Synrad Firestar f201 User manual

f201 Operator’s Manual
4600 Campus Place
Mukilteo, WA 98275
1.800.SYNRAD1
tel [phone]
fax [phone]
e-mail [email protected]om
web www.synrad.com
®

f201 Operator’s Manual
Version 3.2
SYNRAD©is a registered trademark of Novanta Corporation. ©Novanta Corporation 2019. All
Rights Reserved. No reproduction without written authorization.
DATE: March 2019

table of contents
i
SYNRAD f201 Operator’s Manual Version 3.2
Introduction 26
Firestar nomenclature 26
Unpacking 27
Incoming inspection 27
Packaging guidelines 27
Removing the lifting handles 29
Inventory 30
f201 lasers 30
Connecting 34
Cooling connections 34
PS-96 power supply connections 38
PS-96 AC input section 39
Control connections 42
Other connections 43
Getting Started 2
Laser Safety 1
Warranty information vii
Sales and Applications viii
Customer Service viii
Technical Support viii
Reference materials viii
Hazard Information 11
Terms 11
General hazards 12
Other hazards 14
Disposal 14
Additional laser safety information 14
Agency compliance 18
Center for Devices and Radiological Health (CDRH) requirements 18
OEM model 18
Federal Communications Commission (FCC) 19
Requirements 19
European Union (EU) requirements 20
Introduction 26
Firestar nomenclature 26
Unpacking 26

table of contents
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SYNRAD f201 Operator’s Manual Version 3.2
Technical Reference 4
Operation 3
Incoming inspection 27
Packaging guidelines 27
Unpacking 27
Unpacking the laser 27
Getting Started 2
Unpacking 28
Removing the lifting handles 29
Inventory 29
f100/f201 lasers 30
Inventory 30
Mounting 32
f100/f201 mounting 32
Mounting 33
Mounting 33
f201 mounting 33
Mounting 35
Cooling connections 36
PS-96 power supply connections 41
Other connections 50
Controls and indicators 53
f201 lasers 53
Initial start-up 55
With a UC-2000 Controller 55
Initial start-up 57
Without a UC-2000 Controller 57
Initial start-up 58
Technical overview 64
Laser tube 64
Optical resonator 64
Technical overview 65

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SYNRAD f201 Operator’s Manual Version 3.2
Maintenance/Troubleshooting 5
Internal RF power supply 65
Optical setup 66
Technical overview 67
Controlling laser power 68
Control signals 68
Operating modes 70
User I/O connections 73
Input/output signals 74
DC Power cables 86
Integrating Firestar safety features 87
OEM lasers 87
Integrating Firestar safety features 88
Remote interlock functions 88
f201 general specications 90
Maintenance 94
Disabling f201 lasers 94
Daily inspections 94
Storage/shipping 95
Cleaning optical components 95
Troubleshooting 98
Introduction 98
Troubleshooting 99
Operational owchart 99
Troubleshooting 100
Functional block diagram 100
Troubleshooting 101
Status LEDs 101
Troubleshooting 102
Laser fault indications 104
Resetting faults 104
Troubleshooting 105
Other laser faults 106
Troubleshooting 107
Beam delivery optics 109
Troubleshooting 110

table of contents
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SYNRAD f201 Operator’s Manual Version 3.2
List of Figures
Figure 1-1 Labeling terms and denitions. 12
Figure 1-2 Safety goggles. 14
Figure 1-5 F 201 hazard label locations. 18
Table 1-1 Class 4 safety features. 22
Table 1-2 European Union Directives. 23
Figure 1-7 F201 declaration of conformity. 25
Figure 2-1 Unpacking the laser. 29
Figure 2-2 Removing lifting handles. 30
Figure 2-3 F201 shipping box contents. 31
Table 2-1 f100/f201 ship kit contents. 32
Figure 2-5 Fastening f100/f201 from above. 33
Figure 2-7 Improper mounting method. 34
Figure 2-8 Detail of fastening into mounting surface 35
Figure 2-8 Fastening f201 from above. 35
Figure 2-10 Fastening f201 from below. 36
Figure 2-11 Detail of fastening into laser. 36
Table 2-3 Dew point temperatures. 39
Figure 2-12 F100/f201 cooling connections 40
Figure 2-13 F201 cooling connections. 41
Figure 2-14 PS-96 rear view. 43
Table 2-4 Three-phase AC electrical recommendations. 44
Table 2-5 Single-phase AC electrical recommendations. 45
Table 2-6 Purge gas specications. 49
Figure 3-1 F201 controls and indicators (front). 51
Figure 3-2 F201 controls and indicators (rear). 52
Figure 4-1 beam characteristics. 59
Figure 4-2 “Flying optics”beam path. 60
Table 4-1 Assist gas purity specications. 61
Figure 4-3 Typical Firestar f201 waveforms. 63
Figure 4-4 PWM Command signal waveform. 64
Table 4-2 PWM Command signal specications. 64
Table 4-3 User I/O pin descriptions. 67
Table 4-4 Input circuit specications. 72
Table 4-5 Output circuit specications. 74

table of contents
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SYNRAD f201 Operator’s Manual Version 3.2
List of Figures (cont.)
Figure 4-5 User I/O connector pinouts. 69
Figure 4-6 Auxiliary power supply wiring. 70
Figure 4-8 Input equivalent schematic. 72
Figure 4-7 Quick Start Plug wiring diagram. 73
Figure 4-10 Customer-supplied interlock. 75
Figure 4-11 Customer-supplied interlock, negative voltage. 75
Figure 4-12 PLC driven interlock signal. 76
Figure 4-13 Multiple PLC driven inputs. 76
Figure 4-14 Firestar output driving warning lamp. 77
Figure 4-15 Firestar output driving relay. 77
Figure 4-16 Firestar output driving PLC input module. 78
Figure 4-17 Wiring Set 1 and Set 2 to power external circuits. 79
Table 4-7 f201/f400 DC Power connector pinouts. 80
Table 4-10 Firestar f201 general specications. 84
Table 5-1 Required cleaning materials. 90
Figure 5-1 Operational owchart. 93
Figure 5-2 f-Series functional block diagram. 94
Table 5-2 Status signals. 95
Table 5-3 Normal operating condition. 96
Table 5-4 Quick Start Plug or interlock/shutter inputs not connected. 96
Table 5-5 Interlock open condition. 96
Table 5-6 Over Temperature fault. 97
Table 5-7 Shutter closed condition. 97
Table 5-8 VSWR fault. 97
Table 5-9 Laser error codes. 98

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SYNRAD f201 Operator’s Manual Version 3.2
Trademark & Copyright information
SYNRAD©and Firestar™ are registered trademarks of SYNRAD©.
All other trademarks or registered trademarks are the property of their respective owners.
© 2019 by SYNRAD.
All rights reserved.

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SYNRAD f201 Operator’s Manual Version 3.2
Warranty information
This is to certify that Firestar®f-Series lasers are guaranteed by SYNRAD to be free of all defects in materi-
als and workmanship for a period of one year from the date of shipment. This warranty does not apply
to any defect caused by negligence, misuse (including environmental factors), accident, alteration,
or improper maintenance. We request that you examine each shipment within 10 days of receipt and
inform SYNRAD of any shortage or damage. If no discrepancies are reported, SYNRAD shall assume the
shipment was delivered complete and defect-free.
If, within one year from the date of shipment, any part of the f-Series laser should fail to operate, 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 replacement parts
are sent to you, then you are required to send the failed parts back to SYNRAD for evaluation unless
otherwise instructed.
If your f-Series laser fails within the rst 45 days after shipment, SYNRAD 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 f-Series laser, only
authorized SYNRAD replacement parts can be used. This warranty is void if any parts other than those
provided by SYNRAD are used.
SYNRAD and SYNRAD Authorized Distributors have the sole authority to make warranty statements
regarding SYNRAD products. SYNRAD and its Authorized Distributors neither assumes nor authorizes
any representative or other person to assume for us any other warranties in connection with the sale,
service, or shipment of our products. SYNRAD reserves the right to make changes and improvements
in the design of our products at any time without incurring any obligation to make equivalent changes
in products previously manufactured or shipped. Buyer agrees to hold SYNRAD harmless from any and
all damages, costs, and expenses 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.

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SYNRAD f201 Operator’s Manual Version 3.2
Service & support information
SYNRAD worldwide headquarters are located north of Seattle in Mukilteo, Washington. U.S.A.
Our mailing address is:
SYNRAD©
4600 Campus Place
Mukilteo, WA 98275
U.S.A.
Phone us at: 1.800.SYNRAD1 (1.800.796.7231)
Outside the U.S.: +1.425.349.3500
Fax: [phone]
web: www.synrad.com
E-mail: [email protected]om
Sales and Applications
SYNRAD Regional Sales Managers work with customers to identify and develop the best CO2
laser solution for a given application. Because they are familiar with you and your laser appli-
cation, use them as a 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) number, contact SYNRAD at 1.800.SYNRAD1 and ask to speak to a Customer Service rep-
resentative, or you can email us by sending a message to customercar[email protected].
Technical Support
SYNRAD Regional Sales Managers are able to answer many technical questions regarding the
installation, use, troubleshooting, and maintenance of our products. In some cases, they may
transfer your call to a Laser, Marking Head, or Software Support Specialist. You may also e-mail
questions to the Technical Support Group by sending your message to customercare@synrad.
com.
Reference materials
Your Regional Sales Manager can provide reference materials including Outline & Mounting
drawings, Operator’s Manuals, Technical Bulletins, and Application Newsletters. Most of these
materials are also available directly from the SYNRAD web site at http://www.synrad.com.