This is a diagnostic procedure to collect data on the output of the LPSU. It is not necessary to perform this unless instructed to do so by Thunder Laser USA Support & Innovation Labs. But you can if you like.

This instruction is specific to the Thunder Laser USA Nova series machines only.


There is a link to a form HERE and at the end of this article where you can enter your results and it goes to our database. Again, if you weren't asked by support to perform these tests you dont have to enter the values but feel free to do so.


If you have a 100w Thunder Nova you may see some fluctuations at 10% - 30% or so.

This is why: Banding and Plasma Arc Issues and Striking Voltage


If you can, make a note about anything you see in that range when you submit the form.


All of these tests were performed on a mostly stock 2019 Nova 35-80. It shipped with an SPT C-90 tube & 100w MYJG LSPU.

Power Caps are set at 7% Min and 70% Max in Thunder specific machines by the configuration file (machine settings). 

Thunder also runs a custom Ruida firmware for U Channel rotary support and some other things, but the firmware should have little to do with any of this.



So the idea is to fire the laser from 10% to 100% power in 10% increments. 


There are 2 ways we may ask you to do this. The "automatic" way as described in this article using the test file, and/or by manually pulsing the laser then changing the value and pulsing again all at the controller (also described below).




Here is how it works. We are going to fire the laser at different power levels using file (easier for one person) and/or the manual method (you should get a helping hand for this one) to record the readings of the milliammeter for each pulse.


The mA meter is located on the top of the Laser Power supply in the left rear electronics bay of the laser. 

The file will allow you to run it and it will pulse through the power range pausing uniformly so you can get the meter in view to record the values. 


When manually pulsing you should have someone watch and record the meter values while you operate the control panel.



In this example image of a laser power supply you will see that the 6 pin connector is disconnected from the LPSU. 

Some lasers to do have the opto-isolator circuit board and will just have the wires on the 6 pin connector. Do not disconnect anything for these specific tests.


The reason our mA meters are not easily accessible is that they are really only ever used to perform these diagnostics. Our LPSU's are calibrated to the tube so we don't need a "heads up" display of our tube current to operate safely.


PULSE TEST USING THE ATTACHED FILE:


The test file in .lbrn format is HERE and attached at the end of this article. Here is an overview of the test file.




Here is how the meter should respond to the test file. Please record the mA value of each pulse in order from 10% to 100%


NOTE: These resources show our mA meter on the laser near the e-stop button. This is a modification that has been done to the laser in the lab so you do not need to make such modifications.


Here are my values:


Nova 35-80

USING TEST FILE

Current Reading in mA:


10%: 4

20%: 5

30%: 9

40%: 14

50%: 20

60%: 23

70%: 27

80%: 27

90%: 27

100%: 27


If you notice, 70% power and above stayed at 27mA. I rechecked the file to be sure it was correct... and i think it is. 

So, we cap our power at 70% in the machine config. This allows us to match the right power supply with the right tube to get our required 10% over published power safely without worrying about current or overdriving the tube. 


The plateau may be attributed to that cap. We are exploring this to be sure.


Now we are going to gather these values the manual way as well and compare the data.


You can find the test file here: https://support.thunderlaserusa.com/helpdesk/attachments/65002173765

You can find the form to enter your values here: https://forms.gle/tX7w728FAPQ7idhR9


PULSE TEST MANUALLY AT THE LASER:



When you increment the power from the control panel you cannot go to 100%. You will have to enter 99.9%.


Here are my values:


Nova 35-80

PULSING MANUALLY

Current Reading in mA:

10%: 4

20%: 5

30%: 7

40%: 10

50%: 13

60%: 17

70%: 20

80%: 22

90%: 25

99.9%: 27


So there are some differences in the results. We will explore these differences, triple-check our file, and follow up. 


NOTE: Just because the results are different, that does not indicate an issue, just a difference.




You can find the test file here: https://support.thunderlaserusa.com/helpdesk/attachments/65002173765

You can find the form to enter your values here: https://forms.gle/tX7w728FAPQ7idhR9



We had Chris L perform these tests on his Nova 51-100 and these are his results:
















His machine has the same controller and LPSU as the first test on the Nova 35-80. The only difference is the nova 35-80 has a C-90 tube and the Nova 51-100 has aC-100 tube, which is largely inconsequential when testing LPSU current output. However, the current draw of the 2 tubes may differ slightly. Everything else in these machines, as it relates to this test, is identical.


Here are the results of both machines side-by-side:


            NOVA 35-80. C90 TUBE, 100W LPSU                                                                NOVA 51-100. C100 TUBE, 100W LPSU





Nova 35-80 firmware and laser settings:





Nova 51-100 firmware and laser settings:




It appears that Chris' machine has 99% set for laser 1 max in the config. If the above tests were done with this cap, and not out 70% cap, the comparison is not accurate. We are exploring this and will provide updates.