Operator's Manual: An Excel Technology Company

operator’s
manual
An Excel Technology Company

4600 Campus Place
Mukilteo, WA 98275 USA
1.800.SYNRAD1
tel 1.425.349.3500
fax 1.425.349.3667
e-mail [email protected]
www.synrad.com
Series J48 Lasers
Operator’s Manual
Model 48-1
Model 48-2
Model 48-5
Version 6.0
Released April 2005
Part number 900-00007-03
An Excel Technology Company

4600 Campus Place
Mukilteo, WA 98275 USA
1.800.SYNRAD1
tel 1.425.349.3500
fax 1.425.349.3667
e-mail [email protected]
www.synrad.com
table of contents
Laser Safety
Hazard information ................................................................................... 1
Terms ........................................................................................................................ 1
General hazards ........................................................................................................ 1
48-1 label locations .................................................................................. 3
48-2 label locations .................................................................................. 4
48-5 label locations .................................................................................. 5
Agency compliance .................................................................................. 6
Center for Devices and Radiological Health (CDRH) requirements .................... 6
Federal Communications Commission (FCC) requirements ................................. 7
European Union (EU) requirements ....................................................................... 8
Declaration of Conformity ....................................................................... 10
Getting Started 1
Introduction .............................................................................................. 1-2
Series 48 nomenclature ........................................................................................... 1-2
Unpacking ................................................................................................ 1-3
Incoming inspection ................................................................................................ 1-3
Packaging guidelines ................................................................................................ 1-3
Inventory .................................................................................................. 1-4
Contents description ............................................................................................... 1-5
Mounting .................................................................................................. 1-6
Standard mounting .................................................................................................. 1-6
With an FH Series marking head ............................................................................ 1-6
Connecting ............................................................................................... 1-7
Air-cooled connections ........................................................................................... 1-7
Water-cooled connections ...................................................................................... 1-8
Electrical connections ............................................................................................. 1-12
Control connections ................................................................................................ 1-14
DB9 connections ...................................................................................................... 1-15
Operation 2
Controls and indicators ............................................................................ 2-2
Initial start-up ........................................................................................... 2-4
With a UC-2000 Controller ................................................................................... 2-4
Without a UC-2000 Controller .............................................................................. 2-6
Technical Reference 3
Technical overview .................................................................................. 3-2
Introduction ............................................................................................................. 3-2
Plasma section .......................................................................................................... 3-3
Optical resonator ..................................................................................................... 3-3
Synrad S e r i e s 4 8 operator’s manual iii

table of contents
Technical Reference (cont.)
Control circuitry ...................................................................................................... 3-4
Optical setup ............................................................................................................ 3-7
Controlling laser power ............................................................................ 3-9
Control signals ......................................................................................................... 3-9
Operating modes ...................................................................................................... 3-11
DB9 connections ...................................................................................... 3-14
Integrating Series 48 safety features ......................................................... 3-16
Keyswitch functions ................................................................................................. 3-16
Remote interlock functions ..................................................................................... 3-17
Series 48 general specifications ................................................................ 3-18
Model 48-1 package outline drawing ....................................................... 3-20
Maintenance/Troubleshooting 4
Maintenance ............................................................................................. 4-2
Disabling the laser .................................................................................................... 4-2
Daily inspections ...................................................................................................... 4-2
Storage/shipping ...................................................................................................... 4-2
Troubleshooting ....................................................................................... 4-3
Introduction ............................................................................................................. 4-3
J48 interconnect schematic ..................................................................................... 4-4
J48 control board schematic .................................................................................... 4-5
Resetting faults ......................................................................................................... 4-6
Laser faults ................................................................................................................ 4-7
Beam delivery optics ................................................................................................ 4-9
Appendix A
Closed Loop Stabilization Kit .................................................................. A-2
Introduction ............................................................................................................. A-2
Safety precautions .................................................................................................... A-2
Connecting .............................................................................................................. A-3
Operation ................................................................................................................. A-4
Closed loop specifications ....................................................................................... A-4
Index
iv Synrad S e r i e s 4 8 operator’s manual

table of contents
List of Figures
Figure 1 48-1 hazard label and CE label locations ............................. 3
Figure 4 European compliance mark .................................................. 8
Figure 1-1 Series 48 shipping box contents ........................................... 1-4

Figure 1-2 48-1 / 48-2 cooling fan placement ....................................... 1-7
Figure 1-3 48-1 / 48-2 cooling connections ........................................... 1-10
Figure 1-4 48-5 cooling connections ..................................................... 1-11
Figure 1-5 DC-1 (Astec) power supply .................................................. 1-12
Figure 1-6 DC-2/DC-5 (Power-One) power supplies ............................ 1-13
Figure 1-7 Typical Series 48 system interconnection diagram .............. 1-16
Figure 2-1 48-1 / 48-2 controls and indicators ...................................... 2-2

Figure 2-2 48-5 controls and indicators ................................................. 2-3
Figure 3-1 Average laser output vs. percent PWM duty cycle .............. 3-2
Figure 3-2 Cross section of tube ............................................................. 3-3
Figure 3-3 Beam characteristics ............................................................. 3-4
Figure 3-4 RF Driver IV ......................................................................... 3-6
Figure 3-5 “Flying optics” beam path..................................................... 3-7
Figure 3-6 Tickle pulse waveform .......................................................... 3-9
Figure 3-7 Series 48 waveforms .............................................................. 3-10
Figure 3-8 PWM Command signal waveform ....................................... 3-11
Figure 3-9 Factory-installed DB9 jumper plug wiring ........................... 3-14
Figure 3-10 Model 48-1 package outline and mounting dimensions ...... 3-20
Figure 4-1 Model J48 Series interconnect schematic ............................ 4-4

Figure 4-2 J Series control board schematic .......................................... 4-5
Figure A-1 Typical closed loop setup ..................................................... A-3
Synrad S e r i e s 4 8 operator’s manual v

table of contents
List of Tables
Table 1 Class IV safety features ......................................................... 9
Table 1-1 Ship kit contents .................................................................. 1-4

Table 1-2 Dew point temperatures ....................................................... 1-9
Table 3-1 Gas purity specifications ....................................................... 3-8

Table 3-2 PWM Command signal levels .............................................. 3-12
Table 3-3 Remote Keyswitch and Remote Interlock signal
specifications ........................................................................ 3-14
Table 3-4 DB9 pin assignments ............................................................ 3-15
Table 3-5 Series 48 general specifications ............................................ 3-18
Table 4-1 Series 48 cooling specifications ............................................ 4-8
Table A-1 Closed loop general specifications........................................ A-4
vi Synrad S e r i e s 4 8 operator’s manual

Warranty information
This is to certify that Series 48 lasers are guaranteed by SYNRAD, Inc. to be free of all defects in materi-
als 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.
If, within one year from the date of purchase, any part of the Series 48 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 Series 48 laser fails within the first 45 days after purchase, SYNRAD, Inc. will pay all shipping
charges to and from SYNRAD when shipped as specified by SYNRAD Customer Service. After the first
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 efficient operation of your Series
48 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
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.
Trademark/copyright information
Duo-Lase and Power Wizard are registered trademarks of SYNRAD, Inc.
All other trademarks or registered trademarks are the property of their respective owners.
© 2005 by SYNRAD, Inc.

All rights reserved.
Synrad S e r i e s 4 8 operator’s manual vii

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: 1.425.349.3667
Email: [email protected]
Sales and Applications

SYNRAD’s 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 application, use them
as a first 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 specifications. 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 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 email questions to the Technical
Support Group by sending your message to [email protected] or to [email protected].
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
SYNRAD’s European subsidiary, Excel Technology Europe GmbH, covers Austria, Germany, and Italy.
Contact Excel Technology at:
Excel Technology Europe GmbH

Münchner Str. 2a
D-82152 Planegg
Germany
Phone: 49 89 891 462-0

Fax: 49 89 891 462-69
viii Synrad S e r i e s 4 8 operator’s manual

laser safety
Hazard information
Hazard information includes terms and symbols used in this manual or on the equipment to alert both
operating and service personnel to the recommended precautions in the care, use, and handling of laser
equipment.
Terms
Certain terms are used throughout this manual or on the equipment labels. Please familiarize yourself
with their definitions and significance.
Danger: Imminent hazards which, if not avoided, will result in death or serious injury.
Warning: Potential hazards which, if not avoided, could result in death or serious injury.
Caution: Potential hazards or unsafe practices which, if not avoided, may result in minor or
moderate injury.
Caution: Potential hazards or unsafe practices which, if not avoided, may result in product
damage.
Note: Points of particular interest for more efficient or convenient equipment operation;
additional information or explanation concerning the subject under discussion.
General hazards
Following are descriptions of general hazards and unsafe practices that could result in death, severe
injury, or product damage. Specific warnings and cautions not appearing in this section are found
throughout the manual.
Warning This product emits invisible infrared laser radiation at the 10.6 µm
CO2 wavelength. Since direct or diffuse laser radiation can inflict
serious severe corneal injuries, always wear eye protection when in the same
area as an exposed laser beam. Eyewear protects against scattered
personal energy and is not intended to protect against direct viewing of the
injury beam or reflections from metallic surfaces. Protective eyewear that
blocks 10.6 µm CO2 laser radiation is available from SYNRAD, Inc.
Enclose the beam path whenever possible. Direct or diffuse laser

radiation can seriously burn human or animal tissue.
U.S. customers should refer to and follow the laser safety precautions
in ANSI Z136.1-1993, American National Standard for Safe Use of
Lasers. Procedures listed under the Standard include the appoint-
ment of a Laser Safety Officer, operation of the product in an area of
limited access by trained personnel, servicing of equipment only by
trained and authorized personnel, and posting of signs warning of
the potential hazards.
European customers should refer to and follow the laser safety

precautions in EN 60825-1, Safety of Laser Products – Part 1:
Equipment Classification, Requirements, and User’s Guide.
Synrad S e r i e s 4 8 operator’s manual 1

laser safety
Hazard information
Warning Materials processing can generate air contaminants such as vapors,

fumes, and/or particles that may be noxious, toxic, or even fatal.
serious Material Safety Data Sheets (MSDS) for materials being processed
should be thoroughly evaluated and the adequacy of provisions for
personal fume extraction, filtering, and venting should be carefully consid-
injury ered. Review the following references for further information on
exposure criteria:
ANSI Z136.1-1993, American National Standard for Safe Use of

Lasers, section 7.3.
U.S. Government’s Code of Federal Regulations: 29 CFR 1910,

Subpart Z.
Threshold Limit Values (TLV’s) published by the American Confer-

ence of Governmental Industrial Hygienists (ACGIH).
It may be necessary to consult with local governmental agencies

regarding restrictions on the venting of processing vapors.
Caution The use of controls or adjustments or performance of procedures

other than those specified herein may result in hazardous radiation
possible exposure.
personal
injury
Other hazards
The following hazards would be typical for this product family when incorporated for intended use: (A) risk of
injury when lifting or moving the unit; (B) risk of exposure to hazardous laser energy through unauthorized
removal of access panels, doors, or protective barriers; (C) risk of exposure to hazardous laser energy and injury
due to failure of personnel to use proper eye protection or failure to adhere to applicable laser safety proce-
dures; (D) generation of hazardous air contaminants that may be noxious, toxic, or even fatal.
Additional laser safety information

The SYNRAD web site (http://www.synrad.com/LaserFacts/lasersafety.html) contains an online laser safety
handbook that provides information on (1) Laser Safety Standards for OEM’s/System Integrators; (2) Laser
Safety Standards for End Users; (3) References and Sources; and (4) Assistance with Requirements.
In addition, the Occupational Safety and Health Administration (OSHA) has an online Technical
Manual located at http://www.osha-slc.gov/dts/osta/otm/otm_iii/otm_iii_6.html. Section III, Chapter 6
and Appendix III are good resources for laser safety information.
Another excellent laser safety resource is the Laser Institute of America (LIA). Their comprehensive web
site is located at http://www.laserinstitute.org.
2 Synrad S e r i e s 4 8 operator’s manual

laser safety
48-1 label locations
10.6 MICRON
30 WATTS MAX
10200–10800 nm
EN-60825-1, 1993
CAUTION
9.3 MICRON These RF Excited Lasers must be provided with a
pre-ionizing "Tickle" signal during standby or
laser "low" periods. This is automatically provided
with Synrad's UC Series power controller. This signal
INVISIBLE LASER RADIATION 30 WATTS MAX keeps the plasma ionized during laser "low" periods
AVOID EYE OR SKIN EXPOSURE TO
9229–9317 nm and facilitates breakdown and pulse to pulse fidelity.
DIRECT OR SCATTERED RADIATION Damage or malfunction may occur if this or
CLASS 4 LASER PRODUCT
EN-60825-1, 1993 equivalent drive signals are not used. See manual
for tickle pulse specifications or contact factory.
TOP VIEW
CAUTION
CAUTION MODEL#: J48-1W
These RF Excited Lasers must be provided with a
CONDENSATION AND pre-ionizing "Tickle" signal during standby or INPUT POWER: 30 VDC
INVISIBLE LASER RADIATION
30 WATTS MAX
10200–10800 nm
WATER DAMAGE CAN laser "low" periods. This is automatically provided
SYNRAD MFG: October 08, 2001
DIRECT OR SCATTERED RADIATION
OCCUR IF COOLING WATER keeps the plasma ionized during laser "low" periods
4600 Campus Place, Mukilteo WA 98275 (425)349-3500
EN-60825-1, 1993
IS BELOW DEW POINT. and facilitates breakdown and pulse to pulse fidelity.
Damage or malfunction may occur if this or Ser#: 0481281010390
SEE OPERATION MANUAL.
equivalent drive signals are not used. See manual

INPUT POWER: 30 VDC
CONDENSATION AND
WATER DAMAGE CAN
OCCUR IF COOLING WATER
IS BELOW DEW POINT. Ser#: 0481281010390
WATER-COOLED VERSION ONLY
This laser product is manufactured under

one or more of the following U.S. Patents:
4,805,182 5,065,405 6,195,379
4,837,772 5,215,864 6,198,758
5,008,894 5,602,865 6,198,759
Other U.S. and International Patents pending. MADE IN THE U.S.A.
BOTTOM VIEW
IMPORTANT - DB9 wiring change. Pins 3 and 4

This laser manufactured by now provide the remote interlock function and pins
one or more of the following U.S. Patents:
Synrad, Inc 6 and 7 now provide the remote REMOTE INTERLOCK JUMPER
4,805,182 5,065,405 6,195,379
Mukilteo, WA 98275 keyswitch function. If unused 1 2 3 4 5
4,837,772 5,215,864 6,198,758
complies with 21 CFR subchapter J 5,008,894 5,602,865 6,198,759 these pins must be jumpered 6 7 8 9
at the date of manufacture. Other U.S. and International Patents pending. for the laser to operate. Refer
to manual for details. REMOTE KEYSWITCH JUMPER
MADE IN THE U.S.A.
KEYSWITCH VERSION OR OEM VERSION
This laser manufactured by IMPORTANT - DB9 wiring change. Pins 3 and 4

This laser is for use as a component only.
Synrad, Inc now provide the remote interlock function and pins
It does not comply with standards for
Mukilteo, WA 98275 6 and 7 now provide the remote REMOTE INTERLOCK JUMPER
complete laser products specified by
complies with 21 CFR subchapter J keyswitch function. If unused 1 2 3 4 5
21 CFR 1040 or EN 60825.
at the date of manufacture. these pins must be jumpered 6 7 8 9
for the laser to operate. Refer
KEYSWITCH VERSION ONLY
Figure 1 48-1 hazard label and CE label locations

laser safety
CAUTION
This laser product is manufactured under laser "low" periods. This is automatically provided
one or more of the following U.S. Patents: keeps the plasma ionized during laser "low" periods
AVOID EYE OR SKIN EXPOSURE TO 4,805,182 5,065,405 6,195,379 and facilitates breakdown and pulse to pulse fidelity.
DIRECT OR SCATTERED RADIATION 4,837,772 5,215,864 6,198,758 Damage or malfunction may occur if this or
5,008,894 5,602,865 6,198,759 equivalent drive signals are not used. See manual
Other U.S. and International Patents pending.
TOP VIEW
CAUTION
CAUTION These RF Excited Lasers must be provided with a MODEL#: J48-2W
one or more of the following U.S. Patents: CONDENSATION AND pre-ionizing "Tickle" signal during standby or INPUT POWER: 30 VDC
DIRECT OR SCATTERED RADIATION
75 WATTS MAX
10200–10800 nm
4,805,182 5,065,405 6,195,379 WATER DAMAGE CAN laser "low" periods. This is automatically provided
with Synrad's UC Series power controller. This signal SYNRAD MFG: October 08, 2001
CLASS 4 LASER PRODUCT 4,837,772 5,215,864 6,198,758 OCCUR IF COOLING WATER keeps the plasma ionized during laser "low" periods 4600 Campus Place, Mukilteo WA 98275 (425)349-3500
EN-60825-1, 1993 5,008,894 5,602,865 6,198,759 and facilitates breakdown and pulse to pulse fidelity.
Other U.S. and International Patents pending. IS BELOW DEW POINT. Damage or malfunction may occur if this or Ser#:
equivalent drive signals are not used. See manual 0481281010390
SEE OPERATION MANUAL. for tickle pulse specifications or contact factory.

INPUT POWER: 30 VDC
CONDENSATION AND
WATER DAMAGE CAN
10.6 MICRON SEE OPERATION MANUAL.
WATER-COOLED VERSION ONLY

75 WATTS MAX
10200–10800 nm
EN-60825-1, 1993
9.3 MICRON
75 WATTS MAX
9229–9317 nm
EN-60825-1, 1993
MADE IN THE U.S.A.
BOTTOM VIEW

complies with 21 CFR subchapter J these pins must be jumpered 6 7 8 9
at the date of manufacture. for the laser to operate. Refer
MADE IN THE U.S.A.
KEYSWITCH VERSION OR OEM VERSION

21 CFR 1040 or EN 60825.
KEYSWITCH VERSION ONLY

laser safety
CAUTION
This laser product is manufactured under laser "low" periods. This is automatically provided
one or more of the following U.S. Patents: with Synrad's UC Series power controller. This signal
AVOID EYE OR SKIN EXPOSURE TO 4,805,182 5,065,405 6,195,379 keeps the plasma ionized during laser "low" periods
DIRECT OR SCATTERED RADIATION 4,837,772 5,215,864 6,198,758 and facilitates breakdown and pulse to pulse fidelity.
CLASS 4 LASER PRODUCT Damage or malfunction may occur if this or
5,008,894 5,602,865 6,198,759
equivalent drive signals are not used. See manual
Other U.S. and International Patents pending. for tickle pulse specifications or contact factory.
TOP VIEW

DIRECT OR SCATTERED RADIATION CAUTION
CAUTION These RF Excited Lasers must be provided with a MODEL#: J48-5W
one or more of the following U.S. Patents: CONDENSATION AND pre-ionizing "Tickle" signal during standby or INPUT POWER: 30 VDC
4,805,182 5,065,405 6,195,379 WATER DAMAGE CAN
laser "low" periods. This is automatically provided
4,837,772 5,215,864 6,198,758 4600 Campus Place, Mukilteo WA 98275 (425)349-3500
OCCUR IF COOLING WATER keeps the plasma ionized during laser "low" periods
5,008,894 5,602,865 6,198,759
IS BELOW DEW POINT. and facilitates breakdown and pulse to pulse fidelity.
Other U.S. and International Patents pending. Ser#:
Damage or malfunction may occur if this or 0481281010390
150 WATTS MAX SEE OPERATION MANUAL. equivalent drive signals are not used. See manual
10200–10800 nm
EN-60825-1, 1993

INPUT POWER: 30 VDC
CONDENSATION AND
WATER DAMAGE CAN
150 WATTS MAX

10200–10800 nm
EN-60825-1, 1993
MADE IN THE U.S.A.

BOTTOM VIEW

complies with 21 CFR subchapter J these pins must be jumpered 6 7 8 9
at the date of manufacture. for the laser to operate. Refer
REMOTE KEYSWITCH JUMPER
to manual for details.
MADE IN THE U.S.A.
KEYSWITCH VERSION KEYSWITCH VERSION ONLY

OR REMOTE KEYSWITCH JUMPER
to manual for details.
OEM VERSION

21 CFR 1040 or EN 60825.

laser safety
Agency compliance
The Agency compliance section includes subsections:
■ Center for Devices and Radiological Health (CDRH) requirements

■ Federal Communications Commission (FCC) requirements
■ European Union (EU) requirements
Series 48 lasers are designed to comply with certain United States (U.S.) and European Union (EU)
Directives. These Directives impose product performance requirements related to electromagnetic
compatibility (EMC) and product safety characteristics for industrial, scientific, and medical (ISM)
equipment. The associated Directives and specific provisions to which systems containing Series 48 lasers
must comply are identified and described in the following paragraphs.
Series 48 lasers should be installed and operated in manufacturing or laboratory facilities by trained
personnel only. Due to the considerable risks and hazards associated with the installation and operational
use of this apparatus with the incorporated laser, the manufacturer has provided appropriate product
warning labels and instructions to the user regarding laser safety. SYNRAD, Inc. assumes no responsibil-
ity for the compliance of the system into which the Series 48 laser is integrated.
Center for Devices and Radiological

Health (CDRH) requirements
Series 48 Keyswitch models comply with requirements for Class IV laser products imposed by the
Radiation Control for Health and Safety Act of 1968. Under this Act, the U.S. Food and Drug Adminis-
tration (FDA) issued a performance standard in the Code of Federal Regulations (CFR) for laser products.
This performance standard (21 CFR, Subchapter J, Part 1040.10) was developed to protect public health
and safety by imposing requirements upon manufacturers of laser products to provide an indication of the
presence of laser radiation, to provide the user with certain means to control radiation, and to assure that
personnel are adequately warned of potential hazards through the use of product labels and instructions.
Federal regulations require that all laser products manufactured on or after August 2, 1976 be certified as
complying with the performance standard. The manufacturer must demonstrate the product’s compliance
with the standard prior to certification or introduction into commerce by furnishing to the Center for
Devices and Radiological Health (CDRH) reports pertaining to the radiation safety of the product and
the associated quality control program. Failure to provide the required reports or product certification is a
violation of Section 360B of the Radiation Control for Health and Safety Act of 1968.
Product features incorporated into the design of Series 48 lasers to comply with CDRH requirements are
integrated as panel controls or indicators, internal circuit elements, or input/output signal interfaces.
Specifically, these features include a keyswitch (Keyswitch versions), lase and laser ready indicators,
remote interlock for power on/off, a laser aperture shutter switch, and a five-second delay between power
on and lasing. Incorporation of certain features is dependent on the laser version (Keyswitch or OEM).
Product features are summarized in Table 1, Class IV safety features. The table indicates which features
are available on Series 48 lasers, the type and description of the feature, and if the feature is required by,
and complies with, CDRH regulations.
Series 48 OEM (-S) model lasers are OEM products intended for incorporation as components in a laser
processing system and as such, do not comply with 21 CFR, Subchapter J without additional safeguards.
These safeguards will vary depending on the type of system in which the laser will be incorporated. For
instance, if the system is intended to be a Class I laser system, the OEM or System Integrator must
provide guarding to prevent laser emission in excess of the Accessible Emission Limits (AEL) for Class I
devices. For incorporation in a Class IV laser system, the integrated system must include a beam attenua-
tor, a keyswitch, a remote interlock, and other safety features as described under the standard.
laser safety
Agency compliance
Safe operating practices per ANSI Z136.1-1993 should be exercised at all times when actively lasing. To
prevent exposure to direct or scattered laser radiation, follow all safety precautions specified throughout
this manual. The use of controls or adjustments or performance of procedures other than those specified
herein may result in exposure to hazardous invisible laser radiation, damage to, or malfunction of the
laser. Severe burns will result from exposure to the laser beam. Always wear safety glasses with side
shields to reduce the risk of damage to the eyes when operating the laser.
Safe operation of the laser requires the use of an external beam block to safely block the beam from
traveling beyond the desired work area. Use a firebrick or similar non-scattering, noncombustible
material as the beam block. Never use organic material or metals as the beam blocker; organic materials,
in general, are apt to combust or melt and metals act as specular reflectors which may create a hazard
outside the immediate work area.
Federal Communications Commission

(FCC) requirements
The United States Communication Act of 1934 vested the Federal Communications Commission
(FCC) with the authority to regulate ISM equipment that emits electromagnetic radiation in the radio
frequency spectrum. The purpose of the Communication Act was to prevent harmful electromagnetic
interference (EMI) from affecting authorized radio communication services.
The FCC regulations that govern industrial, scientific, and medical (ISM) equipment are fully described
in 47 CFR, Part 18, Subpart C. SYNRAD’s Series 48 lasers have been tested and found to comply by
demonstrating performance characteristics that have met or exceeded the requirements of 47 CFR, Part
18, Radiated and Conducted Emissions.
FCC information to the user

NOTE: The following FCC information to the user is provided to comply with the requirements of 47
CFR, Part 18, Section 213.
Interference Potential
In our testing, SYNRAD, Inc. has not discovered any significant electrical interference traceable to
Series 48 lasers.
System Maintenance
Ensure that all exterior covers are properly fastened in position.
Measures to Correct Interference

If you suspect that your Series 48 laser interferes with other equipment, take the following steps to
minimize this interference:
1 Use shielded cables to and from the equipment that is experiencing interference problems.
2 Ensure that the Series 48 laser is properly grounded to the same electrical potential as the
equipment or system it is connected to.
3 Install bisected ferrite on the laser’s DC power cables; locate them as close as possible to the laser
housing.

laser safety
Agency compliance
FCC caution to the user

The FCC warns the user that changes or modifications of the unit not expressly approved by the party
responsible for compliance could void the user’s authority to operate the equipment.
European Union (EU) requirements

The European Norm (EN) document EN 60825-1 2003-06, Safety of Laser Products, was developed to
protect persons from laser radiation by imposing requirements upon manufacturers of laser products to
provide an indication of laser radiation; to classify laser products according to the degree of hazard; to
require both user and manufacturer to establish procedures so that proper precautions are adopted; to
ensure adequate warning of the hazards associated with accessible radiation through signs, labels, and
instructions; to improve control of laser radiation through protective features; and to provide safe usage
of laser products by specifying user control measures.
Series 48 Keyswitch models are designed to comply with the requirements imposed by EN 60825-1.
Table 1, Class IV safety features, summarizes Series 48 product features, indicating the type and descrip-
tion of features and whether those features are required by European Union regulations.
Series 48 OEM (-S) model lasers are OEM products intended for incorporation as components in a laser
processing system and as such, do not comply with EN 60825-1 without additional safeguards. OEM laser
products which are sold to other manufacturers for use as components of any system for subsequent sale
are not subject to this Standard, since the final product will itself be subject to the Standard.
The European Union’s Electromagnetic Compatibility (EMC) Directive 89/336/EEC is the sole Directive
developed to address electromagnetic interference (EMI) issues in electronic equipment. In particular,
the Directive calls out European Norm (EN) documents that define the emission and immunity standards
for specific product categories. For Series 48 lasers, the standard EN 55011 (CISPR:11) defines the
radiated RF emissions limit. The standard EN 50082-1 defines generic immunity requirements published
by the International Electromechanical Commission (IEC).
SYNRAD’s Series 48 lasers have demonstrated performance characteristics that have met or exceeded
the requirements of EMC Directive 89/336/EEC.
In accordance with Machinery Directive 89/392/EEC, Article 1, paragraph 4 and 5, the Machinery
Directive does not apply to this device. In consideration of the incorporation of the Series 48 laser into
devices that may fall under the definition of a “machine”, SYNRAD, Inc. considers the application of the
EMC Directive as sufficient evidence that the Series 48 laser will not compromise the compliance of the
“machine” into which it is incorporated.
After a product has met the requirements of all applicable EU Directives, the product can bear the
official compliance mark of the European Union as shown in Figure 4.
Figure 4 European compliance mark

laser safety
Agency compliance
Table 1 Class IV safety features
Required by:
Feature Location/Description CDRH EN60825-1
Keyswitch1 Panel control Yes Yes

On/Off Keyswitch controls power to laser electronics. Key can not
be removed from switch in the “On” position.
Shutter Laser control Yes Yes

function1 Attenuates beam / disables RF driver/laser output when closed.
Power2 Panel indicator (Green) Yes No

indicator Indicates that laser has power applied and is capable of lasing.
Lase Panel indicator (Red) Yes Yes

indicator Indicates laser is actively lasing. Illuminates when duty cycle of
Command signal is long enough to produce laser output.
Five-second Circuit element Yes No

delay Disables RF driver/laser output for five to ten seconds after Key-
switch is turned to “On” and remote keyswitch is closed.
Power-on Circuit element Yes No

reset Disables RF driver/laser output if input power is removed then later
reapplied (AC power failure) while Keyswitch is in “On” position.
Remote Panel connection Yes Yes

Interlock1 Disables RF driver/laser output when remote interlock switch on
equipment door or panel is opened.
Remote Panel connection No No

Keyswitch Allows operator to turn laser On/Off from a remote location.
Over/under Circuit element No No

voltage Fault shutdown occurs if supply voltage falls below +15 V or rises
protection above +36 V. Reset laser to restore operation.
Reverse Circuit element No No

voltage Internal diode protects circuitry from reverse input voltages.
protection External fuse will blow.
Overtemp Circuit element No No

protection Over temperature shutdown occurs when temperature of tube
reaches 60 °C ±2 °C. Reset laser to restore operation.
PWM failure Circuit element No No

protection Disables laser if output power exceeds Command input by 20%
or more due to electronics failure. Reset laser to restore operation.
Fault signal Signal output No No

Latches to a logic low state when a fault shutdown occurs.
Message Signal output No No

signal Pre-shutdown warning latches to a logic low state when tube
temperature reaches 54 °C ±2 °C.
Warning Exterior housing Yes Yes

labels Labels attached to various locations to warn of potential hazards.
1 Keyswitch version only

2 On OEM versions, the Power indicator illuminates and the five-second delay begins when DC power is applied to the laser

laser safety
Declaration of Conformity
Declaration Of Conformity
Applicable EU Directive(s): 89/336/EEC EMC Directive
Applicable Standards/Norms: EN 55011 Radiated, Class A, Group 2

EN 60825-1 Laser Safety
EN 50082-1 Generic Immunity
IEC 801-2 Electrostatic Discharge

IEC 801-3 RF Radiated
IEC 801-4 Fast Transients
Manufacturer: SYNRAD, Inc.

4600 Campus Place
Mukilteo, WA 98275
Model Number: Serial Number Date Of Compliance

(Compliant Unit)
J48-1 29 October 1998
J48-2 29 October 1998
J48-5 J48-5S-2197 29 October 1998
We, SYNRAD, Inc., hereby declare under our sole responsibility that the equipment
specified above conforms to the above Directive(s) and Standard(s).
Corporate Officer: European Contact:
Excel Technology Europe GmbH

Münchner Str. 2a
_______________________________ D-82152 Planegg
Dave Clarke, President of SYNRAD Germany
29 October 1998
_______________________________
Date

getting started
1
Use information in this section to prepare your Series 48 laser for operation. The order of
information presented in this section is the same as the order of tasks that you need to
perform. The best way to get your laser ready for operation is to start at Unpacking and
work your way through Connecting.
This section contains the following information:
■ Introduction – introduces Series 48 lasers and lists important features.
■ Unpacking – provides important information about shipping your Series 48 laser.
■ Inventory – displays and describes all components shipped with your laser.
■ Mounting – describes how to attach laser components to a mounting surface.
■ Connecting – explains how to connect power and control cables as well as cooling
connections for water-cooled models.

getting started
Introduction
Thank you for purchasing a Series 48 laser from SYNRAD, Inc. The Series 48 family of lasers incorpo-
rates the latest developments in sealed carbon dioxide devices, combining the best features of both
waveguide and free space CO2 laser technology in an innovative aluminum tube design. J Series lasers
utilize state-of-the-art surface mount electronics, newly patented RF excitation technology, and fully
CE-compliant systems for EMI containment, heat removal, and laser safety. In the 10 W to 50 W range
of continuous optical output, these lasers represent an ideal balance between proven, mature laser tube
technology and reliable, simplified electronic control.
Series 48 features include:
■ Compact resonator design

■ RF power supply integrated into laser chassis
■ Keyswitch air- or water-cooled models available
■ OEM (no Keyswitch/no shutter) air- or water-cooled models available
Series 48 nomenclature
Series 48 lasers are divided into two distinct functional categories: Keyswitch and OEM models. In
addition to a manual Keyswitch, all Keyswitch-equipped lasers include a manual Shutter Switch that allows
the laser output aperture to be blocked. OEM lasers do not incorporate either a manual keyswitch or
shutter assembly since they are designed as components for integration into a larger processing system by
an Original Equipment Manufacturer (OEM) or System Integrator who bears the responsibility for
meeting the appropriate laser safety requirements for Class IV laser systems.
Caution Please read this manual completely before using your laser. To
prevent injury to personnel or damage to the laser, follow all safety
serious precautions, handling, and setup instructions as described herein.
personal
injury

getting started
Unpacking
The Unpacking section includes subsections:
■ Incoming inspection
■ Packaging guidelines
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.
The shipping carrier is responsible for any damage occurring during transportation from SYNRAD, Inc.
to your receiving dock.
Carefully remove your Series 48 laser from the shipping container and remove the outer foam packing
material. Inspect the laser housing for any signs of shipping damage. Verify that all external labels are
attached to the housing (refer to label location drawings in the “Laser Safety” section). Contact
SYNRAD Customer Service if the laser housing is damaged or if any of the required accessory materials
or labels are missing.
Packaging guidelines
■ To prevent equipment damage or loss of small components, use care when removing packaging
materials.
■ Save all shipping containers and packaging materials, including covers and plugs. Use these special-
ized packing materials when shipping the laser to another location.
■ After unpacking, review the Inventory section and verify that all components are on hand.
■ 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, fittings, etc.
■ When shipping water-cooled lasers, remember to drain all cooling water from the laser and then cap
the open fittings to prevent debris from entering the coolant path.
■ Do not lift or support the laser using the cooling fittings; lift the laser by the mounting feet or
baseplate only.

getting started
Inventory
Series 48 Lasers
Operator's Manual
DB9 Connector
and Cover Kit
Spare Fuse(s)
Cooling Kit - water

cooled lasers only
(48-1/48-2 kit shown)
Series 48 Laser
(10 W water-cooled laser shown)
AD
NR
SY
Figure 1-1 Series 48 shipping box contents
Table 1-1 lists items included in the Series 48 ship kit.
Table 1-1 Ship kit contents
Shipping Box Contents Qty
SYNRAD Series 48 Laser ................................... 1

Series J48 Lasers Operator’s Manual .................. 1
DB9 Connector and Cover Kit ........................... 1
Spare Fuse(s) ....................................................... 1
Cooling Kit (water-cooled lasers only) .............. 1
Final Test Report (not shown) ........................... 1

getting started
Inventory
Contents description
Each item listed in Table 1-1 is described below.
SYNRAD Series 48 Laser – for cutting, welding, drilling, and marking a wide variety of products and
materials.
Series 48 Lasers Operator’s Manual – provides setup, operation, and maintenance information for your
Synrad Series 48 laser.
DB9 Connector and Cover Kit – connects to the Series 48 DB9 Connector. Use this connector to replace
the factory jumper plug when integrating Series 48 laser signals into your control system.
Spare Fuse(s) – fast-blow fuse protects Series 48 internal circuitry. A 10 A fuse is included with 48-1
lasers, a 20 A fuse with 48-2 lasers, and two 20 A fuses are shipped with 48-5 lasers.
Cooling Kit (water-cooled lasers only)

(48-1/48-2) – includes quick-disconnect inlet and outlet cooling manifolds, extra 1/4" union elbows,
extra straight 1/8" NPT to 1/4" tube fittings, and 20 feet of 1/4 inch O.D. black polyethylene tubing.
(48-5) – includes quick-disconnect inlet and outlet cooling manifolds, extra 1/4" union elbows, extra
straight 1/4" NPT to 3/8" tube fittings, and 20 feet of 3/8 inch O.D. black polyethylene tubing.
Final Test Report (not shown) – contains data collected during the laser’s final pre-shipment test.

getting started
Mounting
The Mounting section includes subsections:
■ Standard mounting
■ With an FH Series marking head
The recommended mounting orientation for Series 48 lasers is horizontal. If this cannot be accomplished
then the laser may be mounted at an angle of > 20° to the vertical. Consult the factory for limitations if
the laser is mounted in a vertical orientation.
Note: To allow for proper airflow, air-cooled units must have at least 2.25" of unobstructed clearance
between the outside edge of the cooling fan housing and any enclosure or mounting surface.
Standard mounting
Series 48 lasers may be hard-mounted to equipment by removing several of the bottom panel screws and
replacing these with longer screws to secure the laser to optical assemblies. This mounting method is only
recommended as long as the screws do not support the weight of the laser. For a sturdier attachment, the
laser may be clamped to optical assemblies by applying clamping forces between top and bottom cover
screws. Do not apply clamping forces on the longitudinal centerline.
1 Refer to the appropriate outline and mounting diagram in the “Technical Reference” section for
mounting screw locations and then drill four (48-1) or six (48-2/48-5) holes into your mounting
surface. Locate holes in a symmetrical pattern to properly distribute mounting forces.
Note: Do not remove covers from the laser housing when mounting.
2 Place your Series 48 laser on the mounting surface so that the threaded holes on the laser housing
line up with the holes drilled through the mounting surface.
3 Measure the 6–32 screws (48-1/48-2) or 10–32 screws (48-5) you removed from the laser housing
and add a length equivalent to the thickness of the mounting surface.
4 Insert these new screws through the mounting surface into the threaded holes of the laser housing.
Turn the screws by hand until the threads engage and then tighten using an Allen wrench.
With an FH Series marking head

To mount your Series 48 laser to an FH Series marking head, perform the following steps:
Note: The laser’s mounting feet are precisely aligned and shimmed at the factory to ensure alignment
between the marking head and the Mounting Rail. Do not loosen or remove the mounting feet
from the laser. See the FH Series Marking Head Operator’s Manual for further details.
1 Orient the laser on the FH Mounting Rail with the laser’s output aperture facing the L-bracket.
2 Ease the laser forward until the dowel pins on the mounting feet drop into the dowel pin holes in
the Mounting Rail. The screw holes on the ends of the mounting feet should be positioned over the
appropriate mounting holes in the Mounting Rail.
3 Install and tighten four capscrews to secure the laser to the Mounting Rail. 48-1 and 48-2 lasers use
6–32 × 1" socket head capscrews while 48-5 lasers use 10–32 × 3/4" fasteners.

getting started
Connecting
The Connecting section includes subsections:
■ Air-cooled connections
■ Water-cooled connections
■ Electrical connections
■ Control connections
■ DB9 connections
The Connecting section contains all the information you need to connect your Series 48 laser for opera-
tion. Figure 1-7 at the end of this chapter illustrates the connections used in a typical Series 48 laser
system.
Air-cooled connections
Note: 48-5 (50 W) lasers must be water-cooled to prevent damage to the laser. See the Water-cooled
connections section for connection details.
Since air-cooled lasers are shipped without cooling fans, customers must provide air cooling to prevent
overheating of the laser. An airflow of 250 cubic feet per minute (CFM) per fan is required to keep laser
and heatsink temperatures below 50 °C. 48-1 lasers have a heat load specification of 300 W maximum
and requires two cooling fans for a total of 500 CFM. 48-2 lasers have a 500 W heat load and requires
four cooling fans for a total air flow of 1000 CFM.
Place cooling fans symmetrically on each side of the laser so that air flow is directed perpendicular to the
laser’s cooling fins as shown in Figure 1-2. The fans should have a diameter of approximately 4.5" to 5"
and have at least 2.25" of unobstructed clearance between the outside edge of the cooling fan housing
and any enclosure or mounting surface.
FAN
48-1 TOP VIEW
FAN
FAN FAN
48-2 TOP VIEW
FAN FAN
Figure 1-2 48-1 / 48-2 cooling fan placement

getting started
Connecting
Water-cooled connections
Read Guidelines for cutting and installing tubing before installing any cooling tubing and then make sure to
connect the cooling system exactly as described for your particular laser.
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.
Tubing extends into the fitting approximately 7/8 of an inch.
■ If tubing must be disconnected from a fitting, first push and hold the tubing slightly into the fitting.
Next push the white fitting ring evenly towards the fitting, and then pull the tubing free.
■ After disconnecting tubing from a fitting, trim 1/2 inch from its end before reconnecting. Trimming
the end of the tubing before reconnecting the fitting provides an undisturbed sealing surface.
Laser cooling fittings

If your integrated laser application uses metric cooling tubing, we recommend the installation of tubing
adaptors to convert 48-1/48-2 cooling kit fittings from 1/4 inch tubing to 6 mm metric tubing. For 48-5
cooling kits, convert the 3/8 inch tubing to 8 mm metric tubing. These tubing adaptors are available
from many tubing and fitting manufacturers.
Setting coolant temperature

Note: SYNRAD recommends that the laser’s cooling fluid contain no less than 90% water by volume.
In applications where biocides containing chlorides are used, concentrations should not exceed
25 parts per million (PPM).
Choosing the correct coolant temperature is important to the proper operation and longevity of your
laser. 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.
Caution Operating the laser at coolant temperatures above 22 °C (72 °F)

may result in decreased performance and/or premature failure of
possible electronic components.
equipment
damage

getting started
Connecting
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 of the sur-
rounding air or when the system is shut down, but 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.
■ Stop coolant flow when the laser is shut down.
■ Increase coolant flow by an additional 1.0 GPM. Do not exceed a coolant pressure of 60 PSI.
■ Air-condition the room or the enclosure containing the laser.
■ Install a dehumidifier to reduce the humidity of the enclosure containing the laser.
Table 1-2 provides dew point temperatures for a range of air temperature and relative humidity values.
Remember that the laser’s coolant temperature must be set above the dew point temperatures shown in
the chart, but should not exceed 22 °C (72 °F).
Table 1-2 Dew point temperatures
Dew Point Temperatur

Temperatur
emperaturee Chart °F (°C)
Relative Humidity (%)

20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95
Air Temp
°F (°C)
60 (16) — — — 32 36 39 41 44 46 48 50 52 54 55 57 59
(0) (2) (4) (5) (7) (8) (9) (10) (11) (12) (13) (14) (15)
65 (18) — — 33 37 40 43 46 48 51 53 55 57 59 60 62 64
(1) (3) (4) (6) (8) (9) (11) (12) (13) (14) (15) (16) (17) (18)
70 (21) — 33 37 41 45 48 51 53 56 58 60 62 64 65 67 69
(1) (3) (5) (7) (9) (11) (12) (13) (14) (16) (17) (18) (18) (19) (21)
75 (24) — 37 42 46 49 52 55 58 60 62 65 67 68 70 72 73
(3) (6) (8) (9) (11) (13) (14) (16) (17) (18) (19) (20) (21) (22) (23)
80 (27) 35 41 46 50 54 57 60 62 65 67 69 71 73 75 77 78
(2) (5) (8) (10) (12) (14) (16) (17) (18) (19) (21) (22) (23) (24) (25) (26)
85 (29) 40 45 50 54 58 61 64 67 70 72 74 76 78 80 82 83
(4) (7) (10) (12) (14) (16) (18) (19) (21) (22) (23) (24) (26) (27) (28) (28)
90 (32) 44 50 54 59 62 66 69 72 74 77 79 81 83 85 87 88
(7) (10) (12) (15) (17) (19) (21) (22) (23) (25) (26) (27) (28) (29) (31) (31)
95 (35) 48 54 59 63 67 70 73 76 79 81 84 86 88 90 92 93
(9) (12) (15) (17) (19) (21) (23) (24) (26) (27) (29) (30) (31) (32) (33) (34)
100 (38) 52 58 63 68 71 75 78 81 84 86 88 91 93 95 97 98
(11) (14) (17) (20) (22) (24) (26) (27) (29) (30) (31) (33) (34) (35) (36) (37)

getting started
Connecting
48-1 / 48-2 cooling tubing connections

Water enters at the laser’s rear plate through the lower side-mounted 1/4 inch diameter cooling tubes and
exits through the top-mounted cooling tubes. Both circuits must be used in parallel to maintain thermal
balance. The two right angle connections are installed on the front plate. The cooling kit also includes
quantities of both straight and elbow fittings; you can order other compatible fittings from your local
fitting supply house. All fittings are quick-disconnect types.
To connect cooling tubing to your 48-1 or 48-2 water-cooled laser, refer to Figure 1-3 and perform the
following steps:
REAR PLATE FRONT PLATE
WATER OUTLET
DETAIL A WATER INTAKE
STRAIGHT ELBOW
FITTING FITTING
NOTES: DETAIL A
1. ALL FITTINGS NEED TO BE PRESSED COMPLETELY ON. FITTING OPTION
2. QUANTITIES OF BOTH FITTING TYPES ARE SHIPPED WITH LASER. SEE NOTE 2.
Figure 1-3 48-1 / 48-2 cooling connections
1 Connect the Water Intake manifold to both of the laser’s lower coolant tubes on the rear plate.
2 Connect the Water Intake fitting to your coolant source.
3 Connect the Water Outlet manifold to both of the laser’s upper coolant tubes on the rear plate.
4 Connect the Water Outlet fitting to your coolant return or drain.

5 On the front plate, connect one right angle connection between one of the lower coolant tubes and
its corresponding upper coolant tube. Repeat this step on the other set of lower/upper tubes.
Caution Inlet cooling water temperature must always be maintained above

the dew point to prevent condensation and water damage to your
possible laser.
equipment
damage

getting started
Connecting
6 Turn on the chiller and adjust the temperature setpoint to 18 °C to 22 °C. Regulate coolant flow
to 0.5 GPM (48-1) or 0.8 GPM (48-2) at less than 60 PSI of pressure.
7 Closely examine all cooling connections and verify that there are no leaks.
48-5 cooling tubing connections

Cooling water enters the laser through the two lower side-mounted tubes plus one of the center-mounted
cooling tubes located on the laser’s rear plate. Cooling water flows through the tubes and out the two
top-mounted cooling tubes and the other center-mounted tube. The front central tubes are “jumpered”
using a “U” fitting while the front side and top connections on the front plate are also jumpered using
two right angle connections. The cooling kit also includes quantities of both straight and elbow fittings;
you can order other compatible fittings from your local fitting supply house. All fittings are quick-
disconnect types.
To connect cooling tubing to your 48-5 laser, refer to Figure 1-4 and perform the following steps:
REAR PLATE
DETAIL A
FRONT PLATE
WATER OUTLET
WATER INTAKE
STRAIGHT ELBOW
FITTING FITTING
NOTES: DETAIL A
1. ALL FITTINGS NEED TO BE PRESSED COMPLETELY ON. FITTING OPTION
2. QUANTITIES OF BOTH FITTING TYPES ARE SHIPPED WITH LASER. SEE NOTE 2.
Figure 1-4 48-5 cooling connections
1 Connect the Water Intake manifold tubing to both of the laser’s lower side-mounted coolant tubes
and one of the center coolant tubes on the rear plate.
2 Connect the Water Intake fitting to your coolant source.
3 Connect the Water Outlet manifold tubing to both of the laser’s upper coolant tubes and one of
the center coolant tubes on the rear plate.
4 Connect the Water Outlet fitting to your coolant return or drain.

5 On the front plate, connect one right angle connection between one of the lower coolant tubes and
its corresponding upper coolant tube. Repeat this step on the other set of lower/upper tubes.
6 Connect the “U” connector between both of the center coolant tubes.

getting started
Connecting

possible laser.
equipment
damage
7 Turn on the chiller and adjust the temperature setpoint to 18 °C to 22 °C. Regulate coolant flow
to 1.5 GPM at less than 60 PSI of pressure.
8 Closely examine all cooling connections and verify that there are no leaks.
Electrical connections
DC power supply
SYNRAD power supplies, models DC-1, DC-2, and DC-5, are sized to power 48-1, 48-2, and 48-5 lasers
respectively. The 48-1 laser requires a SYNRAD DC-1 or equivalent power supply capable of providing
30 VDC at 7 A maximum; the 48-2 laser requires a SYNRAD DC-2 power supply (30 VDC at 14 A
max.); and the 48-5 requires a SYNRAD DC-5 power supply (30 VDC at 28 A max.).
If substituting power supplies, use a well-regulated DC power supply in the range of 30 V to 32 V with no
more than 3 V overshoot under a 10–90% modulation load. The use of short leads and terminations
rated for the appropriate output current is recommended.
Note: SYNRAD lasers are tested to meet published specifications at an input voltage of 30 VDC.
AC input power requirements for the DC-1 power supply are 85–264 VAC, single phase (1Ø), 20 A
max, 47–440 Hz. Input requirements for both DC-2 and DC-5 supplies are 90–132 VAC (low range)
or 175–264 VAC (high range), single phase (1Ø), 13 A (DC-2) or 25 A (DC-5) max, 47–440 Hz.
DC-1 power supply

To connect the DC-1 power supply, refer to Figure 1-5 and perform the following steps:
OUTPUT
+
V1
30 VDC
–
COM
Output
V4
RET
V3
COM
COM
V2
AC
Input
Figure 1-5 DC-1 (Astec) power supply

getting started
Connecting
1 Verify that input AC to the DC power supply is physically locked out or disconnected.
2 Locate the 30 VDC output terminals on the power supply’s output section and connect the black
(–) DC Power cable from the laser to the negative (– COM) output terminal.
3 Connect the red (+) DC Power cable from the laser to the positive (+ V1) 30 VDC output termi-
nal.
4 Connect the AC line cord to the AC receptacle located on the fan end of the DC-1 power supply.
Note: U.S., European, and UK line cords are available for the DC-1 power supply. If the line cord
provided does not fit your available AC outlet, you will need to provide a cable with the proper
AC outlet plug on one end and a standard IEC 320 female connector on the power supply end.
DC-2 / DC-5 power supply

To connect either the DC-2 or DC-5 power supply for 120 VAC (low range) input, refer to Figure 1-6
and follow the steps listed in the 120 VAC input operation section. If you are connecting the DC-2/DC-5
power supply for 240 VAC (high range) input, refer to Figure 1-6 and follow the steps listed in the 240
VAC input operation section.
SYNRAD DC-2 DC Power Supply SYNRAD DC-5 DC Power Supply
Input Section Output Section Input Section Output Section
+ +
1 1 1
2 2 2
– –
3
VOLT VOLT
L ADJ.
L 4 ADJ.
N N
VOLT
ADJ.
3 12 3 6 3 12 3 6 3 6
2 11 2 5 2 11 2 5 2 5
1 1 4 1 1 4 1 4
10 10
Figure 1-6 DC-2/DC-5 (Power-One) power supplies
120 VAC input operation

1 Verify that input AC power to the DC power supply is physically locked out or disconnected.
(–) DC Power cable from the laser to the negative (–) output terminal.
3 Connect the red (+) DC Power cable from the laser to the positive (+) 30 VDC output terminal.
4 Locate the 5-pin terminal strip on the power supply’s input section, under the protective snap-on
cover.
5 Connect a jumper wire (16 AWG or heavier) between terminals 1 and 2.

getting started
Connecting
6 Connect the AC hot wire, typically black, from your 120 VAC source to the terminal labeled “L”
(AC Line).
7 Connect the neutral wire, typically white, from your voltage source to terminal “N” (AC Neutral).
8 Connect the ground (earth) wire, typically green, from your AC voltage source to the terminal
labeled with the ground symbol.
240 VAC input operation

1 Verify that input AC power to the DC power supply is physically locked out or disconnected.
(–) DC Power cable from the laser to the negative (–) output terminal.
3 Connect the red (+) DC Power cable from the laser to the positive (+) 30 VDC output terminal.
4 Locate the 5-pin terminal strip on the power supply’s input section, under the protective snap-on
cover.
5 Connect one of the two AC hot wires, typically black, from your 240 VAC source to the terminal
labeled “L” (AC Line).
6 Connect the other hot wire, typically black or red, from your voltage source to terminal “N” (AC
Neutral).
7 Connect the ground (earth) wire, typically green, from your AC voltage source to the terminal
labeled with the ground symbol.
Control connections
Warning Always use shielded cable when connecting your PWM Command
signal source to the laser’s CTRL connections. In electrically-noisy
serious environments, long lengths of unshielded wire act like an antenna
and may generate enough voltage to trigger uncommanded lasing.
personal
injury
UC-2000 Universal Laser Controller

The operation of Series 48 lasers requires an external controller that can provide the necessary tickle and
pulse width modulated (PWM) Command signals. SYNRAD recommends the use of a UC-2000 Univer-
sal Laser Controller to generate the PWM signals that control the laser’s output power. The UC-2000
requires 15–50 VDC @ 35 mA, supplied from either its wall plug transformer or from the Auxiliary Power
connector on the side of Series 48 lasers. Refer to the UC-2000 Laser Controller Operator’s Manual for
information about UC-2000 operation.
To connect a UC-2000 Controller (not included with Series 48 lasers), perform the following steps:
1 Connect the mini-DIN connector on the end of the UC-2000 Controller’s Power/Control cable to
the Laser connector on the rear panel of the UC-2000.

getting started
Connecting
2 Connect the miniature DC power plug on the UC-2000’s Power/Control cable to the laser’s side-
mounted Auxiliary Power connector.
To use the UC-2000’s wall plug transformer instead, connect the miniature DC power plug on the
UC-2000’s Power/Control cable to the miniature connector on the wall plug transformer cable
3 On 48-1 and 48-2 lasers, attach the BNC connector on the end of the UC-2000’s Power/Control
cable to the BNC connector labeled CTRL on the rear of the laser.
On 48-5 lasers, attach the long “leg” of the BNC “Y” control cable to the BNC connector on the
UC-2000’s Power/Control cable. Attach the short “legs” of the “Y” cable to the laser’s CTRL1 and
CTRL2 connectors located on the rear of the laser.
Note: When driving the laser from an FH Series marking head, connect the marking head’s Laser
Control cable between the Laser Control connector on the marking head and the CTRL
connectors on the rear of the laser.
4 If your application uses external gating signals to command On/Off switching of the laser, attach a
BNC cable between your gate signal source and the UC-2000’s Gate connector.
5 If your application uses external analog voltage or current signals to control the PWM duty cycle of
the laser, attach a BNC cable between your analog voltage or current source and the UC-2000’s
ANV/ANC connector.
Note: Series 48 lasers can also be controlled from an alternate user-supplied PWM Command signal
source. Refer to Controlling laser power in the “Technical Reference” section for control signal
descriptions.
DB9 connections
48 Series lasers are equipped with a female DB9 connector mounted to the sidewall of the laser. This
connector provides the user with a convenient method for monitoring fault conditions (over-tempera-
ture, control/RF circuitry failure) and adds remote interlock, remote keyswitch (relay or switch), message
output, and remote LED indicator capability. For a complete description of DB9 pin assignments and
functions, see DB9 connections in the “Technical Reference” section.
A factory-installed jumper plug is attached to the DB9 Connector on each laser to enable normal opera-
tion. Two jumpers (see Figure 3-9) are wired to the plug. One jumper between pins 6 and 7 closes the
Remote Keyswitch function, and the other jumper between pins 3 and 4 closes the Remote Interlock. If this
jumper plug is removed, it is essential that pin 3 be jumpered to pin 4 (or pin 2) or be connected to
external “remote interlock” circuitry in order to enable lasing.
Note: On lasers manufactured as OEM (-S) version lasers, i.e. without a keyswitch, the “remote
interlock” function is bypassed internally. For OEM customers wishing to access the “remote
interlock” feature via the DB9 Connector, please consult the factory for details.

FIRE BRICK
BEAM BLOCK
116
WATER CHILLER
COMPUTER
WITH D/A CARD
Connecting
COOLING
WATER OUT
AD
NR
SY
COOLING
CTRL WATER IN
UC-2000
Figure 1-7 Typical Series 48 system interconnection diagram

GATE
+
GND
-
~L
~N
ANV/ANC
DC POWER SUPPLY
getting started
Synrad S e r i e s 4 8 operator’s manual

operation

2
Use information in this section to familiarize yourself with Series 48 controls and indica-
tors and to begin operating your laser.
■ Controls and indicators – displays and describes exterior controls and indicators on
Series 48 Keyswitch and OEM lasers.
■ Initial start-up – explains how to start your Series 48 laser while verifying proper
operation.

operation
Controls and indicators
LASER EXIT SHUTTER POWER LASE LED
APERTURE SWITCH LED
OPTICAL
ON OFF
ACCESSORY
AVOID EXPOSURE
MOUNTING (x6)
CARBON DIOXIDE LASER
INVISIBLE LASER RADIATION PWR LASE

IS EMITTED FROM THIS
APERTURE STATUS
ON
5 SEC DELAY
CTRL FUSE
FRONT VIEW REAR VIEW
DIODE POINTER COMMAND INPUT KEYSWITCH FUSE

POWER CONNECTOR
DB9 CONNECTOR
DC POWER CABLES AUXILIARY POWER
SIDE VIEW
Figure 2-1 48-1 / 48-2 controls and indicators
Shutter Switch (Keyswitch models only) – The Shutter Switch is a mechanical shutter that closes the
laser aperture and also actuates independent micro-switches that interrupt power to the laser
section(s). The shutter should not be used to partially block the beam or to control output power.
Power LED – The PWR LED is a panel mounted LED that illuminates green when the Keyswitch is
turned to the ON position (or when an OEM laser is powered up) to indicate that power is applied
to internal circuitry.
Lase LED – The LASE LED is a panel mounted LED that illuminates red to indicate the lase mode of
operation. If a tickle signal is present, the red LED turns on after the five-second delay and becomes
brighter as the PWM Command duty cycle is increased.
Keyswitch (Keyswitch models only) – The panel-mounted Keyswitch is used to turn the laser on, off, and
to reset faults. The key cannot be removed when the Keyswitch is in the ON position. For OEM
lasers, a plug is installed in place of the Keyswitch and the keyswitch wires are shorted. The remote
keyswitch pins of the DB9 Connector then become the external power on/off/reset control means.
Fuse – The panel-mounted fuse(s) provides overcurrent protection for the internal circuitry of the laser.
The required fuse is a fast-blow type AGC/3AG rated at 32 V minimum with the following current
ratings: 48-1 – 10 A; 48-2 – 20 A; 48-5 – 20 A (2 required)
DB9 Connector – The DB9 Connector is a 9-pin, female subminiature-D connector that provides an
interconnection for message, fault shutdown, remote interlock, remote keyswitch, and interface
signals. Refer to DB9 connections in the “Getting Started” section for connection information.
Command (CTRL) Input – The CTRL connector is a BNC-style jack that accepts tickle and PWM
Command signal inputs. The output of the UC-2000 Controller (or FH Series marking head) is
attached to this connector. For pure CW operation, a steady +5 V signal can be applied through this

operation
Controls and indicators
LASER EXIT SHUTTER POWER LASE LED
APERTURE SWITCH LED
OPTICAL
R
AVOID EXPOSURE ACCESSORY
R
MOUNTING (x6)
POWER LASE POWER LASE
INVISIBLE LASER RADIATION CARBON DIOXIDE LASER
IS EMITTED FROM THIS STATUS
APERTURE
ON
5 SEC DELAY
CTRL 1 CTRL 2 FUSE 1 FUSE 2
FRONT VIEW REAR VIEW
DIODE POINTER COMMAND INPUTS KEYSWITCH FUSE

POWER CONNECTOR
DB9 CONNECTOR
DC POWER CABLES AUXILIARY POWER
SIDE VIEW
Figure 2-2 48-5 controls and indicators
connector (a tickle signal must be applied during laser-off periods). This input is optically-isolated
from the chassis and power supply ground circuit but must not be subjected to common mode
voltages greater than ±50 VDC from chassis ground. The 48-5 laser has two Command inputs,
CTRL1 and CTRL2, that should always be driven identically from the signal source by using a “Y”
cable or “T” BNC connector.
DC Power Cables – The red (+) and black (–) DC Power input cables provide +30 VDC operating
power to the laser. Standard length is 60 inches.
Auxiliary Power Connector – The Auxiliary Power connector is installed in the side panel of the laser
housing and provides an optional 30 VDC @ 350 mA source for powering the UC-2000 Controller.
An auto-resetting solid-state fuse limits line current. Connector power is active after 30 VDC is
applied to the laser.
Laser Exit Aperture – The aperture provides an opening from which the beam is emitted when lasing.
Diode Pointer Power Connector (optional) – The Diode Pointer Power connector is not installed unless
a Diode Pointer is ordered when the laser is built. This connector provides a regulated +5 VDC,
100 mA output for the optional Diode Pointer, available from SYNRAD. The Diode Pointer
connector is internally protected against short circuits by an auto-resetting, solid-state fuse.
Optical Accessory Mounting – The front faceplates of Series 48 lasers are designed with a 6-hole
mounting pattern (refer to the Outline/Mounting diagrams in the “Technical reference” section) to
provide a convenient method for mounting standard beam delivery components available from
SYNRAD. When considering other components not specifically designed as Series 48 options, please
consult the factory for restrictions since excessive weight may cause damage to the laser.
Note: To prevent damage to the laser when mounting optical components, the 8–32 mounting
screws must not extend further than 3/16" into the laser faceplate.

operation
Initial start-up
The Initial start-up section includes subsections:
■ With a UC-2000 Controller

■ Without a UC-2000 Controller
area as an exposed laser beam. Do not allow the laser beam to
personal contact a person. This product emits an invisible laser beam that is
injury capable of seriously burning human tissue.
Always be aware of the beam’s path and always use a beam block
while testing.
With a UC-2000 Controller

Before your Series 48 laser is put into service for the first time, its functionality should be verified. Follow
this procedure to verify the laser system is operating at optimum performance. For this procedure, use the
UC-2000 as a stand-alone controller; do not attempt to control the laser or UC-2000 externally.
Note: When performing the initial start-up sequence, check that the factory-installed DB9 jumper
plug is installed. If not, you must provide the required Remote Interlock and Remote Key-
switch signals to the DB9 Connector. See DB9 connections in the “Getting Started” section for
DB9 pinouts and signal descriptions.
Starting auxiliary equipment

1 Ensure that all personnel in the area are wearing protective eyewear.
2 Place a beam block 24 inches from the laser aperture to prevent the beam from traveling beyond
the work area.
3 On water-cooled systems, turn on the chiller (set between 18 °C to 22 °C) and verify that it is
delivering 0.5 GPM (48-1), 0.8 GPM (48-2), or 1.5 GPM (48-5) at less than 60 psi of pressure.
Examine all cooling connections carefully for leaks.

possible laser.
equipment
damage

operation
Initial start-up
Note: If you have not yet operated your UC-2000 Universal Laser Controller, refer to the UC-2000
Laser Controller Operator’s Manual for setup and operation instructions before continuing.
4 Set the UC-2000 to MANUAL mode, and then set the PWM Adj Knob to provide zero percent
output (0.0%). The UC-2000’s Lase indicator should be Off.
5 Verify that the laser’s Keyswitch (if equipped) is in the OFF position.
Starting your Series 48 laser

1 If the laser has a Diode Pointer installed, remove its aperture dust cover.
2 Move the Shutter Switch (if equipped) to the Open position.

3 Turn on the DC power supply.
4 Rotate the Keyswitch (if equipped) to the ON position. Verify that the green PWR LED illuminates.
If the Keyswitch is already ON, turn it OFF, then back ON (or cycle the Remote Keyswitch input) to
reset the laser.
Note: Each time an OEM laser is powered up or a Keyswitch version is cycled OFF/ON, a five-second
delay occurs between the time that the PWR LED illuminates and the laser is permitted to lase.
5 Verify that the red LASE LED illuminates dimly after approximately five seconds. This indicates
that tickle pulses are being applied to the laser and that it is safe to apply a PWM Command signal.
6 Press the UC-2000’s Lase On/Off button. The Lase indicator on the UC-2000 should illuminate.
7 Use the PWM Adj Knob on the UC-2000 to slowly increase power. The intensity of the laser’s
LASE indicator increases in brightness as the PWM duty cycle increases. The spot where the beam
hits the beam block should also increase in brightness to indicate increased power output.
Check your laser’s output power

1 With the UC-2000 set for maximum power output, measure laser output using a laser 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. Refer to General specifications in the “Technical Reference”
section for output power specifications.
2 Reduce the PWM duty cycle to 0.0% and press the UC-2000’s Lase On/Off button to stop lasing.
The Lase indicator on the UC-2000 turns off and the laser’s LASE LED turns dim.
3 Move the Shutter Switch (if equipped) to the Closed position.

4 Turn off the DC power supply.
If your Series 48 laser fails to lase, refer to Troubleshooting in the “Maintenance/Troubleshooting” section
for troubleshooting information.

operation
Initial start-up
area as an exposed laser beam. Do not allow the laser beam to
personal contact a person. This product emits an invisible laser beam that is
injury capable of seriously burning human tissue.
Always be aware of the beam’s path and always use a beam block
while testing.
Without a UC-2000 Controller

If you have chosen not to use a UC-2000 to control the laser, follow the procedure below to verify the
laser’s functionality. 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” section for tickle and PWM Command signal descriptions.
Note: When performing the initial start-up sequence, check that the factory-installed DB9 jumper
plug is installed. If not, you must provide the required Remote Interlock and Remote Key-
switch signals to the DB9 Connector. See DB9 connections in the “Getting Started” section for
DB9 pinouts and signal descriptions.
Caution Series 48 lasers MUST be provided with a pre-ionizing “tickle”

signal during standby or laser “low” periods. This signal is automati-
possible cally provided by SYNRAD’s UC-2000 Universal Laser Controller
or FH Series marking head.
equipment
damage 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 equiva-
lent drive signals are not provided.
Starting auxiliary equipment

1 Ensure that all personnel in the area are wearing protective eyewear.
2 Place a beam block 24 inches from the laser aperture to prevent the beam from traveling beyond
the work area.
3 On water-cooled systems, turn on the chiller (set between 18 °C to 22 °C) and verify it is deliver-
ing 0.5 GPM (48-1), 0.8 GPM (48-2), or 1.5 GPM (48-5) at less than 60 psi of pressure. Examine
all cooling connections carefully and verify that they do not leak.

operation
Initial start-up

possible laser.
equipment
damage
4 Ensure that your PWM controller is set to zero percent output (0.0%).
5 Verify that the laser’s Keyswitch (if equipped) is in the OFF position.
Starting your Series 48 laser

1 If the laser has a Diode Pointer installed, remove its aperture dust cover.
2 Move the Shutter Switch (if equipped) to the Open position.
3 Turn on the DC power supply.

4 Rotate the Keyswitch (if equipped) to the ON position; the PWR LED illuminates. If the Keyswitch
is ON, turn it OFF, then back ON (or cycle the Remote Keyswitch input) to reset the laser.
Note: Each time an OEM laser is powered up or a Keyswitch version is cycled OFF/ON, a five-second
delay occurs between the time that the PWR LED illuminates and the laser is permitted to lase.
5 Verify that the red LASE LED illuminates dimly after approximately five seconds. This indicates
that tickle pulses are being applied to the laser and that it is safe to apply a PWM Command signal.
6 Apply a PWM Command signal (a +5 VDC, 5 kHz square wave of 1 µs to 3 µs duration) to the
laser’s CTRL connector. If operating a 48-5 laser, apply the signal in parallel to both CTRL1 and
CTRL2 connectors.
7 Slowly increase the duty cycle of the signal. The intensity of the laser’s LASE indicator increases in
brightness as the PWM duty cycle increases. The spot where the beam hits the beam block should
also increase in brightness to indicate an increasing power output.
Check your laser’s output power

1 With your PWM signal source set for maximum power output, measure laser output using a laser
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. Refer to General specifications in the “Technical
Reference” section for output power specifications..
2 Reduce the PWM duty cycle to 0.0%. The LASE indicator on the laser dims (tickle signal only).
3 Move the Shutter Switch (if equipped) to the Closed position.
4 Turn off the DC power supply.
If your Series 48 laser fails to lase, refer to Troubleshooting in the “Maintenance/Troubleshooting” section
for troubleshooting information.

operation
This page intentionally left blank.

technical reference
3
Use information in this section as a technical reference for your Series 48 laser.
■ Technical overview – briefly describes Series 48 technology and basic optical setup.
■ Controlling laser power – explains various aspects of Series 48 control signals.
■ DB9 connections – describes signals and specifications for the side-mounted DB9
connector.
■ Integrating Series 48 safety features – describes how to integrate Series 48 safety

features into your automated control system.
■ Series 48 general specifications – provides specifications for Series 48 lasers.
■ Model 48-1 package outline drawing – illustrates laser package and mounting
dimensions for Keyswitch and OEM 48-1 10 watt lasers.

technical reference
Technical overview
The Technical overview section includes subsections:
■ Introduction
■ Plasma section
■ Optical resonator
■ Control circuitry
■ Optical setup
Introduction
Series 48 lasers incorporate the latest technology in sealed carbon dioxide devices, combining the best
features of both waveguide and free space CO2 laser technology. The all-metal laser tube construction
features the ruggedness, stable optical support, and small size of waveguide lasers. Its larger bore (4.8 mm)
eliminates the high optical power density of waveguide lasers with their predisposition to optical degra-
dation and incorporates the mode purity and easy optical alignment of free space TEM00 lasers. Low cost
is achieved by using simple extruded and welded aluminum structures packaged together with compact,
state-of-the-art RF power supplies. The laser is self-contained requiring only the application of power,
cooling air or water, and a control signal. It is therefore ideally suited for overhead installation where the
laser is gantry-mounted since no RF cable runs are required.
48 Series lasers emit a laser beam with a wavelength of 10.6 microns (µm). The beam shape is square at
the laser output aperture, changing to circular at distances of approximately one meter or more from the
laser. The laser beam diverges due to diffraction at a full angle of 4 mrad (milliradians), with the beam
waist at the output aperture of the laser.
The method of RF excitation on which the Series 48 is based provides excellent discharge stability, easily
controlled output power and modulation, and convenient interfacing to automated systems. Coupling
between the RF driver and the laser is based on patented switching and transmission line technology.
The RF drive operates at around 45 MHz and is matched to the resonant frequency of the plasma tube.
Power control of the laser beam is achieved by pulse width modulation (PWM) of the RF drive circuit.
Modulation control can be used to gate the laser on and off at time intervals synchronized with auto-
mated processing equipment. It can also be used to control instantaneous power by adjusting the pulse
width (PWM duty cycle) at a fixed modulation frequency. Both methods can be used simultaneously.
LASER OUTPUT POWER
(ARBITRARY SCALE)
50 100
% DUTY CYCLE
Figure 3-1 Average laser output vs. percent PWM duty cycle

technical reference
Technical overview
As shown in Figure 3-1, the PWM on-time percentage (PWM duty cycle) exerts a non-linear power
function as power saturation is approached, flattening out at approximately 95% duty cycle. We recom-
mend using a 95% maximum PWM signal since little or no increase in laser output power occurs between
95% and 100% PWM duty cycle. It is safe to operate at 100% duty cycle by eliminating all PWM control
and simply applying on/off gating; however, you can expect a 5% increase in power draw and heat load.
Plasma section
The laser consists of an RF-excited plasma tube with an adjustable mirror on each end, mounted together
with the RF drive assembly in a single aluminum chassis. The plasma tube is made of two-inch square
cross-section extruded aluminum tubing with pre-machined ends welded on. The mechanical and
electrical arrangement of the internal electrode structure is shown schematically in Figure 3-2. The RF
drive power is applied between the lower electrode and the plasma tube. The internal resonant circuit
induces RF drive on the upper electrode that is 180 degrees out of phase with that of the lower electrode.
Thus the voltage between the two RF electrodes is roughly twice that on either electrode, causing the
plasma to form only in the 4.8 mm square bore region. The two sidewalls confine the plasma but carry
negligible current. The RF electrodes are anodized to assure uniform distribution of RF power throughout
the excitation volume. Waste heat is conducted away by all four metal sides of the bore to the outer walls
of the plasma tube, where it is transferred to the chassis. In contrast to waveguide lasers that have a
closed bore periphery, Series 48 lasers have four slots (small gaps) extending longitudinally along the
length of the bore (shown in Figure 3-2). These slots provide electrical insulation between the two pairs
of orthogonal electrodes; however, the slots are also effective for diffusion cooling of the laser gas.
RF FEED THROUGH
AND GAS FILL PORT
COIL IN
RF RESONATOR
LASER
PLASMA
ANODIZED
ALUMINUM GROUND
RF ELECTRODES SPACERS
SMALL
GAPS
GAS ALUMINUM
BALLAST HOUSING
Figure 3-2 Cross section of tube
Optical resonator
The optical resonator consists of a three meter radius of curvature total reflector and a flat Zinc Selenide
(ZnSe) output coupler with reflectivities of 95% or 92%. The mirrors are held on with Viton (fluorocar-
bon) elastomeric o-rings for factory adjustment by means of three Torx head 4–40 screws. No epoxy is
used for sealing. The screws are secured by adhesive after alignment.
The 4.8 mm bore, in conjunction with the mirror curvature selected, limits the output beam to TEM00
modes when the mirrors are properly aligned. Small variations in output power (up to 10%) are seen
during warm-up as the cavity mirror spacing changes due to thermal expansion of the plasma tube.

technical reference
Technical overview
The output wavelength remains at or near 10.6 µm (typically 10.57 µm to 10.63 µm). Beam shape is
square at the laser output aperture, changing to circular at distances of approximately one meter or more
from the laser with a near gaussian profile in the far field (0.6 m or more). The internal structure and
optics of the resonator combine to produce a mode quality of TEM00, 95% purity with an M2 factor less
than 1.2. As shown in Figure 3-3, beam waist diameter is 3.5 mm at the output aperture and full angle
divergence due to diffraction is 4 mrad (a 4 mrad full angle divergence means that beam diameter
increases 4 mm over every one meter distance traveled).
BEAM WAIST DIA. ~ 3.5 mm

1.5 cm 37 cm FOR 10W LASER or 1.5 cm
GAP 75 cm FOR 25W LASER GAP
OUTPUT FULL ANGLE

RF DISCHARGE REGION Ø DIVERGENCE ~ 4 mrad
BEAM
3 METER RADIUS ZnSe FLAT

Si TOTAL REFLECTOR OUTPUT COUPLER
Figure 3-3 Beam characteristics
Control circuitry
Electrical description
Control of laser operation and power output levels is essentially performed using a single PCB. The
Control PCB connects the modulated signal to the RF amplifier. It also provides electronics to monitor
performance of RF control, output circuitry, input power, temperature, PWM accuracy, provides outputs
to an externally accessible connector, and incorporates reverse polarity protection.
Functional differences between model types generally relate to the number of RF channels. Model 48-1
lasers use a single RF electrode requiring a single modulated RF drive input from the Control PCB. The
48-2 uses 2 RF electrodes and requires 2 RF channels, while the 48-5 uses 4 electrodes and 4 RF channels
(2 Control PCB’s). For the purpose of this description, a single channel will be described. Model specific
details relating to differences in electrical characteristics are individually discussed.
The modulated input Command signal is generated externally to the laser and connected to the panel-
mounted BNC connector labeled CTRL. This signal is connected to an optoisolator, the output of which
is applied to the PWM switch control circuit. The PWM switch control circuit gates the PWM switch off
and on at the frequency and duty cycle controlled by the modulation source. When the PWM switch
closes, a potential of +30 VDC is applied to the RF Driver. The PWM control circuit provides on/off
gating of the PWM switch unless disabled by the five-second delay, Shutter Switch, or the fault shutdown
circuits.
The five-second delay disables PWM output to the RF amplifier for a period of approximately five
seconds after the panel-mounted Keyswitch and Remote Keyswitch link are closed (power ON). On OEM
models, the five-second delay period begins on DC power up of the laser.
The Shutter Switch allows the operator to temporarily interrupt laser output during active lase modes. A
mechanical lever physically blocks the exit aperture and at the same time actuates independent micro-
switches that electrically interrupt power to the RF module by disabling the PWM input optoisolator,
forcing an “off” state.

technical reference
Technical overview
Fault shutdown conditions

The power input circuit consists of a panel-mounted fuse for overcurrent protection, a dual Schottky
shunt rectifier for reverse-voltage protection, a panel-mounted keyswitch, and a normally open MOSFET
safety switch. Application of reverse-voltage will normally require fuse replacement.
The output of the Keyswitch is connected to the control board through the DB9 Connector user port.
Note that the supplied DB9 jumper plug can be removed to allow the user to insert a remotely located
relay or switch in series with the Keyswitch. If the Keyswitch is left on or is electrically bypassed, the user
can turn the laser on and off, and reset fault shutdowns from a remote location.
The temperature warning message output (pin 5 of the DB9 connector) goes low when the laser tube
temperature reaches 54 °C ±2 °C and remains low until tube temperature falls 2 °C below the trigger
temperature. The warning message output does not shut down the laser. Over temperature fault shut-
down occurs when laser tube temperature reaches 60 °C ±2 °C.
Control board operation begins when the supply voltage rises above +18 VDC and remains below +36
VDC. After start-up, the control board will shut the laser down if supply voltage falls below +15 VDC or
rises above +36 VDC.
If an electronics failure causes the control board to output PWM power to the RF Drivers in excess of
20% of the commanded PWM input, a fault shutdown will occur.
To reset after any fault shutdown, correct the problem(s) then cycle the Keyswitch (or Remote Keyswitch
if one is present) or remove power to the laser for 30 seconds. During any fault shutdown, the fault
shutdown output (pin 1 of the DB9 connector) will latch to low state until a keyswitched reset occurs.
Power-On reset
The Power-On Reset feature will not allow lasing to restart after a power failure or shutdown has oc-
curred until the Keyswitch or Remote Keyswitch is first cycled off (open circuit condition) and then back
on (closed circuit). Power-On Reset is defeated on all OEM versions. OEM customers must provide this
required safety feature elsewhere as part of their equipment integration.
RF Driver IV
RF power is provided by a patented single MOSFET transistor power oscillator operating in a tuned
feedback circuit. The low-impedance MOSFET output is coupled to the relatively high-impedance laser
tube electrode by a ceramic-substrate micro-strip transmission line integral to the RF circuit board.
RF rise time is about 1 µs to deliver a striking voltage of over 500 V peak to the discharge electrodes. A
pulse-stretching network on the control board widens the incoming Command input so that the tickle
pulses delivered from the RF Driver are sufficient to provide a plasma ready state without emission.
The RF drive is not centered on a frequency authorized for significant incidental radiation (ISM bands
around 27 and 40 MHz). The power module must therefore be shielded effectively which is accomplished
by integrating the plasma tube and drive into a single assembly. Refer to Figure 3-4 for the RF Driver IV
circuit schematic.

technical reference
Technical overview
Figure 3-4 RF Driver IV
Cooling requirements
Series 48 electronics are mounted opposite the laser tube in the smaller section of the “H” bay and share
the same cooling removal as the plasma tube. Typical efficiency of CO2 laser plasma tubes operating in a
TEM00 mode is 10% to 12% (radiation out to RF power in). Factor in the conversion efficiency of AC
input to RF output and the overall “wall plug” efficiency of these lasers drops to about 6% to 8%,
resulting in a considerable amount of heat removal, even at 10 W and 25 W output power levels;
therefore, external cooling in the form of forced air- or water-cooling is required.

technical reference
Technical overview
Duo-Lase® operation (48-5)

The 48-5 laser combines two laser tubes for twice the output of a standard laser. The outputs from two
25 W sealed CO2 tubes are combined optically to provide a single diffraction-limited beam at 50 W. This
optical combining technique is based on the fact that each laser is linearly polarized, allowing the use of a
polarization sensitive beam combiner to achieve 98% efficiency in combining the two beams. The two
components of the resulting beam are spatially parallel and collinear, reducing the normal temporal and
spatial variations of a single laser. Output polarization is random and therefore superior for many cutting
applications.
The 48-5 laser uses two control boards and four RF drivers. The control boards are tied together elec-
tronically so that if a failure mode shuts down either board, both laser tubes are turned off. The control
boards are equipped with individual fuses for each RF driver PWM output. In the event of an RF driver
failure, only that fuse will open, allowing other RF drivers in the system to continue operating. Unless
both fuses are open on a given control board, no shutdown will occur, nor is there a fault output signal.
In general, the two Command inputs (CTRL1 and CTRL2) should always be driven identically with a
“Y” or “T” connector. For special applications in redundant or ultra-wide dynamic range systems, it is
permissible to drive only one Command input; however, the beam’s random polarization is compromised.
Optical setup
After selecting a CO2 laser for your processing system, the two most important elements to consider are:
(1) delivery optics to transmit the beam to the work area; and (2) focusing optics to focus the beam onto
the part or material to be processed. Each element is crucial in the development of a reliable laser-based
material processing system and each element should be approached with same careful attention to detail.
Delivery optics
Divergence, or expansion, of the laser beam is important for materials processing since a larger beam
entering the focusing optic produces a smaller focused spot. Because the laser beam diverges slowly,
increasing 4 mm in diameter over every meter, Series 48 lasers should be mounted a distance of 1.0 m to
1.5 m (40" to 60") away from the work area. Right angle turning mirrors are often used in conjunction
with the laser mounting position to obtain this distance. Figure 3-5 shows how right angle turning
mirrors in a “flying optics” setup create this longer beam path.
Figure 3-5 “Flying optics” beam path

technical reference
Technical overview
Expander/collimators are optical devices that reduce beam divergence while at the same time increasing
beam diameter by a selectable magnification factor. Adding an expander/collimator to the “flying optics”
setup shown above would substantially reduce beam divergence and any variance in beam diameter
caused by the changing optical path length. In fixed-length delivery systems where the laser is positioned
only one meter away from the focusing optic and a small spot size is required, an expander/collimator is
again the best solution to provide the required beam expansion before reaching the focusing optic.
Focusing optics
When selecting a focusing optic, the primary consideration should be material thickness and any vertical
tolerances that occur during final part positioning rather than making a selection based only on mini-
mum spot size. The chosen focal length should create the smallest possible focused spot while providing
the depth of field required for the material to be processed.
Caution Small amounts of contaminants on the laser’s output window (or on

any optic in the beam path) can absorb enough energy to damage
possible the optic. Inspect all beam delivery optics periodically for signs of
contaminants and carefully clean as required. In dirty environments,
equipment purge laser optics using filtered air or nitrogen to prevent vapor and
damage debris from accumulating on optical surfaces.
Optics are fragile and must be handled carefully, preferably by the mounting ring only. Cleanliness is
another important issue affecting performance; a dirty or scratched lens will underperform and exhibit a
vastly shortened lifetime. When the application requires air (instead of nitrogen) as a purge gas, use only
breathing quality air available in cylinders from a welding supply company. Compressed shop air contains
minute particles of oil and other contaminants that will damage optical surfaces. If compressed shop air is
the only choice available, it must be filtered and dried to the specifications shown in Table 3-1.
Table 3-1 Gas purity specifications
Purge Gas Specification
Nitrogen High Purity Grade 99.9500% purity or better
Air Breathing Grade 99.9996% purity or better
Air Compressed 99.9950% purity or better, water-free; oil filtered to 5 mg/m3

or better; particulate filtered to < 1.0 micron; dried to lower
dew point below coolant temperature setpoint

technical reference
Controlling laser power
The Controlling laser power section includes subsections:
■ Control signals
■ Operating modes
Control signals
Much of the information provided in this section describes the use of a SYNRAD UC-2000 Universal
Laser Controller to provide PWM Command signals to the Series 48 laser. If using an alternate method
of laser control, thoroughly review this section, Controlling laser power for an understanding of the signal
requirements necessary to control SYNRAD Series 48 lasers. For more information about UC-2000
operation, please consult the UC-2000 Laser Controller Operator’s Manual.
Tickle pulse
All Series 48 lasers require a 1 µs ‘tickle’ pulse delivered at a 5 kHz clock frequency from the Controller.
Tickle pulses pre-ionize the laser gas to just below the lasing threshold so that a further increase in pulse
width adds enough energy to the plasma to cause laser emission. This tickle signal causes the laser to
respond predictably and almost instantaneously to PWM Command signals, even when there is consider-
able delay (laser off time) between applied Command signals. Series 48 lasers contain a precision pulse
stretching circuit that is preset to accept a 1 µs ±20% no-lase, tickle pulse. Lase threshold is factory-
preset for 3 µs ±0.5 µs based on a PWM and tickle frequency Command input of 5 kHz.
Caution Applying PWM Command pulses directly to the laser without first
sending tickle pulses, will cause unpredictable laser emission,
possible degrade optical rise time, and may lead to RF Driver failure.
equipment
damage
The UC-2000 (or FH Series marking head) does not produce tickle pulses continuously, but generates
them only when the PWM Command signal is low. Tickle pulses are sent one tickle period, 200 µs, after
the falling edge of a PWM Command signal pulse. Figure 3-6 illustrates tickle pulse parameters.
200 µs 1 µs
5 VDC
0 VDC
Figure 3-6 Tickle pulse waveform
A 1 µs tickle pulse at frequencies greater than 5 kHz may cause unintended lasing. Special care must be
taken to maintain plasma ionization without lasing at tickle frequencies greater than 5 kHz. If sending
1 µs tickle pulses at 5 kHz, PWM signals can be sent at an independent, higher frequency but must go to
near zero (< 1%) duty cycle to ensure laser turn-off.

technical reference
Pulse width modulation (PWM)

Pulse Width Modulation, or PWM, controls laser power by varying the duty cycle of the laser’s RF
amplifiers, which in turn control the time-averaged RF power applied to the laser. Because laser output
follows PWM input with a rise and fall time constant of ~100 µs, the laser cannot precisely follow
Command signal frequencies over 5 kHz with duty cycles greater than 50%. Typically, the depth of
modulation for a 50% duty cycle is 90 to 100% at 2 kHz and 60 to 80% at 5 kHz. Figure 3-7 shows Series
48 optical waveforms at two different modulation frequencies.
79 Acqs 34 Acqs
Tek step 500kS/s T Tek step 500kS/s T
Ch2 Freq Ch2 Freq

2.008kHz 4.906kHz
Low signal Low signal
amplitude amplitude
Ch2 +Duty Ch2 +Duty

T
49.4% 50%
1
Low signal 1 Low signal
amplitude amplitude
2 2
Ch 1 100mV Ch 2 1V M 100 µS Ch 2 / 740m V Ch 1 100mV Ch 2 2V M 100 µS Ch 2 / 720m V
2 kHz Modulation 5 kHz Modulation
Figure 3-7 Series 48 waveforms
Series 48 lasers are designed to operate at Command signal base frequencies up to 20 kHz; however, the
choice of PWM frequency depends on the user’s specific application. In the majority of laser applications,
the UC-2000’s default Command signal frequency of 5 kHz has proven to work well. When considering
Command frequencies at 5 kHz or below, please review Marking/engraving operation later in this section.
For high-speed motion applications that cannot tolerate any ripple in the optical beam response but still
need adjustable power levels, we recommend the use of higher PWM frequencies, up to 20 kHz maxi-
mum. At 20 kHz, the laser’s optical beam response no longer follows the Command input and is very
nearly a DC value with just a small amount of ripple present.
Command signal
Warning Always use shielded cable when connecting your PWM Command
signal source to the laser’s CTRL connections. In electrically-noisy
serious environments, long lengths of unshielded wire act like an antenna
and may generate enough voltage to trigger uncommanded lasing.
personal
injury
The modulated Command signal applied to Series 48 lasers has three parameters: signal amplitude, base
frequency, and PWM duty cycle. By changing these parameters, you can command the beam to perform a
variety of marking, cutting, welding, or drilling operations.

technical reference
Signal amplitude is either logic low, corresponding to laser beam off, or logic high, corresponding to
beam on, using TTL- or CMOS-compatible voltage levels. The logic low (laser off) voltage, typically 0 V
can range from 0.0 V to +0.5 VDC while the logic high (laser on) voltage, typically 5 V, can range from
+3.5 V to +10 VDC. As a reference, the signal output for a UC-2000 Controller ranges from 0.0 V to
+0.5 VDC (laser off) and from +3.5 V to +5.0 VDC (laser on).
Base frequency is the rate at which the amplitude is switched between its low and high logic states. The
standard base frequency is 5 kHz, which has a period of 200 µs. Maximum PWM frequency is 20 kHz.
The third parameter, PWM duty cycle, is the percentage of the period that the Command signal is high.
If the Command signal’s amplitude (at 5 kHz) is high for 100 µs and low for 100 µs, it has a 50% duty
cycle; if the amplitude is high for 190 µs and low for 10 µs, it has a 95% duty cycle. Figure 3-8 illustrates
Command signal parameters.
200 µs 200 µs
100 µs 190 µs
5 VDC
0 VDC
5kHz Command Signal at 50% Duty Cycle 5kHz Command Signal at 95% Duty Cycle
Figure 3-8 PWM Command signal waveform
Operating modes
Caution Applying PWM Command pulses directly to the laser without first
sending tickle pulses, will cause unpredictable laser emission,
possible degrade optical rise time, and may lead to RF Driver failure.
equipment
damage
External control
In addition to controlling your Series 48 laser using a UC-2000 Controller, controlling the laser exter-
nally, without a UC-2000, is also possible. The two primary elements of laser control are gating, the
ability to turn the laser on and off at the appropriate times, and power, the ability to control the laser’s
output energy. Both gating and power can be handled by a device such as a personal computer, Program-
mable Logic Controller (PLC), or a function generator capable of sending PWM pulses at the proper
time (gating) and with the proper duty cycle (power) using TTL- or CMOS-compatible voltage levels.
The PWM input on Series 48 lasers consists of an optoisolated input LED. The PWM input frequency
can range from DC (0 Hz) to 20 kHz. Maximum current load for 48-1/48-2 lasers is 6 mA @ 5 VDC; for
48-5 dual-tube lasers, maximum current load is 12 mA @ 5 VDC. Table 3-2 shows minimum, maximum,
and nominal voltage levels for On and Off logic states.

technical reference
Table 3-2 PWM Command signal levels
Laser State Vmin Nominal Vmax
Beam Off
(Logic low) 0.0 VDC 0.0 VDC +0.5 VDC
Beam On
(Logic high) +3.5 VDC +5.0 VDC +10 VDC
Analog voltage or analog current control

Although Series 48 lasers cannot be controlled directly by analog voltage or current signals, this type of
control is possible when using the UC-2000 Controller. The Controller is connected normally to the
laser and analog voltage or current signals sent to the UC-2000’s ANV/C connector then control both
gating and power.
To generate the correct analog voltage from a computer or PLC, a Digital-to-Analog (D/A or DAC) card
capable of generating 0 V (laser off) to 10 V (maximum laser power) must be installed. To generate the
proper analog current, install a D/A card that can generate 4 mA (laser off) to 20 mA (maximum power).
Software able to control your analog output card is required for both configurations.
The UC-2000 Controller can also be commanded remotely through the UC-2000’s RS-232 serial port.
User-developed software can send operating mode, lase, setup, and PWM percentage commands as well
as poll the Controller for its current operating status. Refer to the UC-2000 Laser Controller Operator’s
Manual for further information about REMOTE operation.
Continuous wave (CW) operation

In some applications, such as high speed marking or cutting, the time constant of the laser and the PWM
modulation causes a series of dots that may be visible on the marking surface instead of a “clean” line.
Operating the laser in CW mode will prevent this behavior from occurring.
To operate the laser in CW mode, a constant +5 VDC signal is applied to the CTRL input(s) of the laser.
This constant voltage source forces the internal switching electronics to remain on, providing continuous
and uninterrupted laser output power.
Note: When operating in CW mode, laser power output cannot be adjusted. If you require an adjust-
able output power level, refer to the Pulse width modulation (PWM) section for information
regarding high frequency operation.
Gated operation
In many marking and cutting applications, the laser is required to pulse, or gate, on and off in synchroni-
zation with an external control signal (typically from a computer or function generator operating in the
range from DC to 1 kHz). To pulse or gate the laser, connect a signal providing TTL-level pulses to the
Gate connector on the rear panel of the UC-2000.

technical reference
Users who intend to use a gating signal should set the UC-2000’s gate input logic to internal pull-down
(normally off) mode. This prevents the beam from being enabled unless a TTL logic high (+3.5 V to 5.0
VDC) signal is applied to the Gate input connector. In the pull-down (normally off) mode an asserted
logic low state, short circuit to ground, or an open or disconnected Gate input locks the beam off.
Warning The UC-2000’s default factory gate logic is set to internal Pull-Up
(normally on) mode. A TTL high input signal OR an open (discon-
serious nected) gate connector will cause the beam to turn on. To gate the
beam off, apply a logic low input, short circuit the Gate input
personal connector, or reconfigure the Controller to Gate Pull-Down
injury (normally off) operation.
See the UC-2000 Laser Controller Operator’s Manual for further information on setting up the UC-2000
Controller to gate the laser.
Many CO2 lasers operating in applications requiring short gating pulses at repetition rates below 500 Hz
will exhibit some leading edge overshoot regardless of the PWM frequency. This occurs because a cooler
lasing medium (the CO2 gas) is more efficient than a hotter one. This overshoot is more pronounced at
lower gating frequencies since the gas has a longer time to cool down between Command signal pulses.
Marking/engraving operation
When the delay between the end of one PWM Command signal pulse and the beginning of the next
PWM pulse exceeds 200 µs (less than or equal to 5 kHz), the UC-2000 Controller or FH Series marking
head sends a tickle pulse to maintain plasma ionization in the tube. Because the Controller can not
anticipate when the next PWM Command pulse will arrive, the tickle pulse can effectively merge with a
PWM signal that follows closely afterwards. When the PWM pulse that follows is short, causing the
tickle pulse to become a significant fraction of the PWM pulse duration, then the tickle pulse effectively
substantially increases the length of the PWM pulse it has merged with. For subtle marking applications
on sensitive, low threshold materials this lengthened PWM pulse may affect mark quality.
While this situation can occur when using PWM Command signal frequencies of 5 kHz and less, it is
important to note that it isn’t the Command signal frequency itself that is the determining factor but
rather this behavior happens only when the off time between PWM pulses exceeds 200 µs.

technical reference
DB9 connections
Series 48 lasers are equipped with a female DB9 connector mounted to the sidewall of the laser. This
connector provides the user with a convenient method for monitoring fault conditions (over tempera-
ture, control/RF circuitry failure) and adds remote interlock, remote keyswitch (relay or switch), message
output, and remote LED indicator capability. DB9 pin assignments and functions are fully described in
Table 3-4 on the following page.
A factory-installed jumper plug is attached to the DB9 Connector on each laser to enable normal opera-
tion. Two jumpers (see Figure 3-9) are wired to the plug. One jumper between pins 6 and 7 closes the
Remote Keyswitch function, and the other jumper between pins 3 and 4 closes the Remote Interlock. If this
jumper plug is removed, it is essential that pin 3 be jumpered to pin 4 (or pin 2) or be connected to
external “remote interlock” circuitry in order to enable lasing. To take advantage of the DB9 functions
described in Table 3-4, you must manufacture a connecting cable and configure DB9 connections for
proper operation in your integrated system. A spare DB9 male connector and cover is included with each
laser to facilitate easy cable manufacture.
Note: On lasers manufactured as OEM (-S) version lasers, i.e. without a Keyswitch, the Remote Inter-
lock function is bypassed internally. For OEM customers wishing to access the Remote Interlock
feature via the DB9 connector, please consult the factory for details.
REMOTE INTERLOCK
JUMPER
1 2 3 4 5
6 7 8 9
REMOTE
KEYSWITCH JUMPER
Figure 3-9 Factory-installed DB9 jumper plug wiring
Table 3-3 provides “dry circuit” (zero voltage) specifications for the Remote Keyswitch signal, pin 6 and
pin 7 and the Remote Interlock signal on pin 3.
Table 3-3 Remote Keyswitch and Remote Interlock signal specifications
Signal State Specification
ON
(Contact Closed) < 10 Ohms
OFF
(Open Circuit) > 100 kOhms
Contact rating = 50 VDC, < 2 mA minimum (dry circuit)

technical reference
DB9 connections
Table 3-4 DB9 pin assignments
Pin # Signal Name Description / Purpose
1 Fault Shutdown Indicates failure of internal control/RF circuitry or existence of overtemper-

Output ature (> 60 °C ±2 °C), overvoltage, or undervoltage fault. This active low
signal (in reference to pin 2 or pin 4) transitions from +15 V to 0 VDC
when a fault occurs. Provides user with control signal to disable external
systems in the event of a fault. See Note 1.
2 Signal Ground Signal/chassis ground for pins 1, 3, 5, 8, and 9.
3 Remote Interlock Disables laser when opened by a remote door or housing safety interlock. As
Connection shipped, pins 3 and 4 are jumpered to disable the Remote Interlock function.
Allows an open external interlock switch to shut down the laser. Ground
pin 3 only; do not apply voltage to this pin. See Note 2. This feature is
internally bypassed on OEM models.
4 Signal Ground Signal/chassis ground for pins 1, 3, 5, 8, and 9.
5 Message Output Message Output goes low (in reference to pin 2 or pin 4) when laser tube
temperature reaches 54 °C ±2 °C and remains low until temperature falls
2 °C. Provides user with a pre-shutdown temperature warning. Does not
shut down the laser. See Note 1.
6 Remote For connecting a remote relay or switch in series with the laser Keyswitch.
Keyswitch Input Allows user to control laser on/off /reset from a remote location. Connect
pin 6 to pin 7 to run; open this circuit to stop or reset faults. As shipped,
pins 6 and 7 are jumpered to disable the Remote Keyswitch function.
See Note 2 and Note 3.
7 Remote See pin 6 description above. Pin 7 is at DC line potential (+30 VDC) when
Keyswitch the Keyswitch is on or bypassed. Allows user to control laser on/off /reset
Output functions from a remote location. See Note 3 and Note 4.
8 Remote Lase Current and voltage limited output for direct connection to LED or LED-
LED Output input optoisolator. Allows user to connect a remote LASE LED indicator.
See Note 5.
9 Remote Ready Current and voltage limited output for direct connection to LED or LED-
LED Output input optoisolator. Allows user to connect a remote Ready (PWR) LED
indicator. See Note 5.
1 Allen-Bradley (A-B) compatible outputs (pins 1 and 5) are Active Low.

Specifications: OFF: +15 VDC, 5 mA into 3 kOhm. ON: < 1 VDC, sinking 100 mA.
2 “Dry-circuit” (zero voltage) external switches are required since current into remote interlock and debounced
remote keyswitch pins is negligible.
3 Connecting an LED to pins 6 or 7 to indicate keyswitch status requires an external current-limiting resistor.
4 The remote keyswitch output pin is not current-limited or fused.
5 Pins 8 and 9 can be directly connected to the anodes of LEDs or LED-input optoisolators without external
current limiting devices. Connect LED cathodes to pin 2 or 4. Current is limited internally to 20 mA at
3.3 V maximum.

technical reference
Integrating Series 48 safety features
The Integrating Series 48 safety features section includes subsections:
■ Keyswitch functions
■ Remote Interlock functions
The Series 48 DB9 Connector allows system integrators or end-users to integrate Series 48 laser safety
features into their control system. In particular, the Series 48 Remote Keyswitch and Remote Interlock
functions serve to disable DC power to the laser’s RF driver. Without power, the RF driver cannot supply
PWM Command or tickle signals to the resonator, causing the CO2 gas to remain in a zero-energy state.
Keyswitch functions
Keyswitch lasers
After DC power-up, or after a fault or open interlock condition, the Keyswitch must be toggled to reset
the laser, which enables the PWR LED and signals that DC power is applied to the RF driver. For Key-
switch lasers used in automated control systems, this reset function is provided by the Remote Keyswitch
signal via pins 6 and 7 on the DB9 Connector. To use this “remote keyswitch” functionality, first place
the Keyswitch in the ON position. To reset a fault condition, open and then close a “dry-circuit” (zero
voltage) switch or relay contact between pin 6, Remote Keyswitch Input, and pin 7, Remote Keyswitch
Output. Reconnecting pin 6 to pin 7 applies power to the RF driver and begins a five-second delay after
which lasing is enabled. The RF driver is disabled as long as the remote keyswitch connection is open.
Your control system can monitor the laser’s power-on status through the DB9 Connector by connecting
your system’s input between pin 9, Remote Ready LED Output, and pin 2 or pin 4, Signal Ground. The
Remote Ready LED Output goes active when the laser is enabled (PWR LED turns On), indicating that
lasing is possible after the five-second delay. The output is inactive (PWR LED off) when lasing is
disabled. Refer back to Table 3-4, DB9 pin assignments for specific details.
Important Note: Pin 9, the Remote Ready LED Output, is a current- and voltage-limited output
meant only for direct connection to an LED or LED-input optoisolator.
OEM lasers
On OEM lasers, the PWR LED illuminates on DC power-up and five seconds later DC power is applied
to the RF driver. To reset an OEM fault condition, remove DC power for 30 seconds and then reapply
power to the laser or toggle (open, then close) the Remote Keyswitch signal via pins 6 and 7 on the
DB9 Connector. To use this OEM remote reset functionality, open and then close a “dry-circuit” (zero
voltage) switch or relay contact between pin 6, Remote Keyswitch Input, and pin 7, Remote Keyswitch
Output. Reconnecting pin 6 to pin 7 applies power to the RF driver and begins a five-second delay after
which lasing is enabled.
lasing is possible after the five-second delay. The output is inactive (PWR LED off) when lasing is dis-
abled. Refer back to Table 3-4, DB9 pin assignments for specific details.

technical reference
Integrating Series 48 safety features
Remote interlock functions
Keyswitch lasers
Interlock circuits are often used to disable machinery when a shield, panel, or door is opened. The Series
48 remote interlock wires directly into an external, zero-voltage remote interlock circuit to prevent
lasing by removing DC power from the laser’s RF driver boards when the circuit is electrically “open”.
Remote interlock functionality is provided by the Remote Interlock Connection via pin 3 on the DB9
Connector. Lasing is enabled when the Remote Interlock Connection signal is closed and disabled when
the Remote Interlock Connection signal is electrically “open”. DC power is applied to the RF driver
only when the Remote Interlock Connection signal is closed (PWR LED is illuminated). When the
Remote Interlock Connection is opened and then closed, you must toggle the Keyswitch or Remote
Keyswitch Input to reset the laser.
To use the Series 48 remote interlock feature, connect pin 3, Remote Interlock Connection, through
your “dry-circuit” (zero-voltage) interlock circuit and then ground the circuit to pin 2 or pin 4, Signal
Ground.
Caution Do not apply a voltage to pin 3, Remote Interlock Connection on

the DB9 Connector, the laser will be damaged. This input is a "dry-
possible circuit" (zero voltage) input and must be grounded to either pin 2 or
pin 4 to complete the interlock circuit.
equipment
damage
Lasing is enabled when pin 3 is grounded (when the external interlock circuit is closed). If the external
interlock circuit opens, then pin 3 opens and lasing is disabled. To enable lasing again, you must close
the interlock circuit and toggle the Keyswitch or Remote Keyswitch Input. This resets the laser and
begins a five-second delay after which lasing is enabled.
lasing is possible after the five-second delay. The output is inactive (PWR LED off) when lasing is
disabled. Refer back to Table 3-4, DB9 pin assignments for specific details.
OEM lasers
The remote interlock function is internally bypassed on OEM lasers; to enable this feature, please consult
the factory for details.

technical reference
Series 48 general specifications
Table 3-5 Series 48 general specifications
Parameter Model 48-1 Model 48-2 Model 48-5
Output Specifications
Wavelength (microns) .......................... 10.57–10.63 10.57–10.63 10.57–10.63
Power Output1, 2 ................................... 10 W 25 W 50 W
3
Power Stability ..................................... ±10% ±5% ±5%
Mode Quality (at 1/e2) .......................... TEM00, 95% purity TEM00, 95% purity TEM00, 95% purity
M2 < 1.2 M2 < 1.2 M2 < 1.2
Beam Waist Size .................................... 3.5 mm 3.5 mm 3.5 mm
Beam Divergence .................................. 4 mrad 4 mrad 4 mrad
Ellipticity ............................................... < 1.2 < 1.2 < 1.2
Polarization ............................................ Linear, vertical Linear, vertical Random
Extinction ratio ..................................... 50:1 minimum 50:1 minimum N/A
Rise Time .............................................. < 150 µs < 150 µs < 150 µs
Modulation (Optical response) ............ up to 20 kHz up to 20 kHz up to 20 kHz
Input Specifications
Power Supply
Voltage ........................................... 30 VDC 30 VDC 30 VDC
Maximum Current ......................... 7A 14 A 28 A
Command Input Signal
Voltage ........................................... +3.5 V to +10.0 VDC
Current ........................................... 6 mA @ +5.0 VDC
Frequency4 ...................................... DC–20 kHz
Duty Cycle ..................................... 0%–100%
Logic Low State (Vmin–Vmax) .... 0.0 V to +0.5 VDC
Logic High State (Vmin–Vmax) ... +3.5 V to +10.0 VDC
Cooling Specifications5, 6
Model 48-1 (Air-cooled) (Water-cooled)
Maximum Heat Load, laser .......................... 300 W ............................................. 300 W
Minimum Flow Rate .................................... 250 CFM × 2 fans .......................... 0.5 GPM, < 60 PSI
Coolant Temperature .................................. < 40 °C, ambient ............................ 18 °C to 22 °C
Model 48-2 (Air-cooled) (Water-cooled)

Maximum Heat Load, laser .......................... 500 W ............................................. 500 W
Minimum Flow Rate .................................... 250 CFM × 4 fans .......................... 0.8 GPM, < 60 PSI
Coolant Temperature .................................. < 40 °C, ambient ............................ 18 °C to 22 °C

technical reference
Series 48 general specifications
Parameter
Cooling Specifications (cont.)5, 6

Model 48-5 (Water-cooled)
Maximum Heat Load, laser .......................... 800 W
Minimum Flow Rate .................................... 1.5 GPM, < 60 PSI
Coolant Temperature .................................. 18 °C to 22 °C
Physical Specifications
48-1
Length ................................................... 16.9 in (42.9 cm)
(incl. cooling tubes) .............................. 18.1 in (46.0 cm)
Width .................................................... 2.8 in (7.1 cm)
Height ................................................... 4.2 in (10.7 cm)
Weight ................................................... 9.0 lbs (4.1 kg)
48-2
Length ................................................... 31.9 in (81.0 cm)
Width .................................................... 2.8 in (7.1 cm)
Height ................................................... 4.2 in (10.7 cm)
Weight ................................................... 18.0 lbs (8.2 kg)
48-5
Length ................................................... 34.9 in (88.6 cm)
Width .................................................... 5.3 in (13.5 cm)
Height ................................................... 4.5 in (11.4 cm)
Weight ................................................... 44.0 lbs (20.0 kg)
* Specifications subject to change without notice.

1 This power level is guaranteed for 12 months regardless of operating hours.
2 Minimum 30 VDC input voltage to obtain guaranteed output power.
3 From cold start (guaranteed).
4 FCC and CE tested at 5 kHz.
5 Lasers with output power > 50 W must be water-cooled. Lasers with output < 50 W can be either water- or air-cooled
depending on their duty cycle. For duty cycles > 50%, water-cooling is strongly recommended. Note that water-cooling
improves power stability at any duty cycle.
6 Inlet cooling water temperature should always be maintained above the dew point to avoid condensation and water damage
to the laser.

REV ECO DATE DESCRIPTION DB
F 606 19-Feb-96 ADDED .8 BEAM EXIT DIM
320
18.13 2.80
2.40
SHUTTER 2X .64
.800 UC-2000 POWER

1.600 BEAM EXIT
KEY
PWR LASE
4.15
3.40
2.76
1.500 CTRL
.30
DC POWER CORDS
6X 8-32
OPTIONAL ACCESSORIES FUSE
1.125 2 MOUNTING HOLES
DB9 INPUT .59
REAR VIEW
OPTIONAL ACCESSORIES
POWER OUTPUT 16.85 1.08
FRONT VIEW
SIDE VIEW
.93 5X 3.00 4X REMOVEABLE FEET
BEAM EXIT ON 2.40
12X 6-32 x .30 SCREW DEPTH (WITH COVER)

COVER SCREWS
3
BOTTOM VIEW
NOTES:
1. DO NOT USE COVER SCREW HOLES TO SUPPORT LASER WEIGHT.
Pro/E
2 DO NOT USE OPTIONAL ACCESSORIES MOUNTING HOLES TO MOUNT LASER. TOLERANCES UNLESS NOTED:
PROPRIETARY
SYNRAD INC.
3 LASER IS MOUNTED BY REMOVING COVER SCREWS AND REPLACING WITH APPROPRIATE LENGTH .x = ±0.1 ANGLE = ±1.0˚ THIS DRAWING IS PROPRIETARY TO
SCREWS FOR YOUR MOUNTING APPLICATION. USE A MINIMUM OF FOUR SCREWS IN A SYMMETRICAL SYNRAD INC. AND SHALL NOT BE 4600 Campus Place
PATTERN TO PROPERLY DISTRIBUTE MOUNTING FORCES. DO NOT REMOVE COVER. .xx = ±0.01 USED OR DISCLOSED IN WHOLE Mukilteo, WA 98275
.xxx = ±0.005 OR IN PART WITHOUT WRITTEN Phone: (425)349-3500
4. WEIGHT: 9 LBS PERMISSION OF SYNRAD INC.
MATERIAL: Fax: (425)349-3667
. DESCRIPTION:
.
OUTLINE AND MOUNTING, 48-1
Figure 3-10 Model 48-1 package outline and mounting dimensions

FINISH: PART NUMBER: 48-1 DWG/FILE NUMBER: 16048
. SHEET 1 OF 1 DB: DRAWN BY: DATE: 19-Feb-96
. UNITS: INCHES CATEGORY: CHECKED BY: DATE:
. SIZE: B FINISH CLASS: APPROVED BY: DATE:
Model 48-1 package outline drawing
technical reference

D 606 16-Feb-96 ADDED .8 BEAM EXIT DIM
2.80
33.13 2.40
SHUTTER 2X .64
.800 KEY
1.600 BEAM EXIT
PWR LASE
CONTROL 3.40
2.76 4.15
1.500
.30
DC POWER CORDS
1.125 6X 8-32 FUSE
OPTIONAL ACCESSORIES DB9 INPUT .59
2 MOUNTING HOLES UC-2000 POWER REAR VIEW
31.85 1.08
OPTIONAL ACCESSORIES
POWER OUPUT
SIDE VIEW
FRONT VIEW

.93 11X 3.00
4X REMOVEABLE FEET
2.40 BEAM EXIT

ON
22X 6-32 X .30 SCREW DEPTH (WITH COVER)

COVER HOLES BOTTOM VIEW
3
NOTES:
Pro/E
1. DO NOT USE COVER SCREW HOLES TO SUPPORT LASER WEIGHT.
TOLERANCES UNLESS NOTED:
PROPRIETARY
2 DO NOT USE OPTIONAL ACCESSORIES MOUNTING HOLES TO MOUNT LASER. SYNRAD INC.
.x = ±0.1 ANGLE = ±1.0˚ THIS DRAWING IS PROPRIETARY TO
SYNRAD INC. AND SHALL NOT BE 6500 Harbour Heights Pkwy
3 LASER IS MOUNTED BY REMOVING COVER SCREWS AND REPLACING WITH APPROPRIATE LENGTH .xx = ±0.01 USED OR DISCLOSED IN WHOLE Mukilteo, WA 98275
SCREWS FOR YOUR MOUNTING APPLICATION. USE A MINIMUM OF FOUR SCREWS IN A SYMMETRICAL OR IN PART WITHOUT WRITTEN
PATTERN TO PROPERLY DISTRIBUTE MOUNTING FORCES. DO NOT REMOVE COVER.
.xxx = ±0.005 Phone: (425)349-3500
MATERIAL: PERMISSION OF SYNRAD INC.
Fax: (425)485-4882
4. WEIGHT: 18 LBS DESCRIPTION:
.
.

. SHEET 1 OF 1 DB: DRAWN BY: DATE:
technical reference
321
D 606 2-26-96 REDIMED ENDPLATES, ADDED NOTE 2, AND REMOVED LABELS.
322
CL
1.47 TOP VIEW

1.125
SHUTTER
8-32 5.60
6 PLACES
1 .800
®
AVOID EXPOSURE Duo•Lase
SYNRAD SYNRAD CARBON DIOXIDE LASER
1.600 ®
Duo•Lase
KEY SWITCH POWER LASE POWER LASE
IS EMITTED FROM THIS STATUS
APERTURE 4.45
ON
4.08
5 SEC DELAY
1.500 2.85 FUSE 1 FUSE 2

CTRL 1 CTRL 2
CTRL1
.000
BEAM SIDE VIEW

CTRL2
EXIT
FUSE 1 REAR VIEW
.000
FRONT VIEW
32.505
33.417
34.364
FUSE 2
10-32 MOUNTING SCREWS 9 PLACES.

DO NOT ALLOW SCREW TO PENETRATE
MORE THAN 1/8" INTO INTERIOR OF
LASER.
3X 4.225
CL
BEAM 1.33
3X 1.375
.000
.000
2.115
32.715
34.850
11.215
2X 2.715
2X 27.215
2X 18.925
BOTTOM VIEW Pro/E
TOLERANCES UNLESS NOTED:
PROPRIETARY
SYNRAD INC.
.x = ±0.1 ANGLE = ±1.0˚ THIS DRAWING IS PROPRIETARY TO
SYNRAD INC. AND SHALL NOT BE 6500 Harbour Heights Pkwy
NOTES: .xx = ±0.01 USED OR DISCLOSED IN WHOLE Mukilteo, WA 98275
.xxx = ±0.005 OR IN PART WITHOUT WRITTEN Phone: (425)349-3500
1 DO NOT USE OPTIONAL ACCESSORIES MOUNTING HOLES TO MOUNT LASER.
MATERIAL: PERMISSION OF SYNRAD INC.
Fax: (425)485-4882
. DESCRIPTION:
.

. SHEET 1 OF 1 DB: DRAWN BY: DATE:
technical reference

maintenance/
troubleshooting
Series 48 laser.

4
Use information in this section to perform maintenance or troubleshoot your SYNRAD
■ Maintenance – describes typical Series 48 maintenance procedures.
■ Troubleshooting – explains how to troubleshoot common Series 48 problems.

maintenance/
troubleshooting
Maintenance
The Maintenance section includes subsections:
■ Disabling the laser

■ Daily inspections
■ Storage/shipping
Disabling the laser

Before performing any maintenance on your SYNRAD Series 48 laser, be sure to completely disable the
laser by disconnecting the laser from its DC power source.
Daily inspections
Perform the following steps daily to keep your Series 48 laser in optimum operating condition. Except for
the procedures described below, no other service is required or should be attempted.
Caution If you operate your laser or marking head in a dirty or dusty environ-
ment, contact SYNRAD about the risks of doing so and the precau-
possible tions you can take to increase the longevity of your laser, marking
head, and associated optical components.
equipment
damage
1 For water-cooled lasers, inspect all cooling tubing connections for signs of leakage.
2 Check for signs of condensation that may indicate the cooling water temperature has been set
below the dew point temperature. Condensation will damage electrical and optical components
inside the laser. See Setting coolant temperature in the “Getting Started” section for information on
preventing condensation.
3 Inspect beam delivery components for signs of dust or debris and clean as required. When cleaning
optical surfaces, carefully follow the manufacturer’s instructions.
4 Visually inspect the laser’s exterior housing to ensure that all warning labels are present. Refer to
Model 48-1, 48-2, or 48-5 hazard label drawings in the “Laser Safety” section for label types and
locations.
Storage/shipping
When preparing your water-cooled Series 48 laser for storage or shipping, remember to drain cooling
water from the laser. In cold climates any water left in the cooling system may freeze, which could
damage internal components. After draining thoroughly, use compressed shop air at no more than 29 PSI
(while wearing safety glasses!) to remove any residual water. When finished, cap all cooling connectors
to prevent debris from entering the cooling system.

maintenance/
troubleshooting
Troubleshooting
The Troubleshooting section includes subsections:
■ Introduction
■ J48 interconnect schematic
■ J48 control board schematic
■ Resetting faults
■ Laser faults
■ Beam delivery optics
Introduction
This section is designed to help isolate problems to the module level only. Problems on circuit boards or
the laser tube are not within the scope of this guide because they are not user-serviceable assemblies; do
not attempt to repair them. Contact SYNRAD or a SYNRAD Authorized Distributor for repair or
replacement information.
To quickly troubleshoot the Series 48 laser, it is necessary to understand the sequence of events that
must happen before the laser can turn on and operate. Before you attempt to perform any service,
we advise you to read the entire troubleshooting guide and review the relevant schematic diagrams.
Symptoms and possible causes are highlighted by dark print and bullet points throughout this section.
Information about each symptom and cause can be found in the paragraphs following each heading.
CO2 wavelength. Direct or diffuse laser radiation can inflict severe
serious corneal injuries and can seriously burn human or animal tissue.
Service personnel troubleshooting Series 48 lasers should be thor-
personal oughly trained in laser safety practices and electronic service
injury techniques before attempting repairs.
Caution Attempting repair of a SYNRAD Series 48 laser without the express

authorization of SYNRAD, Inc. will void the product warranty. If
possible troubleshooting or service assistance is required, please contact the
SYNRAD Service Department.
equipment
damage

REAR CHAMBER CONTROL CHAMBER RF CHAMBER FRONT CHAMBER
1 2 # 18 RED 1 2 # 18 RED
44
# 18 YEL 1 2 # 18 YEL RED
F2 2 RF DRIVER IV
# 22 BLK RF 2'
AGC 20 # 18 RED 1 2 # 18 RED # 22 WHT J8 810-16798-00
# 18 ORG 1 2 # 22 WHT WHT
1
STANDARD AND # 22 WHT

1 TUBE # 2
NOTE B
OEM VERSIONS SLAVE BOARD 6 5 4 3 2 1 J7
J4' 1 2 # 18 ORG WHT
2 RF DRIVER IV
P4 POWER RF 1'
810-16798-00
RED
# 22 RED 1 2 # 22 GRY
48J CONTROL BOARD
SCH # 810-17542-00 MTG 4X
# 2-56 SHUTTER
# 22 GRN 1 2 SWITCH
1 1
1 2 # 22 GRY 1 2
LED 2' LED 1' P3 FRNT P2 LINK P1 REAR
RED GREEN J3' J2' J1'
LASE POWER # 22 GRY
5 4 3 2 1 5 4 3 2 1 10 9 8 7 6 5 4 3 2 1
2 2 TH1'
1 2 # 30 WHT PAIR 1 2
BNC 1'
COMMAND
INPUT 2 # 22 GRY 1 2 # 22 RED THERMISTOR SWITCHES CLOSED
# 22 GRN 1 2 WHEN SHUTTER IS
1 # 22 GRY CLOSED (OFF)
# 22 ORG 1 2 # 22 ORG
-5 DUO-LASE VERSION ONLY
-5 DUO-LASE VERSION ONLY
# 22 GRY ALL VERSIONS
ALL VERSIONS 1 2 1 2 # 22 GRY 1 # 22 GRY
# 22 RED # 22 WHT 2
# 22 WHT
SHUTTER
# 22 GRN 1 2 SWITCH
# 22 BRN 5X
LED 1 TH1
GREEN 3.3 V 1 D1 - 1N5226B
1 POWER 1 2 # 22 GRY 1 2 # 30 WHT PAIR 1 2
LED 2
RED 3.3 V 1 D2 - 1N5226B # 22 RED # 22 WHT THERMISTOR # 22 GRY
LASE 2 2 2 # 22 GRN # 22 WHT 1 2
# 22 BLU
# 22 YEL # 22 VIO 1 2 # 22 VIO 1 2 # 22 VIO
BNC 1 2 # 22 GRY 1 2 # 22 GRY

COMMAND # 22 BLK
Troubleshooting
INPUT # 22 ORG -2, -5 VERSIONS ONLY

1 # 22 YEL
ACCY 30 V # 22 ORG 1 2 # 22 GRY 1 2 # 18 YEL RED
2 RF DRIVER IV DIODE
POWER # 22 WHT 810-16798-00 RF 2 POINTER
2 # 22 BRN J6
5V POWER
1 # 22 YEL 1 2 # 22 VIO 1 2 # 22 WHT WHT
1 NOTE B
# 22 WHT
# 22 BRN 1 TUBE # 1
KEYSWITCH J5 E
1 2 1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 1 2 3 4 5
1 2 WHT
1 1 J1 J2 J3 2 RF DRIVER IV US
2 2 # 18 ORG 810-16798-00 RF 1
# 22 RED X2 E
1 2 P1 REAR P2 LINK P3 FRNT RED
OEM JUMPER 1 NC
2 48J CONTROL BOARD
# 22 RED 1 2 SCH # 810-17542-00
E
MTG 4X ALL VERSIONS
# 2-56
# 22 BLK 1 2 F ER LY
# 22 BLK NOTES:
P4 POWER RE
J4
MASTER BOARD
A. DB9 WIRE DETAILS
ON
Figure 4-1 Model J48 Series interconnect schematic

NOTE A
1 2 3 4 5 6
R
1 2 3 4 5 1 - # 22 WHT
DB9 6 7 8 9 2 - # 22 BLK FO
USER 3 - # 22 GRY
RED BLK PORT 4 - # 22 BLK
SYNRAD, Inc.
# 18 YEL 5 - # 22 VIO 6500 Harbour Heights Parkway
1 2 2 6 - # 22 BRN
# 18 RED # 18 RED 1 # 18 RED # 18 BLK 7 - # 22 BRN
Mukilteo, WA 98275
# 22 WHT 8 - # 22 YEL 425-349-3500
F1 - AGC 20 # 18 ORG 9 - # 22 BLU
(AGC 10 FOR -1) # 18 RED 1 2 # 18 RED TITLE
+ - B. FASTENED TO THE
DC INPUT BRASS FEEDTHROUGH
SCHEMATIC, MODEL 48J SERIES LASERS
BARRIER PLATE SIZE DOCUMENT NUMBER REV
NOTE B
Figure 4-1 shows Series 48 interconnections for all Model J48 Series lasers.
B 810-17609-00 R1
DATE: August 20, 1998 SHEET 1 of 1
J48 interconnect schematic
maintenance/
troubleshooting

REV: ECO: DATE: DESCRIPTION: D.B.
B 1465 8/2/99 ADDED PART NUMBERS TO TABLE DWJ
REVERSE SHUNT D1 5.4V REGULATOR POWER SWITCH PWM SWITCH

1
Q3 Q5
2
IRF4905 D10 IRF4905
3 F1
U1 C3 C4 SUP65P06-20 MMSZ5242B C6 SUP65P06-20 DC POWER I/O
+ 7A
HS 560/50 .1/50 TO220Q SOD123 560/50 TO220Q
5.4V SMFOMNI
PG PG 3 R5 LCAP13MM 1206 3 2 12VH2 LCAP13MM 3 2 1
VIN D4
3
MBR256OCT
6
2 22.6K 2
TO220Q OUT MMSZ5242B
1 0805 3
ADJ SOD123 HS HS
2
PG PG R7 R9 R10 + 4
HS 12VH2
R4 + C1 11.3K 1 11.3K 1.69K 1 5
D2 F2
3 LD4 82.5 4.7/16 POWANA 0805 0805 0805 6
1
4
BAW56 LM317HVT 7A
YEL 0805 3528 C5 + 4 3
SOT23 TO220Q SMFOMNI
1206 4.7/16 + PG P4
A1
1 2 R6 C2 2 3528 POWER
2.49K .1/25 -
R3 GND 5.4V 3 MLX6
274 0805 0805 1 1 2
R2 3 3
R13
R1 GND 1206 Q2 D5 D9 R37 D6
2.2K INTERLK U5 2.2K
2.2K BCX55 BAV70 BAW56 10 SS26
2512 LD3 LD2 LD1 MIC4416BM4 2512
2512 SOT89 SOT23 SOT23 0805 SMB POWLED
YEL YEL YEL 1 2 SOT143
BE/BG/BM A4 A1
D8 GND 1206 1206 1206 1 2 D10
5.4V LASLED
MMSZ5245B 8 7 6 5 R8
C7 R12
SOD123 475
S1 .0022/100 2.2K
15VH5 0805 3
D3 SETUP Q4 1206 2512
DIP8 R34 BCX55 PG X7R
MMSZ5245B R11
R35 R23 R24 R25 SOT89 R14
SOD123 1 2 3 4 U4D GND 619
R36 619 619 619 BE/BG/BM 22.6K
15VH5 Q1 R20 74HC14 /PWMEN 0805 1 2
2.49K 0805 0805 0805 0805
POWRON
GND GND NDC7002N 619 0805
SSOT6 0805 9 8 PWMANA 6 5 4 3
NOTE 8
02N R21 R16
C8
619 CMDANA 22.6K U4C U4B
.1/50
6 5 4 R38 0805 11 10 74HC14 74HC14 R15
C9 R17 1206 0805
PS1 GND 22.6K R22 U4E 22.6K 11.3K GND PG
.1/50 X7R
500mA 0805 619 74HC14 0805 MT2 MT4
1206 0805
0805 13 12 Y1
RXE 2 X7R
1 3 4.00MHz
U4F
5.4V SIP3 GND GND MT1 MT3
R18 74HC14
5.4V GND
PS2 11.3K 3 MOUNTING HOLES
170mA 0805 MESSAG U6
V NOTES:
RXE MAX809L-EUR 1 2 3
SOT23 COMMAND 1. RESISTORS GIVEN TO TWO PLACES ARE 5%; THREE PLACES 1%.
R19 /R G

2 1
AAIS
11.3K 2. RESISTOR POWER RATINGS: 0805=.100W, 1206=.125W, 2512=1W.
GND 0805
P3 SHUTDN GND 3. CAPACITORS ARE GIVEN IN µF/WVDC UNLESS NOTED OTHERWISE.
GND µC
5 4. 1206-SIZE CERAMICS: .1/50 & .0022/100 = XR7 10% TOLERANCE.
FRONT 4 TMPANA 1 18
5. 0805-SIZE CERAMICS: .1/25 = Z5U, M5U OR Y5U 20% TOLERANCE.
3 AIN2 AIN1 SE
2 AIN3 AIN0 17 470pF=COG/NP0 TEMPERATURE STABLE TYPES, 50V, 5% TOLERANCE.
WALL 2 U
C17 3 RA4/T0CKI OSC1/CLKIN 16
1 6. ELECTRO-CAPS = 7000HR, 105C, LOW Z, HI RIPPLE PANASONIC TYPE FA
.1/25 4 /MCLR OSC2/CLKOUT 15 5.4V
MLX5L R26 C10 0805 5 VSS VDD 14 CE OR EQUIV.
22.6K .1/25 6 RB0/INT RB7 13 N 7. JEDEC CODES ARE GIVEN FOR PARTS TOO SMALL TO BEAR FULL P/N.
GND 0805 0805 R39 7 RB1 U3 RB6 12
1.69K 8 RB2 PIC16C711 RB5 11 RE 8. SIGNAL AND POWER GROUNDS CONNECT AT ONE POINT ONLY ON PCB.
GND 9 RB3 DIP18 RB4 10 C16
0805 E 9. D1, Q3, Q5, AND U1 ARE MOUNTED ON A HEATSINK USING SILPADS.
Figure 4-2 J Series control board schematic

P2 .1/25 F
5 0805 LY
GND C11 GND MACHINE-PIN SOCKETED
4
OTHER 3 .1/25
RE ON PART NUMBER DESCRIPTION
BOARD IBLINK 0805 GND R
2
1 80-017542-02 WITH REMOTE INTERLOCK
R27 R28 FO
MLX5L 11.3K 80-017542-03 CHANGED CAPS: C2, C10,
22.6K GND 5.4V
KYSWON 0805 0805 R31 PULSE STRETCHER C11, C13, C14, C16-C18
82.5
ORCAD CAPTURE
/SHTCL 0805 C18
3
GND CW .1/25 PROPRIETARY
P1 0805 GND THIS DRAWING IS Synrad, Incorporated
R33
R30 C13 2 PROPRIETARY TO SYNRAD
10 5K1T 6500 Harbour Heights Pkwy
82.5 .1/25 INC. AND SHALL NOT BE
9 STA4 14 USED OR DISCLOSED IN Mukilteo, WA 98275
0805 1 8 0805 C14
8 1 WHOLE OR IN PART WITHOUT
3 D7 2 7 .1/25 1 2 PHONE: (425) 349-3500
7 C12 WRITTEN PERMISSION OF
R29 BAV70 3 6 0805 FAX: (425) 485-4882
6 470pF U4A SYNRAD, INC.
REAR 5
619
NP0
SOT23 4 5 7
74HC14 DESCRIPTION:
SYNRAD
1 2
Figure 4-2 schematically illustrates the layout of J Series control boards.
0805 A4 R32
WALL 4 0805 SO14NB SCHEMATIC, J48 CONTROL PCB ASSY W/ REMOTE INTRLK
U2 475
3 C15 CATEGORY: PART No: DRAWING FILE No:
HCPL-061N 0805
2 2200pF SEE TABLE 810-17542-02
SO8NB GND
1 INPUT OPTO-ISOLATOR 0805 GND SHEET: DRAWN BY: DATE:
61N NP0 1 OF 1 B. Morrison 11/17/98
MLX10L INTERLK UNITS: CHECKED BY: DATE:
POWLED
LASLED SIZE: APPROVED BY: DATE:
B
J48 control board schematic
45
Troubleshooting
troubleshooting
maintenance/
maintenance/
troubleshooting
Troubleshooting
Resetting faults
Keyswitch lasers
On Keyswitch lasers, the PWR indicator illuminates green only when the Remote Interlock input is closed
and the Keyswitch is cycled from OFF to the ON position (or the Remote Keyswitch input is opened and
then closed). After the PWR indicator illuminates, a five-second delay occurs before the laser is permit-
ted to lase. The LASE LED illuminates dimly when tickle pulses are applied to the laser and when PWM
Command pulses are applied (and are long enough to produce laser output) the LASE LED illuminates
and appears to brighten in relation to an increasing PWM duty cycle.
To reset a remote interlock fault after the fault condition has been cleared, the Keyswitch must be cycled
from OFF to ON (or with the Keyswitch ON, cycle the Remote Keyswitch input open and then closed).
When the PWR indicator illuminates, lasing is enabled after the five-second delay.
To reset an over temperature fault, lower coolant temperature below 22 °C (water-cooled) or below
40 °C (air-cooled). When the laser cools sufficiently, remove DC power for 30 seconds and then reapply
power to the laser or cycle the Keyswitch from OFF to ON (or with the Keyswitch ON, cycle the Remote
Keyswitch input open and then closed). When the PWR indicator illuminates, lasing is enabled after the
five-second delay.
A closed shutter is not considered a fault condition; when the shutter is opened, lasing is enabled after a
five-second delay provided that the PWR indicator is illuminated green.
OEM lasers
On OEM lasers, the PWR lamp illuminates on DC power-up. After the PWR indicator illuminates, a
five-second delay occurs before the laser is permitted to lase. The LASE LED illuminates dimly when
tickle pulses are applied to the laser and when PWM Command pulses are applied (and are long enough
to produce laser output) the LASE LED illuminates and appears to brighten in relation to an increasing
PWM duty cycle.
To reset an over temperature fault, the coolant temperature must be lowered below 22 °C (water-cooled)
or below 40 °C (air-cooled). When the laser cools sufficiently, remove DC power for 30 seconds and
then reapply power to the laser or toggle (open, then close) the Remote Keyswitch signal via pin 6 and
pin 7 on the DB9 Connector. When the PWR indicator illuminates, lasing is enabled after the five-second
delay.

maintenance/
troubleshooting
Troubleshooting
Laser faults
Each Symptom listed below describes a particular fault condition. For each Symptom, specific causes and
solutions are described in the Possible Causes section.
Symptom:
■ There is no output laser beam; PWR and LASE indicators are off.
Possible Causes:
■ No DC voltage is applied or the voltage level is out of specification.
Check that +30 VDC is available on the power supply output terminals and ensure that DC Power cable
terminal connections are tight.
Check the fuse(s) on the rear of the laser. Replace with fast-blow 10 Amp (48-1) or 20 Amp (48-2/48-5)
AGC/3AG fuses as required.
If your DC-2 or DC-5 power supply is operating at an input voltage of 120 VAC, ensure that a jumper
wire is connected between pins 1 and 2 on the input terminal strip. Refer to Connecting in the “Getting
Started” section for details.
Possible Causes:
■ The laser’s DB9 Connector is not configured correctly.
Ensure that the factory-wired DB9 jumper plug is firmly plugged into the laser’s DB9 Connector.
If the laser is connected through the DB9 Connector to external circuits, check that field wiring is
correct. The remote interlock connection (pin 3) must be grounded through your external interlock
circuit to pin 2 or pin 4. Pin 6 must be connected to pin 7 through your external keyswitch circuitry.
Refer to Connecting in the “Getting Started” section and DB9 connections in the “Technical Reference”
section for details. A quick method to isolate the problem to either the laser or the field wiring is to
disconnect field wiring and plug in the factory-wired jumper plug; if the lasers operates normally with the
jumper plug installed, verify external wiring and circuit devices.
Possible Causes:
■ The laser’s Keyswitch or aperture shutter are not set properly.
Cycle the Keyswitch to the OFF position for a few seconds, then cycle back to ON.
Close and then re-open the Shutter Switch.

maintenance/
troubleshooting
Troubleshooting
Possible Causes:
■ The laser is in an over temperature condition.
Allow the laser to cool. Water-cooled lasers–check for proper coolant temperature and flow rate. Air-
cooled lasers–verify fan operation and check for at least 2.25" of unobstructed clearance around the fan
housing. To restart the laser, disconnect DC power, wait 30 seconds, and then reapply DC power.
Symptom:
■ No output beam, but the PWR LED is On. The LASE indicator is dim and does not brighten.
Possible Causes:
■ A PWM Command input signal is not present.
Verify that a PWM Command signal is present on the CTRL input. On 48-5 dual-tube lasers, a Com-
mand signal must be applied to both CTRL1 and CTRL2 inputs simultaneously. See Controlling laser
power in the “Technical Reference” section for PWM Command signal details.
Symptom:
■ Laser output power is low.
Possible Causes:
■ Electrical inputs are not in specification.
Check that the laser’s DC supply voltage measures +30 VDC under full load.
Symptom:
■ The laser spot is not circular or does not stay circular during operation.
Possible Causes:
■ The laser is overheating.
Verify that the laser is receiving the proper air or water flow per Table 4-1 below.
Table 4-1 Series 48 cooling specifications
Model Air-cooled Water-cooled
48-1 250 CFM × 2 fans (1 per side) 0.5 GPM, < 60 PSI
48-2 250 CFM × 4 fans (2 per side) 0.8 GPM, < 60 PSI
48-5 N/A 1.5 GPM, < 60 PSI

maintenance/
troubleshooting
Troubleshooting
Symptom:
■ Laser power varies or responds intermittently to input PWM Command pulses.
Possible Causes:
■ Verify that your UC-2000 or equivalent PWM controller is delivering tickle pulses of the proper
duration. See Controlling laser power in the “Technical Reference” section for tickle pulse details.
Beam delivery optics
Symptom:
■ The laser appears to slowly lose power over time; laser output power must be increased to maintain
previous performance.
Possible Causes:
■ Beam delivery optics are coated by vapor residue or debris.
Shut down the laser and carefully inspect each optic in the beam delivery path, including the laser’s
output coupler. Remember that optics are fragile and must be handled carefully; preferably by the
mounting ring only. If the optic requires cleaning, then refer to the optic manufacturer’s instructions for
cleaning. Use only recommended cleaning materials to prevent scratching delicate optical surfaces.
If the focusing optic is pitted, it must be replaced. The laser’s high power density will cause pits or debris
on the lens to absorb enough energy that the lens may crack. If this happens, other optics in the beam
path may be contaminated or damaged as well.
When the application requires air (instead of nitrogen or argon) as an assist gas, we recommend the use
of breathing quality air available in cylinders from a welding supply company. Because compressed shop
air contains minute particles of oil and other contaminants that will damage optical surfaces, shop air
must be carefully filtered and dried before use as a purge or assist gas. Refer to Table 3-1, Gas purity
specifications, in the “Technical Reference” section for filtering/drying specifications.
Caution If you operate your laser or marking head in a dirty or dusty environ-
ment, contact SYNRAD about the risks of doing so and precautions
possible you can take to increase the longevity of your laser, marking head,
and associated optical components.
equipment
damage

maintenance/
troubleshooting
This page intentionally left blank.

appendix a

A
Use information in this section to connect and operate your Closed Loop (C/L) Stabili-
zation Kit.
■ Introduction – explains how the closed loop kit functions.
■ Safety precautions – lists laser safety precautions.
■ Connecting – describes how to connect the closed loop kit to your laser and
UC-2000 Controller.
■ Operation – describes closed loop operation.
■ Closed loop specifications – provides technical specifications for the Closed Loop
Stabilization Kit.
Synrad S e r i e s 4 8 operator’s manual A1

appendix a
Closed Loop Stabilization Kit
Introduction
The Closed Loop (C/L) Stabilization Kit, available for 10 W and 25 W Series 48 lasers, must be installed
and calibrated at the factory. The closed loop kit provides an effective, reliable method of stabilizing laser
power output by optically sampling the beam and providing feedback to adjust the PWM duty cycle per-
centage of the UC-2000’s output PWM Command signal.
After installation, the beam passes through an optical sampler (which replaces the standard front plate)
before it exits the closed loop housing. Optical beam transmission is 92% since the sampler diverts
approximately 8% of the output beam to a diffuser and thermopile detector. The detector signal is
amplified and sent to the UC-2000 where the Controller generates a variable duty cycle signal to
maintain constant average laser output power.
Note: Once installed and aligned on the laser, the Closed Loop Stabilization Kit becomes part of the
loop response/gain parameter and must NOT be moved or adjusted. Any user modifications or
adjustments will void the product warranty.
Safety precautions
Warning Please read these instructions carefully before using your Series 48
laser with a Closed Loop Stabilization Kit. To prevent injury to
possible personnel or damage to your laser or CL Kit, follow all safety
precautions and setup instructions as described here and in your
personal laser’s Operator’s Manual. Safe operating practices should be exer-
injury cised at all times when actively lasing to prevent exposure to direct
or scattered laser radiation. Improper handling or operation may
result in exposure to hazardous invisible laser radiation, damage to,
or malfunction of the laser or Closed Loop Stabilization Kit. Severe
burns will result from exposure to the laser beam. Always wear safety
glasses with side shields to reduce the risk of damage to the eyes
when operating the laser.
A2 Synrad S e r i e s 4 8 operator’s manual

appendix a
Connecting
Refer to Figure A-1 for an illustration showing a typical closed loop system and then perform the follow-
ing steps:
Beam
Blocker
CL
SYNRAD Laser Kit
UC-2000 Universal
Laser Laser Controller
Power Supply ANV/
ANC Laser C/L Gate
If Required If Required
Figure A-1 Typical closed loop setup
1 Disconnect power from your laser and the UC-2000 Controller.

2 Connect one end of the CL Interconnect cable to the laser-mounted closed loop assembly and the
other end to the UC-2000’s 8-pin mini-DIN C/L connector.
3 If required, connect a gating signal to the UC-2000’s Gate BNC connector.
4 If required, connect an ANV signal from your analog voltage source to the UC-2000’s ANV/ANC
BNC connector.
5 Set the UC-2000 to MAN. CLOSED or ANV CLOSED mode.
6 Apply power to both the laser and UC-2000 and then verify proper system operation.
Synrad S e r i e s 4 8 operator’s manual A3

appendix a
Operation
Set the UC-2000 to MAN. CLOSED or ANV CLOSED mode. Adjust the regulated setpoint to provide
a laser power output between approximately 20% and 80% of full power. This 20% window on either
side of the range allows the Controller to maintain full dynamic power regulation. Within the dynamic
response time of the system, the UC-2000 Controller can be gated from an external, low-frequency signal
source through the Gate connector.
Note: When operating in either closed loop mode, power output is no longer a curve of laser output
versus PWM duty cycle but instead, laser power output becomes a linear function of the desired
setpoint percentage.
For the closed loop kit, servo settling time to 90% of final value occurs within approximately 2 ms. Out-
put power regulation is typically ±2%, even when the beam “line hops” between 10.57 and 10.63 µm.
Closed loop specifications
Table A-1 Closed loop general specifications
Parameter Specification
Optical Transmission 92%, ±1%

Power Input, optical 150 W maximum
Power Input, electrical 12 VDC @ 3 mA (provided by UC-2000)
Power Stability, five minutes
after cold start ±2%
Control Range 20%–80% of rated output power
1
Control Frequency 5 kHz
Servo Settling Time, typical 2 ms
* Specifications subject to change without notice.

1 The Closed Loop Stabilization Kit is calibrated for operation at a PWM Command frequency of 5 kHz.
A4 Synrad S e r i e s 4 8 operator’s manual

index
A Collimators 3 -8
Agency compliance Command signal 2 -7, 3 -10 – 3 -11, 4 -8

see Compliance base frequency, 3 -11
PWM duty cycle, 3 -11
Air-cooled connections 1 -7 signal amplitude, 3 -10 – 3 -11
Analog current control 1 -15, 3 -12 Compliance 6 – 9
Analog voltage control 1 -15, 3 -12, A -3 CDRH, 6 – 7
Class IV safety requirements 9
Aperture Declaration of Conformity 10
see Laser aperture EU, 8 – 9
Applications viii FCC, 7 – 8
Connecting 1 -7 – 1 -16
B air cooling, 1 -7
control, 1 -14 – 1 -15
Beam attenuator 6, 9
DB9, 1 -15
Beam block 7, 2 -4, 2 -6 electrical, 1 -12 – 1 -14
Beam characteristics 3 -2, 3 -4 water cooling, 1 -8 – 1 -12
UC-2000 Controller, 1 -14 – 1 -15
Beam delivery optics 2 -3, 3 -7 – 3 -8
caution, 3 -8, 4 -9 Contact information viii
inspection, 4 -2 Continuous wave (CW) 3 -12
troubleshooting, 4 -9
Control board schematic 4 -5
Beam diameter 3 -4
Control connections 1 -14 – 1 -15
specifications, 3 -18
Control signals 3 -9 – 3 -11
BNC Control cable 1 -14, 1 -15
Command signal, 3 -10 – 3 -11
connecting, 1 -14 – 1 -15
Pulse width modulation (PWM), 3 -10
Tickle pulse, 3 -9
C
Controlling laser power 3 -9 – 3 -13
Caution control signals, 3 -9 – 3 -11
condensation, 1 -10, 1 -12, 2 -4, 2 -6 operating modes, 3 -11 – 3 -13
coolant temperature, 1 -8
Controls and indicators 6, 2 -2 – 2 -3
definition, 1
48-1 / 48-2 diagram, 2 -2
dirty/dusty environments, 4 -2, 4 -9
48-5 diagram, 2 -3
laser safety, 1 -2
optics damage, 3 -8 Cooling connections 1 -7, 1 -8 – 1 -12
radiation exposure, 2 Cooling fans
tickle signal, 2 -6, 3 -9, 3 -11 clearance, 1 -6, 1 -7, 4 -8
voiding warranty, 4 -3 recommended location, 1 -7
CDRH requirements 6 – 7 Cooling fittings 1 -8
CE mark 8 Cooling kit 1 -4, 1 -5
label location, 3, 4, 5 connecting, 1 -10 – 1 -12
Chiller guidelines, 1 -8
connection, 1 -10, 1 -11 Cooling water
coolant temperature, 1 -8 – 1 -9, 1 -11, draining, 4 -2
1 -12, 4 -10 flow rate, 1 -9, 1 -11, 1 -12, 2 -4, 2 -6, 4 -8
dew point temperature, 1 -9 temperature setpoint, 1 -8, 1 -9, 1 -11,
fittings, 1 -8 1 -12, 2 -4, 2 -6
flow rate, 1 -9, 1 -11, 1 -12, 2 -4, 2 -6,
3 -18, 3 -19, 4 -8 Copyright information vii
temperature setpoint, 1 -8, 1 -9, 2 -4, 2 -6, CTRL (Control) input connector 1 -15, 2 -2 –
3 -18, 3 -19 2 -3, 2 -7, 3 -4, 3 -7, 3 -10, 3 -12, 4 -8
Class IV safety requirements 9
Synrad S e r i e s 4 8 operator’s manual i1
index
Customer Service viii F
D Fan clearance 1 -6, 1 -7, 4 -8

Fault Shutdown Output 3 -15
Daily inspections 4 -2
Faults
Danger laser, 4 -7 – 4 -9
definition, 1 resetting, 4 -6
DB9 connections 1 -15, 3 -14 – 3 -15, 3 -16, FCC requirements 7 – 8
3 -17 caution to the user, 8
jumper plug, 1 -15, 3 -14 information to the user, 7
pinout diagram, 3 -14
signal descriptions, 3 -15 Final Test report 1 -4, 1 -5
DB9 Connector 1 -4, 1 -5, 2 -2, 2 -4, 2 -6, Focusing optics 3 -8
3 -14, 3 -16, 3 -17, 4 -7 Fuse 1 -4, 1 -5, 2 -2
DC-1 DC power supply 1 -12 – 1 -13 replacement, 4 -7
AC input requirements, 1 -12
connecting, 1 -12 – 1 -13 G
DC-2/DC-5 DC power supply 1 -13 – 1 -14, Gas purity specifications 3 -8
4 -7
AC input requirements, 1 -12 General hazards 1 – 2
connecting, 1 -13 – 1 -14 General specifications 3 -18 – 3 -19
DC Power cable 1 -13, 1 -14, 2 -3
connecting, 1 -12 – 1 -13, 1 -13 – 1 -14 H
DC power supply 1 -12, 1 -14 Hazard information 1 – 2
connecting, 1 -12 – 1 -13, 1 -13 – 1 -14 additional laser safety information, 2
troubleshooting, 4 -7, 4 -8 general hazards, 1 – 2
Declaration of Conformity 10 label locations, 3, 4, 5
other hazards, 2
Delivery optics 3 -7 – 3 -8, 4 -9 terminology, 1
caution, 3 -8, 4 -9
Dew point 1 -8, 1 -9 Heat load
caution, 1 -10, 1 -12, 2 -4, 2 -6 air-cooled, 1 -7, 3 -18, 3 -19
chart, 1 -9 water-cooled, 3 -18, 3 -19
Diode Pointer I
aperture dust cover, 2 -5, 2 -7
power connector, 2 -3 Indicators and controls 6, 2 -2 – 2 -3
Disabling Firestar 4 -2 Initial start-up 2 -4 – 2 -7
Divergence 3 -2, 3 -4, 3 -7 – 3 -8 with a UC-2000 Controller, 2 -4 – 2 -5
specifications, 3 -18 without a UC-2000 Controller, 2 -6 – 2 -7
Duty cycle 2 -5, 2 -7, 3 -10, 3 -11 Inspections

daily, 4 -2
incoming, 1 -3
E
Integrating safety features 3 -16 – 3 -17
Electrical connections 1 -12 – 1 -14 Keyswitch functions, 3 -16
EU requirements 9 Remote interlock functions, 3 -17
Expander/collimator 3 -8 Interconnect schematic 4 -4
External control 3 -11 – 3 -12 Interconnection diagram 1 -16
Eye protection 1, 2 -4 Interlock
see Remote Interlock
i2 Synrad S e r i e s 4 8 operator’s manual

index
Introduction 1 -2 O
Inventory 1 -4 – 1 -5 OEM lasers
contents description, 1 -5 resetting, 4 -6
ship kit contents, 1 -4
Operating modes 3 -11 – 3 -13
J analog current control, 3 -12
analog voltage control, 3 -12
Jumper plug 1 -15, 3 -14, 4 -7 continuous wave, 3 -12
external control, 3 -11
K low frequency gated operation, 3 -13
marking/engraving operation, 3 -13
Keyswitch 6, 9, 1 -2, 2 -2, 2 -5, 2 -6, 2 -7,
3 -4, 3 -5, 3 -14, 3 -15, 3 -16, 3 -17, 4 -6, Operator's manual 1 -4, 1 -5
4 -7, 4 -8 Optical accessories mounting 2 -3
Optical output pulse
Keyswitch functions
waveforms, 3 -10
integrating, 3 -16
Optical resonator 3 -3 – 3 -4
Keyswitch lasers
resetting, 4 -6 Optical setup
cleanliness, 3 -8
L delivery optics, 3 -7 – 3 -8
focusing optics, 3 -8
Label locations 3, 4, 5 troubleshooting, 4 -9
LASE indicator 6, 9, 2 -2, 2 -5, 2 -7, 3 -15, Optics damage 3 -8, 4 -9
4 -6, 4 -7, 4 -8
Outline and Mounting drawings 3 -20 – 3 -22
Laser aperture 6, 2 -2, 2 -4, 2 -6, 3 -4, 4 -7 48-1, 3 -20
Laser faults 4 -7 – 4 -9 48-2, 3 -21
48-5, 3 -22
Laser safety information 1 – 10
Laser tube 3 -2, 3 -3 P
Low frequency gated operation 3 -13 Package outline drawings 3 -20 – 3 -22
48-1, 3 -20
M 48-2, 3 -21
48-5, 3 -22
Maintenance 4 -2
daily inspections, 4 -2 Packaging
disabling the laser, 4 -2 guidelines, 1 -3
storage/shipping, 4 -2 Pulse Width Modulation (PWM) 2 -2, 2 -5,
Marking/engraving operation 3 -13 2 -6, 2 -7, 3 -2, 3 -4
description, 3 -10
Material Safety Data Sheets (MSDS) 2
PWM Command signal 3 -10, 3 -11, 3 -13,
Message Output 3 -15
4 -6, 4 -8
Modulation 3 -4, 3 -10, 3 -11
PWR (Power) indicator 6, 9, 2 -2, 2 -5, 2 -7,
Mounting 1 -6 3 -15, 3 -16, 3 -17, 4 -6, 4 -7, 4 -8
standard, 1 -6
with FH Series marking head, 1 -6 R
Mounting Rail 1 -6
Ready indicator
see PWR (Power) indicator
N
Reference materials viii
Nomenclature 1 -2
Remote Interlock 6, 9, 1 -15, 3 -14, 3 -16,
3 -17, 4 -6
Synrad S e r i e s 4 8 operator’s manual i3

index
Remote Interlock Connection 3 -15, 3 -17 introduction, 3 -2 – 3 -3
Remote Interlock functions optical resonator, 3 -3 – 3 -4
integrating, 3 -17 optical setup, 3 -7 – 3 -8
plasma section, 3 -3
Remote Interlock signal 2 -4, 2-
2-6, 3 -14, 3 -15
Technical support viii
Remote Keyswitch 6, 9, 1 -15, 2 -5, 2 -7,
3 -4, 3 -5, 3 -14, 3 -16, 3 -17, 4 -6 Tickle pulse 1 -14, 2 -2, 2 -5, 2 -6, 2 -7, 4 -9
caution, 3 -9, 3 -11
Remote Keyswitch functions description, 3 -9
integrating, 3 -16
Trademark information vii
Remote Keyswitch Input 3 -15, 3-
3-16, 3 -17
Troubleshooting 4 -3 – 4 -9
Remote Keyswitch Output 3 -15, 3-
3-16 beam delivery optics, 4 -9
Remote Keyswitch signal 2 -4, 2-
2-6, 3 -14, introduction, 4 -3
3 -15, 3 -16 J48 control board schematic, 4 -5
J48 interconnect schematic, 4 -4
Remote Lase LED Output 3 -15 keyswitch faults, 4 -6
Remote Ready LED Output 3 -15, 3-
3-16, 3 -17 laser faults, 4 -7 – 4 -9
OEM faults, 4 -6
Resetting faults 4 -6
resetting faults, 4 -6
Keyswitch lasers, 4 -6
OEM lasers, 4 -6 Tubing adaptors 1 -8
RF driver board 3 -4, 3 -5, 3 -16
schematic, 3 -6 U
UC-2000 Laser Controller 1 -14, 1 -15, 2 -2,
S 3 -9, 3 -10, 3 -11, 3 -12, 3 -13
connecting, 1 -14 – 1 -15
Safety features 6, 8
initial start-up, 2 -4, 2 -5
Class IV, 9
integrating, 3 -16 – 3 -17 Unpacking 1 -3
Safety precautions 1 – 2
W
Sales and Applications viii
Warning
Ship kit contents 1 -4, 1 -5
air contaminants, 2
Shorting plug definition, 1
see Jumper Plug eye protection, 1, A -2
Shutter Switch 6, 9, 2 -2, 2 -5, 2 -7, 3 -4, 4 -7 gate logic, 3 -13
laser output, 2 -4, 4 -3
Signal Ground 3 -15, 3-
3-16, 3 -17 laser safety, 1, A -2
Specifications PWM control, 1 -14, 3 -10
cooling, 4 -8 Warranty information vii
gas purity, 3 -8
general, 3 -18 – 3 -19 Water cooling ports 1 -10, 1 -11
Storage/shipping 4 -2
Synrad
European headquarters, viii
worldwide headquarters, viii
System interconnection diagram 1 -16
T
Technical overview 3 -2 – 3 -8
control circuity, 3 -4 – 3 -6
Duo-Lase operation, 3 -7
i4 Synrad S e r i e s 4 8 operator’s manual

Operator's Manual: An Excel Technology Company

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An Excel Technology Company

Released April 2005

Part number 900-00007-03

An Excel Technology Company

Synrad S e r i e s 4 8 operator’s manual iii

iv Synrad S e r i e s 4 8 operator’s manual

Figure 1-1 Series 48 shipping box contents ........................................... 1-4

Figure 2-1 48-1 / 48-2 controls and indicators ...................................... 2-2

Figure 4-1 Model J48 Series interconnect schematic ............................ 4-4

Figure A-1 Typical closed loop setup ..................................................... A-3

Synrad S e r i e s 4 8 operator’s manual v

Table 1-1 Ship kit contents .................................................................. 1-4

Table 3-1 Gas purity specifications ....................................................... 3-8

Table 4-1 Series 48 cooling specifications ............................................ 4-8

Table A-1 Closed loop general specifications........................................ A-4

vi Synrad S e r i e s 4 8 operator’s manual

Duo-Lase and Power Wizard are registered trademarks of SYNRAD, Inc.

© 2005 by SYNRAD, Inc.

Synrad S e r i e s 4 8 operator’s manual vii

Phone us at: 1.800.SYNRAD1 (1.800.796.7231)

Sales and Applications

Excel Technology Europe GmbH

Phone: 49 89 891 462-0

viii Synrad S e r i e s 4 8 operator’s manual

Enclose the beam path whenever possible. Direct or diffuse laser

European customers should refer to and follow the laser safety

Synrad S e r i e s 4 8 operator’s manual 1

Warning Materials processing can generate air contaminants such as vapors,

ANSI Z136.1-1993, American National Standard for Safe Use of

U.S. Government’s Code of Federal Regulations: 29 CFR 1910,

Threshold Limit Values (TLV’s) published by the American Confer-

It may be necessary to consult with local governmental agencies

Caution The use of controls or adjustments or performance of procedures

Additional laser safety information

2 Synrad S e r i e s 4 8 operator’s manual

CAUTION MODEL#: J48-1W

SEE OPERATION MANUAL.

WATER-COOLED VERSION ONLY

This laser product is manufactured under

IMPORTANT - DB9 wiring change. Pins 3 and 4

MADE IN THE U.S.A.

KEYSWITCH VERSION OR OEM VERSION

This laser manufactured by IMPORTANT - DB9 wiring change. Pins 3 and 4

KEYSWITCH VERSION ONLY

Figure 1 48-1 hazard label and CE label locations

Synrad S e r i e s 4 8 operator’s manual 3

CAUTION MODEL#: J48-2W

10.6 MICRON SEE OPERATION MANUAL.

WATER-COOLED VERSION ONLY

MADE IN THE U.S.A.

IMPORTANT - DB9 wiring change. Pins 3 and 4

MADE IN THE U.S.A.

KEYSWITCH VERSION OR OEM VERSION

KEYSWITCH VERSION ONLY

Figure 2 48-2 hazard label and CE label locations

4 Synrad S e r i e s 4 8 operator’s manual

INVISIBLE LASER RADIATION

CAUTION MODEL#: J48-5W