54 in lb). Attention: When mounting from below, mounting bolts must not extend further than 6.0 mm (0.24 ) into the base plate. Otherwise damage to the laser may occur. 3 vi30/40 Dual Cooled QSG Version 2.0

4 Mounting (Continued): Standard vi30 Baseplate (Smallest Footprint) Tall Mounting Feet (Matches v30 Beam Exit Height) Tall/Wide Mounting Feet (Matches v30 Beam Exit & Mounting) Important When mounting the Firestar laser, use only one metric or SAE fastener per mounting tab on the baseplate. Do not use any type of jackscrew arrangement as this will twist the baseplate and may distort the tube. Optional mounting feet Tall mounting shown 4 vi30/40 Dual Cooled QSG Version 2.0

5 Cooling Connections: 8. If temperature monitoring is desired, see the following figure for customer supplied external temperature sensor. Front Top View Measure chassis temperature at this location 9. Installing the fans: Assure the gap between fan and laser must be less than 3.0 (76 mm). Minimum fan-to-wall clearance is 2.25 (57.2 mm) otherwise damage will occur! < 3.0 (76 mm) < 3.0 (76 mm) >2.25 (57.2 mm) Minimum clearance 9.1 Dual-cooled units can be cooled with either fans or water. (vi30 shown). 5 vi30/40 Dual Cooled QSG Version 2.0

6 Cooling (Continued): 10. If rear cooling is desired: Design the cooling shroud so that it encloses the full length of the laser and cooling fan. Assure the shroud fits snugly against the heatsink fins so that cooling air is conducted through them and not around them. For adequate heat removal, open the shroud at the front to direct air flow through the laser. Use a cooling fan rated at least 8.5 m 3 /min (300 cfm) at a static pressure of 23.9 mm H 2 O (0.94 in H 2 O) and position it approximately 150 mm (6.0 in) from the rear of the laser. See the cooling specifications in the Technical Reference section of the Operation Manual. Airflow Direction - Front to Rear Allow 6 inches clearance Recommended fan shroud design for rear cooling. Caution possible equipment damage Customer designed fan shroud must enclose both the OEM laser and cooling fan! 6 vi30/40 Dual Cooled QSG Version 2.0

7 Cooling (Continued): 11. Water cooling: Assure the water in from the chiller and out to the chiller are aligned appropriately with the In and Out markings on the back of the laser. Caution possible equipment damage Do not exceed coolant pressure of 414 kpa (60 PSI)! Attention: The stability of the unit will be affected if the water in/out is reversed! Water In from chiller Water Out to chiller 7 vi30/40 Dual Cooled QSG Version 2.0

8 Cooling (Continued): Important When filling your chiller, use at least 90% distilled or tap water by volume. If you must use glycol, do not add more than 10% by volume. See the technical reference chapter in the laser s Operation Manual for the dew point table and cooling specifications. Operating the laser with a coolant temperature below the dew point of the surrounding air may cause condensation to occur that will damage the laser! The setpoint temperature MUST be maintained above the dew point temperature. If tubing needs to be disconnected from a fitting: First push and hold the tubing slightly into the fitting. Next push the orange 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 reconnecting. Trimming the end of the tubing before reconnecting provides an undisturbed sealing surface. If your integrated laser application uses metric cooling tubing, we recommend the installation of tubing adaptors to convert cooling kit fittings from 1/2 (8 mm) tubing to the desired metric tubing. These tubing adaptors are available from many tubing and fitting manufacturers. Guidelines for cutting and installing tubing Cut tubing lengths generously to allow for trimming. Cut tubing squarely; diagonal cuts may not seal properly. Trim away 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 properties of the fitting. Never allow the tubing to kink, since kinking severely restricts coolant flow. Push tubing completely into the fitting, then pull the tubing to verify that it is locked into place. 8 vi30/40 Dual Cooled QSG Version 2.0

9 Cooling (Continued): 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, and coolant continues to flow through the laser for extended periods of time. The chiller s temperature setpoint must always be set above the dew point temperature. In cases where this is not possible within the specified coolant temperature range of 18 C to 22 C (64 F to 72 F), then the following steps MUST be taken to reduce the risk of condensation damage. A. Stop coolant flow when the laser is shut down. B. Increase coolant flow by an additional 3.8 LPM (1.0 GPM). C. Air-condition the room or the enclosure containing the laser. D. Install a dehumidifier to reduce the humidity of the enclosure containing the laser. Important Choosing the correct coolant temperature is important to the proper operation and longevity of your laser otherwise internal condensation damage will occur! Reference the dew point chart for temperatures and range of air temperature and relative humidity values in the technical references chapter of the vi30/40 Operation Manual. Remember that the laser s coolant temperature must be set above dew point temperatures. Caution possible equipment damage Do not flow coolant through the laser for an extended period of time when the laser is shutdown. This causes condensation to form inside the laser which may result in catastrophic damage to internal optics and electronic circuits. Inlet cooling water temperature must always be maintained above the dew point to prevent condensation and water damage to your laser. 9 vi30/40 Dual Cooled QSG Version 2.0

10 Electrical & Control Connections: 12. Connect the Laser negative (black) and the positive (red) DC power into the laser s power supply. (-) Black DC Cable (+) Red DC Cable DC Power Note Do not reverse polarity when connecting the DC Power cable to the vi30/40 laser. Attach the red (+) wire(s) from the DC Power cable to the positive (+) 48 VDC output terminal and attach the black (-) wire(s) from the DC Power cable to the negative (-) 48 VDC output terminal. Refer to the appropriate Quick Start Guide & Technical Drawings on our website. DC Power connection locations (for the Laser). Caution: The Quick Start Plug bypasses the laser s safety interlock function, potentially exposing personnel to hazardous invisible laser radiation. 13. If using the UC-2000 controller, see the UC-2000 QSG located on our website, then connect the laser s control DB-9/BNC interface to the laser. (See the following figures.) 13.1 DB- 9 Connector. 10 vi30/40 Dual Cooled QSG Version 2.0

11 Electrical & Control Connections (Continued): Controlling your laser with a UC-2000 controller: If using a UC-2000 Universal Laser Controller, refer to the UC-2000 Laser Controller Quick Start Guide and it s Operator s Manual for setup and operation instructions located on our website DB- 9 Interface Optional Quick Start Plug for the Laser. Controlling your laser without a UC-2000 controller: Important Before your OEM vi30/40 laser is put into service for the first time, its functionality should be verified. Follow this procedure if you are not utilizing the UC-2000 controller to verify the laser system is operating at optimum performance. Be sure to also reference the technical reference chapter of the laser s operation manual. When applying 48 VDC, but before operating the laser, you must provide a Laser Enable input signal to the DB-9 I/O connector. See DB-9 I/O connections in the Technical Reference chapter within the operation manual for pinouts and signal descriptions. 11 vi30/40 Dual Cooled QSG Version 2.0

12 Caution possible equipment damage Do not reverse polarity when connecting DC power cables to your DC power source. Reversed DC polarity will damage the vi30/40 s internal RF and control board circuitry. Carefully follow the directions below to ensure that DC cable leads are properly connected to the correct DC output terminals. Turn off DC power before installing or removing any plug or cable from the DB-9 I/O connector. Ensure that user connections are made to the appropriate pins and that the appropriate signal levels are applied. Failure to do so may damage the laser. Vi-Series lasers MUST be provided with a pre-ionizing tickle signal during standby or laser low periods. This signal is automatically provided by SYNRAD s UC-2000 Universal Laser Controller. A tickle signal keeps the plasma ionized during laser low periods and facilitates plasma breakdown and pulse-to-pulse fidelity. Damage to or malfunction of the laser may occur if this, or equivalent drive signals are not provided. If the laser has been OFF or the tickle has not been applied for any length of time apply the tickle signal for at least two seconds before applying any PWM command signal. Warning Serious personal injury Always wear safety goggles. Always use shielded cable when connecting your PWM Command signal source to PWM Positive/PWM Negative inputs. In electrically-noisy environments, long lengths of unshielded wire act like an antenna and may generate enough voltage to trigger uncommanded lasing. DC power: The negative ( ) side of the DC input to the laser is internally connected so that the laser chassis serves as DC power ground. If you need to isolate the body of the laser from the equipment chassis ground, use an insulating pad or film and insulated mounting hardware. OEM vi30 lasers can also be controlled from an alternate user-supplied Command signal source. Refer to Controlling laser power in the Technical Reference chapter for control signal descriptions and refer to DB-9 I/O connections, also in the Technical Reference chapter, for signal specifications and connection details. 12 vi30/40 Dual Cooled QSG Version 2.0

13 Initial startup of your OEM vi30/40 laser: Important You will need to provide a tickle signal and a pulse width modulated (PWM) Command signal to the laser s CTRL input connector. Refer to Controlling laser power in the Technical Reference chapter in your laser s Operation Manual for tickle and PWM Command signal descriptions. When performing the initial start-up sequence, check that the factory-installed DB-9 jumper plug is installed. If not, you must provide the required Remote Interlock and Remote Keyswitch signals to the DB-9 Connector. See the laser s Operation Manual for DB-9 connections, pinouts and signal descriptions. The laser s control board does not incorporate a built-in tickle generator nor the applied PWM signals. If you are not using a SYNRAD UC-2000 Universal Laser Controller to operate the laser, you must provide a 5 khz, 1 µs tickle pulse between applied PWM signals. See Controlling laser power in the laser s Operation Manual Technical Reference chapter for tickle signal descriptions. The OEM vi30/40 laser requires a DC power supply capable of providing 48 VDC at minimum (12 A (vi30) 20A (vi40) peak for less than 1 ms). To connect the vi30/40 laser to a 48 VDC power supply, perform the following steps: Verify your laser power to ensure output is consistent with the rating of your particular model. 14. If the laser has a Diode Pointer installed, remove its aperture dust cover. 15. Ensure that all personnel in the area are wearing protective eye-wear! 16. Assure the red self-adhesive aperture seal has been removed from the laser s faceplate. 17. Verify that input AC power to the DC power supply is physically locked out or disconnected. 18. Place an appropriate beam block 61cm (24 in) from the laser aperture, in this case a power meter, (such as SYNRAD s PW-250 Power Wizard ) to verify that output power is consistent with the power rating for your particular model. Beam block prevents the beam from traveling beyond the work area. If using water for cooling, see the laser s Operation Manual for specifications, review the water cooling sections within this guide and the laser s operation manual. 19. Ensure your controller is set to provide a 1 µs square wave tickle pulse at a frequency of 5 khz during any 200-µs measurement period where a PWM signal is not applied. 20. Connect the output of your PWM controller to PWM Positive (Pin 1) on the laser s DB-9 I/O connector and connect the ground or return of the Controller to PWM Negative (Pin 6). Reference the laser s Operation Manual Technical Reference section for DB-9 connections. See the following figure. 13 vi30/40 Dual Cooled QSG Version 2.0

14 Initial Start up without a UC-2000 Controller (Continued): Pin 5 Pin 1 Pin 9 Pin Restore power to the laser and turn on the +48 VDC power supply. Turn on the +48 VDC power supply. The laser s PWR LED should illuminate green. After a five-second delay, lasing is enabled when a PWM Command signal is received. PWR LED. 22. Set your PWM controller to a frequency of 5 khz (at a +5 volt level) and ensure that the controller s duty cycle is set to zero percent output (0.0%). 23. Apply a Laser Enable signal to the DB-9 I/O connector. The yellow RDY lamp turns on to indicate that, after a five-second delay, lasing is enabled when a PWM Command signal is received. Lase LED will illumate red. RDY LED. LASE LED. 24. If your laser fails to lase, reference the laser s Troubleshooting Section within the Operation Manual, SYNRAD s website for more information or contact SYNRAD support. 14 vi30/40 Dual Cooled QSG Version 2.0