Leister NOVOLAS Basic AT User guide

System Manual
NOVOLAS Basic AT
Version 2.1 09/2010
Subject to change without notice
Änderungen vorbehalten

Leister Process Technologies
Galileo -Strasse 10
CH-6056 Kägiswil
Switzerland
phone: [phone]
fax: [phone]
e-mail: [e-mail]
http:// www.leister.com
This is a translated version. Original language version: German.
Sales and Service
USA Germany China
Leister Technologies, LLC
1253 Hamilton Parkway
Itasca, Illinois 60143
phone:
[phone]
fax:
[phone]
e-mail:
[e-mail]
http://
www.leisterlaser.com
Leister Technologies GmbH
Steinbachstrasse 15
D-52074 Aachen / Germany
phone:
[phone]
fax:
[phone]
e-mail:
[e-mail]
http://
www.leister-technologies.de
Leister Technologies Ltd.
Building A, 1588 Zhuanxing Road
Shanghai 201 108 PRC
phone:
[phone]
fax:
[phone]
e-mail:
[e-mail]
http://
www.leister.cn
Leister reserves the right to update the content of this manual at any time without prior notification.
Copyright
This document may not be copied. All rights reserved, including those of translation, reprinting and
reproduction of the document or parts thereof. No part of the document may be reproduced or
distributed without the permission of the author (or the board of management), in any form, including
for purposes of conference, presentation and advertising.

Version 2.1
09/2010 NOVOLAS Basic AT
General 3
Contents
1General 4
1.1 About this Manual 4
1.2 Specialist personnel 4
1.3 Proper Use 5
1.4 Proper handling / Warranty 5
1.5 rganizational Measures 6
1.6 Reporting Requirement 6
2Safety Instructions 7
2.1 General Introductory Remark 7
2.1.1 Laser Safety Class 8
2.2 Safety of the N V LAS Basic AT system 8
2.2.1 Hazards from Laser Light 9
2.2.2 Hazards from electrical energy 11
2.2.3 Hazards from gases or vapours 12
2.3 N V LAS Basic AT Safety Devices 13
2.3.1 Laser safety interlock (external) 13
2.3.2 Laser enable key switch (internal) 13
2.3.3 Emergency stop button (internal and external) 13
2.3.4 Laser Warning device 13
3System Description 14
3.1 Hardware verview 14
3.2 System States 17
4Interfaces 18
4.1 verview 18
4.2 Terminal block (X90, X91-94) 19
4.2.1 Common Control Interface (X 90) 19
4.2.2 Individual Laser Unit Control Interface (X91-X94) 20
4.3 Customer I/ 21
4.3.1 Digital Inputs (X14) 21
4.3.2 Digital outputs (X15) 22
4.3.3 Interface pin assignements X15, including good/bad
evaluation 23
4.3.4 Analogue Inputs (X16) 24
4.3.5 Analogue utputs (X17) 24
4.3.6 Serial Interface RS232 (X18) 25
4.3.7 Serial Interface RS422 (X36) 25
4.4 External Laser Interface (X80/81, Coolant) 26
4.4.1 High Current Connector (X 80.+, X80.-) 26
4.4.2 Interlock To Laser Module (X81) 27
4.4.3 Cooling Supply To External Laser Modules 27
5Installation 28
5.1 Important notices 28
5.2 Transportation 28
5.2.1 Local transportation 28
5.2.2 Long-distance transportation 29
5.2.3 Transport damage 29
5.2.4 Packaging materials 29
5.3 Location 29
5.4 Conditions for setting-up 30
5.5 Installation instructions 30
5.5.1 Time scheme for typical Integration 37
5.5.2 Typical wiring of a Basic AT with an external laser unit
(I.e. Linebeam) 38
6Operation 39
6.1 Switching on the N V LAS Basic AT 39
6.2 Configuring the N V LAS Basic AT 40
6.3 peration modes and modifications of the Basic AT
6.3.1 Current Setting Mode 46
6.3.2 Activating the Laser (Register 3) 48
6.3.3 n- ff Temperature Regulator (Register 1 and 6) 48
6.4 Switching off the N V LAS Basic AT 49
6.5 Behaviour during operations 49
6.6 Diagnostics LEDs 50
6.6.1 Diagnostic Lamp L1 50
6.6.2 Diagnostic Lamp L2 50
7Service and Troubleshooting 51
7.1 Repair / Service 51
7.2 System faults 51
7.3 Laser Module Faults 53
7.4 ptics fault 53
8Maintenance 54
8.1 Time intervals 54
8.2 Spare parts 55
8.3 Disposal of replacement parts 55
9Warning Notices and
Abbreviations 56
9.1 Symbols in the manual 56
9.2 Abbreviations and terms 57
9.3 Labels on the N V LAS Basic AT 58
10Technical Data 60
10.1 Installation data 60
10.2 Dimensions and weight 60
10.3 Environmental conditions 60
10.4 Laser power supply and laser module 61
10.5 Liquid Cooling System 61
10.6 Conductor cross-sections 61
11Notes 62

NOVOLAS Basic AT Version 2.1
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4 General
1 General
1.1 About this Manual
This manual describes the NOVOLAS Basic AT laser system.
This manual includes information on the equipment’s:
•Safety
•Installation
•Interfaces
•Operation
•Troubleshooting
•Maintenance
The meaning of the symbols and Warning labels used on the NOVOLAS Basic AT
system may be found in chapter 9 of this manual. Checklists for installation found in
Chapter 5.5 , for maintenance in chapter Maintenance of this Manual.
1.2 Specialist personnel
This manual, with the following stipulations, is addressed to specialist personnel
Transportation:
Personnel with the relevant knowledge
Installation:
End user having read and understood this manual
Wartung:
End user having read and understood this manual
Repair:
Only through verifiably trained persons authorized by Leister Process Technologies
and with knowledge of Laser safety regulations.

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General 5
1.3 Proper Use
The NOVOLAS Basic AT system may not be operated as a standalone system. It
must be integrated into equipment, which complies with the applicable directives and
standards. The Basic AT may only brought in to service after a laser warning lamp or
other warning device complying with EN60825-1 has been installed.
The NOVOLAS Basic AT system is exclusively designed for plastics welding in
combination with suitable plastics or soldering. Regarding question about the
material, please contact your material supplier.
Any other use or extension of use is considered as improper use. The manufacturer is
not liable for resulting damages and the risk lies solely with the user.
The materials and components processed as well as the parameters set are to be
selected such that no emissions (vapors, smoke, etc.) arise during proper use of the
system. If this cannot be avoided, care must be taken that the emissions arising are
completely extracted and filtered (observe the relevant regulations). The NOVOLAS
Basic AT system must not be used for welding of materials that are flammable or
explosive.
Proper use also involves:
•following the manual
•observance of the inspection and maintenance measures
1.4 Proper handling / Warranty
NOTICE:
Some components of the NOVOLAS Basic AT are delicate and/or have sensitive
elements. Warranty is void in case of damage if the component is not handled
carefully and in the manner described / according to specifications prvided in theis
manual and in the Technical Data.

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1.5 Organizational Measures
Always keep this manual with your NOVOLAS Basic AT. In addition to this manual,
please observe the generally applicable legal and other statutory regulations
pertaining to accident prevention and environmental protection and instruct all
NOVOLAS Basic AT operators accordingly. Some important standards and
regulations are listed in chapter 2.1 of this manual.
Observe all safety and hazard warnings on the laser system. No warning signs are to
be removed. Replace damaged or illegible ones immediately.
Those persons entrusted to work on the NOVOLAS Basic AT must have read and
understood the manual, especially the chapter on safety, prior to commencing work.
This also applies to persons who only occasionally come into contact with the
NOVOLAS Basic AT, e.g. when maintaining the system.
No alterations should be carried out on the NOVOLAS Basic AT without prior
consultation and written approval from Leister Process Technologies. The safety of
the NOVOLAS Basic AT is compromised at best as a result of modifications. The user
is exclusively liable for all damages arising from alterations, which are not expressly
approved by Leister Process Technologies.
Replacement parts must conform to Leister Process Technologies’ specified technical
requirements. This is always ensured with original replacement parts.
Do not carry out any alterations on the operating system and control program of the
NOVOLAS Basic AT. Take care when testing and initial implementing newly generated
programs and be aware of potential collisions and emissions.
1.6 Reporting Requirement
The NOVOLAS Basic AT is a Laser Class 4 laser system. The emitted radiation
(direct radiation and/or scattered radiation) is partly invisible and can cause
irreparable damage to the eye or skin
As the owner, you might be obliged to report the operation of Class 4 equipment to
the authorities responsible.
Observe the statutory local laws and regulations governing the operation of laser
products.

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Safety Instructions 7
2 Safety Instructions
2.1 General Introductory Remark
The NOVOLAS Basic AT is an OEM product intended for integration into equipment.
The NOVOLAS Basic AT must not be operated as a stand-alone system.
The equipment into which the NOVOLAS Basic AT is integrated must comply with all
applicable directives and standards. In Europe the following European directives will
apply to the equipment.
•Machinery directive 2006/42
•Low voltage directive 2006/95
•Electromagnetic compatibility directive 2008/108
It is the responsibility of the integrator to ensure that the equipment into which the
NOVOLAS Basic AT is integrated complies with all requirements of these and/or other
local directives and applicable standards in their entirety. Only when this is ensured,
the NOVOLAS Basic AT may be put into operation as a component of the entire
equipment. Pay special attention to the hazards arising from the NOVOLAS Basic AT
itself, as described in this manual.
The NOVOLAS Basic AT should particularly only be put into operation if:
• The accessibility to the laser radiation has been prevented beyond the limit
value of Laser Safety Class 2M (protective guards, protection of the danger
zone etc., see EN60825-1)
• The NOVOLAS Basic AT is correctly connected to a separate power supply
fused by a line
The NOVOLAS Basic AT is designed and built according to state-of-the-art technology
and accepted safety rules. Nevertheless, operation of the machine can endanger life
and limb of the operator or other persons. Similarly, damage can arise to the
NOVOLAS Basic AT or to other property.
The NOVOLAS Basic AT may only be used if:
• All safety regulations are respected
• The system is in a technically perfect condition
• The system is operated properly
• The operator is trained and is fully aware of safety and hazard issues.
• The instructions in this manual and the other supplied manuals are read,
understood and observed

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Faults, especially those compromising safety, must be eliminated without delay.
Below, several standards are listed, which could be relevant for the use of the
NOVOLAS Basic AT and/or of the equipment in which the Basic AT is integrated. The
list is purely informative. Leister Process Technologies accepts no responsibility for
the completeness of this list.
Standard Brief description
EN 14121 Safety of machines, guidelines for risk assessment
EN 12626 Safety of machines: laser processing machines
EN 12100-1
EN 12100-2 Safety of Machinery. Basic concepts, general principles for design. Basic terminology and methodology.
EN 60204 Electrical equipment of industrial machines
EN 13849 Safety-related control systems
EN60825-1 Safety of laser products: Equipment classification, requirements and
user’s guide
2.1.1 Laser Safety Class
The NOVOLAS Basic AT system itself is a Laser Class 4 laser system in accordance
with EN60825-1:2007. The emitted radiation (direct radiation and/or scattered
radiation) is partly invisible and can cause irreparable damage to the eye or skin
(warning labels – see chapter 9 ).
It is the responsibility of the system integrator to integrate the system such that no
hazardous laser radiation escapes from any part of the equipment. The entire
equipment must at least conform to Laser Class 2M in accordance with EN 60825-
1:2007.
2.2 Safety of the NOVOLAS Basic AT system
Only operate the NOVOLAS Basic AT system if all protective and safety devices - e.g.
removable guards, EMERGENCY STOP devices – are present and functional. It is in
the operating company's responsibility to install a laser warning lamp or other warning
device complying with EN60825-1 is installed prior to commissioning.
In the case of functional faults, switch off the NOVOLAS Basic AT immediately and
remove the mains plug. Have the fault corrected by an authorized specialist without
delay.
Carry out the setting-up, maintenance and inspection work as described in this
manual and observe the instructions on replacing parts. Repairs may only be carried
out by Leister Process Technologies or its authorized sales partners or certified
trained persons.
Particular hazards, which may arise from the NOVOLAS Basic AT, are described in
the following sections.

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Safety Instructions 9
2.2.1 Hazards from Laser Light
Laser diodes, as fitted in the NOVOLAS Basic AT, generate intense radiation in the
invisible, near infrared spectral range (800 – 1000 nm). Direct laser light and/or
scattered radiation can be hazardous to eyes and skin.
• Laser light can reach your skin or eyes if the laser aperture and processing
area are not under a laser safety guard. Direct laser light and/or scattered
radiation can burn your skin or permanently damage your eyes.
• Do not put your NOVOLAS Basic AT into operation until all safety measures
required in the standard EN60825-1 have been implemented.
• For fiber-coupled laser modules: Never put the NOVOLAS Basic AT into
operation without having connected the optical fiber at both ends (Laser
module and processing optics).
• Wear EN207/208 compliant laser protection goggles – eye protection for laser
radiation – when you disable the laser protection devices for repair work.
The most important protective measures when dealing with laser radiation are
contained in the standard EN60825-1 – Radiation safety of laser products.
An important aspect of the regulations is the division of laser devices into different
Laser Safety Classes, dependent on the hazard presented by the emitted light.
Leister Process Technologies’ NOVOLAS Basic AT conforms to Laser Class 4 on
delivery.
Laser Class 4
Laser Class 4 means that the direct and scattered radiation is hazardous to skin and
eyes. It can lead to burns and irreversible damage of eyes. The invisible radiation
from the NOVOLAS Basic AT high power lasers is assigned to Laser Class 4.

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10 Safety Instructions
The NOVOLAS Basic AT must not be operated without additional protective guards or
alarmed danger zone. If this really is required, the relevant protective measures
(Laser protective goggles with adapted optical density for the wavelength range
described in EN 207/208, protective clothing etc.) must be implemented (see
EN60825-1).
• Direct laser light and/or scattered radiation can burn your skin or permanently
damage your eyes.
• Implement the necessary protective measures in the danger zone of the
NOVOLAS Basic AT in order to avoid exposure of eyes or skin from direct or
scattered radiation and to warn of hazards (also see the standard EN60825-
1).
• Observe the statutory and local laws & regulations governing the operation of
laser products.
Laser Class 2M
The aiming laser, which is installed in the NOVOLAS Basic AT, belongs to Laser Class
2M (according to EN60825-1, wavelength 635-670nm, power ≤5 mW).
This laser radiation is generally harmless to the eye as the eyelid reflex prevents long
exposure. It is however not advisable to stare directly into the beam.