How To Replace The Nova Series DC Tubes

Preface: This article covers the basics of swapping out the tube of your Nova series Laser. Depending on the model and vintage, there will be some slight differences. We recommend reading the literature below the video to get a better understanding.

⚠️ Warning: Firstly, turn off the whole machine power and disconnect from the wall.

Quick Start Videos

Example 1

Example 2

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Complete Guide

⚠️ Warning: This work should only be performed with the machine powered off and unplugged.

ℹ️ Note: Each machine may vary a little if the model or vintage is different from what is shown.

Tools/Supplies Needed

• 3mm Allen Key (For Tube Straps, Extension Access Panel and HV plug retainer set screw)
• Flat Head Screw Driver for Negative Lead on 80W and higher machines
• 5.5mm Wrench or Socket for Analog Ammeter Machines (60w and lower tubes)
• Snips - For Zip-ties on Water hose connection on Old Tube
• Zip-ties (2 min) for Water Hose connections on New Tube
• Gloves - To protect from glass

Removing the old Laser Tube

1. Disconnect the power wiring between laser tube and laser power supply. There will be a black wire and red wire to disconnect.

Nova 24/Min 60:

The tube connections are on the left side of the machine but will need to access the back of the machine

Black Wire on Ammeter	White Connector for Red Wire
Use the 5.5 wrench or socket to remove the nut from the post. Then remove the ring terminal off the post.	Use the allen key to loosen the bolt holding the white connector in place. Remove the white connector out of the holder and unscrew the two halves.

Feed the wiring back up into the tube box area in preparation for removal.

ℹ️ Tech Tip for Nova 24 and Mini 60: When installing or removing the HV white connector on the right hand side, it may be easier to pull the flexible water hose through the bushing to create more space for the larger white HV connector to fit through

Nova 35-80W:

For the 80w tube, you can just unscrew the ring terminals at each end of the tube, no need to trace the wiring back to a terminal or to the quick connect by the LPSU.

Nova 35-100W, 51 and 63:

The tube connections are on the left side of the machine but will need to access the back of the machine

Negative Wire	Wire Connector for Red Wire

Fish the red wire back up top to the tube box area to facilitate tube removal

2. Prepare the tube for removal

① Cut the zip ties that are holding the water tubes and red wires in place. Also you will need to bend some retainer tabs out some to release the tubing and wire. Do not over bend.

For Nova 24-60W and 100W Nova 35, you will need to access the tube end behind the extension panel:

② Remove the Tube Strap screws with 3mm Allen wrench. The straps may be "stuck" to the tube somewhat. Lift them up and around off the tube surface

ℹ️ Note: At this point the tube is loose in the machine and is just resting in the tube mounts. Be very careful with the tube.

3. Drain the water away from the tube

Lift the tube up gently on the right side to let the water drain back out to the chiller

Then Remove the Water Tube Feed Lines:

Cut the Zip-ties holding the tubes in place. Gently twist and pull them off. If they will not come off, cut the water feed lines flush with the Laser Tube bung.

Install New Tube

In order to ensure laser path correct, location of new tube should be the same with the old one. The total distance to the beam combiner is not critical but do allow for the dust cover to fit on the 100W and 130W tubes. Install in reverse and be sure to terminate the Black wire on the proper terminals.

SEE ATTACHED PDF FOR LEGACY INSTRUCTIONS AND INFO ON SPLICING HV WIRES.