Overview

A few minutes of checks before each work session prevents most of the cutting, engraving, and reliability problems we see in support. This article walks through the daily pre-use checklist for Thunder Laser CO2 machines (Nova, Nova Plus, Bolt, Odin, and Titan series). Items marked (If equipped) apply only to machines with that accessory installed.

The checks are split into two parts: Part 1 is done with the laser powered off, and Part 2 is done after power-up, ending with tests that confirm the machine's safety protections are working.

Quick Checklist

Part 1 — Laser Powered Off

1. Check External Air Compressor for Water (If equipped)

Compressors collect condensation in the tank, especially in humid environments. Move the compressor to a location that you can drain.

1. Locate the drain valve at the bottom of the compressor tank.

2. Open the valve and let any water purge out until only air escapes.

3. Close the valve before running the laser.

2. Check Air Pressure Regulator (If equipped)

Some customers add an aftermarket regulator and water trap between their compressor and the laser.

1. Inspect the filter bowl for water or oil. Drain it if any is present.

2. Replace the filter element if it is discolored or clogged.

3. Once the compressor is running, confirm the gauge reads your normal working pressure. (Must not exceed 55psi)

3. Check Fan Filters

The cooling fans that protect the machine's electronics pull air through filters. Clogged filters cause components to run hot.

1. Inspect each fan filter on the machine for dust and debris buildup.

2. Clean or replace any filter that is visibly dirty or restricts airflow.

4. Check Lens and Mirrors

Dirty optics absorb laser energy instead of passing it on, which reduces power and can crack or burn the lens.

1. Inspect the focus lens and each mirror for smoke residue, spots, or haze.

2. Clean any dirty optics with lens wipes or cotton swabs and optical-grade cleaner (or high-purity isopropyl alcohol), wiping gently in one direction.

3. Look for pitting, cracks, or burn marks. Damaged optics will not clean up and should be replaced.

4. Reinstall the lens in the correct orientation and make sure all optics are seated securely.

5. Check and Clean Auto Focus Sensor

Debris or residue on the auto focus sensor can cause inaccurate focus or a crash into the material.

Touch Type:

1. Inspect the auto focus sensor and post for dust, resin, or residue and clean it with a soft cloth.

2. Confirm that the touch post moves freely and returns fully.

3. Check for signal on the machine's Diagnosis Screen (Red Box indicator)

Through Beam Type:

1. Inspect the auto focus sensor for dust, resin, or residue and clean it with a soft cloth.

2. Confirm the lights indicate on the right side sensor when the sensor path is blocked and cleared

3. Check for signal on the machine's Diagnosis Screen (Red Box indicator)

6. Check Chiller Water Level (If equipped)

1. Check the water level indicator on the chiller and confirm the level is within the normal range.

2. Top off with distilled water if the level is low.

3. Look for leaks at the hose connections on both the chiller and the machine.

4. If the water looks cloudy or shows algae growth, flush and refill the system before use.

Part 2 — Laser Powered On

7. Check Water Chiller Temperature (If equipped)

CO2 laser tubes perform best and last longest when cooled to a stable temperature.

1. Power on the chiller before the laser and let it reach temperature.

2. Confirm the chiller display reads at or near the 20°C (68°F) target.

3. If the chiller shows an alarm or cannot hold temperature, do not run the laser until the issue is resolved.

8. Power Up, Home, and Let the RF Tube Ionize (if equipped)

1. Power on the laser and let the machine complete its homing sequence.

2. Watch and listen as it homes. Motion should be smooth, with no grinding, skipping, or limit errors.

3. Allow the tube to ionize before starting any job.

4. Allow about 2 minutes total for homing and ionizing before running a job.

9. Check Air Assist Function

Air assist keeps flames down, clears debris from the cut, and protects the focus lens from smoke and residue. Weak or missing air assist is a leading cause of dirty lenses and poor cuts.

1. Turn on the air assist and confirm you can feel steady airflow at the nozzle.

2. Check the air line for kinks, cracks, or loose fittings along its path to the laser head.

3. Adjust the airflow to suit the job — higher flow for cutting, lower flow for engraving to avoid blowing dust across the work surface.

4. If there is no airflow, confirm the air pump or compressor is running before troubleshooting further.

10. Check Exhaust Flow

Good exhaust removes smoke and fumes before they settle on the optics or escape into your workspace.

1. Turn on the exhaust fan and confirm a strong draw at the machine.

2. Check that any blast gates or dampers in the duct are fully open.

3. Inspect the ducting for crushed sections, disconnected joints, or heavy residue buildup.

4. If you use a fume extractor, check its filter status and replace filters as needed.

5. Check for air flow at the exit of the exhaust system

11. Check Stored File Count

Every job sent to the machine is stored in the controller's memory. Too many stored files can cause slow file handling and job errors.

1. Open the file list on the machine's control panel.

2. Confirm fewer than 99 files are stored.

3. Delete any files you no longer need. Keep only jobs you rerun frequently.

12. Check the Safety System (Lid Interlock)

The lid interlock prevents the laser from firing while the lid is open. This test confirms it is working.

1. Open the lid.

2. Start the test job.

3. Expected result: the machine shows a fault or warning and will not run.

4. Close the lid and clear the fault.

13. Check Chiller Alarm Protection (If equipped)

The chiller alarm stops the laser from firing without cooling, which protects the tube from overheating.

1. Power off the chiller.

2. Close the lid and start the same minimum-power test job.

3. Expected result: the machine shows a water or chiller fault and will not run.

4. Power the chiller back on and let it return to about 20°C before starting any work.

Still Need Help?

If you are a Thunder Laser USA client and still need Technical Support after exhausting the resources in the Knowledge Base, email [email protected] and the Technical Support Team will promptly assist you.