Novanta i401 User manual

i401 Series Operator’s Manual
4600 Campus Place
Mukilteo, WA 98275
1.800.SYNRAD1
tel [phone]
fax [phone]
e-mail [e-mail]
web www.synrad.com
®

i401 Operator’s Manual
Version 2.0
SYNRAD©is a registered trademark of Novanta Corporation. ©Novanta Corporation 2019. All Rights Re-
served. No reproduction without written authorization.
DATE: July 2019

table of contents
i
SYNRAD i401 Operator’s Manual Version 2.0
Laser Safety 2
Introduction/Getting Started 1
Introduction .............................................................................................................. 1
Terms...................................................................................................................................................................................... vii
Introduction........................................................................................................................................................................... 2
Unpacking, inventory......................................................................................................................................................... 3
Mounting................................................................................................................................................................................ 8
Connecting ..........................................................................................................................................................................13
Introduction ............................................................................................................27
Hazard information.........................................................................................28
General hazards ...............................................................................................29
Other hazards ...................................................................................................31
Disposal...............................................................................................................31
Additional laser safety information...........................................................31
Labeling ..............................................................................................................32
Agency Compliance .......................................................................................33
CDRH requirements........................................................................................33
FCC requirements............................................................................................34
EU requirements ..............................................................................................35
Declaration of Conformity .................................................................................38
Operation 3
Introduction ............................................................................................................39
Controls and indicators .................................................................................40
Initial start-up ...................................................................................................41
Technical Reference 4
Technical overview .........................................................................................59
Laser design.......................................................................................................59
RF power supply ..............................................................................................64
Optical setup.....................................................................................................64
Controlling laser power.......................................................................................64
Control signals..................................................................................................64
Operating modes ............................................................................................66
User I/O connections............................................................................................68
User I/O connection summary....................................................................68
Input/output signals ......................................................................................70

table of contents
ii SYNRAD i401 Operator’s Manual Version 2.0
Firestar i401 packaging instructions ..............................................................99
Maintenance ........................................................................................................ 100
Disabling the i401 laser.............................................................................. 101
Daily inspections........................................................................................... 102
Storage/shipping.......................................................................................... 103
Cleaning optical components.................................................................. 104
Troubleshooting ................................................................................................. 106
Operational owchart................................................................................. 106
Maintenance/Troubleshooting 4
Technical Reference 4
Firestar i401 outline and mounting drawings ............................................96
Sample I/O circuits ..........................................................................................77
DC power/DC sense cables................................................................................81
DC power cables..............................................................................................81
DC voltage sense cable .................................................................................81
Firestar i401 web interface.................................................................................82
Accessing the i401 web page......................................................................82
Home page layout...........................................................................................82
Event log page layout....................................................................................83
Changing the i401’s IP address.........................................................................85
Alternate Ethernet connection...................................................................86
Firestar i401 rmware upgrade........................................................................87
Firmware upgrade procedure.....................................................................90
Integrating Firestar safety features ................................................................92
Keyswitch functions .......................................................................................93
Shutter functions.............................................................................................93
Remote interlock functions ...............................................................................93
Firestar i401 general specications.................................................................94

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SYNRAD i401 Operator’s Manual Version 2.0
List of Figures
Figure 1 Firestar i401 hazard label and CE label locations.....................4
Figure 2 European compliance mark ............................................................9
Figure 1-1 Unpacking the i401 laser..................................................................1-4
Figure 1-2 Removing the i401 lifting handles................................................1-5
Figure 1-3 Firestar i401 shipping box contents.............................................1-6
Figure 1-4 Mounting locations for four-point mount with feet...............1-9
Figure 1-5 Mounting locations for four-point mount without feet........1-10
Figure 1-6 Mounting locations for three-point mount without feet.....1-11
Figure 1-7 Firestar i401 cooling connections .................................................1-16
Figure 1-8 PS-401 voltage selection access panel........................................1-17
Figure 1-9 PS-401 input section..........................................................................1-18
Figure 1-10 DC power connection locations – rear view..............................1-19
Figure 1-11 DC power connection locations – side view .............................1-20
Figure 1-12 Gas purge kit assembly.....................................................................1-23
Figure 1-13 Firestar i401 home page...................................................................1-26
Figure 2-1 Firestar i401 front panel controls and indicators.....................2-2
Figure 2-2 Firestar i401 rear panel controls and indicators.......................2-3
Figure 3-1 Hybrid waveguide/unstable resonator design ........................3-2
Figure 3-2 Firestar i401 beam ellipticity...........................................................3-3
Figure 3-3 Converting 45° linear polarization to circular polarization..3-4
Figure 3-4 PWM Command signal waveform.................................................3-7
Figure 3-5 User I/O connector pinouts .............................................................3-10
Figure 3-6 Auxiliary DC power diagram...........................................................3-13
Figure 3-7 Quick Start Plug wiring diagram....................................................3-15
Figure 3-8 Input equivalent schematic.............................................................3-16
Figure 3-9 Output equivalent schematic.........................................................3-18
Figure 3-10 Customer-supplied interlock ..........................................................3-19
Figure 3-11 Customer-supplied interlock, negative voltage ......................3-19
Figure 3-12 PLC driven interlock signal...............................................................3-20
Figure 3-13 Multiple PLC driven inputs...............................................................3-20
Figure 3-14 Firestar output driving warning lamp .........................................3-21
Figure 3-15 Firestar output driving relay............................................................3-21
Figure 3-16 Firestar output driving PLC input module .................................3-22
Figure 3-17 Firestar i401 home page...................................................................3-25
Figure 3-18 Firestar i401 event log page............................................................3-27

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iv SYNRAD i401 Operator’s Manual Version 2.0
List of Figures (cont.)
Figure 3-19 Firestar i401 Change IP Address page .........................................3-28
Figure 3-20 Windows Control Panel.....................................................................3-29
Figure 3-21 Programs and Features dialog........................................................3-30
Figure 3-22 Windows Features dialog.................................................................3-30
Figure 3-23 Local Area Connection Properties dialog...................................3-31
Figure 3-24 Internet Protocol (TCP/IP) Properties dialog ............................3-31
Figure 3-25 Congure IP Address link on Firestar i401 home page..........3-32
Figure 3-26 Firestar i401 Change IP Address page .........................................3-33
Figure 3-27 Firestar i401 web browser display.................................................3-33
Figure 3-28 Firestar i401 outline & mounting dimensions ..........................3-38
Figure 3-29 Firestar i401 outline & mounting dimensions
(mounting feet removed).................................................................3-39
Figure 3-30 Firestar i401 packaging instructions ............................................3-40
Figure 4-1 Firestar i401 operational owchart...............................................4-7
Figure 4-2 Firestar i401 functional block diagram........................................4-8
Figure 4-3 Enable Java script in browser..........................................................4-19
Figure 4-4 Add IP addresses to list of authorized/trusted websites.......4-20

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SYNRAD i401 Operator’s Manual Version 2.0
List of Tables
Table 1 Class 4 safety features........................................................................8
Table 2 European Union Directives..............................................................9
Table 1-1 Firestar i401 ship kit contents.........................................................1-6
Table 1-2 Dew point temperatures ..................................................................1-15
Table 1-3 AC three-phase electrical recommendations ...........................1-18
Table 1-4 Purge gas specications ...................................................................1-24
Table 3-1 Assist gas purity specications.......................................................3-5
Table 3-2 PWM Command signal specications .........................................3-8
Table 3-3 User I/O pin descriptions..................................................................3-11
Table 3-4 Input circuit specications...............................................................3-16
Table 3-5 Output circuit specications...........................................................3-18
Table 3-6 Firestar i401 general specications ..............................................3-36
Table 4-1 Required cleaning materials ...........................................................4-4
Table 4-2 Status signals........................................................................................4-9
Table 4-3 Eect of Remote Interlock input on operating parameters 4-10
Table 4-4 Normal operating condition ...........................................................4-10
Table 4-5 Quick Start Plug or interlock/shutter inputs not
connected..............................................................................................4-11
Table 4-6 Interlock Open condition.................................................................4-11
Table 4-7 Over Temperature fault.....................................................................4-11
Table 4-8 Shutter Closed condition .................................................................4-12
Table 4-9 No-Strike condition ............................................................................4-12
Table 4-10 Laser fault codes..................................................................................4-13

vi SYNRAD i401 Operator’s Manual Version 2.0
Trademark/copyright information
SYNRAD and Firestar are registered trademarks of SYNRAD, Inc.
All other trademarks or registered trademarks are the property of their respective owners.
© 2013 by SYNRAD, Inc.
All rights reserved.

vii
SYNRAD i401 Operator’s Manual Version 2.0
Warranty information
This is to certify that Firestar®i401 lasers are guaranteed by SYNRAD, Inc. to be free of all defects in
materials and workmanship for a period of one year from the date of purchase. This warranty does not
apply to any defect caused by negligence, misuse (including environmental factors), accident, alteration,
or improper maintenance. 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, 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 Firestar i401 laser should fail to oper-
ate, contact the SYNRAD Customer Service department at 1.800.SYNRAD1 (outside the U.S. call
1.425.349.3500) and report the problem. When calling for support, please be prepared to provide the date
of purchase, model number and serial number of the unit, and a brief description of the problem. When
returning a unit for service, a Return Authorization (RA) number is required; this number must be clearly
marked on the outside of the shipping container in order for the unit to be properly processed. If replace-
ment parts are sent to you, then you are required to send the failed parts back to SYNRAD for evaluation
unless otherwise instructed.
If your Firestar i401 laser fails within the rst 45 days after purchase, SYNRAD, Inc. will pay all shipping
charges to and from SYNRAD when shipped as specied by SYNRAD Customer Service. After the rst 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 ecient operation of your Firestar i401 laser,
only authorized SYNRAD replacement parts can be used. This warranty is void if any parts other than
those provided by SYNRAD, Inc. are used.
SYNRAD, Inc. and SYNRAD Authorized Distributors have the sole authority to make warranty state-
ments 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 improve-
ments 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.

viii SYNRAD i401 Operator’s Manual Version 2.0
Contact information
Worldwide headquarters
SYNRAD’s worldwide headquarters are located north of Seattle in Mukilteo, Washington, U.S.A. Our
mailing address is: SYNRAD, Inc.
4600 Campus Place
Mukilteo, WA 98275
U.S.A.
Phone us at: 1.800.SYNRAD1 (1.800.796.7231)
Outside the U.S.: +1.425.349.3500
Fax: [phone]
E-mail: [email protected]om
Sales and Applications
SYNRAD’s Regional Sales Managers work with customers to identify and develop the best CO2laser solu-
tion for a given application. Because they are familiar with you and your laser application, use them as a
rst 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 specications. 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) num-
ber, contact SYNRAD at 1.800.SYNRAD1 and ask to speak to a Customer Service representative.
Technical Support
SYNRAD’s Regional Sales Managers are able to answer many technical questions regarding the installa-
tion, 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 [email protected] or to [e-mail].
Reference materials
Your Regional Sales Manager can provide reference materials including Outline & Mounting drawings,
Operator’s Manuals, Technical Bulletins, and Application Newsletters. Most of these materials are also
available directly from SYNRAD’s web site at http://www.synrad.com.
European headquarters
For assistance in Europe, contact SYNRAD’s European subsidiary, Synrad Europe, at:
Synrad Europe
Münchener Straße 2A
D-82152 Planegg, Germany
Phone: [phone]
Fax: [phone]
E-mail: info[email protected]

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SYNRAD i401 Operator’s Manual Version 2.0
This page intentionally left blank.

Use information in this chapter to prepare your Firestar i401 laser for operation. The or-
der of information presented in this chapter is the same as the order of tasks that you will
need to perform. The best way to get your laser ready for operation is to start at Unpack-
ing and work your way through Connecting.
This chapter contains the following information:
Introduction – introduces the Firestar i401 laser, lists important features, and de-
scribes Firestar nomenclature.
Unpacking – provides important information about unpacking your Firestar i401
laser.
Inventory – displays and describes all components shipped with your i401 laser.
Mounting – describes how to attach your i401 laser to a mounting surface.
Connecting – explains how to connect cooling tubing, power, and control cabling.

getting started
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SYNRAD i401 Operator’s Manual Version 2.0
Introduction
The Introduction section includes subsections:
Firestar nomenclature
Model numbers
The Firestar®i401 laser is a new addition to SYNRAD’s Firestar series of high power lasers. This single-
tube 400 W laser features an integrated RF power supply with no external RF cables. The compact, single-
tube design mounts easily to atbed cutters, robotic arms, or gantry systems making integration into your
production line simple and fast.
Firestar i401 features include:
Built-in electromechanical shutter Built-in gas purge port
TCP/IP web-based Internet interface Color-coded LEDs mirror user output status
Field-replaceable integrated RF modules “Industrial-strength” ±5 V to 24 VDC I/O
Built-in internal humidity sensor Beam output pre-aligned to within ±1.0 mm
Duty cycles from 1% to 100% (CW) Low 6 kW heat load
Firestar nomenclature
Firestar lasers are divided into two distinct functional categories: Keyswitch and OEM models. OEM lasers,
like the Firestar i401, do not incorporate keyswitch or shutter functions required by CDRH and EN 60825-
1 regulations because they are designed as components for integration into larger processing systems by the
Original Equipment Manufacturer (OEM) or System Integrator who bears full responsibility for meeting
the appropriate laser safety requirements for systems incorporating Class 4 lasers.
Although Firestar i401 lasers are available only as OEM lasers, they do include a built-in electromechani-
cal shutter assembly.
Model numbers
The last three characters in the Firestar model number serve to designate the functional category, cool-
ing method, and model version. The functional category is indicated by either a “K”for Keyswitch or“S”
(Switch-less) for OEM models. The next letter indicates the cooling method: “W” for water-cooled units,
“F” for fan-cooled units, and “A” for air-cooled lasers (the cooling method, the “W”, is omitted on all i401
lasers since they are all water-cooled lasers). The last letter in the model number indicates the current
model version beginning with“B”.

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12
SYNRAD i401 Operator’s Manual Version 2.0
Warning
possible
personal
injury
Lifting or moving the Firestar i401 laser poses a potential for injury.
Use appropriate lifting techniques and/or equipment to prevent a risk
of injury. In some cases, you may require assistance from additional
personnel to safely unpack and move this equipment.
Unpacking
The Unpacking section includes subsections:
Incoming inspection
Packaging guidelines
Unpacking the i401
Removing the lifting handles
Incoming inspection
Upon arrival, inspect all shipping containers for signs of damage. If you discover shipping damage,
document the damage (photographically if possible), then immediately notify the shipping carrier and
SYNRAD, Inc.
The shipping carrier is responsible for any damage occurring during transportation from SYNRAD, Inc. to
your receiving dock.
Packaging guidelines
To prevent equipment damage or loss of small components, use care when removing packaging materi-
als.
After unpacking, review the Inventory section and verify that all components are on hand.
Do not lift or support the laser using the cooling ttings; lift the laser by the lifting handles or base
plate only.
Save all shipping containers and packaging materials, including covers and plugs. Use these special-
ized packing materials when shipping the laser to another location.
When packing a laser for shipment, be sure to remove all accessory items not originally attached to
the laser including beam delivery components, cooling tubing, etc.
Refer to Packaging instructions drawings in the Technical Reference chapter for details on packaging
i401 lasers using SYNRAD-supplied shipping materials.
When storing or shipping water-cooled lasers, remember to drain all cooling water from the laser and
then cap the open ttings to prevent debris from entering the coolant path.
Firestar i401 lasers are heavy and awkward to move. Use appropriate lifting techniques, additional
personnel, and/or hoisting equipment to prevent a risk of injury when rigging this equipment.

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SYNRAD i401 Operator’s Manual Version 2.0
Unpacking
Unpacking the i401 laser
To unpack the i401 laser, refer to Figure 1-1 and perform the following steps. The numbered items in Fig-
ure 1-1 correspond to the step numbers in the following procedure.
Figure 2-1 Unpacking the i401 laser.
1 Carefully cut the shipping straps wrapped around the shipping container.
2 Remove the upper lid and set it aside.
SAVETHIS BOX
FRAGILE
FRAGILE
FRAGILE
4
4
1
3
3
5
1
2
4

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SYNRAD i401 Operator’s Manual Version 2.0
Unpacking
3 Carefully lift or hoist the sling containing the i401 laser out of the container and place it on a solid
surface. To prevent injury to personnel or damage to the laser, always use at least two people to lift
and move the sling.
4 Lift or hoist the i401 laser out of the container using the three lifting handles. To prevent injury to
personnel or damage to the laser, always use at least two people to handle the i401 laser.
Note: Do not lift or support the i401 laser using the cooling ttings. Lift the laser by the lifting handles
or base plate only.
5 After removing the laser, pull out all accessory items and paperwork packaged behind the laser in the
shipping container’s accessory compartment.
6 Save the shipping container and sling. Use these specialized packaging materials when shipping the
laser to another location.
Removing the lifting handles
Once you have placed the i401 laser in its nal mounting location, perform the following steps to remove
the lifting attachments.
1 Remove the 1/4–20 × 5/8" capscrews from two locations on each of the three handles as shown in
the gure below.
2 Save the lifting handles and capscrews so the handles can be reinstalled if the i401 is moved to
another location.
Figure 2-2 Removing the i401 lifting handles.
i401 Front View i401 Rear View

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SYNRAD i401 Operator’s Manual Version 2.0
Inventory
Figure 1-3 Firestar i401 shipping box contents.
Table 1-1 Firestar i401 ship kit contents.
Shipping Box Contents Qty Shipping Box Contents Qty
Firestar i401 400 W Laser ............................1 Quick Start Plug ............................................ 1
Customer Communication Flier...............1 1/2" Tubing Fitting Kit ................................ 1
Ethernet Crossover Cable...........................1 Mounting Hardware Kit ............................. 4
BNC Control Cable .......................................1 Gas Purge Kit................................................... 1
12 mm Cooling Tubing................................1 Spare Fuses (not shown) ............................ 4
DC Power Cables ...........................................1 Final Test Report (not shown) .................. 1
Customer
Welcome Flier
12 mm Cooling Tubing
DC Power Cables
Quick Start Plug
BNC Control Cable
Ethernet Crossover
Cable
Firestar i401 Laser
Mounting Hardware
Kit
Gas Purge Kit
1/2” Tubing Fittings

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SYNRAD i401 Operator’s Manual Version 2.0
Inventory
i401 contents description
Each item listed in the prior table is described below:
Firestar i401 400 W Laser – The Firestar i401 laser is a compact, single tube 400 W laser producing near-
perfect beam quality with < 100 µs rise/fall times and a PWM duty cycle range from 1% up to 100% (full
CW operation).
Customer Communication Flier – contains a Firestar i401 website location information that provides
setup, operation, and maintenance information for your i401 laser.
Ethernet Crossover Cable – provides the communications link between a host and the laser for accessing
operating parameters via a TCP/IP web-based interface.
BNC Control Cable – Coaxial cable carries the PWM Command signal from the UC-2000 Controller to
the laser’s Quick Start Plug.
12 mm Cooling Tubing – carries cooling water from the chiller to the laser and back. This clear polyethyl-
ene tubing is 12 mm O.D. by 30 feet and must be cut to length.
DC Power Cables – carry DC power from the 48 V power supply to your i401 laser. Standard cable length is
2.0 meters (6.5 feet) while optional 5.0 m (16 ft) power cables are available.
Quick Start Plug – connects to Firestar’s User I/O connector. Jumpers are built into the plug to enable Fire-
star’s interlock circuits for initial start-up and testing.
1/2" Tubing Fitting Kit – provides a means to replace the i401’s 12 mm ttings with ttings that accept
1/2" coolant tubing. See the Connecting section for installation details.
Mounting Hardware Kit – fasten Firestar to your mounting surface. Four each M10 × 1.5 × 35 mm
capscrews and M10 washers are provided for mounting the Firestar i401 laser.
Gas Purge Kit – provides a ltering and connection point to the laser from your facility’s purge gas system.
Spare Fuses (not shown) – 40 ampere fast-blow fuses protects Firestar’s internal RF circuitry.
Final Test Report (not shown) – contains data collected during the laser’s nal pre-shipment test.

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SYNRAD i401 Operator’s Manual Version 2.0
Mounting
The Mounting section includes subsections:
 Four-point mount with feet
 Four-point mount without feet
 Three-point mount without feet
The Firestar i401 base plate is designed so that the laser is easily mounted in various congurations as
described in the subsections below. Refer to the Firestar i401 package outline drawing in the Technical
Reference chapter for mounting locations and dimensions.
Caution
possible
equipment
damage
SYNRAD does not recommend mounting lasers in a vertical “head-
down”or “tail-down” orientation. If you must mount your laser in
this manner, please contact the factory for limitations as a vertical
orientation increases the risk of damage to the laser’s output optic.
Four-point mount with feet
Use this scheme to mount the laser to a horizontal or vertical surface (or to a surface that will move
dynamically in multiple axes) using the factory-installed mounting feet. To use a four-point mount, the
variation in mounting surface atness must not exceed 1.02 mm (0.040").
To install a Firestar i401 (with feet) using the four-point mounting method, perform the following steps:
1 Determine whether you will use metric (ISO) or inch (SAE) fasteners to mount the laser. Four M10
(metric) capscrews and M10 at/split washers are included in the ship kit.
2 Refer to the i401 outline and mounting drawing (Sheet 1 of 2) for Option ‘A’ mounting dimensions,
then drill and tap four M10 × 1.5 or four 3/8" (UNC or UNF) holes into your mounting surface.
These holes should correspond with the holes labeled“A”shown in following gure.
Note: Each mounting foot also contains a 9.65 mm (0.380") dowel pin guide (labeled“B” in the following)
for applications that require precision positioning for alignment purposes.

getting started
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SYNRAD i401 Operator’s Manual Version 2.0
Mounting
Caution
possible
equipment
damage
When removing the mounting feet, raise the laser by placing sup-
port blocks under the base plate. Do not lay or place the i401 laser
on its side or top, even temporarily, because the sheetmetal covers
are not designed to support the weight of the laser. Always support
and mount the laser using the mounting feet or base plate to avoid
damaging the laser.
A
B
A
A A
B
i401 Top View
Figure 1-4 Mounting locations for four-point mount with feet.
3 Carefully place the i401 laser on the mounting surface so the holes in the mounting feet line up
over the threaded holes in the mounting surface.
4 Place a split washer and at washer on each capscrew and insert the fasteners through the feet into
the mounting surface. Turn the screws by hand until the threads fully engage.
5 Evenly tighten all four fasteners to a torque of 40 N m (29 ft lb).
Note: After the laser is fastened into position, remove the lifting handles if necessary.
Four-point mount without feet
Use this scheme to mount the laser to a horizontal or vertical surface (or to a surface that will move dy-
namically in multiple axes) by fastening directly into the laser’s base plate. To use a four-point mount, the
variation in mounting surface atness must not exceed 1.02 mm (0.040").
To install a Firestar i401 (without feet) using the four-point mounting method, perform the following
steps:
1 Raise the i401 laser and place support blocks under the base plate.
2 Unscrew the four M10 capscrews fastening the feet to the bottom of the i401 laser and remove the
factory-installed mounting feet.