Thunder Laser NOVA Series User manual

USERS MANUAL NOVA SERIES
www.thunderlaser.com DONGGUAN THUNDER LASER EQUIPMENT CO.,LTD
[email protected] Shatian Town, Shatian Dadao, Mintian
Tel :[phone] Dongguan City, Guangdong Province, China
1
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THUNDER LASER
SYSTEMS
NOVA Series
Unified User’s Manual
For NOVA 24, 35, 51, and 63
Thunder Laser
www.thunderlaser.com
[e-mail]
March 2020
Adapted from Original Instruction Dec 2019
DONGGUAN THUNDER LASER EQUIPMENT CO.,LTD
Dongguan City, Guangdong Province, China

USERS MANUAL NOVA SERIES
www.thunderlaser.com DONGGUAN THUNDER LASER EQUIPMENT CO.,LTD
[email protected] Shatian Town, Shatian Dadao, Mintian
Tel :[phone] Dongguan City, Guangdong Province, China
2
2
Introduction
This manual has been designated as the thunder laser systems, laser cutting machine
installation and user guide；The manual is divided into five chapters，Including general
information instructions, safety instructions, the key components of every laser cutting
systems and the installation steps, operation instructions and maintenance instructions
from THUNDERLASER Company.
First, it should be emphasized that the installation of each system must meet the
requirements, and make it consistent with the installation requirements of
THUNDERLASER. If not, themachinewill not working properly，poor performance，life
shortened，maintenance costs increased and even machine damage .
The note is for getting a specific requirement of system installation，and we hope
every customer try to understand these notes before installation and usage, thus you
can correctly install and use. If you meet any installation problems，you can contact our
technical staff and customer service staff.
At the same time, you can also refer to the machine installation video that we
posted on YouTube. The specific URL is:
http://www.thunderlaser.com/how-to-use-your-laser-machine/how-to-setup-your-
nova-laser-cutter.html
Or
https://www.youtube.com/watch?v=NpLo1L0NQx8&list=PLjSZrgjcrhs7QucNN-
3jx7rZapDGfjG-5

USERS MANUAL NOVA SERIES
www.thunderlaser.com DONGGUAN THUNDER LASER EQUIPMENT CO.,LTD
[email protected] Shatian Town, Shatian Dadao, Mintian
Tel :[phone] Dongguan City, Guangdong Province, China
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Contents
CHAPTER 1. GENERAL....................................................................................................................5
1.1 GENERAL INFORMATION............................................................................................................5
1.2 DESIGNATED ..........................................................................................................................6
1.3 DISPOSAL REMARKS .................................................................................................................6
1.4 TECHNICAL DATA /DEVICE SPECIFICATION .....................................................................................7
1.5 EC DECLARATION OF CONFORMITY ..............................................................................................9
1.6 MANUFACTURER'S LABEL...............................................................................................................10
CHAPTER 2. SAFETY.....................................................................................................................11
2.1 GENERAL SAFETY INFORMATION................................................................................................11
2.2LASER SAFETY INFORMATION....................................................................................................12
2.3 SAFETY PRECAUTIONS WHEN OPERATING THE DEVICE.....................................................................13
2.4 WARNING AND INFORMATION LABELS ........................................................................................14
CHAPTER 3. PROCESS OF INSTALLING ..........................................................................................16
3.1 UNPACKING .........................................................................................................................16
3.2 LOCATION............................................................................................................................17
3.3 BEFORE INSTALLATION ............................................................................................................18
3.4 EXHAUST SYSTEM –REQUIREMENTS ..........................................................................................20
3.5 AIR SYSTEM –REQUIREMENTS..................................................................................................20
3.6 WATER COOLING SYSTEM –REQUIREMENTS ................................................................................21
3.7 COMPUTER –REQUIREMENTS ..................................................................................................22
3.8 CONNECTIONS ......................................................................................................................23
3.8.1 Connecting the Mains ...................................................................................................23
3.8.2 Connecting the Computer .............................................................................................24
3.8.3 Connecting the Air System.............................................................................................25
3.8.4 Connecting the Exhaust System..................................................................................... 27
3.8.5 Connecting the Cooling System .....................................................................................29
CHAPTER 4. OPERATION..............................................................................................................30
4.1 MACHINE VIEW ....................................................................................................................30
4.2 ON/OFF SWITCH .................................................................................................................35
4.3 HOW TO SETUP THE OEM SOFTWARE.........................................................................................36
4.3.1 Software installation.....................................................................................................36
4.3.2 Make connection between PC and machine...................................................................38
4.4 HOW TO USE THE DISPLAY........................................................................................................41
4.4.1 Function of the Buttons................................................................................................. 41
4.4.2 The main interface........................................................................................................43
4.4.3 Speed button....................................................................................................................43
4.4.4 Max Power buttons.......................................................................................................44
4.4.5 Set the Layer Parameters ..............................................................................................44
4.4.6 Menu button.................................................................................................................45
4.4.7 File button ....................................................................................................................46
4.5 HOW TO USE THE DIFFERENT NOZZLES LASER HEAD CONE .................................................................49

USERS MANUAL NOVA SERIES
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4.6 HOW TO REPLACE THE 4INCH AND HR LASER HEAD........................................................................50
4.7 HOW TO ADJUST FOCUS DISTANCE BY MANUAL OR AUTO ..................................................................52
4.8 HOW TO USE THE TL-TIMER.....................................................................................................55
4.9 HOW TO USE AIR-ASSIST CONTROL (IF EQUIPPED).......................................................................57
4.10 HOW THE HEAT ALARM SYSTEM WORKS .......................................................................................60
4.11 THE FIRST TIME RUNNING THE LASER .........................................................................................61
4.12 WORKSTATION AREA INDICATION ..............................................................................................64
4.13 HOW TO USE THE CHUCK ROTARY AXIS ATTACHMENT......................................................................65
4.14 FOR LASER ENGRAVING...........................................................................................................67
CHAPTER 5. MAINTENANCE.........................................................................................................68
5.1 CLEANING THE LASER MACHINE ................................................................................................68
5.2CLEANING THE OPTICAL PARTS..................................................................................................69
5.2.1 Cleaning the Focus Lens ................................................................................................69
5.2.2 Cleaning the Mirrors .....................................................................................................71
5.2.3 Cleaning Laser Combiner...............................................................................................73
5.3 MAINTAIN THE X/Y/Z RAILS.....................................................................................................74
5.4 CHECK THE BEAM PATH...........................................................................................................75
5.5 CHANGE COOLING WATER FOR THE WATER CHILLER.......................................................................76
5.6 MAINTENANCE PLAN .............................................................................................................77

USERS MANUAL NOVA SERIES
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[email protected] Shatian Town, Shatian Dadao, Mintian
Tel :[phone] Dongguan City, Guangdong Province, China
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Chapter 1. General
1.1 General Information
Please read this documentation carefully before installation and operation.
Injury, death, loss of property, fire, electric shock, malfunction, reduced
performance & machine life, and critical failures can result from not reading,
understanding, and following the Operation Manual!
Operation of the system is permitted only with equipment and spare parts supplied or
listed in the spare parts and consumables lists. The use of 3rd Party components may
void the warranty.
Auxiliary equipment must be adjusted to the base machine (contact us for further info).
The following symbols are used throughout the Operation Manual:
Caution: Warnings to keep in mind when operating the laser.
High Voltage: Care must be taken to prevent injury and/or death.
Laser Radiation: Pay attention to the dangers of the laser beam.
Fire Hazard: High potential for fire. NEVER RUN UNATTENDED!
Tips: Helpful notes or info that simplify the use or understanding.

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1.2 Designated
The THUNDER LASER NOVA SERIES is used for engraving and cutting of signs,
stamps and suchlike.
A wide variety of materials such as rubber, acrylic, coated metal, tin, special steel,
anodized aluminum, cork, cardboard, glass, leather, marble, several plastics and wood
can be processed on the laser.
1. The engraving process must only be performed with a perfectly
adjusted machine.
2. For cutting applications with 80 W the use of the cutting table is
absolutely necessary.
3. Use of the system in other areas is against the designated use. The
manufacturer does not admit liability for damage to personal and/or
equipment resulting from such use.
4. The system must only be operated, maintained and repaired, by
personnel that are familiar with the designated field of use and the
dangers of the machine!
5. Non-observance of the instructions for operation, maintenance and
repair described in this Operation Manual excludes any liability of the
manufacturer if a defect occurs.
6. Caution when processing conductive materials (carbon fibers),
Conductive dust or particles in the ambient air might damage electrical
components and lead to short circuits. Bear in mind that those defects
are not warranted.
1.3 Disposal remarks
Do not dispose the machine with domestic waste!
Electronic devices have to be disposed according to the regional directives on electronic
and electric waste disposal. In case of further questions, please ask your supplier. He
might take care of proper disposal.

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1.4 Technical Data / Device Specification
Mechanics
NOVA 24
NOVA 35
NOVA 51
NOVA 63
Working Area
23.6“x 15.7“
(600 x 400 mm)
35.4“x 23.6“
(900 x 600 mm)
51.2“x 35.4“
(1300 x 900 mm)
63.0“x 39.4“
(1600 x 1000 mm)
Table Size
27.6“x 20.9“
(700 x 530mm)
39.4“x 28.7“
(1000 x 730mm)
55.1“x 40.6“
(1400 x 1030mm)
66.9“x 44.5“
(1700 x 1130mm)
Z Axis Height
6.1” / 155 mm
8.9” / 225 mm
Max Work Height
6.1” / 155 mm
8.9” / 225 mm
Max. Speed
RASTER: 39”/sec. (1000 mm/sec) VECTOR: Varies with job
Motor
Easy Servo Motor
Drive
Hybrid Servo Drive
Work piece table
Solid metal blades & Honey comb table
Max. table load
20kg / 44lbs
40kg / 88lbs.
30kg / 66lbs
30 kg / 66lbs
Net Weight
140kgs / 308lbs
310kgs / 682lbs
430kgs / 946lbs
470kgs / 1,034lbs
Standard Head
2.0” (50.8mm)
Lens Diameter
20mm
Mirror Diameter
25mm
Beam Comb. Dia.
20mm
25mm
Dimensions
NOVA 24
NOVA 35
NOVA 51
NOVA 63
W x D x H
42.1“ x 31.9“ x 24“
(1070x810x610mm)
59.1“ x 43.5“ x 40.9“
(1500x1105x1040mm)
74.8“ x 55.3“ x 40.9“
(1900x1405x1040mm)
86.6“ x 59.3“ x 40.9”
(2200x1505x1040mm)
Max Part Size (W x L x H)
NOVA 24
NOVA 35
NOVA 51
NOVA 63
Door
Closed
27.6“x 20.9“x 8.3“
(700 x 530 x 155mm)
39.4“x 28.7“x 8.9 “
(1000 x 730 x 225mm)
55.1“x 40.6“x 8.9 “
(1400 x 1030 x
225mm)
66.9“x 44.5“x 8.9 “
(1700 x 530 x 225mm)
Pass
Thru
27.6“ x ∞“ x 1.2““
(700 x ∞mm x 20 mm)
39.4“ x ∞“ x 1.2“
(1000 x ∞mm x 20 mm)
55.1“ x ∞“ x 1.2“
(1400 x ∞mm x 20 mm)
66.9“ x ∞“ x 1.2“
(1700 x ∞mm x 20 mm)

USERS MANUAL NOVA SERIES
www.thunderlaser.com DONGGUAN THUNDER LASER EQUIPMENT CO.,LTD
[email protected] Shatian Town, Shatian Dadao, Mintian
Tel :[phone] Dongguan City, Guangdong Province, China
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Features
Standard:
Open flap protection, “No Water “protection, Fire alarm protection, Dual air-assist control,
Red Dot Pointer, Auto Focus, Smart board, Motorized Table, Honey Comb Table,
Aluminum blade cutting table, Pass-Through Door, 2,0”(50.8mm) Focus Lens, Warning
light, Emergency Stop, LCD Display, EasilyAdjustable Home Position, 3D Engraving,
Maintenance mode, Air pump, Water chiller, Exhaust Fan.
Optional:
RotaryAttachment, High Resolution head (up to 1000DPI, while standard laser head Max
is 500DPI), High air compressor set (Includes water filter).
Control System
Laser power Adjustable from 1 - 100% (typically 5-100%)
Interface Hardware USB: connect to PC and U-disk
Ethernet: connect to PC
Interface Software LightBurn - RDWorksV8
Operating Modes Optimized raster, vector, and combined mode
Buffer Memory 128 MB standard
Laser Equipment
Laser Type: Sealed CO2 Glass Laser Tube
Standard Laser Power: 40W, 60W, 80W, 100W, 130W
Wavelength: 10.6µm
Red dot pointer: Laser Power< 1mW
Wavelength: 630nm –680nm
Cooling System
Machine Cooling System: Air-Cooled
Tube Cooling System: Water Cooled
Electricity, Power, Breaker INCLUDING THE CHILLER
40 WATT
60 WATT
80 WATT
100 WATT
130 WATT
Electricity
Requirement
110 or 220 Volt AC,50 or 60Hz,Single phase
Power
consumption
1600W
1700W
1900W
2000W
2200W
Recommended
circuit breaker
20A,110V
10A,220V
20A,110V
10A,220V
20A,110V
10A,220V
20A,110V
10A,220V
25A,110V
15A,220V
Ambient Conditions
Ambient temperature +15°C to +35°C / 59°F to 95°F
Humidity 40% to max. 70%, not condensing
Laser Safety
Laser class CDRH Laser Safety
Laser Class 2
CE compliant FDA approved

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[email protected] Shatian Town, Shatian Dadao, Mintian
Tel :[phone] Dongguan City, Guangdong Province, China
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1.5 EC Declaration of Conformity

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1.6 Manufacturer's Label
The manufacturer's label is located on the back of the device (see Figure below).
It is recommended to record all of the data so that you always have this handy. You will
need to supply your Serial Number to our Support Team on occasion.

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Chapter 2. Safety
2.1 General Safety Information
All personnel involved in installation, set-up, operation maintenance and repair of the
machine, must have read and understood the Operation Manual and in particular the
"Safety" section. The user is recommended to generate company-internal instructions
considering the professional qualifications of the personnel employed in each case, and
the receipt of the instruction/Operation Manual or the participation at introduction/training
should be acknowledged in writing in each case.
Safety-conscious of Working
The machine must only be operated by trained and authorized personnel.
The scopes of competence for the different activities in the scope of operating the
machine must be clearly defined and observed, so that under the aspect of safety no
unclear questions of competence occur. This applies in particular to activities on the
electric equipment, which must only be performed by special experts.
For all activities concerning installation, set-up, start-up, operation, modifications of
conditions and methods of operation, maintenance, inspection and repair, the switch-off
procedures that may be provided in the Operation Manual must be observed.
Safety Information for the User and/or Operating Personnel
1. No working methods are permitted that affect the safety of the
machine.
2. The operator must also ensure that no unauthorized persons work with
the machine (e.g. by activating equipment without authorization).
3. It is the duty of the operator, to check the machine before start of work
for externally visible damage and defects, and to immediately report
changes that appear (including behavior during operation) that affect
the safety.
4. The user must provide that the machine is only operated in perfect
condition.
5. The user must guarantee the cleanness and accessibility at and
around the machine by corresponding instructions and controls.
6. No safety components may be removed or disabled (again we
emphasize the imminent dangers, for example severe burns, loss of
eyesight, etc…). If the removal of safety components is required during
repair and service, the replacement of the safety components must be
performed immediately after completion of the service and repair

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activities.
7. Preparation, retooling, change of work piece, maintenance and repair
activities must only performed with equipment switched off and by
trained personnel.
8. Any attempt to perform unauthorized modifications and changes
to the machine can VOID THE WARRANTY. This does not apply to
preventative & general maintenance, adjustment and alignment, etc…
that follow Thunder Laser’s best practices.
2.2 Laser Safety Information
1. To assess the potential dangers laser systems pose, they are
classified into 2 safety classes, Thunder Laser NOVA series is a device
of class 2. This is guaranteed by the protective housing and the safety
installations.
Please note that improper and warranty operation of the device can
override the status of Safety class 2 and can cause the emission of
harmful radiation.
2. This laser engraving system contains a carbon dioxide (CO2) laser
of class 2 that emits intensive and invisible laser radiation. Without
safety precautions the direct radiation or even diffuse reflected
radiation is dangerous!
3. Without safety precautions, the following risks exist with exposure to
laser radiation:
Eyes: Burns to the cornea
Skin: Burns
Clothing: Danger of fire
4. Never try to modify or disassemble the laser and do not try to start
up a system that had been modified or disassembled!
5. Dangerous radiation exposure can result from the use of operation
or adjustment equipment other than that described here, and if different
operational methods are performed.

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2.3 Safety Precautions when Operating the Device
Your Thunder Laser NOVA SERIES has an integrated safety system which immediately
stops the job when the protection cover (Lid) is opened. An incomplete job will occur if
the cover is opened during operation. Press the "PAUSE" button first if you want to
interrupt an engraving process.
Please remember the following safety precautions when working with this device:
1. CO2 Fire extinguishers should be placed near laser. Always keep a
properly maintained and inspected fire extinguisher on hand.
2. Do not store any flammable materials in the inside of the device.
Particularly leftovers of produced materials have to be removed to
prevent fire hazard.
3. Please maintain free airflow around this system at all times. Do not
cover the machine while in operation.
4. Stay with the laser. Do not leave the laser unattended when it is
working, small scraps can ignite and without supervision can destroy the
machine if not checked.
5. Use Air Assist. Always use the system’s Air Assist feature when vector
cutting.
1. These lasers emit invisible radiation; safety glasses should be worn
when maintaining these machines for your protection.
2.Adjustment of the beam path must be performed only by specially
trained personnel. An improper setting can lead to uncontrolled
emission of the laser radiation.
1. Do not disable limit switches or safety features as this can invalidate
warranties and cause damage to you and the machine.
2. Before processing materials the user must verify whether harmful
materials can be generated and whether the filter equipment of the
exhaust system is suitable for the harmful materials. We emphasize
that it is the responsibility of the user, to consider the national and
regional threshold values for dust, fogs and gases when selecting the
filters and the exhaust system. (The values for the maximum workplace
concentration must not be exceeded.)
3. PVC (polyvinyl chloride) must under no circumstances be processed
with the laser.

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2.4 Warning and Information Labels
The warning and information labels in various locations if the machine
should always be read carefully and understood. If labels are lost or
damaged, they must be replaced immediately.
`

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Chapter 3. Process of Installing
3.1 Unpacking
You receive your THUNDER LASER NOVA SERIES packed in a wooden box which
contains the laser machine and additional accessories. The following steps give you an
overview of the unpacking and assembly of the laser. Please follow these steps carefully.
Keep the packing box. You will require it in case of a return.
Dispose all waste according to the applicable waste disposal law.
1. Put the wooden box on a flat and spacious room for unpacking.
2. Remove the machine box; carefully remove the protective foam, wraps, films, etc…
3. Take out the key，open the door of thelaser, remove the accessories boxwhich contains
all accessory parts required for the installation of the laser machine and check the contents
carefully.
4. You will see an attachment table on the machine; please check whether the accessories
are all on the table.
5.Pleasekeep the keys and the warrantycertificate as well as themodelandserial number
of the machine. If you need tech support we may ask you for this information.
6. Remove the sponges and nylon cable ties from inside the machine, and then start to
install the machine, carefully following the instructions in this manual.

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3.2 Location
Before you install the laser system, you should select an appropriate location. Follow the
guidelines shown below:
1. Avoid locations where the system is exposed to high temperatures,
dust and high humidity. (The humiditymust not exceed 70% and the
temperature must not be close to the dew point.)
2.Avoid locations, where the system is exposed to mechanical shocks.
1. Circuit Breaker protection: Do not connect other devices on the same
circuit as the laser system. It requires a dedicated circuit.
2. DO NOT open any of the machine’s access panels while the unit is
plugged in. Opening a panel may expose the operator to severe
electric shock, invisible CO2 laser radiation, mechanical pinch points,
burns, blindness, and other hazards. ALWAYS POWER OFF AND
UNPLUG!
3. DO NOT make or break any electrical connections to the system
while the unit is turned on.
1.Avoid locations with poor air circulation; select a location close to
ventilation (if available).Select a location, whose room temperature is
between 15 °C and 25 °C (59°–77°F).
2. This is fundamental to maintain consistent and reliable operation of a
CO2 laser, Metal RF or Glass tube and the machine itself. Avoid higher
ambient temperatures and strong exposure of the engraver to the sun.
Use blinds, if required.
3. Mechanical shock and vibration of the laser will have detrimental
effects on the performance and life expectancy of the machine. It will
manifest (over a period of time) with a noticeable decrease in
performance and increased maintenance required, possibly even
damage. Setting your Thunder Laser up in s suitable temperature
controlled, dust free, moisture free, level, stable surface (a level
concrete floor) with the recommended extraction is critical to the
ongoing performance of the machine. It is also a warranty condition.

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3.3 Before Installation
1. Take out the sponge around the laser tube. Like below:
2. Remove the nylon cable ties around the honey comb plate.
Remove the transparent bag from the front of honey comb plate, Like below:
The transparent bag has a set of machine door keys, USB flash drive,
and an engraving test sample. The USB flash drive stores software,
manuals, libraries, etc… that you will need.

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Reverse Offset/Scan Offset compensation settings for this specific machine are included.
These settings need to be entered into your RDWorks and/or LightBurn
settings to ensure the highest engraving quality. Refer to the Ruida
and/or LightBurn Manuals for these necessary procedures.
3. Rotate the E-Stop switch in the direction of the arrows to reset. Familiarize
yourself with the emergency stop button’s operation and location.
4. When you have the machine in its final position, please be sure to re-fix the feet
in all four corners. Please see below:
The main power cable is in the tool box that came with the machine.

USERS MANUAL NOVA SERIES
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3.4 Exhaust System –Requirements
Proper fume extraction is imperative to evacuate the combustible and noxious fumes that
are created during the lasing process. This machine must be equipped with an adequate
exhaust system. This includes a blower of rated flow, volume, and duty cycle as well as
properly installed ducting and peripherals. You can further reduce smells from fine
particulate matter with an inline filtering system (not included. Call TL-USAfor info).
Connection - see section 3.7.3 connecting the Exhaust System.
Do not start the machine without an adequate exhaust system.
3.5 Air System –Requirements
The included air pump supplies the dual stage air assist control and is a critical component.
This helps keep the focusing lens clean and cool during the engraving process. Air assist
is also critical when cutting to reduce flame-ups and clear the debris field.
Always use the system’s Air Assist feature when vector cutting.