How to Connect Thunder Air fume extractor to Laser Machine

How to Connect Thunder Air fume extractor to Laser Machine

Preface：

As of June 2026, the Thunder Air 700 fume extractor supports linkage control with Thunder laser machines via a signal cable. The extractor can automatically start and stop together with the laser machine, with support for pre-start and delayed shutdown functions. The control logic is consistent with the standard Thunder exhaust fan system and is designed to reduce energy consumption, minimize operating noise, avoid unnecessary filter wear caused by idle running, and extend filter service life.

Note: Currently, alarm pop-up notifications are displayed only on the fume extractor's control panel and cannot yet be synchronized to the laser machine's panel. Please regularly check the extractor's operating status and filter condition, perform maintenance in a timely manner, and replace filters when necessary to ensure effective fume filtration.

This document describes two connection methods for the signal cable

Choose the appropriate method according to whether your laser machine is equipped with a DB9 signal port.

1. New Thunder Laser Machines (with built-in DB9 fume extractor signal port)

Use the signal cable supplied with the fume extractor to establish communication between the laser machine and the extractor.  

 Interface on the fume extractor   

Interface on the machine



2. Existing Thunder Machines (without a dedicated DB9 fume extractor signal port)

Introduction：

Current versions of Thunder engraving machines do not include a dedicated signal port for the fume extractor. Therefore, the supplied signal cable must be modified and connected to the spare relay terminals used for fan start/stop control, allowing the laser machine and extractor to operate in linkage mode.

Operating Procedure:


2.1 Remove the DB9 connector from one end of the signal cable and use the two functional wires inside.


Tools required

  • Phillips screwdriver, flat-head screwdriver, Electrical insulation tape (user supplied)
  • DB9 male-to-male extension cable (included with the extractor)
  • Crimp terminals, crimping tool, wire stripper (optional)

1. Open the DB9 connector at one end of the cable and remove the housing to expose the soldered pins.  

2. Locate the leftmost and rightmost wires in the 5-pin row, mark them, and then cut off the DB9 connector.  

3. Keep the two marked wires, trim the remaining wires short and insulate them with electrical tape.  

Note: Due to different manufacturing batches, some cables may already contain only two conductors. In this case, simply remove the DB9 housing and proceed to the next step.   


4. Strip the insulation from the selected wires to expose the metal conductors. If available, you may crimp terminals onto the wires, which will make relay connection easier.  


2.2 Connect the two prepared wires to the spare terminals of the relay that has the wire labeled “L6”. This will enable normal linkage control between the laser machine and the fume extractor.


Connect the two wires to the machine relay


TITAN:

BOLT:

NOVA:

AURURA:



2.3 Route the signal cable through the machine panel：

Opening the side door and temporarily connecting the cable to the relay can be used as an emergency temporary solution.

For standard long-term installation:

Drill a cable entry hole in the machine's metal panel, install a rubber grommet, and secure the cable to prevent crushing or abrasion.

  1. Drill a cable hole of appropriate size according to the cable diameter and terminal dimensions.
  2. Install a rubber grommet to protect the cable from sharp metal edges.
  3. Route the cable into the machine and secure it according to normal wiring practices (for example, inside the cable duct), ensuring it does not interfere with moving parts.


If the machine does not have a reserved or spare opening available for cable routing, you may drill a hole in a suitable location if necessary. It is recommended to drill the hole in a removable or replaceable sheet metal panel whenever possible (recommended hole diameter: 8 mm).

The cable routing and drilling methods vary depending on the machine series. Please refer to the table below.
Machine Model
Hole Position
Nova & Nova Plus Series: There are two existing openings at the bottom of the machine near the main power inlet. Either opening can be used to route the cable. Route the relay end of the air purifier signal cable through one of the openings and into the machine. Then locate the relay that controls the exhaust fan and complete the signal cable connection according to the instructions in the table on the right.
 
Bolt Series: Bolt and Bolt Plus machines do not have a suitable existing opening at the bottom for routing the cable. You can use the existing air pump ventilation opening instead. Route the air purifier signal cable through the air pump ventilation opening and into the machine. Then route the cable to the relay that controls the exhaust fan and complete the connection.
 
Bolt Plus 24, Bolt Pro 22/32/36: These machine models do not have suitable existing openings for cable routing. You may drill a hole on the machine housing at suitable location. It is recommended to drill a hole on a removeable panel or door that can be replaced if needed. For example the panel on the rear of the machine shown on the right.

After drilling a hole and routing the cable, reinstall the sheet metal panel, and then connect the signal cable to the relay connected to the wire labeled L6.
Note: Before drilling, it is recommended to cover the components in the relevant electrical areas with a dust-proof cloth to prevent metal debris or dust generated during drilling from entering the components.		  
Aurora Series: Aurora machines do not have a suitable existing opening for routing the cable.  You may drill a hole on the machine housing at suitable location. It is recommended to drill a hole on a removeable panel or door that can be replaced if needed. For example the panel on top of the machine shown on the right.

Route the air purifier signal cable through the hole and into the machine, then route the cable to the relay that controls the exhaust fan and complete the connection. 
Note: For Aurora machines, before drilling, be sure to completely cover the laser source and all components in the electrical area with a dust-proof cloth to prevent metal debris or dust generated during drilling from entering the laser source or electrical components.
  
TITAN & TITAN Pro Series: There are two existing openings at the bottom of the machine near the main power inlet. Either opening can be used to route the cable. Route the relay end of the air purifier signal cable through one of the openings and into the machine. Then locate the relay that controls the exhaust fan and complete the signal cable connection according to the instructions that follow.
 

Notes
Some users may wonder why the sheet metal panel around the main power inlet cannot simply be replaced with the newer version that includes a dedicated air purifier interface, as used on newer machines. This is because, for safety reasons, the factory has permanently secured the ground wire at the power inlet by soldering it in place.
As a result, it is not convenient to remove and replace this sheet metal panel. For more details, please refer to the link below.
https://youtube.com/shorts/obn68_GsG7w

3. Extending the signal cable (optional)

If the supplied 2-meter cable is too short, you may extend it yourself or contact Thunder to purchase a custom cable with the required length and terminals.


3.1 Purchase Custom Signal Cables

  • Custom options may include:
  • Specific connection terminals
  • Finished cables of specific lengths
  • Direct connection between the machine relay and the extractor signal port. Follow Step 1 or Step 2.2 for installation.
3.2 Modify the supplied signal cable (if needed)
Method 1: Direct wire splice (soldering recommended)

1. Prepare a 2-core cable (or use two conductors from a multi-core cable).

2. Splice the prepared DB9 wires to the extension cable wires. Soldering is recommended for reliability.

3. Insulate the joint completely with electrical tape.

Method 2:Terminal block connection (if available)

1. Insert both the DB9 wire and the extension wire fully into the terminal block.

2. Tighten both sides with a flat-head screwdriver.

Note: Wrap any exposed conductors with insulation tape.

Safety Notes

  1. All exposed metal connections must be fully insulated to prevent short circuits.
  2. Route the signal cable away from high-voltage laser cables and power cables to avoid signal interference.
  3. After installation, perform a full functional test, including laser machine start/stop, extractor linkage operation, and alarm signal transmission.
  4. During routine maintenance, inspect cable insulation and wear at the cable entry hole regularly.   


Still need help?

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