Leister NOVOLAS Basic AT User Manual (English)

April HuntAug 17, 2025

What to do if Leister NOVOLAS Basic AT Welding System system does not start up (“System error or not ready signal” of Customer I/O always active)?

R
randysmithAug 17, 2025
If your Leister Welding System fails to start up and shows a “System error or not ready signal” that is always active, it could be due to the power supply, a defect in the System Master, or missing Ethernet connections. Ensure and check the power supplies. Inspect all RJ45 Ethernet connectors, and verify that the green LED of the RJ45 connectors are lit.

Voltage	230 V
Frequency	50/60 Hz
Laser Type	Diode laser
Operating Temperature	0 - 40 °C
Storage Temperature	-20 - 60 °C

Voltage

230 V

Frequency

50/60 Hz

Laser Type

Diode laser

Operating Temperature

0 - 40 °C

Storage Temperature

-20 - 60 °C

Summary

General

About this Manual

Describes the NOVOLAS Basic AT laser system and its contents.

Specialist Personnel

Defines the target audience and required qualifications for using the manual.

Proper Use

Specifies correct applications and conditions for the NOVOLAS Basic AT system.

Proper Handling and Warranty

Details careful handling requirements and warranty void conditions for system components.

Organizational Measures

Outlines essential procedures and responsibilities for safe system operation and maintenance.

Reporting Requirement

Discusses system classification and potential reporting obligations for Class 4 laser operation.

Safety Instructions

General Introductory Remark

States the system is an OEM product for integration and outlines compliance requirements.

Laser Safety Class

Explains the system is Laser Class 4 and requires integration to Class 2M standards.

Safety of the NOVOLAS Basic AT System

Details essential safety device functionality and operational prerequisites for system safety.

Hazards from Laser Light

Warns about intense laser radiation, potential skin/eye damage, and required protective measures.

Hazards from Electrical Energy

Highlights dangers from live parts, permanent mains connection, and electrical work procedures.

Hazards from Gases or Vapours

Addresses potential toxic or irritating emissions during material processing and required extraction/filtration.

NOVOLAS Basic AT Safety Devices

Lists and describes integrated safety features like interlocks and emergency stops.

System Description

Hardware Overview

Provides a general overview of the NOVOLAS Basic AT platform and its modular structure.

System States

Details the various operational states of the main system and individual laser units.

Interfaces

Overview

Lists the electrical interfaces provided by the NOVOLAS Basic AT for system control and monitoring.

Terminal Block (X90, X91-94)

Describes terminal blocks for system control, emergency stop, and laser enable functions.

Individual Laser Unit Control Interface (X91-X94)

Details interface connections for controlling individual laser modules, including interlocks.

Digital Inputs (X14)

Lists and describes DC-isolated digital inputs for system control and status monitoring.

Digital Outputs (X15)

Lists and describes DC-isolated digital outputs for system status, errors, and ready signals.

Interface Pin Assignments X15, Including Good/Bad Evaluation

Details specific pin assignments for good/bad evaluation signals from digital output X15.

Analogue Inputs (X16)

Specifies voltage range, impedance, and signals for analogue inputs.

Analogue Outputs (X17)

Specifies voltage range, impedance, and signals for analogue outputs.

Serial Interface RS232 (X18)

Describes the RS232 interface for communication and data exchange.

Serial Interface RS422 (X36)

Details the RS422 interface for communication and data exchange.

External Laser Interface (X80/81, Coolant)

Describes interfaces for external laser diodes, including high current and coolant connections.

Interlock to Laser Module (X81)

Details the connector for the external laser module's interlock circuit.

Cooling Supply to External Laser Modules

Specifies connections for the cooling circuit of external laser modules.

Installation

Important Notices

Provides critical safety and handling instructions before and during system installation.

Local Transportation

Guides on safe internal movement of the system within a building.

Long-Distance Transportation

Details procedures for safe transportation of the system over longer distances.

Transport Damage

Instructs on checking for and reporting any damage incurred during transportation.

Packaging Materials

Advises on retaining original packaging for future use.

Location

Specifies environmental and physical requirements for the installation site.

Conditions for Setting-Up

Lists necessary information and considerations for setting up and connecting the system.

Installation Instructions

Provides guidance on the installation and wiring procedures for the system.

Time Scheme for Typical Integration

Illustrates a signal timing diagram for typical system integration.

Typical Wiring of a Basic AT with an External Laser Unit (i.e. Linebeam)

Shows a wiring diagram for integrating an external Linebeam laser unit.

Operation

Switching on the NOVOLAS Basic AT

Details the step-by-step procedure for powering on and initializing the system.

Configuring the NOVOLAS Basic AT

Explains how to configure the system using the RS232 interface and ASCII protocol.

Operation Modes and Modifications of the Basic AT

Discusses different operation modes affecting system behavior and current settings.

Current Setting Mode

Explains how the laser current is set via analogue or digital inputs.

Activating the Laser (Register 3)

Details the conditions and register settings required for laser activation.

On-Off Temperature Regulator (Register 1 and 6)

Explains the temperature regulation function using pyrometer feedback.

Switching off the NOVOLAS Basic AT

Provides the procedure for safely shutting down the system.

Behaviour during Operations

Describes system monitoring functions for temperature and interlocks during operation.

Diagnostics LEDs

Explains the meaning and states of the diagnostic lamps (L1 and L2) for system status.

Service and Troubleshooting

Repair / Service

Outlines who is authorized to perform repairs and where to find maintenance interval information.

System Faults

Provides guidance for diagnosing and resolving system issues, including log file submission.

Laser Module Faults

Lists common errors related to laser modules and their possible causes and fixes.

Optics Fault

Describes issues related to optics and fiber connections, with troubleshooting measures.

Maintenance

Time Intervals

Details the scheduled maintenance tasks and their recommended intervals.

Spare Parts

Lists available spare parts and ordering information from Leister.

Disposal of Replacement Parts

Provides guidelines for the proper disposal of used replacement parts.

Warning Notices and Abbreviations

Symbols in the Manual

Explains the meaning of various warning symbols used throughout the manual.

Abbreviations and Terms

Defines common abbreviations and technical terms used in the documentation.

Labels on the NOVOLAS Basic AT

Identifies warning labels, their meanings, and locations on the system.

Technical Data

Installation Data

Specifies electrical requirements, voltage, frequency, and fuse protection.

Dimensions and Weight

Provides physical specifications including dimensions, height options, and weight.

Environmental Conditions

Outlines the required ambient temperature, humidity, and operating environment.

Laser Power Supply and Laser Module

Details laser safety classes, wavelengths, power ratings, and operating types.

Liquid Cooling System

Describes the cooling medium, capacity, and filter specifications.

Conductor Cross-Sections

Lists recommended conductor sizes for various electrical connections.

Leister NOVOLAS Basic AT User Manual

Table of Contents

Questions and Answers:

Leister NOVOLAS Basic AT Specifications