Eliminating The Opto Isolator Board For Nova Series Machines

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Important Information* This field is required.Please carefully read and understand this important information
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Overview

Here is what we are going to do, in summary:

De-energize the system and locate the laser power supply (LPSU)

Locate the Opto board, snap a clear pic of it, and identify the version

Locate the DSP and identify the wire color of PIN 3 on CN5

Remove the opto board and wire directly to the LPSU bypassing the opto board

This tool will walk you through each step, and the team is ready to assist should this diagnostic prove inconclusive. Just report back in the ticket with the issue.
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We will need to gather some tools and info to sucessfully complete this procedure.

Here is what we need to have and know:

Tools

A small flat-blade screwdriver to loosen screw terminals

A peice of wire for a jumper (a paperclip works!)

Info

Location and identification of the laser power supply and optoisolator board

Location and identification of the DSP controller and a specific wire on that DSP

Prep

Before attempting diagnostics or repairs on the machine, make sure you have all power switches off and have the machine power cable removed from its outlet, so the system is completely deenergized. And take before pics always.
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LPSU Location

All Nova series machines except Nova 24 has the LPSU mounted behind the doors on the BACK of the machine. The opto board is conected to the LPSU:

The Nova 24 LPSU is on the LEFT side. The opto board is conected to the LPSU:

Be sure to de-energize the system
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Identify Opto Version

There is a revision number on the opto board attached to the LPSU. Look for (snap a clear pic if you like) and note the revision number so you can select it in the next step.
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Select The Version of your Opto Board* This field is required.Please select the correct version of the opto board on your LPSU
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Please Select
Rev 2_2
Rev 2_1
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DSP Location

The DSP will be located in the RIGHT side electronics bay door usually towards the front of the machine.
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Wire Color Identification

Note the color so you can make the correct selection in the next step.

You will be looking for PIN 3 on connector 5 (CN5). The wire should either be Gray or Brown.

If this is not true, please reply with this information in the ticket you have open or open another, please. Otherwise, note the wire color and select it in the next step.

The example below shows a Gray wire at CN5-3:
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Select The Wire Color On CN5-3* This field is required.Please select the color of the wire on your machine going to Connector 5 Pin 3
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Please Select
Brown
Gray
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Remove Opto

Unplug the Opto-Isolator from the LPSU

Take a picture of your Opto-Isolator Wiring

Loosen all the terminals with wires on them and remove the wires.

Loosen all the terminals on the green 6 pin connector and remove it.

This image may differ from yours, it is used as an example.

We will update with better imagery as we evolve this resource.
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Rewire Specific to Brown Opt 1

Schematic:
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Rewire Specific to Gray Opt 2

Schematic:
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Please run a test file, preferably one that has been problematic with this issue, and see it removing the Opto Isolator resolved or helped the issue.
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Did Bypassing The Opto Fix Your Issue?* This field is required.Please tell us if your test was successful
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Yes, it looks good with the opto bypassed
No, that didn't help anything
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Test Successful

Okay, so this likely means the optoisolator board is the fault.

It can be run temporarily without one (most lasers dont even have them) but does need to be replaced.

Please reply back to the support ticket that the test showed your optoisolator has failed, and the team can assist with replacement.
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Test Failed

If you are a Thunder Laser USA client and are running this test at our request, please reply to the ticket with your findings and the team will continue to assist.
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Would you like to leave feedback about this form?this is not for machine tech questions, please let us know your experience of using this tool
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Sure, I'll leave feedback on this tool
No, thank you. I need to get back to work
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Thank You For Your InputPlease provide your feedback below
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The Configurator Will Now Close* This field is required.Would you mind providing feedback (negative and positive) about this resource, please?
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The diagnostic will now exit and direct you to our knowledge base. Thanks again, we are here if you need us.
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