Laser Operator's Manual M Version: 4600 Campus Place Mukilteo, WA 98275 1.800.SYNRAD1

Laser Operator’s Manual
M Version
4600 Campus Place

Mukilteo, WA 98275
1.800.SYNRAD1
tel 1.425.349.3500
fax 1.425.349.3667
e-mail [email protected]
web www.synrad.com
M Version Laser
Operator’s Manual
Model 48-1
Model 48-2
Model 48-5
Version 8.2
Released February 2014
Part number 900-00007-04
4600 Campus Place

Mukilteo, WA 98275
1.800.SYNRAD1
tel 1.425.349.3500
fax 1.425.349.3667
e-mail [email protected]
web www.synrad.com
table of contents
Laser Safety
Hazard information.....................................................................................1
Terms........................................................................................................................... 1
General hazards.......................................................................................................... 1
Other hazards.............................................................................................................. 3
Disposal....................................................................................................................... 3
Additional laser safety information............................................................................ 3
48-1 label locations.....................................................................................4
48-2 label locations.....................................................................................5
48-5 label locations.....................................................................................6
Agency compliance....................................................................................7
Center for Devices and Radiological Health (CDRH) requirements........................ 7
Federal Communications Commission (FCC) requirements.................................... 8
European Union (EU) requirements.......................................................................... 9
Declaration of Conformity.........................................................................12
Getting Started 1
Introduction................................................................................................1-2
Series 48 features........................................................................................................ 1-2
Series 48 nomenclature.............................................................................................. 1-2
Model numbers........................................................................................................... 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............................................................................... 1-7
Connecting.................................................................................................1-8
Air-cooled connections.............................................................................................. 1-8
Water-cooled connections ......................................................................................... 1-9
Electrical connections................................................................................................ 1-14
Control connections................................................................................................... 1-16
DB-9 connections....................................................................................................... 1-17
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
Synrad Series 48 operator’s manual iii

table of contents
Technical Reference 3
Technical overview.....................................................................................3-2
Introduction................................................................................................................ 3-2
Plasma section............................................................................................................ 3-2
Optical resonator........................................................................................................ 3-2
Control circuitry......................................................................................................... 3-3
Optical setup............................................................................................................... 3-5
Controlling laser power..............................................................................3-7
Control signals............................................................................................................ 3-7
Operating modes......................................................................................................... 3-10
DB-9 connections ......................................................................................3-12
Sample DB-9 Connector I/O circuits......................................................................... 3-15
Integrating Series 48 safety features ..........................................................3-18
Remote keyswitch functions....................................................................................... 3-18
Remote interlock functions........................................................................................ 3-19
Model 48-1 general specifications..............................................................3-20
Model 48-1 package outline drawing.........................................................3-26
Series 48 packaging instructions.................................................................3-29
Maintenance/Troubleshooting 4
Maintenance...............................................................................................4-2
Disabling the 48 Series laser....................................................................................... 4-2
Daily inspections........................................................................................................ 4-2
Storage/shipping......................................................................................................... 4-3
Cleaning optical components..................................................................................... 4-3
Troubleshooting..........................................................................................4-6
Introduction................................................................................................................ 4-6
Resetting faults........................................................................................................... 4-7
Laser faults.................................................................................................................. 4-8
Beam delivery optics................................................................................................... 4-10
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-5
iv Synrad Series 48 operator’s manual

table of contents
List of Figures
Figure 1 48-1 hazard label and CE label locations...............................4
Figure 4 European compliance mark....................................................11
Figure 1-1 Series 48 shipping box contents.............................................1-4

Figure 1-2 48-1/48-2 cooling fan placement............................................1-8
Figure 1-3 48-1/48-2 cooling connections...............................................1-12
Figure 1-4 48-5 cooling connections ......................................................1-13
Figure 1-5 DC-1 (Emerson LPS) power supply........................................1-14
Figure 1-6 PS-2 (Emerson iMP4) power supply.......................................1-15
Figure 1-7 PS-6 (Emerson iVS1) power supply.......................................1-16
Figure 1-8 Typical Series 48 system interconnection..............................1-18
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 Beam characteristics...............................................................3-3

Figure 3-2 “Flying optics” beam path.......................................................3-5
Figure 3-3 Tickle pulse waveform............................................................3-8
Figure 3-4 Series 48 waveforms................................................................3-8
Figure 3-5 PWM Command signal waveform..........................................3-9
Figure 3-6 Factory-installed DB-9 jumper plug wiring............................3-12
Figure 3-7 Physical layout of Series 48 DB-9 Connector........................3-14
Figure 3-8 Remote Keyswitch circuit.......................................................3-15
Figure 3-9 Remote Interlock circuit.........................................................3-15
Figure 3-10 Remote Ready output to PLC input (PLC sourcing).............3-15
Figure 3-11 Remote Ready output to PLC input (PLC sinking)...............3-16
Figure 3-12 Remote Ready output to PLC input using pull-up resistor....3-16
Figure 3-13 Message Output to PLC input................................................3-16
Figure 3-14 Fault Shutdown Output to PLC input...................................3-17
Figure 3-15 Model 48-1 package outline and mounting dimensions........3-26
Figure 3-18 Model 48-1 packaging instructions........................................3-29
Figure 3-21 FLMK-1A (10W fan shroud) packaging instructions............3-32
Synrad Series 48 operator’s manual v

table of contents
List of Figures (cont.)
Figure 3-22 FLMK-2A (25W fan shroud) packaging instructions............3-33
Figure A-1 Typical closed loop setup........................................................A-3

Figure A-2 Graph of duty cycle vs. power output before/after
C.L. kit installed.....................................................................A-4
vi Synrad Series 48 operator’s manual

List of Tables
Table 1 Class 4 safety features..............................................................10
Table 2 European Union Directives....................................................11
Table 1-1 Ship kit contents.....................................................................1-4

Table 1-2 Dew point temperatures..........................................................1-11
Table 3-1 Assist gas purity specifications................................................3-6

Table 3-2 Input signal specifications.......................................................3-7
Table 3-3 Tickle pulse specifications.......................................................3-7
Table 3-4 PWM Command signal specifications....................................3-10
Table 3-5 DB-9 pin assignments.............................................................3-13
Table 3-6 DB-9 Connector input signal specifications...........................3-14
Table 3-7 DB-9 Connector output signal specifications.........................3-14
Table 3-8 Model 48-1 general specifications..........................................3-20
Table 4-1 Required cleaning materials...................................................4-4

Table 4-2 Series 48 cooling specifications..............................................4-9
Table A-1 Closed loop general specifications..........................................A-5
Synrad Series 48 operator’s manual vii

Trademark/copyright information
SYNRAD, Duo-Lase and Power Wizard are registered trademarks of SYNRAD, Inc.
All other trademarks or registered trademarks are the property of their respective owners.
© 2006, 2007, 2009, 2010, 2011, 2012, 2014 by SYNRAD, Inc.

All rights reserved.
viii Synrad Series 48 operator’s manual

Warranty information
This is to certify that Series 48-1 lasers are guaranteed by SYNRAD, Inc. to be free of all defects in materi-
als and workmanship for a period of three years from the date of purchase. Series 48-2 and 48-5 lasers are
guaranteed to be free of all defects in materials and workmanship for a period of one year from the date of
purchase. This warranty does not apply to any defect caused by negligence, misuse (including environmen-
tal factors), accident, alteration, or improper maintenance. We request that you examine each shipment
within 10 days of receipt and inform SYNRAD, Inc. of any shortage or damage. If no discrepancies are
reported, SYNRAD shall assume the shipment was delivered complete and defect-free.
If, within one year from the date of purchase, any part of the 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 other-
wise 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 improve-
ments in the design of our products at any time without incurring any obligation to make equivalent
changes in products previously manufactured or shipped. Buyer agrees to hold SYNRAD harmless from
any and all damages, costs, and expenses relating to any claim arising from the design, manufacture, or use
of the product, or arising from a claim that such product furnished Buyer by SYNRAD, or the use thereof,
infringes upon any Patent, foreign or domestic.
Synrad Series 48 operator’s manual ix

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 solu-
tion 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) num-
ber, contact SYNRAD at 1.800.SYNRAD1 and ask to speak to a Customer Service representative.
Technical Support
SYNRAD’s Regional Sales Managers are able to answer many technical questions regarding the instal-
lation, 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
For assistance in Europe, contact SYNRAD’s European subsidiary, Synrad Europe, at:
Synrad Europe
Münchener Straße 2A
D-82152 Planegg, Germany
Phone: +49 (0) 89 31 707-0

Fax: +49 (0) 89 31 707-222
Email [email protected]
x Synrad Series 48 operator’s manual

laser safety
Hazard information
Hazard information includes terms, symbols, and instructions 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 Class 4 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.

Important Note: Important information or recommendations concerning the subject under discussion.

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.
Danger This Class 4 laser product emits invisible infrared laser radiation in
the 9.3–10.6 µm CO2 wavelength band depending on model.
serious
Do not allow laser radiation to enter the eye by viewing direct or re-
personal
flected laser energy. CO2 laser radiation can be reflected from metallic
injury objects even though the surface is darkened. Direct or diffuse laser
radiation can inflict severe corneal injuries leading to permanent eye
damage or blindness. All personnel must wear eye protection suitable
for 10.6 µm CO2 radiation when in the same area as an exposed laser
beam. Eyewear protects against scattered energy but is not intended
to protect against direct viewing of the beam—never look directly
into the laser output aperture or view scattered laser reflections from
metallic surfaces.
Enclose the beam path whenever possible. Exposure to direct or dif-

fuse CO2 laser radiation can seriously burn human or animal tissue,
which may cause permanent damage.
This product is not intended for use in explosive, or potentially

explosive, atmospheres.
Synrad Series 48 operator’s manual 1

laser safety
Hazard information
Warning For laser systems being used or sold within the U.S.A., customers
should refer to and follow the laser safety precautions described in the
serious American National Standards Institute (ANSI) Z136.1-2007 docu-
personal ment, Safe Use of Lasers.
injury For laser systems being used or sold outside the U.S.A., customers
should refer to and follow the laser safety precautions described in
European Normative and International Electrotechnical Commis-
sion documents EN 60825-1:2007—Safety of Laser Products – Part 1:
Equipment Classification and Requirements and IEC/TR 60825-14:2004,
Safety of Laser Products – Part 14: A User’s Guide.
Warning Materials processing with a laser can generate air contaminants such
as vapors, fumes, and/or particles that may be noxious, toxic, or
serious even fatal. Material Safety Data Sheets (MSDS) for materials being
personal processed should be thoroughly evaluated and the adequacy of provi-
sions for fume extraction, filtering, and venting should be carefully
injury considered. Review the following references for further information
on exposure criteria:
ANSI Z136.1-2007, Safe Use of Lasers, section 7.3.
United States 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.
Warning The use of controls or adjustments or performance of procedures

serious other than those specified herein may result in hazardous radiation
exposure.
personal
injury
Warning The use of aerosol dusters containing difluoroethane causes “bloom-

serious ing”, a condition that significantly expands and scatters the laser
beam. This beam expansion can affect mode quality and/or cause
personal laser energy to extend beyond the confines of optical elements in
injury the system, possibly damaging acrylic safety shielding. Do not use air
dusters containing difluoroethane in any area adjacent to CO2 laser
systems because difluoroethane persists for long time periods over
wide areas.
2 Synrad Series 48 operator’s manual

laser safety
Hazard information
Series 48 lasers should be installed and operated in manufacturing or laboratory facilities by trained per-
sonnel only. Due to the considerable risks and hazards associated with the installation and operational use
of any equipment incorporating a laser, the operator must follow product warning labels and instructions
to the user regarding laser safety.
To prevent exposure to direct or scattered laser radiation, follow all safety precautions specified throughout
this manual and exercise safe operating practices per ANSI Z136.1-2007 at all times when actively lasing.
Always wear safety glasses or protective goggles with side shields to reduce the risk of damage to the eyes
when operating the laser.
A CO2 laser is an intense heat source and will ignite most materials under the proper conditions. Never
operate the laser in the presence of flammable or explosive materials, gases, liquids, or vapors.
The use of controls or adjustments or performance of procedures other than those specified herein may re-
sult in exposure to hazardous invisible laser radiation, damage to, or malfunction of the laser. Severe burns
will result from exposure to the laser beam.
Safe operation of the laser requires the use of an external beam block to safely block the beam from travel-
ing beyond the desired work area. Do not place your body or any combustible object in the path of the
laser beam. Use a water-cooled beam dump or power meter, 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 serious hazard
outside the immediate work area.
Other hazards
The following hazards are 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 and/or failure to adhere to applicable laser
safety procedures; (D) risk of exposure to hazardous or lethal voltages through unauthorized removal of
covers, doors, or access panels; (E) generation of hazardous air contaminants that may be noxious, toxic, or
even fatal.
Disposal
This product contains components that are considered hazardous industrial waste. If a situation occurs
where the laser is rendered non-functional and cannot be repaired, it may be returned to SYNRAD, Inc.
who, for a fee, will ensure adequate disassembly, recycling, and/or disposal of the product.
Additional laser safety information

The SYNRAD web site at 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 Require-
ments.
In addition, the Occupational Safety and Health Administration (OSHA) provides an online Technical
Manual (located at http://www.osha.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.
laser safety
48-1 label locations
10.6 MICRON
INVISIBLE LASER RADIATION 30 WATTS MAX

AVOID EYE OR SKIN EXPOSURE TO
DIRECT OR SCATTERED RADIATION 10200–10800 nm
CLASS 4 LASER PRODUCT
EN-60825-1, 2007
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
30 WATTS MAX keeps the plasma ionized during laser "low" periods
9229–9317 nm and facilitates breakdown and pulse to pulse fidelity.
Damage or malfunction may occur if this or
EN-60825-1, 2007 equivalent drive signals are not used. See manual
for tickle pulse specifications or contact factory.
TOP VIEW
CAUTION
CAUTION MODEL #: 48-1KWM
These RF Excited Lasers must be provided with a
CONDENSATION AND pre-ionizing "Tickle" signal during standby or SERIAL #: 0481263115066
30 WATTS MAX TESTED AT 30 Volts MFG September 20, 2011
INVISIBLE LASER RADIATION
AVOID EYE OR SKIN EXPOSURE TO WATER DAMAGE CAN laser "low" periods. This is automatically provided
Complies with IEC 60825-1 (2007) and 21 CFR 1040.10 except
10200–10800 nm with Synrad's UC Series power controller. This signal
DIRECT OR SCATTERED RADIATION
CLASS 4 LASER PRODUCT OCCUR IF COOLING WATER keeps the plasma ionized during laser "low" periods for deviations pursuant to Laser Notice No. 50 dated June 24, 2007.
EN-60825-1, 2007
IS BELOW DEW POINT. and facilitates breakdown and pulse to pulse fidelity.
Damage or malfunction may occur if this or
SEE OPERATION MANUAL. equivalent drive signals are not used. See manual SYNRAD, Inc. 4600 Campus Place, Mukilteo WA 98275 425.349.3500
AVOID EXPOSURE Keyswitch version

CAUTION
INVISIBLE LASER RADIATION MODEL #: 48-1KWM
IS EMITTED FROM THIS
CONDENSATION AND SERIAL #: 0481263115066
APERTURE WATER DAMAGE CAN TESTED AT 30 Volts MFG September 20, 2011
OCCUR IF COOLING WATER Complies with IEC 60825-1 (2007) and 21 CFR 1040.10 except
for deviations pursuant to Laser Notice No. 50 dated June 24, 2007.
IS BELOW DEW POINT.
SEE OPERATION MANUAL.
SYNRAD, Inc. 4600 Campus Place, Mukilteo WA 98275 425.349.3500
or
AVOID EXPOSURE
WATER-COOLED VERSION ONLY

OEM version
APERTURE
MODEL #: 48-1SWM
SERIAL #: 0481263115066
TESTED AT 30 Volts MFG September 20, 2011
This laser component does not comply with standards for complete
FRONT VIEW laser products as specified by 21 CFR 1040.10 or IEC 60825-1.
IMPORTANT - DB9 wiring change. Pins 3 and 4

now provide the remote interlock function and pins
This laser product is manufactured under 6 and 7 now provide the remote REMOTE INTERLOCK JUMPER
one or more of the following U.S. Patents: keyswitch function. If unused 1 2 3 4 5
5,602,865 6,195,379 6,198,758 6,198,759 these pins must be jumpered 6 7 8 9
6,603,794 6,614,826 7,480,323 for the laser to operate. Refer
MADE IN THE U.S.A. to manual for details. REMOTE KEYSWITCH JUMPER
Other U.S. and International Patents pending.
KEYSWITCH VERSION ONLY

This laser product is manufactured under now provide the remote interlock function and pins
one or more of the following U.S. Patents:
6 and 7 now provide the remote REMOTE INTERLOCK JUMPER
5,602,865 6,195,379 6,198,758 6,198,759 keyswitch function. If unused 1 2 3 4 5
6,603,794 6,614,826 7,480,323 these pins must be jumpered 6 7 8 9
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.
BOTTOM VIEW
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
with Synrad's UC Series power controller. This signal
one or more of the following U.S. Patents:
INVISIBLE LASER RADIATION keeps the plasma ionized during laser "low" periods
DIRECT OR SCATTERED RADIATION 5,602,865 6,195,379 6,198,758 6,198,759 and facilitates breakdown and pulse to pulse fidelity.
CLASS 4 LASER PRODUCT 6,603,794 6,614,826 7,480,323 Damage or malfunction may occur if this or
equivalent drive signals are not used. See manual
Other U.S. and International Patents pending. for tickle pulse specifications or contact factory.
TOP VIEW
CAUTION MODEL #: 48-2KWM

CAUTION These RF Excited Lasers must be provided with a SERIAL #: 0482263115066
This laser product is manufactured under
one or more of the following U.S. Patents: CONDENSATION AND pre-ionizing "Tickle" signal during standby or TESTED AT 30 Volts MFG September 20, 2011
75 WATTS MAX laser "low" periods. This is automatically provided
AVOID EYE OR SKIN EXPOSURE TO 5,602,865 6,195,379 6,198,758 6,198,759
WATER DAMAGE CAN with Synrad's UC Series power controller. This signal Complies with IEC 60825-1 (2007) and 21 CFR 1040.10 except
10200–10800 nm
CLASS 4 LASER PRODUCT 6,603,794 6,614,826 7,480,323 OCCUR IF COOLING WATER keeps the plasma ionized during laser "low" periods for deviations pursuant to Laser Notice No. 50 dated June 24, 2007.
EN-60825-1, 2007 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
SEE OPERATION MANUAL. equivalent drive signals are not used. See manual
for tickle pulse specifications or contact factory. SYNRAD, Inc. 4600 Campus Place, Mukilteo WA 98275 425.349.3500
Keyswitch version
CAUTION
CONDENSATION AND MODEL #: 48-2KWM
SERIAL #: 0482263115066
WATER DAMAGE CAN TESTED AT 30 Volts MFG September 20, 2011
IS BELOW DEW POINT. for deviations pursuant to Laser Notice No. 50 dated June 24, 2007.
10.6 MICRON SEE OPERATION MANUAL.

WATER-COOLED VERSION ONLY or

75 WATTS MAX
10200–10800 nm OEM version
EN-60825-1, 2007
MODEL #: 48-2SWM
AVOID EXPOSURE SERIAL #: 0482263115066
INVISIBLE LASER RADIATION This laser component does not comply with standards for complete
9.3 MICRON IS EMITTED FROM THIS laser products as specified by 21 CFR 1040.10 or IEC 60825-1.
APERTURE
75 WATTS MAX
9229–9317 nm
EN-60825-1, 2007
AVOID EXPOSURE

APERTURE
FRONT VIEW
MADE IN THE U.S.A.
BOTTOM VIEW

keyswitch function. If unused 1 2 3 4 5
these pins must be jumpered 6 7 8 9
for the laser to operate. Refer
MADE IN THE U.S.A.


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
keeps the plasma ionized during laser "low" periods
5,602,865 6,195,379 6,198,758 6,198,759 and facilitates breakdown and pulse to pulse fidelity.
CLASS 4 LASER PRODUCT 6,603,794 6,614,826 7,480,323 Damage or malfunction may occur if this or
Other U.S. and International Patents pending. equivalent drive signals are not used. See manual
TOP VIEW

DIRECT OR SCATTERED RADIATION CAUTION
CLASS 4 LASER PRODUCT CAUTION These RF Excited Lasers must be provided with a MODEL #: 48-5KWM
This laser product is manufactured under pre-ionizing "Tickle" signal during standby or SERIAL #: 0485263115066
one or more of the following U.S. Patents: CONDENSATION AND laser "low" periods. This is automatically provided TESTED AT 30 Volts MFG September 20, 2011
WATER DAMAGE CAN with Synrad's UC Series power controller. This signal Complies with IEC 60825-1 (2007) and 21 CFR 1040.10 except
5,602,865 6,195,379 6,198,758 6,198,759 keeps the plasma ionized during laser "low" periods for deviations pursuant to Laser Notice No. 50 dated June 24, 2007.
6,603,794 6,614,826 7,480,323 OCCUR IF COOLING WATER 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
equivalent drive signals are not used. See manual
150 WATTS MAX SEE OPERATION MANUAL. for tickle pulse specifications or contact factory.
10200–10800 nm
EN-60825-1, 2007
Keyswitch version
CAUTION
CONDENSATION AND MODEL #: 48-5KWM
SERIAL #: 0485263115066
WATER DAMAGE CAN TESTED AT 30 Volts MFG September 20, 2011
for deviations pursuant to Laser Notice No. 50 dated June 24, 2007.
IS BELOW DEW POINT.
SEE OPERATION MANUAL. SYNRAD, Inc. 4600 Campus Place, Mukilteo WA 98275 425.349.3500
or
WATER-COOLED VERSION ONLY
150 WATTS MAX OEM version
10200–10800 nm MODEL #: 48-5SWM
EN-60825-1, 2007
AVOID EXPOSURE SERIAL #: 0485263115066
INVISIBLE LASER RADIATION This laser component does not comply with standards for complete
IS EMITTED FROM THIS laser products as specified by 21 CFR 1040.10 or IEC 60825-1.
APERTURE
AVOID EXPOSURE
FRONT VIEW
APERTURE

to manual for details.
MADE IN THE U.S.A.
REMOTE KEYSWITCH JUMPER

MADE IN THE U.S.A.
BOTTOM VIEW

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
SYNRAD lasers are designed, tested, and certified to comply with certain United States (U.S.) and Eu-
ropean Union (EU) regulations. These regulations impose product performance requirements related to
electromagnetic compatibility (EMC) and product safety characteristics for industrial, scientific, and medi-
cal (ISM) equipment. The specific provisions to which systems containing Series 48 lasers must comply
are identified and described in the following paragraphs. Note that compliance to CDRH, FCC, and EU
requirements depends in part on the laser version selected—Keyswitch or OEM.
In the U.S., laser safety requirements are governed by the Center for Devices and Radiological Health
(CDRH) under the auspices of the U.S. Food and Drug Administration (FDA) while radiated emission
standards fall under the jurisdiction of the U.S. Federal Communications Commission (FCC). Outside the
U.S., laser safety and emissions are governed by European Union (EU) Directives and Standards.
In the matter of CE-compliant laser products, SYNRAD, Inc. assumes no responsibility for the compliance
of the system into which the product is integrated, other than to supply and/or recommend laser compo-
nents that are CE marked for compliance with applicable European Union Directives.
Because OEM laser products are intended for incorporation as components in a laser processing system,
they do not meet all of the Standards for complete laser processing systems as specified by 21 CFR, Part
1040 or EN 60825-1. SYNRAD, Inc. assumes no responsibility for the compliance of the system into
which OEM laser products are integrated.
Center for Devices and Radiological

Health (CDRH) requirements
Keyswitch models
Series 48 Keyswitch model lasers comply with requirements for Class 4 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
all personnel are adequately warned of potential hazards through the use of product labels and instructions.
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. Spe-
cifically, 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). Table 1,
Class 4 safety features, indicates which features are available on Series 48 lasers, the type and description of
the feature, and if the feature is required by CDRH regulations.

laser safety
Agency compliance
OEM models
Series 48 OEM lasers are OEM products intended for incorporation as components in laser processing
systems. As supplied by SYNRAD, these lasers do not meet the requirements of 21 CFR, Subchapter J
without additional safeguards. In the U.S., the Buyer of these OEM laser components is solely responsible
for the assurance that the laser processing system sold to an end user complies with all laser safety require-
ments before the actual sale of the system. Under CDRH regulations, the Buyer must submit a report to
the CDRH prior to shipping the system. In jurisdictions outside the U.S., it is the sole responsibility of the
Buyer of these OEM components to ensure that they meet all applicable local laser safety requirements. In
cases where the Buyer is also the end-user of the OEM laser product, the Buyer/end-user must integrate the
laser so that it complies with all applicable laser safety standards as set forth above. Table 1, Class 4 safety
features, indicates which features are available on Series 48 lasers, the type and description of the feature,
and if the feature is required by CDRH regulations.
Federal Communications Commission

(FCC) requirements
The United States Communication Act of 1934 vested the Federal Communications Commission (FCC)
with the authority to regulate equipment that emits electromagnetic radiation in the radio frequency spec-
trum. 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.
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 trace-
able 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 prob-
lems.
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 Federal Communications Commission 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

Laser safety standards
Under the Low Voltage Directive, 2006/95/EC, the European Norm (EN) document EN 60825-1 was de-
veloped to protect persons from laser radiation by imposing requirements upon manufacturers of laser prod-
ucts 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.
Keyswitch models
Series 48 Keyswitch models are designed to comply with the requirements imposed by EN
60825-1 for Class 4 laser products. Table 1, Class 4 safety features, summarizes Series 48 product
features, indicating the type and description of features and whether those features are required
by European Union regulations.
OEM models
Series 48 OEM lasers are OEM products intended for incorporation as components in laser
processing systems. As supplied by SYNRAD, these lasers do not meet the requirements of
EN 60825-1 without additional safeguards. European Union Directives state that “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.” This means that Buyers of OEM laser components are solely responsible for
the assurance that the laser processing system sold to an end-user complies with all laser safety
requirements before the actual sale of the system. Note that when an OEM laser component is
incorporated into another device or system, the entire machinery installation may be required
to conform to EN 60825-1; EN 60204-1, Safety of Machinery; the Machinery Directive EN
2006/42/EC; and/or any other applicable Standards. In cases where the Buyer is also the end-
user of the OEM laser product, the Buyer/end-user must integrate the laser so that it complies
with all applicable laser safety standards as set forth above. Table 1, Class 4 safety features, in-
dicates which features are available on Series 48 lasers, the type and description of the feature,
and if the feature is required by European Union regulations.
Electromagnetic interference standards

The European Union’s Electromagnetic Compatibility (EMC) Directive, 2004/108/EC, is the sole Direc-
tive 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, EN 55011 and CISPR:11 define radiated and conducted
RF emission limits while the generic Standards EN 61326 and EN 50082-1 define 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 2004/108/EC.
laser safety
Agency compliance
Table 1 Class 4 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.
Power Panel indicator (Green) Yes No

indicator2 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 Yes

reset1 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
Agency compliance
When integrating SYNRAD’s Series 48 OEM lasers, the Buyer and/or integrator of the end system is
responsible for meeting all applicable Standards to obtain the CE mark. To aid this compliance process,
SYNRAD’s testing program has demonstrated that Series 48 lasers comply with the relevant requirements
of 2004/108/EC, the Electromagnetic Compatibility Directive, as summarized in Table 2 below.
Table 2 European Union Directives

Applicable Standards/Norms
2004/108/EC Electromagnetic Compatibility Directive
2006/95/EC Low Voltage Directive
2011/65/EU RoHS Directive
EN 60825-1:2007 Safety of Laser Products (Keyswitch models only)
EN 61010-1:2001 Safety Requirements for Electrical Equipment for Measurement, Control, and
Laboratory Use - Part 1: General Requirements
EN 55011:1998 Conducted and Radiated Emissions Group 2, Class A
EN 50082-1:1997 RF Electromagnetic Immunity
IEC 1000-4-2:1995 Electrostatic Discharge Immunity
IEC 1000-4-3:1995 RF Electromagnetic Fields Immunity
IEC 1000--4-4:1995 Electrical Fast Transient/Burst Immunity
RoHS compliance
SYNRAD Series 48 M version lasers meet the requirements of the European Parliament and Council
Directive 2011/65/EU on the Restriction of the Use of Certain Hazardous Substances in Electrical and
Electronic Equipment that establishes maximum concentration values for certain hazardous substances in
electrical and electronic equipment.
After a laser or laser processing system has met the requirements of all applicable EU Directives, the prod-
uct can bear the official compliance mark of the European Union as shown in Figure 4 and a Declaration
of Conformity is provided for the compliant component.
Figure 4 European compliance mark

laser safety
Declaration of Conformity
Declaration of Conformity
in accordance with ISO/IEC 17050-2:2004
We,
Manufacturer’s Name: SYNRAD, Inc.
Manufacturer’s Address: 4600 Campus Place

Mukilteo, WA 98275
U.S.A.
hereby declare under our sole responsibility that the following equipment:
Product Name: Series 48 M Version Laser
Model Number: 48-1KxM, 48-2KxM, 48-5KWM (Keyswitch)

48-1SxM, 48-2SxM, 48-5SWM (OEM*)
conforms to the following Directive(s) and Standard(s):
Applicable Directive(s): 2004/108/EC Electromagnetic Compatibility Directive

2011/65/EU RoHS Directive
Applicable Standard(s): EN 61010-1:2001 Safety Requirements for Electrical Equipment

for Measurement, Control, and Laboratory
Use - Part 1: General Requirements
EN 60825-1:2007 Safety of Laser Products (Keyswitch only)
EN 55011:1998 Conducted and Radiated Emissions, Group 2,

Class A
EN 50082-1:1997 RF Electromagnetic Immunity
IEC 1000-4-2:1995 Electrostatic Discharge Immunity
IEC 1000-4-3:1995 RF Electromagnetic Field Immunity
IEC 1000-4-4:1995 Electrical Fast Transient/Burst Immunity
*
OEM lasers do not comply with EN 60825-1:2007, Safety of Laser Products. Buyers of OEM laser products are solely responsible
for meeting applicable Directives and Standards for CE compliance and marking.
Corporate Officer: European Contact:

Synrad Europe
Münchener Straße 2A
D-82152 Planegg
Dave Clarke, President of SYNRAD, Inc. Germany
Dated 09 May 2012

1
getting started
Use information in this chapter to prepare your Series 48 laser for operation. The order
of information presented in this chapter 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 chapter 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.
Synrad Series 48 operator’s manual

11
getting started
Introduction
The Introduction section includes subsections:
■ Series 48 features
■ Series 48 nomenclature
■ Model numbers
Series 48 features
The Series 48 family of lasers incorporates the latest developments in sealed carbon dioxide devices, com-
bining the best features of both waveguide and free space CO2 laser technology in an innovative aluminum
tube design. Series 48 lasers utilize state-of-the-art surface mount electronics, newly patented RF excita-
tion 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
■ 10 W and 25 W models available in 9.3 µm or standard 10.6 µm wavelengths
■ 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 addi-
tion 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 primarily designed as components for integration into a larger processing system by
an Original Equipment Manufacturer (OEM) or System Integrator who bears the responsibility for meet-
ing the appropriate laser safety requirements for Class 4 laser systems.
Model numbers
The last three characters in the Series 48 model number serve to designate the functional category, cool-
ing method, and model version. The functional category is indicated by either a “K” for Keyswitch or “S”
(Switch-less) for OEM models. The next letter indicates the cooling method: “W” for water-cooled units,
“F” for fan-cooled units, and “A” for air-cooled lasers (where the customer must provide the proper cooling
via fans). The last letter in the model number indicates the current model version beginning with “B”. For
example, the model number 48-1SAM designates that particular 48-1 (10 W) laser as an OEM, air-cooled,
“M” version model.

getting started
Unpacking
The Unpacking section includes subsections:
■ Incoming inspection
■ Packaging guidelines
Incoming inspection
Upon arrival at your facility, 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 chapter). 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.
■ Refer to the Packaging instructions drawings in the Technical Reference chapter for information on
packaging a Series 48 laser for shipment using SYNRAD-supplied packaging materials.
■ 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.

13
getting started
Inventory
SYNRAD CO2
synrad
co 2 laser
manuals
Laser's Manual CD P/N

90
0-2
0 33 6
- 01
© 20
11
, In c. A ll righ ts reserved
SYNR AD
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
SYNRAD CO2 Lasers Manual CD (Keyswitch models only).... 1
Mounting Kit (not shown, Keyswitch models only).................. 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.
SYNRAD CO2 Lasers Manual CD (Keyswitch models only) – contains a Series 48 M Version Operator’s
Manual that provides setup, operation, and maintenance information for your laser.
Mounting Kit (Keyswitch models only) – contains components to mount the laser and also includes a
DB-9 connector and cover 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" 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" O.D. black polyethylene tubing.
Final Test Report (not shown) – contains data collected during the laser’s final pre-shipment test.

15
getting started
Mounting
The Mounting section includes subsections:
■ Standard mounting
■ With an FH Series marking head
Standard mounting
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.
Caution SYNRAD does not recommend mounting lasers in a vertical “head-

down” or “tail-down” orientation. If you must mount your laser in
possible this manner, please contact the factory for limitations as vertical
equipment orientation increases the risk of damage to the laser’s output optic.
damage
Note: To allow for proper airflow, air-cooled units must have at least 57.2 mm (2.25 in) of unobstructed
clearance between the outside edge of the cooling fan and any enclosure or mounting surface.
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 chapter 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.

getting started
Mounting
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 Flyer 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.

17
getting started
Connecting
The Connecting section includes subsections:
■ Air-cooled connections
■ Water-cooled connections
■ Electrical connections
■ Control connections
■ DB-9 connections
The Connecting section contains all the information you need to connect your Series 48 laser for opera-
tion. Figure 1-8 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 con-
nections 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 7.1 m3/min (250 CFM) per fan is required to keep laser and heatsink
temperatures below 50 °C (122 °F) . 48-1 lasers have a heat load specification of 300 W maximum and
requires two cooling fans for a total of 14.2 m3/min (500 CFM). 48-2 lasers have a 500 W heat load and
requires four cooling fans for a total air flow of 28.3 m3/min (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 114–127 mm
(4.5–5 in) and have at least 57.2 mm (2.25 in) 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 fit-
tings. 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.
■ 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 12.7 mm (0.5 in) from its end before reconnecting.
Trimming the end of the tubing before reconnecting 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" tubing to 6 mm metric tubing. For 48-5 cooling
kits, convert the 3/8" tubing to 8 mm metric tubing. These tubing adaptors are available from many tubing
and fitting manufacturers.
Chiller preparation guidelines

■ You must provide fittings that will adapt the laser’s 1/4" or 3/8" O.D. polyethylene cooling tubing to
your chiller’s Inlet and Outlet ports. These fittings can be either “quick disconnect” or compression
type fittings.
■ Because Series 48 cooling tubing is specified in inch sizes, the use of metric tube fittings is discouraged
unless you have installed the appropriate inch-to-metric tubing adaptors. The use of metric fittings on
inch size tubing will lead to coolant leaks or may allow pressurized tubing to blow-off the fitting.
Coolants
SYNRAD recommends that the laser’s cooling fluid contain at least 90% distilled water by volume. In
closed-loop systems, use a corrosion inhibitor/algaecide such as Optishield® Plus or equivalent as required.
Avoid glycol-based additives because they reduce the coolant’s heat capacity and high concentrations may
affect power stability. For SYNRAD lasers, the minimum coolant setpoint is 18 °C (64 °F) so glycol is not
necessary unless the chiller is subjected to freezing temperatures. If tap water is used, chloride levels should
not exceed a concentration of 25 parts per million (PPM) and total hardness should be below 100 PPM.
Install a filter on the chiller’s return line and inspect frequently.
Note: DO NOT use de-ionized (DI) water as a coolant. DI water is unusually corrosive and is not rec-
ommend for mixed material cooling systems.
19
getting started
Connecting
Setting coolant temperature
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.
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 temperature of
the surrounding 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 3.8 lpm (1.0 GPM). Do not exceed a coolant pressure of 414
kPa (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; however, for best results and performance, use a coolant temperature in the range of 18–22 °C
(64–72 °F).
Caution Operating the laser at coolant temperatures above 22 °C (72 °F) may
result in decreased performance and/or premature failure of electronic
possible components.
equipment
damage

getting started
Connecting
Table 1-2 Dew point temperatures

Dew Point Temperature 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)
To use Table 1-2, look down the Air Temp column and locate an air temperature in Fahrenheit or Cel-
sius (°C values are shown in parentheses) that corresponds to the air temperature in the area where your
laser is operating. Follow this row across until you reach a column matching the relative humidity in your
location. The value at the intersection of the Air Temp and Relative Humidity columns is the Dew Point
temperature in °F (or °C). The chiller’s temperature setpoint must be set above the dew point temperature.
For example, if the air temperature is 85 °F (29 °C) and the relative humidity is 60%, then the dew point
temperature is 70 °F (21 °C). Adjust the chiller’s temperature setpoint to 72 °F (22 °C) to prevent con-
densation from forming inside the laser.

111
getting started
Connecting
48-1/48-2 cooling tubing connections
Water enters the laser’s rear plate through the lower 1/4" diameter cooling tubes and exits through the top-
mounted cooling tubes. The two right angle connections are installed at the front. Both circuits must be
used in parallel to maintain thermal balance. All fittings are quick-disconnect, push-on types.
To connect coolant tubing to your 48-1/48-2 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.
6 Turn on the chiller and adjust the temperature setpoint between 18–22 °C. For 48-1 lasers, regulate
coolant flow to 1.9 lpm (0.5 GPM) at less than 414 kPa (60 PSI) of pressure. For 48-2 lasers set a
coolant rate of 3.0 lpm (0.8 GPM) at less than 414 kPa (60 PSI) of pressure.
7 Closely examine all cooling connections and verify that there are no leaks.
Important Note: Inlet cooling water temperature must always be maintained above the dew point
temperature to prevent condensation and water damage to your laser.

getting started
Connecting
48-5 cooling tubing connections
Cooling water enters 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. All fittings are quick-disconnect, push-on 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.
7 Turn on the chiller and adjust the temperature setpoint between 18 °C–22 °C. Regulate coolant flow
to 5.7 lpm (1.5 GPM) at less than 414 kPa (60 PSI) of pressure.
8 Closely examine all cooling connections and verify that there are no leaks.
Important Note: Inlet cooling water temperature must always be maintained above the dew point to
prevent condensation and water damage to your laser.

113
getting started
Connecting
Electrical connections
DC power supply
Note: The negative (–) side of the DC input to the laser is internally connected so that the laser chas-
sis serves as DC power ground. You should isolate the laser’s DC power supply so that the only
grounded connection is at the laser. Alternatively, you can mount the laser chassis on an insulat-
ing pad or film in order to electrically isolate the laser when other equipment is grounded to the
laser’s DC power supply.
The 48-1 laser requires a DC power supply capable of providing 30 VDC at 7 A minimum; the 48-2 laser
requires 30 VDC at 14 A and the 48-5 requires 30 VDC at 28 A min. For the 48-1 laser, SYNRAD recom-
mends the DC-1, a 30 V, 250 W DC power supply; for 48-2 lasers, we recommend the PS-2, a 30 V, 750 W
DC power supply; and for the 48-5 laser, we recommend the PS-6, a 30 V, 1500 W DC power supply.
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: Series 48 lasers are tested to meet published specifications at an input voltage of 30.0 VDC.
DC-1 DC power supply (48-1 laser)

AC input power requirements for the DC-1 power supply are 85–264 VAC, single phase (1Ø), 4 A max,
47–440 Hz. To connect the DC-1 power supply, refer to Figure 1-5 and perform the following steps:
OUTPUT
+
V1
30 VDC
Output
–
COM
V4
Top View RET

V3
COM
COM
V2
AC
Input
Figure 1-5 DC-1 (Emerson LPS) power supply
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 terminal.
4 Connect an AC line cord to the AC receptacle located on the fan end of the DC-1 power supply.
Note: Because AC input connections and requirements vary from country to country, customers must
provide an AC power cable with the proper AC outlet plug on one end and a standard IEC 320
female connector, for the DC-1 power supply, on the other end.

getting started
Connecting
PS-2 DC power supply (48-2 laser)
AC input requirements for the PS-2 power supply are 90–264 VAC (auto-ranging) single phase (1Ø), 10
A max, 47–440 Hz. To connect the PS-2 power supply, refer to Figure 1-6 and perform the following steps:
Front View Rear View

+30 VDC Output
+
–
– DC Output
Figure 1-6 PS-2 (Emerson iMP4) power supply
1 Verify that input AC power to the DC power supply is physically locked out or disconnected.
2 Locate the 30 VDC output terminals on the power supply’s rear (output) section and connect the
black (–) DC Power cable from the laser to the negative (–) DC output terminal.
3 Connect the red (+) DC Power cable from the laser to the positive (+) 30 VDC output terminal.
4 On the supply’s front (input) section, connect the neutral wire, typically white, from your AC volt-
age source to the terminal labeled “N” (Neutral).
5 Connect the AC hot wire, typically black, from your AC voltage source to the terminal labeled “~”
(AC Hot Line).
6 Connect the ground (earth) wire, typically green, from your AC voltage source to the terminal
labeled with the ground symbol.
provide the appropriately sized AC power cable or wiring.

115
getting started
Connecting
PS-6 DC power supply (48-5 laser)
AC input requirements for the PS-6 power supply are 90–264 VAC (auto-ranging) single phase (1Ø), 20
A max, 47–440 Hz. To connect the PS-6 power supply, refer to Figure 1-7 and perform the following steps:
+30 VDC Output
– DC Output
Figure 1-7 PS-6 (Emerson iVS1) power supply
1 Verify that input AC power 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 (–) DC output terminal.
3 Connect the red (+) DC Power cable from the laser to the positive (+) 30 VDC output terminal.
4 On the supply’s input section, connect the neutral wire, typically white, from your AC voltage
source to terminal “N” (Neutral).
5 Connect the AC hot wire, typically black, from your AC voltage source to the terminal labeled “~”
(AC Hot Line).
6 Connect the ground (earth) wire, typically green, from your AC voltage source to the terminal
labeled with the ground symbol.
provide the appropriately sized AC power cable or wiring.
Control connections
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 Universal
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 connec-
tor 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:

getting started
Connecting
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
personal and may generate enough voltage to trigger uncommanded lasing.
injury
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.
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.
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: You can control Series 48 lasers from an alternate user-supplied PWM Command signal source.
See Controlling laser power in the Technical Reference chapter for control signal descriptions.
DB-9 connections
48 Series lasers are equipped with a female DB-9 connector mounted to the sidewall of the laser that
provides a means of monitoring fault conditions (over-temperature, control/RF circuitry failure) and adds
remote interlock, remote keyswitch (relay or switch), message output, and remote LED indicator capabil-
ity. For a complete description of DB-9 pin assignments and functions, see the DB-9 connections section in
the Technical Reference chapter.
A factory-installed jumper plug is attached to the DB-9 Connector to enable normal laser operation (see
Figure 3-6). If the jumper plug is removed, you must (1) jumper Pin 3 to Pin 4 (or Pin 2) or connect to ex-
ternal “remote interlock” circuitry and (2) you must jumper Pin 6 to Pin 7 or connect to external “remote
keyswitch” circuitry as described in the DB-9 connections section in the Technical Reference chapter.
Note: On lasers manufactured as OEM (-S) version lasers, i.e. without a Keyswitch, the Remote Interlock
function is bypassed internally; however, the Remote Keyswitch function on Pin 6 and Pin 7 pro-
vides a similar functionality.

117
BEAM BLOCK
118
RECIRCULATING CHILLER
CUSTOMER-SUPPLIED
AUTOMATED CONTROLLER
FOR LASE ON-OFF AND
Connecting
POWER CONTROL
COOLING
WATER OUT
AD
NR
SY
COOLING
CTRL WATER IN
UC-2000
Figure 1-8 Typical Series 48 system interconnection

GATE
+
GND
-
~L
~N
ANV/ANC
DC POWER SUPPLY
getting started

2
operation
Use information in this chapter 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
APERTURE
SEAL
LASER EXIT POWER LASE LED

APERTURE SHUTTER
LED
SWITCH
OPTICAL
ON OFF
ACCESSORY
AVOID EXPOSURE
MOUNTING (x6)
CARBON DIOXIDE LASER
INVISIBLE LASER RADIATION PWR LASE

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
Aperture Seal – prevents dust from damaging the output coupler during shipping. Remove the red self-
adhesive label before applying power to the laser.
Shutter Switch (Keyswitch models only) – manually closes the laser aperture and interrupts power to the
RF section(s). Do not use the shutter to partially block the beam or to control output power.
Power LED – 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 – illuminates red to indicate the lase mode of operation. If a tickle signal is present, the LASE
LED turns on after the five-second delay and becomes brighter as the PWM duty cycle is increased.
Keyswitch (Keyswitch models only) – 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 remote keyswitch pins of the DB-9 Connector then become the external power on/off/
reset control means.
Fuse – provides overcurrent protection for the internal circuitry of the laser.
DB-9 Connector – provides an interconnection for message, fault shutdown, remote interlock, remote
keyswitch, and interface signals. Refer to the DB-9 connections section in the Technical Reference chapter
for information on pin assignments and function.

operation
Controls and indicators
APERTURE
SEAL
LASER EXIT SHUTTER POWER LASE LED
APERTURE SWITCH LED
OPTICAL
ACCESSORY
R
AVOID EXPOSURE
MOUNTING (x6)
CARBON DIOXIDE LASER
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
Command (CTRL) Input – 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 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 – red (+) and black (–) DC Power input cables are manufactured from #12 AWG (48-
1/48-2) or #8 AWG (48-5) wire and measure 1.1 meters (3.5 feet) in length.
Auxiliary Power Connector – 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 – provides an opening from which the beam is emitted when lasing.
Diode Pointer Power Connector (optional) – provides a regulated +5 VDC, 100 mA output and is inter-
nally protected against short circuits by an auto-resetting fuse. The Diode Pointer Power connector is not
installed unless the optional Diode Pointer is ordered when the laser is manufactured.
Optical Accessory Mounting – provides six threaded holes for mounting standard beam delivery compo-
nents. 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. To prevent damage to the
laser when mounting optical components, the 8–32 mounting screws must not extend further than 4.8 mm
(0.1875 in) 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
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.
the 9.3–10.6 µm CO2 wavelength band depending on model. Because
serious direct or diffuse laser radiation can inflict severe corneal injuries,
personal always wear eye protection when in the same area as an exposed laser
beam. Do not contact the laser beam. This product emits an invisible
injury laser beam that is capable of seriously burning human tissue.
Always be aware of the beam’s path and always use a beam block
while testing.
Note: When performing the initial start-up sequence, check that the factory-installed DB-9 jumper plug
is installed. If not, you must provide the required Remote Interlock and Remote Keyswitch sig-
nals to the DB-9 Connector. See DB-9 connections in the Getting Started chapter for DB-9 pinouts
and signal descriptions.
Starting auxiliary equipment

1 Ensure that all personnel in the area are wearing protective eyewear.
2 Remove the red self-adhesive aperture seal from the laser faceplate.
3 Place a power meter, or appropriate beam block, 61 cm (24 in) from the laser aperture to prevent the
beam from traveling beyond the work area.
4 On water-cooled systems, turn on the chiller (set between 18 °C and 22 °C) and verify it is deliver-
ing the specified flow rate (see page 1-12 or 1-13) at less than 414 kPa (60 PSI) of pressure. Examine
all cooling connections carefully for leaks.
Caution Inlet cooling water temperature must always be maintained above the
dew point to prevent condensation and water damage to your laser.
possible
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.
5 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.
6 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
chapter 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.
5 On water-cooled lasers, shut off the chiller or otherwise stop coolant flow through the laser.
Important Note: Do not flow coolant through the laser for an extended period of time when the laser
is shutdown. This causes condensation to form inside the laser that may result in
catastrophic damage to internal optics and electronic circuits.
If your Series 48 laser fails to lase, refer to Troubleshooting in the Maintenance/Troubleshooting chapter for
troubleshooting information.

operation
Initial start-up
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) Com-
mand signal to the laser’s CTRL input connector. Refer to Controlling laser power in the Technical Refer-
ence chapter for tickle and PWM Command signal descriptions.
while testing.
Note: When performing the initial start-up sequence, check that the factory-installed DB-9 jumper plug
is installed. If not, you must provide the required Remote Interlock and Remote Keyswitch sig-
nals to the DB-9 Connector. See DB-9 connections in the Getting Started chapter for DB-9 pinouts
and signal descriptions.
Starting auxiliary equipment

1 Ensure that all personnel in the area are wearing protective eyewear.
2 Remove the red self-adhesive aperture seal from the laser faceplate.
3 Place a power meter, or appropriate beam block, 61 cm (24 in) from the laser aperture to prevent the
beam from traveling beyond the work area.
4 On water-cooled systems, turn on the chiller (set between 18 °C and 22 °C) and verify it is deliver-
ing the specified flow rate (see page 1-12 or 1-13) at less than 414 kPa (60 PSI) of pressure. Examine
all cooling connections carefully for leaks.
Caution Inlet cooling water temperature must always be maintained above the
dew point to prevent condensation and water damage to your laser.
possible
equipment
damage
5 Ensure that your PWM controller is set to zero percent output (0.0%).
6 Verify that the laser’s Keyswitch (if equipped) is in the OFF position.

operation
Initial start-up
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 Apply a tickle signal (a +5 VDC, 5 kHz square wave of 1 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.
Caution Series 48 lasers MUST be provided with a pre-ionizing “tickle” signal

during standby or laser “low” periods. This signal is automatically
possible provided by SYNRAD’s UC-2000 Universal Laser Controller or FH
equipment Series marking head.
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 equivalent drive
signals are not provided.
6 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.
7 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 simultaneously.
8 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 Ref-
erence chapter 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.

operation
Initial start-up
5 On water-cooled lasers, shut off the chiller or otherwise stop coolant flow through the laser.
Important Note: Do not flow coolant through the laser for an extended period of time when the laser
is shutdown. This causes condensation to form inside the laser that may result in
catastrophic damage to internal optics and electronic circuits.
If your Series 48 laser fails to lase, refer to Troubleshooting in the Maintenance/Troubleshooting chapter for
troubleshooting information.

3
technical reference
Use information in this chapter 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.
■ DB-9 connections – describes signals and specifications for the side-mounted DB-9
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.
■ Series 48 packaging instructions – describes how to package Series 48 lasers for ship-
ment.

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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 degrada-
tion 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.
48 Series lasers emit a laser beam with a wavelength of 9.3 or 10.6 microns (µm) depending on model.
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.
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 automated
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.
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. 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. Waste heat is
conducted away by all four metal sides of the bore to the outer walls of the plasma tube, where it is trans-
ferred to the chassis.
Optical resonator
The optical resonator consists of a curved total reflector and a flat Zinc Selenide (ZnSe) output coupler.
The mirrors are held on with Viton (fluorocarbon) elastomeric o-rings for factory adjustment by means of
three screws that are secured by adhesive after alignment. The 4.8 mm bore, in conjunction with the mir-
ror curvature selected, limits the output beam to TEM00 modes when the mirrors are properly aligned.

technical reference
Technical overview
On 10.6 µm models, the output wavelength remains at or near 10.6 µm (typically 10.57 µm to 10.63 µm).
At the 9.3 µm wavelength, laser output is in the range of 9.229–9.317 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 resona-
tor combine to produce a mode quality (M2 factor) of less than 1.2. As shown in Figure 3-1, 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 in
the far field).
BEAM WAIST DIA. ~ 3.5 mm
FULL ANGLE
RF DISCHARGE REGION Ø DIVERGENCE ~ 4 mrad
OUTPUT COUPLER
TOTAL REFLECTOR
Figure 3-1 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 clos-
es, 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.

33
technical reference
Technical overview
Fault shutdown conditions
The output of the Keyswitch is connected to the control board through the DB-9 Connector user port. Note
that the supplied DB-9 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 DB-9 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 shutdown
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 shut-
down output (Pin 1 of the DB-9 connector) will latch to low state until a keyswitched reset occurs.
The Power-On Reset feature will not allow lasing to restart after a power failure or shutdown has occurred
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.
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.
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 electroni-
cally 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.

technical reference
Technical overview
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 permis-
sible 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 enter-
ing 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 1.0–1.5 m (40–60 in)
away from the work area. Right angle turning mirrors are often used in conjunction with the laser mount-
ing position to obtain this distance. Figure 3-2 shows how right angle turning mirrors in a “flying optics”
setup create this longer beam path.
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.
Figure 3-2 “Flying optics” beam path

35
technical reference
Technical overview
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 minimum
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
equipment contaminants and carefully clean as required. In dirty environments,
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. Be careful to select
optics that are thick enough to withstand the maximum assist gas pressure available for the process. This is
especially important in metal cutting applications using high-pressure assist gases.
Cleanliness is another important issue affecting performance and becomes increasingly important as laser
power increases. Dirty or scratched lenses will under perform, exhibit a vastly shortened lifetime, and may
fail catastrophically.
When the application requires air (instead of nitrogen) as an assist gas, use only breathing quality air avail-
able 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 ISO 8573-1:2010 Class 1, 2, 1 specifications shown in Table 3-1.
Table 3-1 Assist gas purity specifications

Assist Gas Typical Purpose Specification
Air Cutting/Drilling Breathing Grade > 99.9996% purity; filtered to ISO Class 1
particulate level
Air Cutting/Drilling Compressed Instrument-grade air filtered and dried to

ISO 8573-1:2010 Class 1, 2, 1 (< 10 1.0–
5.0 µm particles/m3; < –40 °F dew point;
< 0.01 mg/m3 oil vapor)
Argon Welding High Purity Grade > 99.998% purity; filtered to ISO Class 1
particulate level
Helium Welding High Purity Grade > 99.997% purity; filtered to ISO Class 1
particulate level
Nitrogen Cutting/Drilling High Purity Grade > 99.9500% purity; filtered to ISO Class 1
particulate level
Oxygen Cutting/Drilling Ultra Pure Grade > 99.9998% purity; filtered to ISO Class 1
particulate level

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 tickle and PWM Command signals to the laser. If you are using an alternate
method of laser control, thoroughly review this section for an understanding of the signal requirements
necessary to control SYNRAD Series 48 lasers. Table 3-2 lists input voltage and current specifications for
48 Series control (CTRL) inputs. Table 3-3 and Table 3-4 provide specific tickle pulse and PWM Com-
mand signal parameters.
Table 3-2 Input signal specifications

Parameter Specification
Logic Low (Off State) 0.0 V to +0.5 VDC; 0.0 VDC nominal
Logic High (On State) +3.5 V to +10.0 VDC; +5.0 VDC nominal
Maximum Current Load 6 mA (48-1 / 48-2); 12 mA (48-5)
Tickle pulse
Series 48 lasers require a 1 µs tickle pulse delivered at a nominal 5 kHz clock frequency from the Control-
ler. Tickle pulses pre-ionize the laser gas to just below the lasing threshold so that any 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. The lase threshold is preset for 3 µs ±0.5 µs
based on a PWM and tickle frequency input of 5 kHz. See Table 3-3 for tickle specifications.
Caution Applying PWM Command pulses directly to the laser without first
sending tickle pulses will cause unpredictable laser emission, degrade
possible optical rise time, and may lead to RF Driver failure.
equipment
damage
Table 3-3 Tickle pulse specifications

Tickle Frequency 5 kHz
Pulse Length 1.0 µs ± 0.2 µs
Pulse Rise/Fall Time < 100 ns between +0.5 V to +3.5 VDC

37
technical reference
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 3-3 illustrates tickle pulse parameters.
200 µs 1 µs
5 VDC
0 VDC
Figure 3-3 Tickle pulse waveform
Series 48 lasers are designed to operate at a tickle frequency of 5 kHz, which allows the laser to meet
published specifications. Tickle frequencies lower than 4.5 kHz may compromise laser performance,
particularly optical rise times, and stress the RF electronics thereby reducing long term reliability while
tickle 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. When 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.
Pulse width modulation (PWM)

Pulse Width Modulation, or PWM, controls laser power by varying the duty cycle of the laser’s RF ampli-
fiers, 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 3-4 shows Series 48 optical wave-
forms 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 3-4 Series 48 waveforms

technical reference
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 chapter.
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 maximum.
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
personal and may generate enough voltage to trigger uncommanded lasing.
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.
The first Command signal parameter, signal amplitude, is either logic low—corresponding to laser beam
off, or logic high—corresponding to beam on. The laser off voltage, typically 0 V, can range from 0.0 V to
+0.5 VDC while the laser on voltage, typically 5 V, can range from +3.5 V to 10.0 VDC.
Base frequency, the second parameter, 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 Command signal parameter, PWM duty cycle, is the percentage of the period that the Com-
mand 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
3-5 illustrates Command signal parameters while Table 3-4 lists PWM Command signal specifications.
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 3-5 PWM Command signal waveform

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technical reference
Table 3-4 PWM Command signal specifications
Laser State Minimum Nominal Maximum
Laser Off Voltage 0.0 VDC 0.0 VDC +0.5 VDC
Laser On Voltage +3.5 V +5.0 VDC +10.0 VDC
Current (@ 5 VDC) — — — — 6 mA (48-1/48-2)

12 mA (48-5)
Frequency Range 0 Hz (DC) 5 kHz 20 kHz
Duty Cycle 0% — — 100%
Caution Applying PWM Command pulses directly to the laser without first
sending tickle pulses will cause unpredictable laser emission, degrade
possible optical rise time, and may lead to RF Driver failure.
equipment
damage
Operating modes
External control
In addition to controlling your Series 48 laser using a UC-2000 Controller, controlling the laser externally,
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 en-
ergy. Both gating and power can be handled by a device such as a personal computer, Programmable Logic
Controller (PLC), or a function generator capable of sending PWM pulses at the proper time (gating) and
with the proper duty cycle (power).
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.
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.

technical reference
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 +5.0 VDC pulses to the
Gate connector on the rear panel of the UC-2000.
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 high level (+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 gate logic is factory set to internal Pull-Up
(normally on) mode so that an open (disconnected) Gate input
serious causes the laser to turn on. This functionality allows the user to easily
personal test and verify laser operation prior to integration.
injury In an integrated system, you should configure the UC-2000’s gate

input logic to internal Pull-Down (normally off) mode. This prevents
the beam from being enabled unless a high level (+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 signal, short circuit
to ground, or an open or disconnected Gate input locks the beam off.
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.

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technical reference
DB-9 connections
Series 48 lasers are equipped with a female DB-9 connector mounted to the sidewall of the laser. The DB-9
Connector provides the user with a convenient method for monitoring fault conditions (over temperature,
control/RF circuitry failure, etc.) and adds remote interlock, remote keyswitch (relay or switch), message
output, and remote LED indicator capability. These signals allow you to connect remote keyswitch, LASE,
and ready (PWR) indicators to a remote operator’s station or connect a remote interlock safety switch to
interlock equipment doors or panels.
A factory-installed jumper plug is attached to the DB-9 Connector on each laser to enable normal opera-
tion on initial start-up. Two jumpers are wired into the plug as shown in Figure 3-6. The jumper between
Pin 6 and Pin 7 closes the Remote Keyswitch Input and the jumper between Pin 3 and Pin 4 closes the
Remote Interlock Input. If the jumper plug is removed, then you must connect the appropriate external
remote interlock or remote keyswitch circuitry in order to enable lasing. To take advantage of the DB-9
functions described in Table 3-5, you must manufacture a connecting cable that properly integrates the
DB-9 signals into your automated system. A spare DB-9 male connector and cover is included with each
laser (Keyswitch only) to facilitate cable manufacture.
REMOTE INTERLOCK
JUMPER
1 2 3 4 5
6 7 8 9
REMOTE
KEYSWITCH JUMPER
Figure 3-6 Factory-installed DB-9 jumper plug wiring
Caution Do not ground Remote Keyswitch or Remote Interlock inputs to

an external circuit—this will damage laser circuitry. Any external
possible circuit(s) connected to these terminals must be floating with respect
equipment to ground. We recommend using “dry circuit” (zero voltage) switches
or relay circuitry.
damage
Caution Do not apply a voltage to the Remote Interlock Input on DB-9 Con-
nector Pin 3 as this will damage internal laser circuitry. The Remote
possible Interlock Input on Pin 3 is a “dry-circuit” (zero voltage) input and
equipment must connect only to Pin 2 or Pin 4 to complete the interlock circuit.
damage

technical reference
DB-9 connections
Table 3-5 DB-9 pin assignments
Pin # Function Description
1 Fault Shutdown Output
Indicates failure of internal circuitry or existence of over temperature (> 60 °C ±2 °C), over
voltage, or under voltage fault. This active low signal (referenced to Pin 2 or Pin 4) transitions
from +15 V (normal operation) to 0 VDC when a fault occurs. Use this output signal to disable
external processes during a fault. See Note 1 and Table 3-7 for output signal specifications.
2 Signal Ground
Signal ground/chassis ground for Pins 1, 3, 5, 8, and 9.
3 Remote Interlock Input

Disables the laser when an interlock switch wired to this input from an equipment door or panel
is opened. Ground this input to Pin 2 or Pin 4 only. Do not apply a voltage to this pin—see Note
2 and Table 3-6 for input signal specifications. As shipped, Pins 3 and 4 are connected by the
factory-installed jumper plug to enable the Remote Interlock function.
4 Signal Ground
Signal ground/chassis ground for Pins 1, 3, 5, 8, and 9.
5 Message Output
This active low signal (referenced to Pin 2 or Pin 4) transitions from +15 V (normal operation)
to 0 VDC when a pre-shutdown temperature warning occurs (when laser temperature reaches 54
°C ±2 °C) and remains low until temperature falls 2 °C. Use this output to notify user of need to
increase laser cooling or risk shutdown. See Note 1 and Table 3-7 for output signal specifications.
6 Remote Keyswitch Input

Connect a remote relay or switch in series with the laser Keyswitch to control laser On / Off /
Reset functions. Connect Pin 6 to Pin 7 to run; open this connection to halt lasing or reset faults.
As shipped, Pins 6 and 7 are connected by the factory-installed jumper plug to enable the Remote
Keyswitch function. See Note 2, Note 3, and Table 3-6 for input signal specifications.
7 Remote Keyswitch Output

Connect Pin 7 to Pin 6 to enable the Remote Keyswitch function (see Pin 6 description above).
Pin 7 is at DC line potential (+30 VDC) only when the Keyswitch is set to ON. As shipped, Pins
6 and 7 are connected by the factory-installed jumper plug. See Note 3, Note 4, and Table 3-7
for output signal specifications.
8 Remote Lase LED Output

Connect an LED or LED-optoisolator between Pin 8 and Signal Ground for a remote LASE indi-
cation. See Note 5, Note 6, and Table 3-7 for output signal specifications.
9 Remote Ready LED Output

Connect an LED or LED-optoisolator between Pin 9 and Signal Ground for a remote Ready
(PWR) indication. See Note 5 and Table 3-7 for output signal specifications.
1 Pin 1 and Pin 5 are active low outputs. 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.
6 The output of Pin 8, the Remote Lase LED Output, is a Pulse Width Modulated (PWM) signal based on the PWM Command
input signal. It is not a steady state (on/off) output.

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technical reference
DB-9 connections
Figure 3-7 shows the physical layout and pin identification of the Series 48 DB-9 Connector. Table 3-6
describes input signal specifications while Table 3-7 lists output signal specifications.
DB-9 Connector
PIN 5 PIN 1
PIN 9 PIN 6
Figure 3-7 Physical layout of Series 48 DB-9 Connector
Table 3-6 DB-9 Connector input signal specifications
Pin # Input Signal Name Input Specifications
3 Remote Interlock Input 50 mA maximum @ 30 VDC. Important Note: Use “dry

6 Remote Keyswitch Input circuit” (zero-voltage) external switches to prevent internal circuit
damage.
Table 3-7 DB-9 Connector output signal specifications
Pin # Output Signal Name Output Specifications
1 Fault Shutdown Output Active Low output signal: Off: + 15 VDC, 5 mA into 3 kOhm;
5 Message Output On: < 1 VDC, sinking 100 mA.
7 Remote Keyswitch Output 50 mA maximum @ 30 VDC. Output active (+30 VDC) when
Keyswitch ON or bypassed (OEM models).
8 Remote Lase LED Output Current-limited to 11 mA @ 2.4 VDC maximum. Voltage output
is pulse width modulated at input PWM Command signal
frequency, not a steady state on/off signal.
9 Remote Ready LED Output Current-limited to 11 mA @ 2.4 VDC maximum.

technical reference
DB-9 connections
Sample DB-9 Connector I/O circuits
Sample input circuits
Figure 3-8 illustrates a method of connecting a relay contact or limit switch to act as a remote keyswitch.
Remember that Remote Keyswitch and Remote Interlock inputs are “dry circuit” or zero-voltage inputs.
DB-9 CONNECTOR PINS
(7) REMOTE KEYSWITCH

RELAY CONTACT OR OUTPUT
LIMIT SWITCH
(6) REMOTE KEYSWITCH
INPUT
Figure 3-8 Remote Keyswitch circuit
Figure 3-9 shows how to connect the laser’s Remote Interlock input in series with one or more door safety
switches or relay contacts.
DB-9 CONNECTOR PINS
(2) SIGNAL GROUND

DOOR SAFETY SWITCHES
OR RELAY CONTACTS
(3) REMOTE INTERLOCK

INPUT
Figure 3-9 Remote Interlock circuit
Sample output circuits

Figures 3-10 through 3-12 illustrate how to connect the laser’s Remote Ready LED Output to a Program-
mable Logic Controller (PLC) DC input module using current sourcing, current sinking, and resistive
pull-up methods.
Note: You can use these same circuits to monitor the laser’s Remote Lase LED Output (DB-9, Pin 8);
however, the Remote Lase LED Output is not a steady state (on/off) output. It is a Pulse Width
Modulated (PWM) signal based on the PWM Command input signal to the laser.
PLC
DB-9 CONNECTOR PINS
4N29 OPTOISOLATOR
+24 VDC
1 6
(9) REMOTE READY NC INPUT
LED OUTPUT 5
RTN
2
(2) SIGNAL GROUND
4
NC 3
24 VDC GND
Figure 3-10 Remote Ready output to PLC input (PLC sourcing)

315
technical reference
DB-9 connections
PLC
DB-9 CONNECTOR PINS
4N29 OPTOISOLATOR
+24 VDC
1 6
(9) REMOTE READY NC
LED OUTPUT 5
2
(2) SIGNAL GROUND
4
NC 3 INPUT
RTN
24 VDC GND
Figure 3-11 Remote Ready output to PLC input (PLC sinking)
PLC
+24 VDC
DB-9 CONNECTOR PINS
4N29 OPTOISOLATOR
1 6
(9) REMOTE READY NC
LED OUTPUT 5
INPUT
2
(2) SIGNAL GROUND
4
NC 3 RTN
24 VDC GND
Figure 3-12 Remote Ready output to PLC input using pull-up resistor
Figure 3-13 shows how to connect the Message Output signal on the DB-9 Connector to a PLC. The
Message Output function provides a pre-shutdown temperature indication when laser tube temperature
reaches 54 °C ±2 °C, signaling the need to increase laser cooling or risk laser shutdown if laser tempera-
ture rises to > 60 °C ±2 °C.
PLC
DB-9 CONNECTOR PINS
(5) MESSAGE OUTPUT INPUT
(2) SIGNAL GROUND RTN
Figure 3-13 Message Output to PLC input

technical reference
DB-9 connections
Figure 3-14 illustrates how to connect the Fault Shutdown Output signal to a PLC. The Fault Shutdown
Output function signals a laser shutdown due to an under/over voltage condition, an over temperature
condition, or failure of internal circuitry.
PLC
DB-9 CONNECTOR PINS
(1) FAULT SHUTDOWN INPUT

OUTPUT
(2) SIGNAL GROUND RTN
Figure 3-14 Fault Shutdown Output to PLC input

317
technical reference
Integrating Series 48 safety features
The Integrating Series 48 safety features section includes subsections:
■ Remote keyswitch functions

■ Remote interlock functions
The Series 48 DB-9 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 func-
tions 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.
Remote 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. Over tempera-
ture faults are reset by removing, then reapplying DC power after the laser has cooled.
For Keyswitch lasers in automated control systems, this reset function is provided by the Remote Key-
switch signal via pins 6 and 7 on the DB-9 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 when the remote keyswitch circuit is open.
Your control system can monitor the laser’s power-on status through the DB-9 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 3-6, DB-9 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 a 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 DB-9 Connector.
To use this “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.

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 connects 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 DB-9
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, to 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 DB-9 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
equipment Pin 4 to complete the interlock circuit.
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.
OEM lasers

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technical reference
Model 48-1 general specifications
Table 3-8 Model 48-1 general specifications
Parameter
Output Specifications 10.6 µm 9.3 µm
Wavelength (microns) ............................... 10.57–10.63 .....................................9.23–9.31
†
Power Output1, 2 ........................................10 W.................................................8 W

Power Stability3 ..........................................±10%................................................±15%
Mode Quality.............................................. M2 < 1.2............................................M2 < 1.2
Beam Waist Diameter (at 1/e2)4 ................. 3.5 mm..............................................3.5 mm
Beam Divergence, full angle ...................... 4 mrad...............................................4 mrad
Ellipticity .................................................... < 1.2..................................................< 1.2
Polarization ................................................ Linear, vertical..................................Linear, vertical
Extinction ratio........................................... 50:1 minimum..................................50:1 minimum
Rise Time ................................................... < 150 µs............................................< 150 µs
Electrical Specifications
Power Supply Output
Voltage................................................. 30 VDC
Maximum Current .............................. 7 A
Control (CTRL) Input

Logic Low (Off State) ......................... 0.0 V to +0.5 VDC; 0.0 V nominal
Logic High (On State)........................ +3.5 V to +10.0 VDC; +5.0 V nominal
Maximum Current Load...................... 6 mA @ +5.0 VDC
Tickle Pulse Signal

Tickle Frequency5................................5 kHz
Pulse Length........................................ 1.0 µs ± 0.2 µs
Pulse Rise/Fall Time............................. < 100 ns between +0.5 V to +3.5 VDC
PWM Command Input Signal

PWM Frequency6 ................................DC to 20 kHz
PWM Duty Cycle ............................... 0% to 100%
* Specifications subject to change without notice.

† Typical. Actual wavelength range may vary from 10.2–10.8 µm.
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) at 95% duty cycle.
4 Measured at laser output.
5 48 Series lasers are designed to operate at a tickle frequency of 5 kHz, which allows the laser to meet published specifications.
Tickle frequencies lower than 4.5 kHz may compromise laser performance, particularly optical rise times, and stress the RF
electronics thereby reducing long term reliability while tickle frequencies greater than 5 kHz may cause laser emission.
6 FCC and CE tested at 5 kHz.

technical reference
Parameter
Cooling Specifications7 (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
Environmental Specifications
Operating Temperature8 ............................15 °C to 40 °C
Humidity..................................................... 0% to 95%, non-condensing
Physical Specifications
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)

7 Inlet cooling water temperature should always be maintained above the dew point to avoid condensation and water damage
to the laser.
8 Published specifications guaranteed at a cooling temperature of 22 °C. Some performance degradation may occur when operated
in ambient air or coolant temperatures above 22 °C.

321
technical reference
Parameter
Output Specifications 10.6 µm 9.3 µm
Wavelength (microns) ............................... 10.57–10.63 .....................................9.23–9.31
†
Power Output1, 2 ........................................25 W.................................................18 W

Power Stability3 ..........................................±5%..................................................±7%
Mode Quality.............................................. M2 < 1.2............................................M2 < 1.2
Beam Waist Diameter (at 1/e2)4 ................. 3.5 mm..............................................3.5 mm
Beam Divergence, full angle ...................... 4 mrad...............................................4 mrad
Ellipticity .................................................... < 1.2..................................................< 1.2
Polarization ................................................ Linear, vertical..................................Linear, vertical
Extinction ratio........................................... 50:1 minimum..................................50:1 minimum
Rise Time ................................................... < 150 µs............................................< 150 µs
Power Supply Output
Voltage................................................. 30 VDC

Logic High (On State)......................... +3.5 V to +10.0 VDC; +5.0 V nominal
Tickle Pulse Signal

Tickle Frequency5.................................5 kHz
Pulse Length......................................... 1.0 µs ± 0.2 µs

PWM Duty Cycle ................................ 0% to 100%


technical reference
Parameter
Cooling Specifications7 (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
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)

to the laser.

323
technical reference
Parameter
Output Specifications 10.6 µm
Wavelength (microns) ............................... 10.57–10.63†
Power Output1, 2 ........................................50 W
Power Stability3 ..........................................±5%
Mode Quality.............................................. M2 < 1.2
Beam Waist Diameter (at 1/e2)4 ................. 3.5 mm
Beam Divergence, full angle ...................... 4 mrad
Ellipticity .................................................... < 1.2
Polarization ................................................ Random
Extinction ratio........................................... N/A
Rise Time ................................................... < 150 µs
Power Supply Output
Voltage................................................. 30 VDC

Logic High (On State)........................ +3.5 V to +10.0 VDC; +5.0 V nominal
Tickle Pulse Signal

Tickle Frequency5................................5 kHz
Pulse Length........................................ 1.0 µs ± 0.2 µs

PWM Duty Cycle ............................... 0% to 100%


technical reference
Parameter
Cooling Specifications7, 8 (Water-cooled)
Maximum Heat Load, laser ........................ 800 W
Minimum Flow Rate .................................. 1.5 GPM, < 60 PSI
Coolant Temperature ................................. 18 °C to 22 °C
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)

7 Lasers with output power > 50 W must be water-cooled. Lasers with output < 50 W can be water- or air-cooled although
water-cooling is strongly recommended for duty cycles > 50%. Water-cooling improves power stability at any duty cycle.
to the laser.

325
technical reference
Model 48-1 package outline drawing
Figure 3-15 Model 48-1 package outline and mounting dimensions

technical reference

327
technical reference

technical reference
Series 48 packaging instructions
Figure 3-18 Model 48-1 packaging instructions

329
technical reference

technical reference

331
technical reference
Figure 3-21 FLMK-1A (10W fan shroud) packaging instructions

technical reference
Figure 3-22 FLMK-2A (25W fan shroud) packaging instructions

333
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4
maintenance/
troubleshooting
Use information in this chapter to perform maintenance or troubleshoot your SYNRAD
Series 48 laser.
■ 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 48 Series laser

■ Daily inspections
■ Storage/shipping
■ Cleaning optical components
Disabling the 48 Series laser

Before performing any maintenance on your SYNRAD 48 Series 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.
Warning A risk of exposure to toxic elements, like zinc selenide, may result
when certain optical or beam delivery components are damaged. In
serious the event of damage to laser, marking head, or beam delivery optics,
personal contact SYNRAD, Inc. or the optics manufacturer for handling
instructions.
injury
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
equipment head, and associated optical components.
damage
1 For water-cooled lasers, inspect cooling tubing connections for signs of leakage. Check for signs of
condensation that may indicate the cooling water temperature is set below the dew point tempera-
ture. Condensation will damage electrical and optical components inside the laser. See Setting coolant
temperature in the Getting Started chapter for information on preventing condensation.
2 Inspect beam delivery components for signs of dust or debris and clean as required. When cleaning
the optical surfaces of beam delivery components, carefully follow the manufacturer’s instructions.

maintenance/
troubleshooting
Maintenance
3 When using compressed air as a purge/assist gas for your beam delivery system, empty water traps and
oil separators on each filter and/or dryer between the laser and your compressed air source. Com-
pressed air purity must meet the gas purity specifications shown in Table 3-1 in the Technical Refer-
ence chapter.
4 Visually inspect the laser’s exterior housing to ensure that all warning labels are present. Refer to
hazard label drawings in the Laser Safety chapter for label types and locations.
Storage/shipping
When preparing a water-cooled 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 com-
ponents. 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.
When shipping SYNRAD lasers to another facility, we highly recommend that you ship the unit in its
original SYNRAD shipping container. If you no longer have the original shipping box and inserts, contact
SYNRAD Customer Service about purchasing replacement packaging. Refer to Series 48 packaging instruc-
tions in the Technical Reference chapter for detailed instructions on properly packaging the laser for ship-
ment.
Important Note: Failure to properly package the laser using SYNRAD-supplied shipping boxes and
foam/cardboard inserts as shown in the Packaging Instructions may void the war-
ranty. Customers may incur additional repair charges for shipping damage caused by
improper packaging.
Cleaning optical components
Danger Ensure that DC power to the laser is turned off and locked out before
inspecting optical components in the beam path. Invisible CO2 laser
serious radiation is emitted through the aperture. Corneal damage or blind-
personal ness may result from exposure to laser radiation.
injury
Caution A small amount of contamination on the laser’s output window (or

on any optic in the beam path) can absorb enough energy to damage
possible the optic. Inspect the output window and other beam delivery optics
equipment periodically for signs of contaminants and carefully clean as required.
damage In dirty environments, purge laser optics using filtered air or nitrogen
to prevent vapor and debris from accumulating on optical surfaces.

maintenance/
troubleshooting
Maintenance
Debris or contaminants on the laser’s output coupler or external beam delivery components may affect la-
ser processing and lead to damage or failure of the optics and/or the laser. Carefully follow the steps below
to inspect and clean the optical components in the beam path. Before beginning the cleaning process,
read this entire section thoroughly to ensure that all cleaning materials are available and that each step is
completely understood.
Important Note: Exercise great care when handling infrared optics; they are much more fragile than
common glass materials. Optical surfaces and coatings are easily damaged by rough
handling and improper cleaning methods.
Cleaning guidelines
■ Wear latex gloves or finger cots (powder-free) to prevent contamination of the optical surfaces by dirt
and skin oils.
■ Never handle optics with tools; always use gloved hands or fingers.
■ Hold optics by the outer edge; never touch the coated surface.
■ Always place optics on lens tissue for protection; never place optics on hard or rough surfaces.
■ It may be necessary to use a fluffed cotton swab or cotton ball instead of a lens wipe to uniformly clean
the entire surface of small-diameter mounted optics.
■ Before using any cleaning agents, read Material Safety Data Sheets (MSDS) and observe all necessary
safety precautions.
Required cleaning materials

Table 4-1 lists the type and grade of materials required to properly clean optical surfaces.
Table 4-1 Required cleaning materials

Cleaning Material Requirements
Latex gloves or finger cots Powder free
Air bulb Clean air bulb
Ethyl or isopropyl alcohol Spectroscopic or reagent grade
Acetone Spectroscopic or reagent grade
Lens wipe (preferred) Optical (cleanroom) quality
Cotton balls or cotton swabs High-quality surgical cotton/high-quality paper-bodied

maintenance/
troubleshooting
Maintenance
Cleaning optics
1 Shut off and lock out all power to the laser. You must verify that the laser is in a zero-energy state
before continuing with the optical inspection!
2 Visually inspect all optical surfaces in the beam path, including the laser’s output coupler, for con-
taminants.
Caution Do not allow the nozzle of the air bulb to touch the optical surface.
Any contact may damage the optic by scratching coatings on the
possible optical surface.
lens
Do not use compressed shop air to blow contamination from the op-
damage tic. Compressed air contains significant amounts of water and oil that
form adsorbing films on the optical surface.
Do not exert pressure on the surface of the optic during cleaning.

Optical surfaces and coatings are easily scratched by dislodged con-
taminants.
Use a new lens wipe on each pass as contaminants picked up by the

wipe may scratch the optical surface.
3 Remove loose contaminants from the optic by holding a clean air bulb at an angle to the optic and
blow a stream of air at a glancing angle across the lens surface. Repeat as necessary.
4 Dampen a lens wipe with the selected cleaning agent. Alcohol (least aggressive) is best for initial
surface cleaning. Acetone (moderately aggressive) is best for oily residue or minor baked-on vapors
and debris.
Important Note: If acetone is used as a cleaning solvent, a second follow-up cleaning of the optical
surface using alcohol is required to remove any acetone residue.
5 Gently, and without applying pressure, drag the damp lens wipe across the optical surface in a single
pass. Do not rub hard or apply any pressure, especially when using a cotton swab. Drag the wipe
without applying any downward pressure.
Note: Use a clean lens wipe on each pass. The wipe will pick up and carry surface contaminants that
may scratch optical surfaces or coatings if reused.
To prevent streaking during the final alcohol cleaning, drag the lens wipe slowly across the surface
so that the cleaning liquid evaporates right behind the wipe.
6 Carefully examine the optic under a good light. Certain contaminants or damage such as pitting
cannot be removed. In these cases the optic must be replaced to prevent catastrophic failure.
7 Repeat Steps 4 through 6 as required, removing all traces of contaminants and deposits.

maintenance/
troubleshooting
Troubleshooting
The Troubleshooting section includes subsections:
■ Introduction
■ 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 replace-
ment information.
To troubleshoot the Series 48 laser, it is necessary to understand the sequence of events that must hap-
pen 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.
while testing.
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
equipment SYNRAD Service Department.
damage

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 provided
the PWR indicator is illuminated green.
After a power failure or shutdown has occurred, the Power-On Reset feature will not allow lasing to restart
until the Keyswitch or Remote Keyswitch is first cycled off (open circuit condition) and then back on (closed
circuit).
During any fault shutdown, the Fault Shutdown Output (Pin 1 on the DB-9 Connector), which is nor-
mally at +15 VDC, latches to a low state (0 VDC) until a keyswitched reset occurs.
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 DB-9 Connector. When the PWR indicator illuminates, lasing is enabled after the five-second delay.
The Power-On Reset feature is not available on OEM models; OEM customers must provide this required
safety feature as part of their equipment integration.
During any fault shutdown, the Fault Shutdown Output (Pin 1 on the DB-9 Connector), which is nor-
mally at +15 VDC, latches to a low state (0 VDC) until the laser is reset by removing DC power for 30
seconds and then reapplying power to the laser.

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 (rated at 32 V minimum) as required.
■ A reverse DC voltage was applied to the laser.
Replace the fuse(s) with a fast-blow 10 Amp (48-1) or 20 Amp (48-2/48-5) AGC/3AG fuse (rated at 32 V
minimum) as required.
■ The laser’s DB-9 Connector is not configured correctly.
Ensure that the factory-wired DB-9 jumper plug is firmly plugged into the laser’s DB-9 Connector.
If the laser is connected through the DB-9 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 Connect-
ing in the Getting Started chapter and DB-9 connections in the Technical Reference chapter 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.
■ The laser’s Keyswitch is not set properly.
Cycle the Keyswitch to the OFF position for a few seconds, then cycle back to ON.
■ The laser is in an over temperature condition.
Allow the laser to cool. Verify that the laser is receiving the proper air or water flow per Table 4-2. On
air-cooled lasers, verify fan operation and check for at least 57.2 mm (2.25 in) of unobstructed clearance
around the fan housing. To restart the laser, disconnect DC power, wait 30 seconds, and then reapply DC
power.

maintenance/
troubleshooting
Troubleshooting
Table 4-2 Series 48 cooling specifications
Model Air-cooled Water-cooled
48-1 7.1 m3/min × 2 fans (1 per side) 1.9 lpm at < 414 kPa
250 CFM × 2 fans (1 per side) 0.5 GPM at < 60 PSI
48-2 7.1 m3/min × 4 fans (2 per side) 3.0 lpm at < 414 kPa
250 CFM × 4 fans (2 per side) 0.8 GPM at < 60 PSI
48-5 N/A 5.7 lpm at < 414 kPa

N/A 1.5 GPM at < 60 PSI
Symptom:
■ No output beam and the PWR and LASE LEDs are Off, but +30 VDC is applied.
Possible Causes:
■ A fault shutdown has occurred. Pin 1 on the DB-9 Connector is at 0 VDC in reference to Pin 2 or
Pin 4 (Pin 1 is at +15 VDC during normal operation).
An over temperature, overvoltage/undervoltage, or RF circuitry failure has occurred.
Correct the problem(s), then remove power from the laser for 30 seconds. Re-apply power (on Keyswitch
lasers, cycle the Keyswitch or Remote Keyswitch).
Symptom:
■ No output beam, the PWR LED is On, but the LASE indicator is off.
Possible Causes:
■ The Shutter Switch is closed or not fully open.
Close and then re-open the Shutter Switch.
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 Command
signal must be applied to both CTRL1 and CTRL2 inputs simultaneously. See Controlling laser power in the
Technical Reference chapter for PWM Command signal details.

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 chapter for tickle pulse details.
Beam delivery optics
Warning The use of aerosol dusters containing difluoroethane causes “bloom-

serious ing”, a condition that significantly expands and scatters the laser
beam. This beam expansion can affect mode quality and/or cause
personal laser energy to extend beyond the confines of optical elements in
injury the system, possibly damaging acrylic safety shielding. Do not use air
dusters containing difluoroethane in any area adjacent to CO2 laser
systems because difluoroethane persists for long time periods over
wide areas.
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
equipment head, and associated optical components.
damage
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.
Danger Ensure that DC power to the laser is turned off and locked out before
inspecting optical components in the beam path. Invisible CO2 laser
serious radiation is emitted through the aperture. Corneal damage or blind-
personal ness may result from exposure to laser radiation.
injury

maintenance/
troubleshooting
Troubleshooting
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 back to Maintenance for cleaning instructions. Use only
recommended cleaning materials (see Table 4-1) to prevent scratching delicate optical surfaces.
If the focusing optic is pitted, it must be replaced immediately. 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.
Warning A risk of exposure to toxic elements, like zinc selenide, may result
when certain optical or beam delivery components are damaged. In
serious the event of damage to laser, marking head, or beam delivery optics,
personal contact SYNRAD, Inc. or the optics manufacturer for handling
instructions.
injury
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, it must be care-
fully filtered and dried before use as a purge or assist gas. Refer to Table 3-1, Assist gas purity specifications, in
the Technical Reference chapter for filtering specifications.

maintenance/
troubleshooting

A
appendix a
Use information in this Appendix to connect and operate your Closed Loop (C/L) Sta-
bilization Kit.
This Appendix contains the following information:
■ 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 Series 48 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 ap-
proximately 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
Danger 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 C/L Kit, follow all safety precau-
personal tions and setup instructions as described here and in your laser’s
Operator’s Manual. Safe operating practices should be exercised at all
injury times when actively lasing to prevent exposure to direct or scattered
laser radiation. Improper handling or operation may result in expo-
sure 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 Series 48 operator’s manual

appendix a
Connecting
Refer to Figure A-1 for an illustration showing a typical closed loop system and then perform the following
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 C/L 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.

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: On the UC-2000 Controller, the displayed setpoint (SET) value may differ from the actual PWR
reading by 0.5% due to the display resolution when rounding.
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.
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.
However it is important to note, for example, that setting a setpoint value of 50% will not result in a 5 W
output. This is because actual laser output is greater than the rated output wattage of 10 W (48-1) or 25 W
(48-2). Figure A-2 shows a graph of duty cycle percentage versus power output for a standard 10 W laser
and the same unit with a closed loop kit installed.
Representative Power Curve for 48-1 Laser
11
10
Approximate Power Output (W)
7 Standard
6 With CL Kit
2
20 30 40 50 60 70 80
Duty Cycle (%)
Figure A-2 Graph of duty cycle vs. power output before/after C.L. kit installed

appendix a
Closed loop specifications
Table A-1 Closed loop general specifications

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
Control Frequency1 5 kHz
Servo Settling Time, typical 2 ms

1 The Closed Loop Stabilization Kit is calibrated for operation at a PWM Command frequency of 5 kHz.

appendix a

index
A fittings, 1-9
flow rate, 1-10, 1-12, 1-13, 2-4, 2-6,
Agency compliance. See Compliance 3-21, 3-23, 3-25, 4-8– 4-9
Air-cooled connections 1-8 preparation, 1-9
temperature setpoint, 1-10, 1-11, 2-4, 2-6,
American National Standards Institute (ANSI)
3-21, 3-23, 3-25
2, 3
Class 4 safety requirements 10
Analog current control 1-17, 3-10
Cleaning optics 4-3 – 4-5
Analog voltage control 1-17, 3-10, A-3, A-4
C/L Interconnect cable A-3
Aperture. See Laser aperture
Code of Federal Regulations (CFR) 2, 7, 8
Aperture seal 2-2, 2-4, 2-6
Closed loop stabilization kit A-2 – A-5
Applications x
connecting, A-3
Auxiliary Power connector 2-3 introduction, A-2
operation, A-4
B safety precautions, A-2
specifications, A-5
Beam attenuator 7, 10
Collimators 3-5
Beam block 3, 2-4, 2-6
Command signal 2-7, 3-3, 3-9 – 3-10, 4-9
Beam characteristics 3-3 base frequency, 3-10
Beam delivery optics 2-3, 3-5 – 3-6 PWM duty cycle, 3-10
caution, 3-6 signal amplitude, 3-10
cleaning, 4-3 – 4-5 Compliance 7 – 11
inspection, 4-2 – 4-3 CDRH, 7 – 8
troubleshooting, 4-10 Class 4 safety requirements 10
Beam diameter 3-3 Declaration of Conformity 12
specifications, 3-20, 3-22, 3-24 EU, 9 – 11
FCC, 8 – 9
BNC Power/Control cable 1-17 RoHS, 11
connecting, 1-16 – 1-17
Connecting 1-8 – 1-18
air cooling, 1-8
C
closed loop stabilization kit, A-3
Caution control, 1-16 – 1-17
condensation damage, 2-4, 2-6 DB-9, 1-17
coolant temperature, 1-10 electrical, 1-14 – 1-16
definition, 1 water cooling, 1-9 – 1-13
dirty/dusty environments, 4-2, 4-3, 4-10 UC-2000 Controller, 1-16 – 1-17
equipment damage, 3-19, 4-5 Contact information x
mounting, 1-6
optics damage, 3-6 Continuous wave (CW) 3-10 – 3-11
tickle signal, 2-7, 3-7, 3-10 Control connections 1-16 – 1-17
voiding warranty, 4-6 schematic, 1-18
CDRH requirements 7 – 8 Controlling laser power 3-7 – 3-11
CE mark 11 control signals, 3-7 – 3-10
label location, 4, 5, 6 operating modes, 3-10 – 3-11
Chiller Controls and indicators 2-2 – 2-3
connection, 1-12, 1-13 48-1 / 48-2 diagram, 2-2
coolant temperature, 1-10, 1-12, 1-13, 48-5 diagram, 2-3
4-8 Control signals 3-7 – 3-10
dew point temperature, 1-10, 1-11
Synrad Series 48 operator’s manual i1

index
Command signal, 3-9 – 3-10 AC input requirements, 1-14
Pulse width modulation (PWM), 3-8 – 3-9 connecting, 1-14
Tickle pulse, 3-7 – 3-8 PS-2 DC power supply 1-15
Coolants 1-9 AC input requirements, 1-15
setting temperature, 1-10, 1-11 connecting, 1-15
Cooling connections 1-8, 1-9 – 1-14 PS-6 DC power supply 1-16
AC input requirements, 1-16
Cooling fans
connecting, 1-16
clearance, 1-6, 1-8, 4-8
recommended location, 1-8 DC Power cable 1-14, 1-15, 1-16, 2-3, 4-8
Cooling fittings 1-9
DC power supply 1-14
Cooling kit 1-4, 1-5
connecting, 1-12, 1-13
troubleshooting, 4-8
guidelines, 1-9
Declaration of Conformity 12
Cooling water
draining, 4-3 Delivery optics 3-5 – 3-6, 4-10
flow rate, 1-10, 1-12, 1-13, 2-4, 2-6, caution, 3-6, 4-2, 4-3
4-9 cleaning, 4-3 – 4-5
recommended coolants, 1-9 Danger, 4-10
temperature setpoint, 1-10, 1-11, 1-12, Warning, 4-10
1-13, 2-4, 2-6 Dew point 1-10, 1-11
Copyright information viii caution, 2-4, 2-6
chart, 1-11
CTRL (Control) input connector 1-17, 2-3,
2-7, 3-3, 3-5, 3-7, 3-9, 3-11, 4-9 Diode Pointer
aperture dust cover, 2-5, 2-7
Customer Service x
power connector, 2-3
CW operation. See Continuous wave (CW)
Disabling the laser 4-2
D Divergence 3-2, 3-3, 3-5
specifications, 3-20, 3-22, 3-24
Daily inspections 4-2 – 4-3
Duty cycle 2-5, 2-7, 3-8, 3-9
Danger
closed loop stabilization kit, A-2 E
definition, 1
explosive atmospheres, 1 Electrical connections 1-14 – 1-16
eye protection, 1 EU requirements 9 – 11
laser radiation exposure, 1, 2-4, 2-6, 4-3, Declaration of Conformity 12
4-6, 4-10, A-2 Electromagnetic interference standards, 9
DB-9 connections 1-17, 3-12 – 3-17, 3-18, – 11
3-19 Laser safety standards, 9
jumper plug, 1-17, 2-4, 2-6, 3-12 RoHS compliance, 11
pinout diagram, 3-14 European headquarters x
sample input circuits, 3-15
sample output circuits, 3-15 – 3-17 Expander/collimator 3-5
signal descriptions, 3-13 External control 3-10
signal specifications, 3-14
Eye protection 1, 2-4, 2-6, 4-3, 4-6, 4-10
DB-9 Connector 1-4, 1-5, 1-17, 2-2, 2-4,
2-6, 3-4, 3-12, 3-14, 3-16, 3-18,
F
3-19, 4-7, 4-8, 4-9
DC-1 DC power supply 1-14 Fan clearance 1-6, 1-8, 4-8
i2 Synrad Series 48 operator’s manual

index
Faults Interlock. See Remote Interlock
laser, 4-8 – 4-10 Introduction 1-2
resetting, 4-7
Inventory 1-4 – 1-5
Fault Shutdown Output 3-13, 3-17, 4-7 contents description, 1-5
signal specifications, 3-14 ship kit contents, 1-4
FCC requirements 8 – 9
caution to the user, 9 J
information to the user, 8
Jumper plug 1-17, 3-12, 4-8
Final Test report 1-4, 1-5 pinout diagram, 3-12
Focusing optics 3-6
cleaning, 4-3 – 4-5 K
Fuse 1-4, 1-5, 2-2 Keyswitch 7, 9, 10, 1-2, 2-2, 2-5, 2-6, 2-7,
replacement, 4-8 3-3, 3-4, 3-12, 3-13, 3-18, 3-19, 4-7,
type, 2-2, 4-8 4-8, 4-9
G Keyswitch functions
integrating, 3-18
Gas purity specifications 3-6
Keyswitch lasers
Gated operation 3-11 resetting, 4-7
General hazards 1 – 3
General specifications 3-20 – 3-25 L
Label locations 4, 5, 6
H
LASE indicator 7, 10, 2-2, 2-5, 2-7, 3-12,
Hazard information 1 – 3 3-13, 4-7, 4-8, 4-9
additional laser safety information, 3 Laser aperture 7, 2-2, 2-3, 2-4, 2-6, 3-3,
disposal, 3 4-10
general hazards, 1 – 3
label locations, 4, 5, 6 Laser faults 4-8 – 4-10
other hazards, 3 Laser Institute of America (LIA) 3
terminology, 1
Laser safety information 1 – 12
Heat load
air-cooled, 1-8, 3-21, 3-23, 3-25 Laser tube 3-2, 3-4
water-cooled, 3-21, 3-23, 3-25 L-bracket 1-7
I M
Indicators and controls 2-2 – 2-3 Maintenance 4-2 – 4-5
Initial start-up 2-4 – 2-8 cleaning optical components, 4-3 – 4-5
with a UC-2000 Controller, 2-4 – 2-5 daily inspections, 4-2 – 4-3
without a UC-2000 Controller, 2-6 – 2-8 disabling the laser, 4-2
storage/shipping, 4-3
Inspections
daily, 4-2 – 4-3 Marking/engraving operation 3-11
incoming, 1-3 Material Safety Data Sheets (MSDS) 2, 4-4
Integrating safety features 3-18 – 3-19 Message Output 3-13, 3-16
Keyswitch functions, 3-18 signal specifications, 3-14
Remote interlock functions, 3-19
Modulation 3-3, 3-8, 3-9
Interconnection diagram 1-18
Mounting 1-6 – 1-7

index
standard, 1-6 drawings, 3-29 – 3-33
with FH Series marking head, 1-7 Pulse Width Modulation (PWM) 2-2, 2-5,
Mounting Rail 1-7 2-6, 2-7, 3-2, 3-3
description, 3-8 – 3-9
N PWM Command signal 3-7, 3-8, 3-9,
Nomenclature 1-2 3-10, 3-11, 4-7, 4-9
PWR (Power) indicator 7, 10, 2-2, 2-5,
O 2-7, 3-12, 3-13, 3-18, 3-19, 4-7,
4-8, 4-9
Occupational Safety and Health Administration
(OSHA) 3 R
OEM lasers
resetting, 4-7 Ready indicator. See PWR (Power) indicator
Operating modes 3-10 – 3-11 Reference materials x

analog current control, 3-10 Remote Interlock 7, 10, 1-17, 3-12, 3-13,
analog voltage control, 3-10 3-14, 3-15, 3-19, 4-7
continuous wave, 3-10 – 3-11
Remote Interlock Connection 3-13, 3-15,
external control, 3-10
3-19
gated operation, 3-11
marking/engraving operation, 3-11 Remote Interlock functions
integrating, 3-19
Operator’s manual 1-4, 1-5
Remote Interlock signal 2-4, 2-6, 3-12, 3-13,
Optical accessories mounting 2-3
3-14, 3-15, 3-19, 4-7
Optical output pulse specifications, 3-14
waveforms, 3-8
Remote Keyswitch 7, 10, 1-17, 2-4, 2-5,
Optical resonator 3-2 – 3-3 2-6, 2-7, 3-3, 3-4, 3-12, 3-13, 3-14,
Optical setup 3-15, 3-18, 3-19, 4-7, 4-9
cleaning components, 4-3 – 4-5 Remote Keyswitch functions
cleanliness, 3-6 integrating, 3-18
delivery optics, 3-5
Remote Keyswitch Input 3-13, 3-14, 3-15,
focusing optics, 3-6
3-18
troubleshooting, 4-10
Remote Keyswitch Output 3-13, 3-15, 3-18
Optics damage 3-6, 4-10
Remote Keyswitch signal 2-5, 2-7, 3-12,
Outline and Mounting drawings 3-26 – 3-28
3-13, 3-14, 3-18, 4-7, 4-9
48-1, 3-26
specifications, 3-14
48-2, 3-27
48-5, 3-28 Remote Lase LED Output 3-13, 3-14, 3-15
Over temperature fault Remote Ready LED Output 3-13, 3-14, 3-15,
resetting, 4-7, 4-9 – 4-9 3-18, 3-19
Resetting faults 4-7
P Keyswitch lasers, 4-7
OEM lasers, 4-7
Package outline drawings 3-26 – 3-28
48-1, 3-26 RF driver board 3-3, 3-4, 3-18, 3-19
48-2, 3-27 RoHS compliance 11
48-5, 3-28
Packaging S
guidelines, 1-3
Safety features 7, 9, 10
Packaging instructions 1-3

index
Class 4, 10 laser faults, 4-8 – 4-10
integrating, 3-18 – 3-19 OEM faults, 4-7
resetting faults, 4-7
Safety precautions 1 – 3
Tubing adaptors 1-9
Sales and Applications x
Ship kit contents 1-4, 1-5 U
Sample input circuits 3-15
UC-2000 Laser Controller 1-16, 1-17, 2-2,
Sample output circuits 3-15 – 3-17 2-5, 3-7, 3-9, 3-10, 3-11, A-3, A-4,
Series 48 features 1-2 A-5
Series 48 nomenclature 1-2 initial start-up, 2-4, 2-5
Shorting plug. See Jumper Plug Unpacking 1-3
Shutter Switch 7, 10, 1-2, 2-2, 2-5, 2-7,
3-3, 4-9 W
Signal Ground 3-13, 3-15, 3-16, 3-17, Warning
3-18, 3-19 aerosol dusters, 2, 4-10
Specifications air contaminants, 2
closed loop stabilization kit, A-5 definition, 1
cooling, 4-9 gate logic, 3-11
gas purity, 3-6 laser safety, 2
general, 3-20 – 3-25 PWM control, 1-16, 3-9
input signals, 3-7 radiation exposure, 2
PWM Command signal, 3-10 toxic exposure, 4-2, 4-11
tickle pulse, 3-7 Warning labels 4, 5, 6, 10
Storage/shipping 4-3 Warranty information ix
Synrad Water cooling ports 1-12, 1-13
European headquarters, x
worldwide headquarters, x Worldwide headquarters x
System interconnection diagram 1-18
T
Technical overview 3-2 – 3-6
control circuity, 3-3 – 3-5
Duo-Lase operation, 3-4 – 3-5
introduction, 3-2
optical resonator, 3-2 – 3-3
optical setup, 3-5 – 3-6
plasma section, 3-2
Technical support x
Tickle pulse 1-16, 2-2, 2-5, 2-6, 2-7, 4-10
caution, 3-7, 3-10
description, 3-7 – 3-8
Trademark information viii
Troubleshooting 4-6 – 4-10
beam delivery optics, 4-10
introduction, 4-6
keyswitch faults, 4-7

index

Laser Operator's Manual M Version: 4600 Campus Place Mukilteo, WA 98275 1.800.SYNRAD1

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Laser Operator’s Manual

4600 Campus Place

Released February 2014

Part number 900-00007-04

4600 Campus Place

Synrad Series 48 operator’s manual iii

iv Synrad Series 48 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 3-1 Beam characteristics...............................................................3-3

Synrad Series 48 operator’s manual v

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

vi Synrad Series 48 operator’s manual

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

Table 3-1 Assist gas purity specifications................................................3-6

Table 4-1 Required cleaning materials...................................................4-4

Table A-1 Closed loop general specifications..........................................A-5

Synrad Series 48 operator’s manual vii

© 2006, 2007, 2009, 2010, 2011, 2012, 2014 by SYNRAD, Inc.

viii Synrad Series 48 operator’s manual

Synrad Series 48 operator’s manual ix

Phone us at: 1.800.SYNRAD1 (1.800.796.7231)

Sales and Applications

Phone: +49 (0) 89 31 707-0

x Synrad Series 48 operator’s manual

Enclose the beam path whenever possible. Exposure to direct or dif-

This product is not intended for use in explosive, or potentially

Synrad Series 48 operator’s manual 1

ANSI Z136.1-2007, Safe Use of Lasers, section 7.3.

United States Government’s Code of Federal Regulations: 29 CFR

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

It may be necessary to consult with local governmental agencies

Warning The use of controls or adjustments or performance of procedures

Warning The use of aerosol dusters containing difluoroethane causes “bloom-

2 Synrad Series 48 operator’s manual

Additional laser safety information

INVISIBLE LASER RADIATION 30 WATTS MAX

for tickle pulse specifications or contact factory.

AVOID EXPOSURE Keyswitch version

WATER-COOLED VERSION ONLY

SYNRAD, Inc. 4600 Campus Place, Mukilteo WA 98275 425.349.3500

IMPORTANT - DB9 wiring change. Pins 3 and 4

KEYSWITCH VERSION ONLY

IMPORTANT - DB9 wiring change. Pins 3 and 4

MADE IN THE U.S.A.

Figure 1 48-1 hazard label and CE label locations

4 Synrad Series 48 operator’s manual

CAUTION MODEL #: 48-2KWM

10.6 MICRON SEE OPERATION MANUAL.

WATER-COOLED VERSION ONLY or

INVISIBLE LASER RADIATION

IMPORTANT - DB9 wiring change. Pins 3 and 4

MADE IN THE U.S.A.

IMPORTANT - DB9 wiring change. Pins 3 and 4

KEYSWITCH VERSION ONLY

Figure 2 48-2 hazard label and CE label locations

Synrad Series 48 operator’s manual 5

INVISIBLE LASER RADIATION

SYNRAD, Inc. 4600 Campus Place, Mukilteo WA 98275 425.349.3500