redPOWER 300W to 2.0kW Module Fiber Lasers Instructions ... · 7.8 Connecting the PIPA-Q Optical...

redPOWER PRISM

300W to 2.0kW Fiber Lasers

Instructions for Use

© 2017 SPI Lasers UK Ltd.

Commercial in Confidence

SM-S00481 Revision F 02 August 2017

redPOWER 300W to 2.0kW Module Fiber Lasers


2

Safety Notes These safety notes indicate potential hazards associated with this PRISM Fiber Laser and the

probable consequences of not avoiding them. Directions on the safe use of this Laser are

provided in the remainder of these instructions for use, particularly Sections 3 Health and

Safety, 7 Installation, and 8 Operating Instructions.

Throughout these Instructions for Use warning messages are given in contexts in which a

hazard may occur.

General Hazard Information

WARNING: Ensure that all Users are fully aware of all safety

implications identified in these Instructions for Use before

attempting to install, operate or maintain this Laser.

WARNING: Attempts to modify or alter this PRISM Fiber Laser or

the use of controls or adjustments or performance of procedures

other than those specified in these Instructions for Use may render

this Laser unsafe.

Attempts to modify or alter this Laser or the use of controls or adjustments or performance of

procedures other than those specified in these Instructions for Use additionally will invalidate

the warranty and may result in patent infringement.

Laser Integrators are not authorised to modify this Laser.






3

Laser Hazard Information

WARNING: The output aperture of this PRISM Fiber Laser may

emit both invisible and visible laser radiation.

The invisible laser radiation will be Class 4 laser radiation. The

invisible radiation can be up to approximately 115% of rated power

CW in normal operation and 150% with a single fault. The

wavelength of this invisible radiation is in the range 1050-1250nm.

Additionally, this Laser contains embedded lasers that emit invisible

laser radiation up to approximately 170% of rated power CW in

normal operation and 250% CW with a single fault. The wavelength

of this invisible radiation is in the range 900-1000nm.

AVOID EYE OR SKIN EXPOSURE TO DIRECT OR SCATTERED

RADIATION.

Contact with direct or scattered laser radiation can cause damage

to the eyes, burn human tissue and start fires.

The optical connector shall be mounted in a protective housing

which prevents human access to laser radiation (including errant

radiation) in excess of the AEL for class 1, for example a housing

meeting the requirements of EN 60825-4.

WARNING: The output aperture of this PRISM Fiber Laser may

emit both invisible and visible laser radiation.

The visible laser radiation is below the Accessible Emission Limit

(AEL) for a Class 2 laser. The wavelength of the visible laser

radiation is in the range 630 – 680nm.

DO NOT STARE INTO BEAM.

WARNING: This PRISM Fiber Laser must only be operated when

the optical connector is mounted in an appropriate receiver.

Care must be taken to prevent the electrical contacts on the optical

connector being accidentally connected. Do not place the optical

connector on a metal surface.

The protective cap must be placed over the connector whenever

the connector is not in a receiver.

WARNING: Before carrying out any maintenance task detailed in

these Instructions for Use ensure that power to the Laser is

disconnected. Failure to do so may lead to serious personal injury.






4

WARNING: This PRISM Fiber Laser does not control the pump

power supply and has no safety function to de-energise or control

the pump diodes or the output power.

Failure to provide external safety systems may result in exposure to

harmful levels of radiation.

Electrical Hazard Information

CAUTION: This PRISM Fiber Laser must be grounded for safety

and to comply with regional electrical codes.

Failure to do so may result in electric shock and incorrect operation

of the Laser.

Weight Hazard Information

CAUTION: This PRISM Fiber Laser is heavy and so precautions

must be taken when lifting and moving.

Failure to do so may cause serious injury.

Pressure Hazard Information

CAUTION: Ensure an approved overpressure safety device

compliant with ISO4126-1 (or equivalent) is installed when

connecting the PRISM Fiber Laser to an external chiller or factory

water supply.

Failure to do so may result in water leaks and damage to the Laser

and auxiliary equipment.

Laser for Incorporation

CAUTION: This PRISM Fiber Laser is specifically designed to be a

laser for incorporation or integration into other equipment. As such,

it is not required to, and does not, meet the requirements for a

stand-alone laser system as defined by IEC/EN 60825-1.






5

CONTENTS 1 Structure and Scope of these Instructions for Use 9

2 Definition of Symbols and Terms 10

3 Health and Safety 12

3.1 General 12 3.2 Intended Use of the PRISM Fiber Laser 12 3.3 Hazards 13 3.4 Compliance 14 3.5 Labelling 17

4 Document References 19

5 redPOWER PRISM Tour 20

5.1 Key Parts 21 5.2 Key Features 21 5.3 Auxiliary Equipment 25 5.4 Software Tools 26 5.5 Explanation of Order Codes 27

6 Getting Started 29

6.1 Receiving and Inspection 29 6.2 Unpacking and Handling 29 6.3 Unpacking the Beam Delivery Optic 33

7 Installation 34

7.1 Safety and Compliance During Installation 34 7.2 Location and Environment 34 7.3 Mounting 35 7.4 PRISM Fiber Lasers with Bare Fiber Output 35 7.5 Cooling Water Connections 35 7.6 Electrical Connections 39 7.7 Routing the Beam Delivery Optic 49 7.8 Connecting the PIPA-Q Optical Connector to the Process Head 51 7.9 Removing PIPA-Q Optical Connector from the Process Head 54

8 Operating Instructions 55

8.1 Before Operation 55 8.2 Modes of Operation 56 8.3 Turning the Laser On and Off 58 8.4 Turning the Alignment Laser On and Off 62 8.5 Monitoring, Alarms and Diagnostics 62 8.6 Laser Control Using PrismView 65 8.7 Serial Control of the Laser 65






6

9 Maintenance 66

9.1 Periodic Inspection 66 9.2 General Cleaning 66 9.3 Maintenance of Optics 67

10 Disposal 72

11 Specifications 73

11.1 Operating Conditions 73 11.2 Non-Operating Conditions 75 11.3 Utility Requirements 75 11.4 Optical Specifications 80 11.5 Mechanical Specifications 83

12 General Information 91

12.1 Trade Marks 91 12.2 Licensing 91 12.3 Software 91 12.4 Warranties 91 12.5 Copyright 91 12.6 Changes 92

13 Contact Information 93

14 Customer Service 94

FIGURES Figure 1 WEEE Symbol ........................................................................................................................... 14

Figure 2 PRISM Fiber Laser with Optical Connector Key Parts .............................................................. 21

Figure 3 PRISM Fiber Laser Key Features ............................................................................................. 22

Figure 4 PIPA-Q Optical Connector with Protection Against Back-Reflection ........................................ 24

Figure 5 PRISM Fiber Laser with Auxiliary Equipment ........................................................................... 26

Figure 6 Laser in Crate as Received ....................................................................................................... 29

Figure 7 Removing Fastener ................................................................................................................... 30

Figure 8 Crate without Lid and Top Layer of Foam Packaging ............................................................... 31

Figure 9 Lift BDO to Enable the Next Layer of Packaging to be Removed ............................................ 31

Figure 10 BDO Replaced ........................................................................................................................ 32

Figure 11 Lifting Laser from Crate ........................................................................................................... 33

Figure 12 Cooling Water Connections .................................................................................................... 36






7

Figure 13 Electrical Connections and Status Indicators .......................................................................... 40

Figure 14 Star Earthing Configuration ..................................................................................................... 41

Figure 15 Bus Bar Connection ................................................................................................................ 42

Figure 16 User Interface Connector ........................................................................................................ 43

Figure 17 PLC Logic Levels .................................................................................................................... 44

Figure 18 TTL Logic Levels ..................................................................................................................... 44

Figure 19 RS-232 and RS-485 Connector .............................................................................................. 48

Figure 20 PIPA-Q with Protective Cap .................................................................................................... 52

Figure 21 Connector Before Removal of Protective Tape ...................................................................... 52

Figure 22 Red Dots Aligned .................................................................................................................... 53

Figure 23 Connector Inserted into Receiver ............................................................................................ 53

Figure 24 Timing Diagram for CW Operation .......................................................................................... 59

Figure 25 Timing Diagram for Operation in Analogue Modulation Mode ................................................ 60

Figure 26 Timing Diagram for Operation in Digital Modulation Mode ..................................................... 61

Figure 27 PIPA-Q Window Assembly ...................................................................................................... 68

Figure 28 Removing Sleeve .................................................................................................................... 69

Figure 29 Placing Lens Cleaning Paper on top of the Window ............................................................... 69

Figure 30 Wetting the Lens Paper ........................................................................................................... 70

Figure 31 Cleaning the Window .............................................................................................................. 70

Figure 32 Removing Window .................................................................................................................. 71

Figure 33 Environmental Conditions for Non-Condensing Operation ..................................................... 74

Figure 34 Minimum Flow Rate against Inlet Water Temperature ............................................................ 79

Figure 35 Modulation Bandwidth as a Function of Set Power ................................................................ 81

Figure 36 Outline Drawing – Short Module ............................................................................................. 84

Figure 37 Mounting Locations – Short Module ........................................................................................ 85

Figure 38 Outline Drawing – Long Module .............................................................................................. 86

Figure 39 Mounting Locations – Long Module ........................................................................................ 87

Figure 40 PIPA-Q Optical connector ....................................................................................................... 87

Figure 41 Outline Drawing – PIPA-Q Beam Delivery Optic .................................................................... 88

Figure 42 Outline Drawing – Bare Fiber Output ...................................................................................... 89






8

TABLES Table 1 Safety, Explanatory and Compliance Labels ............................................................................. 17

Table 2 Information Labels ...................................................................................................................... 18

Table 3 Explanation of Order Code ......................................................................................................... 27

Table 4 Water Tubing and Fittings .......................................................................................................... 37

Table 5 Electrical Interface Connections ................................................................................................. 40

Table 6 Pinout of User Interface Connector ............................................................................................ 45

Table 7 RS-232 and RS-485 Control ...................................................................................................... 48

Table 8 Meaning of Status Words ........................................................................................................... 62

Table 9 Replacement Window Kit and Replacement Window ................................................................ 67

Table 10 Environmental Operating Conditions........................................................................................ 73

Table 11 Non-Operating Conditions ........................................................................................................ 75

Table 12 Electrical Requirements ........................................................................................................... 75

Table 13 Power Supply Output Capability Requirements ....................................................................... 76

Table 14 Cooling Water Requirements ................................................................................................... 77

Table 15 Cooling Requirements (Base Plate) ......................................................................................... 78

Table 16 Required Chiller Capacity ......................................................................................................... 79

Table 17 Cooling Requirements (PIPA-Q Optical Connector) ................................................................ 79

Table 18 General Laser Optical Specifications ....................................................................................... 80

Table 19 Maximum Modulation Bandwidth ............................................................................................. 81

Table 20 Single Mode Optical Specification ............................................................................................ 82

Table 21 Multimode Optical Specifications: 50µm Fiber ......................................................................... 82

Table 22 Multimode Optical Specifications: 100µm Fiber ....................................................................... 82

Table 23 Multimode Optical Specifications: 300µm Fiber ....................................................................... 82

Table 24 Mechanical Specifications – Short Modules ............................................................................. 83

Table 25 Mechanical Specification – Long Modules ............................................................................... 85

Table 26 Mechanical Specifications – PIPA-Q Optical Connector .......................................................... 87

Table 27 Bare Fiber Output Interface ...................................................................................................... 89

Table 28 Contact Information .................................................................................................................. 93






9

1 Structure and Scope of these Instructions for Use

These Instructions for Use for SPI Lasers’ redPOWER® PRISM Fiber Lasers contain all the

information that Users need to know for their safe and efficient use. This information is

important. These Instructions for Use must be read before installing and using the Laser and

made available for reference at the location where the Laser is being used. Additional or

replacement copies are available from SPI Lasers.

These Instructions for Use are divided into the sections below which provide Users with health

and safety information before introducing the Laser and then guiding them through its

installation, operation, maintenance and disposal. Lastly they provide other useful information

and the Lasers’ specifications.

2 Definition of Symbols and Terms

3 Health and Safety

4 Document References

5 redPOWER PRISM Tour

6 Getting Started

7 Installation

8 Operating Instructions

9 Maintenance

10 Disposal

11 Specifications

12 General Information

13 Contact Information

14 Customer Service

The PRISM Fiber Laser variants covered by these Instructions for Use have order codes:

SP -

0300

0500

0750

1000

1500

2000

- M - W -

014

020

050

100

300

-

02

05

10

15

20

30

- FBR

PIQ - 0

0

1 0 - 00

0

1 - 0

1 0 0

2

The order code can be found on a label on the rear panel of the Laser.

Details of the options shown in bold are expanded in Section 5.5 below.






10

2 Definition of Symbols and Terms

This symbol alerts the user to the hazard of exposure to laser

radiation.

This symbol alerts the user to the hazard of exposure to electricity.

This symbol alerts the user to the hazard caused by the weight of

this Laser.

This general warning symbol emphasises important information

needed during installation and operation.

This symbol identifies the protective conductor terminal (ground

point).

WARNING: Indicates a hazard with a medium level of risk which, if not avoided,

could result in death or serious injury.

Warnings must be observed to prevent personal injury to yourself

and others.

CAUTION: Indicates a hazard with a low level of risk which, if not avoided,

could result in minor or moderate injury.

Cautions must be observed to prevent personal injury and damage

to or destruction of equipment or loss of operational effectiveness.






11

PRISM Fiber

Laser and

Laser:

PRISM Fiber Laser and Laser as used herein means the item that

was procured from SPI Lasers.

The PRISM Fiber Laser is a complete fiber laser system. By

‘complete’ it is meant a laser system as sold and ready for use for

its intended purpose without modifications to the specification of

the product.

The PRISM Fiber Laser is specifically designed to be a laser for

incorporation or integration into other equipment. As such, it does

not meet the full requirements for a stand-alone laser system as

defined by 21 CFR 1040.10 and IEC/EN 60825-1.

The PRISM Fiber Laser is not a consumer product and is not to be

sold on or made available as such.

Laser

Integrator:

Any person who integrates the Laser into equipment, or any person

who uses the Laser in the form as supplied by SPI Lasers.

User: Individuals or organizations that use the Laser. User includes the

Laser Integrator and the end user.

Authorised

Personnel:

Those who have attended official Training Courses and have been

certified as competent.

OEM: Original Equipment Manufacturer. A company or organisation

which is skilled in and understands the integration issues

surrounding the use, design and supply of laser products to end

users in the end markets which it supplies.

SPI Lasers: SPI Lasers UK Ltd.






12

3 Health and Safety

3.1 General

This section gives information on the hazards which may be encountered during installation,

operation and maintenance of this PRISM Fiber Laser and steps to reduce the risk. Also

included is information on laser and electrical safety compliance. All safety instructions

including the instructions mentioned in other sections of these Instructions for Use must be

followed. Not following safety instructions may constitute a hazard to Users and third parties or

cause damage to property and the Laser.

Only Authorised Personnel who have been instructed in, and fully understand, the necessary

safety procedures should use this laser. Access to the laser must be restricted to Authorised

Personnel.

Any local safety requirements for the operation of this equipment must be complied with.

Throughout the documentation, ‘WARNING’, and ‘CAUTION’ paragraphs appear. It is the

responsibility and duty of all Users who operate and maintain this equipment to fully

understand the WARNING and CAUTION and act in order to reduce or eliminate hazards.

3.2 Intended Use of the PRISM Fiber Laser

This Laser has been designed exclusively for incorporation or integration into other equipment

for processing:

solid metals, including metal alloys and metal powders

ceramics in both solid and powder form

composite materials

Operating the device within the limits of its designated use requires the user to:

observe the instructions set out in these Instructions for Use

install and use this Laser in compliance with international, national and local

regulations regarding laser safety, for example IEC/EN 60825-1 and 21 CFR 1040.10.

install and use this Laser in compliance with international, national and local

regulations regarding the safety of electrical equipment, for example BS EN 60204

wire and connect the electrical lines to this Laser in compliance with international,

national and local regulations regarding electromagnetic compatibility (EMC), for

example the relevant sections of IEC/EN 61000 and FCC CFR47

not move this Laser when it is switched on (except that the optical connector may be

moved provided that the bending limits of the conduit are observed)






13

carry out necessary inspection and maintenance work

This Laser is not intended:

for processing in connection with flammable or explosive materials

for use in an explosion prone environment

SPI Lasers cannot be held liable for any damage resulting from such use. The risk lies entirely

with the User.

3.3 Hazards 3.3.1 Laser Hazards

All Warnings, including those in the Safety Notes and those in other sections of these

Instructions for Use, must be heeded.

Laser emissions from the housing of the Laser and the conduit of the beam delivery optic are

less than the AEL for Class 1 of IEC/EN 60825-1 with a single fault providing that the Fiber

Continuity Monitoring System (FCMS) is correctly implemented by the Laser Integrator.

WARNING: Care must be taken especially when controlling this

PRISM Fiber Laser remotely across a network.

Failure to do so could result in another User being exposed to

hazardous levels of radiation.

It is the responsibility of the Laser Integrator to ensure that when

controlled remotely no hazardous levels of radiation are emitted

when unsafe to do so.

3.3.2 Thermal Hazard

This Laser is designed to be used in a 19” rack cabinet or other housing which prevents

access to surfaces which may get hot during operation.

3.3.3 Materials Processing Hazards

Materials processing can generate vapour, fumes, solid particulates and other air

contaminants that may irritate, be toxic, or even fatal. It is the responsibility of the user to

ensure that all relevant safety precautions are followed and that any legal requirements are

adhered to in accordance with local legislation. It is advised that Material Safety Data Sheets

(MSDS) for any material to be processed are evaluated and that adequate measures for fume

extraction and venting are considered. Interaction of the beam with certain materials can

cause potentially harmful levels of visible radiation to be emitted. Appropriate protective

measures must be taken.






14

CAUTION: It is essential that any debris associated with laser

processing is removed and cleaned away on a regular basis.

Failure to do so may result in fire.

3.3.4 Other Hazards

While most of the hazard comes from laser radiation, there are certain non-beam hazards that

are often associated with use of laser systems. The Laser requires an electrical supply and is

water-cooled. Electricity and water, individually or in combination, may create hazards.

It is recommended that the Laser should be installed sufficiently far above the floor to reduce

the risk from electricity in the case of flooding: at least 250mm is recommended.

Mechanical hazards may include moving parts in cutting, welding and material handling

systems.

High temperatures and fire hazards may also result from the operation of Class 4 lasers.

3.4 Compliance

Within the EU, the Laser is CE marked and is supplied with a Declaration of Conformity. The

standards which SPI Lasers declares that the Laser is in conformity with, and the directives

which SPI Lasers declares that the Laser complies with the requirements of are listed in the

Declaration of Conformity.

Within the USA, the Laser is shipped with an appropriately completed FDA 2877 form.

It is the responsibility of the Laser Integrator to ensure that the integrated laser system

conforms with the appropriate standards and complies with the appropriate directives.

Nonetheless, many of the electronic and labelling requirements have been incorporated into

the Laser to facilitate compliance.

3.4.1 Europe: WEEE Directive

Figure 1 WEEE Symbol

This symbol indicates that, at end of life, this Laser should be separately collected from

unsorted waste.






15

3.4.2 Europe: RoHS Directive

This Laser is in conformity with European RoHS Directive. Compliance is demonstrated

through conformance with this standard which is harmonised to the RoHS directive:

BS EN 50581:2012

3.4.3 Europe: Machinery Directive

This Laser does not fall within the meaning of ‘machinery’ given in the Machinery Directive,

2006/42/EC, and therefore SPI Lasers cannot declare conformity with the Directive. However

SPI Lasers recognises that Laser Integrators may require the integrated laser system to

comply with the Directive. SPI Lasers has therefore designed for compliance to parts of the

standards listed below which are harmonised to the Machinery Directive:

EN11252:2013

EN13849-1:2015

EN13849-2:2012

EN11554:2008

EN12100:2010

EN12198-1:2000+A1:2008, EN12198-2:2002+A1:2008, EN12198-3:2002+A1:2008

3.4.4 Europe: Low Voltage Directive

This Laser falls outside the scope of the Low Voltage Directive as the Directive applies to

electrical equipment designed for use with a voltage rating of between 75V and 1500V for

direct current. However SPI Lasers recognises that Laser Integrators may require the

integrated laser system to comply with the Directive. SPI Lasers has therefore demonstrated

compliance to parts of the standard given below which is harmonised to the Low Voltage

Directive:

IEC/EN 60825-1

This Laser is specifically designed to be a laser for incorporation or integration into other

equipment. As such, it is not required to, and does not, meet the requirements for a stand-

alone laser system as defined by IEC/EN 60825-1.

During installation it is vital that the laser hazard is fully managed. In particular, the Laser

Integrator is required to provision the engineering requirements detailed in IEC/EN 60825-1.

These include, but are not limited to:

Provision of an additional protective housing which prevents human access or

exposure to laser radiation in excess of the AEL for Class 1 laser systems from the

output aperture. (IEC/EN 60825-1 section 4.2).






16

Provision of a remote interlock connector which when open-circuit prevents access to

laser radiation in excess of Class 1M (IEC/EN 60825-1 section 4.4).

Provision of a manual reset to enable resumption of accessible Class 4 laser radiation

emission after interruption of emission caused by use of the remote interlock connector

or an interruption of longer than 5s of electrical mains power (IEC/EN 60825-1 section

4.5).

Provision of a key-operated master control. The key must be removable and the laser

radiation shall not be accessible when the key is removed (IEC/EN 60825-1 section

4.6).

Provision of a fail-safe or redundant audible or visible emission indicator. This must be

repeated at the laser aperture if it is located more than 2m from the original emission

indicator (IEC/EN 60825-1 section 4.7).

Provision of one or more permanently attached means of attenuation (eg beam stop,

attenuator or switch). The beam stop, attenuator or switch shall prevent access to laser

radiation in excess of Class 1M (IEC/EN 60825-1 section 4.8)

Note that the visible alignment laser (if fitted) carries a Class 2 laser rating as defined by

IEC/EN 60825-1.

3.4.5 Europe: EMC Directive

This Laser falls outside the scope of the EMC Directive as it is intended exclusively for an

industrial assembly operation for incorporation into other apparatus. However SPI Lasers

recognises that Laser Integrators may require the integrated laser system to comply with the

directive. SPI Lasers has therefore designed for compliance to parts of the standards listed

below which are harmonised to the EMC Directive:

BS EN 50370-1:2005

BS EN 55011:2009+A1:2010.

3.4.6 USA: CFR Title 21 Part 1040, Food And Drug Administration

This Laser falls outside the scope of 21 CFR part 1040 as 21 CFR part 1040 does not apply to

laser products which are sold to a manufacturer for use as components. However SPI Lasers

recognises that Laser Integrators may require the integrated laser system to comply with the

regulation. SPI Lasers has therefore demonstrated compliance to parts of the European

standard:

IEC/EN 60825-1

Under Laser Notice 50, CDRH will not object to conformance with many sections of IEC

60825-1, as amended, as alternatives to comparable sections of 21 CFR §1040.10.






17

3.4.7 USA: CFR Title 47, Federal Communications Commission

This Laser is designed for compliance with:

FCC CFR47: §15.109 Radiated emission limits.

3.5 Labelling

Labels are placed on the top and rear panels of the Laser to warn of potential hazards and to

provide other useful information.

Table 1 and Table 2 below show the labels and give their locations.

Table 1 Safety, Explanatory and Compliance Labels

Rating plate label (example) (rear panel)

Different Laser variants have different voltage and current ratings. Refer to the label on

the Laser

Laser label (example) (rear panel)

Cautions label (top panel)

Laser emission, pipes and cautions label (top panel)






18

Laser aperture warning

(Optical connector)

Protective conductor terminal indicator

(rear panel adjacent to protective conductor

terminal)

Table 2 Information Labels

Laser identification (example) (rear panel)

Address, Patents, WEEE and CE label (rear panel)






19

4 Document References

Document

number

Description

SM-S00482 redPOWER PRISM Module Fiber Laser Command Reference

SM-S00483 redPOWER PRISM Fiber Laser GUI Manual






20

5 redPOWER PRISM Tour

The range of redPOWER PRISM Fiber Lasers builds on many years of experience of SPI

Lasers in designing, developing and supplying fiber lasers into a wide range of industrial laser

processing applications. It gives laser integrators the capability to manufacture industrial laser

machines with maximum output power levels from 300W to 1.5kW. They can be operated in

continuous wave (CW) or modulated (CWM) modes for applications enabled by fiber lasers

and applications traditionally serviced by lamp pumped and diode pumped solid-state lasers.

A flexible control architecture has been implemented using a combination of analogue, serial

and logic user interfaces.

The optical power is generated by SPI Lasers’ proprietary1 GTWave® active fiber technology

and reliable pump diodes to produce a high power, high brightness output. The output is

guided to the Laser Integrator’s optics by single mode (SM) or multimode (MM) delivery fibers.

The delivery fiber is usually supplied with a PIPA-Q optical connector, which is compatible with

industry standards, and a ruggedized conduit including SPI Lasers’ Fiber Continuity

Monitoring System (FCMS) to protect it.

To give Laser Integrators a flexible approach to multi-kW fiber lasers, PRISM Fiber Lasers

may be supplied without an optical connector to allow a spliced connection to a High Power

Combiner (HPC) supplied by SPI Lasers.

1 US 6,826,335, US 7,221,822, US 7,660,034, US 8,270,070, US 8,743,454 and granted patents in other territories






21

5.1 Key Parts

Figure 2 PRISM Fiber Laser with Optical Connector Key Parts

The Laser has many key parts. These are indentified in Figure 2. The names given in Figure 2

are used throughout these Instructions for Use.

PRISM Fiber Lasers are available with different rated output powers. Lasers with rated powers

of 1kW or less are shorter than those with higher rated powers. The dimensions are given in

section 11.5.1. The key parts and key features are the same for all rated powers.

5.2 Key Features

A schematic block diagram of the Laser is shown in Figure 3, which also indicates the main

User interfaces. In Figure 3 the Laser is represented by the red rectangle and the cooling

water circuit is indicated schematically in blue.






22

Key features of the Laser are given below.

Figure 3 PRISM Fiber Laser Key Features

Optical Engine

The heart of the Laser is the optical engine based on SPI Lasers’ proprietary

GTWave® active fiber technology. GTWave takes the optical power of the pump diodes

to generate the high beam quality output of the Laser. It requires no optical or

mechanical adjustments.

Pump Diodes

The pump diodes provide the power to the optical engine. Their high reliability means

that they will last for the life of the Laser.

Pump Drivers

The pump drivers control the current to the pump diodes allowing the CW power level

of the Laser to be adjusted and the Laser to be modulated over the specified power

and frequency ranges.






23

Beam Delivery

The delivery fiber guides the laser power from the optical engine into the Laser

Integrator’s optics. Options are available for the delivery fiber type and output

connector. Types include single mode and multimode, with different multimode core

diameters available. The delivery fiber is usually supplied with an industry standard

PIPA-Q optical connector. In this case a ruggedized conduit including SPI Lasers’

Fiber Continuity Monitoring System (FCMS) protects the delivery fiber. The optical

connector and ruggedized conduit with FCMS are referred to as the beam delivery

optic (BDO). When supplied without an optical connector mechanical protection is

provided by polymer jacket and Kevlar® reinforcement within a conduit, but there is no

FCMS.

Fiber Continuity Monitoring System (FCMS)

The FCMS is a thin copper wire wound around the delivery fiber. Should the delivery

fiber fail, the escaping laser power fuses the FCMS wire. The Laser Integrator must

monitor the continuity of the FCMS as described in Section 7.6.5 and shut the Laser

down to prevent the beam burning through the conduit and so prevent exposure of

Users to laser radiation.

Back Reflection Monitoring and Protection

In some laser processes the laser power couples poorly into the work piece causing

some of the power to be reflected back into the optical connector and coupled into the

delivery fiber. This back reflection is most likely to occur

o when setting focus at high power

o when processing highly reflective materials such as brass, copper and

aluminium, especially at normal incidence

o when operating away from the focal point of the process head

o during the piercing phase of laser cutting

This back reflected power has the potential to cause damage to the optical connector

and delivery fiber due to overheating. It may also to produce power instabilities due to

interaction with the optical engine.

The Laser is protected against back reflected power with active and passive measures.

Thus there is no need to employ additional optical components (such as optical

isolators), as is common with other fiber lasers, bringing cost and processing

disadvantages. The protection offered by the Laser comes from the design of the

optical connector and optical engine, and the use of sensors to monitor the back-

reflected power. In extreme cases, the Laser shuts itself down before damage occurs.






24

The optical connector incorporates the SPI Lasers patented2 technology, which

channels back-reflected laser light away from the delivery fiber via a capillary tube into

a water cooled beam dump, as shown in Figure 4, preventing damage to the delivery

fiber or its mechanical fixings.

Figure 4 PIPA-Q Optical Connector with Protection Against Back-Reflection

Thermal monitoring is also used within the optical connector and optical engine to

protect the Laser against back reflected power. If a temperature threshold is exceeded

a warning is generated. When the temperature falls below the threshold the warning

will clear. If higher temperature threshold is exceeded an alarm is generated and the

laser will shut down. The laser can be restarted when the temperature falls below the

threshold after the alarm has been cleared.

When processing highly reflective materials such as brass, copper and aluminium, or if

in doubt, contact SPI Lasers for applications advice.

Alignment Laser

An alignment laser provides a visible guide for the alignment of process heads. The

alignment laser is a Class 2 laser, meaning that it is safe to view the beam on a diffuse

work piece, although it is not safe to stare into the beam. (As an option, the alignment

laser may not be fitted.)

Low Power Mode

Low power mode allows the Laser to operate stably at lower powers so that, for

example, marking and cutting can be carried out consecutively on the same work

piece. Low power mode is not available in 300W Lasers.

2US6347178, JP3520044, GB1096285, DE60037091






25

Control and Monitoring Electronics

The control and monitoring electronics provide basic control and monitoring of the

Laser. Logic and analogue interfaces give Laser Integrators basic set point control and

status monitoring.

o Logic controls include Enable and Modulate, and monitors include Ready and

Emitting as well as alarms and warnings.

o Analogue controls include Power Set, and monitors include Output Power

Monitor and Back Reflected Power Monitor.

The Output Power Monitor may be used to improve power stability during changes in

ambient conditions as it allows Laser Integrators to provide closed loop control.

However the monitor may not accurately represent the output power when the output

is modulated or when processing highly reflective materials. Under such conditions,

SPI Lasers does not recommend using closed loop control.

To facilitate integration of multiple Lasers, all control and monitoring functions are

available using RS-232 and RS-485 serial interfaces. CAN bus is also available using

SPI Lasers’ proprietary protocol.

Mounting

The Laser can be fitted into a standard 19” rack cabinet. The front panel has the

conventional 2U dimensions.

5.3 Auxiliary Equipment

Installation of the Laser within an integrated laser system requires the provision of auxiliary

equipment for power and control as shown in Figure 5. A low noise DC power supply is

required to power the pump diodes. A temperature controlled supply of water is required for

cooling. A low noise 24V DC power supply is required for the monitoring circuits.

Requirements for the auxiliary equipment are given in the sections indicated below.

Pump power supply – Section 11.3.1

Auxiliary power supply – Section 11.3.1

Chiller – Section 11.3.2

It is the responsibility of the Laser Integrator to provide an integrator safety circuit which can

enable the Laser when the process cabinet doors are shut and disable it to make the process

cabinet safe both as required in normal operation and after activation of the emergency stop.

The Laser has no internal safety circuits.

SPI Lasers does not assume responsibility for specific integration decisions affecting the

safety and compliance to international standards of the Laser Integrator’s final laser product or

system.






26

Figure 5 PRISM Fiber Laser with Auxiliary Equipment

5.4 Software Tools

SPI Lasers’ Graphical User Interface for PRISM Module Fiber Lasers, PrismView, allows

Users to control the Laser over a serial interface. Operation of the Laser using PrismView is

described in the redPOWER PRISM Fiber Laser GUI Manual SM-S00483.






27

5.5 Explanation of Order Codes

The PRISM Fiber Laser variants covered by these Instructions for Use have order codes:

SP -

0300

0500

0750

1000

1500

2000

- M - W -

014

020

050

100

300

-

02

05

06

10

15

20

30

- FBR

PIQ - 0

0

1 0 - 00

0

1 -

0

1 0

0

2

Pow

er

Fib

er

BD

O le

ng

th

Co

nn

ecto

r

Alig

nm

ent la

ser

Win

dow

Be

am

qua

lity

Ba

se le

ng

th

Details of the options shown in bold are expanded in Table 3 below with reference to the

categories indicated above.

Table 3 Explanation of Order Code

Category Option Description Reference

Power Rated output power

0300 300W Rated power





2000 2000W Rated Power

Fiber Core diameter of delivery fiber

014 14µm Table 27

020 20µm Table 20

050 50µm Table 21

100 100µm Table 22

300 300µm Table 23






28

Category Option Description Reference

BDO length

02 2m

05 5m

10 10m

15 15m

20 20m

30 30m

Connector Optical connector type

FBR Bare fiber Section 11.5.3

PIQ PIPA-Q Section 11.5.2

Alignment laser

0 Not fitted

1 Fitted

Window

0 Not fitted Bare fiber

1 Fitted PIPA-Q

Beam quality

0 Standard Table 22

1 Enhanced Table 22

Base length

0 Standard Table 24 and Table 25

2

Medium power Lasers built on

long base plate Table 25

Not all combinations of options are available. Further information can be provided by request

from SPI Lasers






29

6 Getting Started

6.1 Receiving and Inspection

Figure 6 Laser in Crate as Received

Before installing or operating the PRISM Fiber Laser, you should:

Inspect the shipping container for damage

Inspect the Laser for signs of damage

Inspect the optical connector and conduit for any signs of damage

Confirm that the shipping carton contains all items on the shipping inventory list

including any accessories ordered as separate line items

Retain all packaging materials until the Laser has been commissioned. If anything is missing

or defective contact SPI Lasers. See Section 13 for contact details.

6.2 Unpacking and Handling









30

This Laser is heavy. Two people are required to unpack it. To avoid the risk of personal injury

or damage to the Laser when lifting or moving, lift with two people and use a trolley or similar

mechanical assistance when moving over distance.

Figure 7 Removing Fastener

1. Undo all the fasteners which secure the lid (Figure 7).

2. Lift off the lid.

3. Remove the top layer of foam packaging. The Laser will appear as shown in Figure 8.






31

Figure 8 Crate without Lid and Top Layer of Foam Packaging

4. Remove the documentation.

5. Free the foam block containing the optical connector.

6. Lift and hold the BDO away from the packaging (Figure 9) while a second person

removes the next layer of foam packaging.

Figure 9 Lift BDO to Enable the Next Layer of Packaging to be Removed

7. Replace the BDO (Figure 10).






32

Figure 10 BDO Replaced

8. Remove the foam inserts, if any (Figure 10).

9. Lift the Laser from the crate (Figure 11). Do NOT use the BDO termination block on

front panel as a lifting handle.






33

Figure 11 Lifting Laser from Crate

6.3 Unpacking the Beam Delivery Optic

Take care not to twist the conduit when uncoiling the BDO. Always unroll the conduit from the

free end, compensating for any twist that might occur. The conduit is very flexible and easily

bent when uncoiling. Ensure that is never bent to less than the minimum bend radius. Never

pull on the optical connector to untangle the conduit.

Particular care should be taken with regard to possible damage to the optical connector when

uncoiling the bean delivery optic as there is a tendency for the coil to spring apart, which may

cause the optical connector to collide with other objects. Do not drop the optical connector or

allow it to hit surfaces or other objects.

Finally remove the optical connector from the foam block by pushing the connector out of the

block. Use a finger inserted in the top of the block to push against the protective cap on the

optical connector.

Do not pull the block off as the protective cap may be inadvertently removed from the optical

connector exposing the window to contamination.






34

7 Installation

7.1 Safety and Compliance During Installation




The Laser is heavy. To avoid the risk of personal injury or damage to the Laser when lifting or

moving, lift with two people and use a trolley or similar mechanical assistance when moving

over distance.

Before installation reference must be made to Section 3 regarding laser safety, electrical

safety, EMC and compliance. When installed, the laser and the additional equipment required

to operate it must not obstruct access to safety devices or impair their operation.

It is recommended that installation is done in the sequence of the following sections, with

water connections made and checked before electrical connections are made.

7.2 Location and Environment

This Laser is designed to be used in a 19” rack cabinet or other housing.

This Laser is designed for operation within the environment specified in Table 10. Operating

the Laser beyond the limits of the environmental specification may lead to accelerated

component ageing and performance degradation. As the Laser is water-cooled care must be

taken to ensure that it is always operated above the dew point so that internal condensation is

avoided. Refer to Figure 33 for a chart showing the relationship between relative humidity,

ambient air temperature and cooling water temperature for non-condensing operation.

This Laser must not be installed in a corrosive atmosphere.

This Laser must not be exposed to high levels of optical radiation, for instance laser radiation

from materials processing.

This Laser is sealed against dust and water ingress to IP52 to BS EN 60529:1992+A2:2013

with the exception of the electrical connectors which are rated IP50. The laser integrator must

ensure that when installed the Laser is not likely to be exposed to water, for instance from

coolant leaks.

At least 100mm clear space must be provided around the Laser to allow the BDO to be routed

correctly.






35

The optical connector shall be mounted in a protective housing which prevents human access

to laser radiation (including errant radiation) in excess of the AEL for class 1, for example a

housing meeting the requirements of EN 60825-4. The protective housing shall withstand

exposures under reasonably foreseeable single fault conditions without human intervention.

7.3 Mounting

The total weight of the Laser is approximately 38kg for the long version and 26kg for the short

version. The front panel has the conventional 2U dimensions enabling the Laser to be fitted

into a standard 19” rack cabinet with its weight supported on runners. If mounted using the

mechanical mounting points specified in Section 11.5.1, all 8 (short modules) or all12 (long

modules) must be used to support its weight. The recommended torque for the M5 bolts is

3.5Nm. This value should be confirmed by the Laser Integrator. Alternatively, the Laser can be

placed on a clean, stable surface that will support its weight.

Ensure that the conduit carrying the delivery fiber is not kinked or snagged. Follow the

guidance given in Section 0 and allow sufficient space for correct routing of the conduit so that

all bends have radii greater than minimum bend radius. Failure to do so may result in

permanent damage to the delivery fiber.

7.4 PRISM Fiber Lasers with Bare Fiber Output

WARNING: PRISM Fiber Lasers with bare fiber output must be

spliced to an SPI Lasers High Power Combiner.

Failure to do so will result in catastrophic damage to the Laser and

may result in exposure to hazardous laser radiation.

If the Laser is powered up without proper termination of the delivery fiber, the delivery fiber

and Laser may be catastrophically damaged. Laser Integrators must ensure that the delivery

fiber is properly terminated, for example by splicing to an SPI Lasers HPC, prior to turning on

the Laser. Failure to do so may invalidate the warranty.

Further information on terminating the delivery fiber and HPCs can be provided by request

from SPI Lasers.

7.5 Cooling Water Connections

CAUTION: Ensure an approved overpressure safety device is

installed when connecting this Laser to an external chiller or factory

water supply. This should comply with ISO4126-1 (or equivalent)

and be rated to protect the Laser against a flow or differential water

pressure in excess of that specified.






36

CAUTION: If coolant is allowed to enter this Laser enclosure, do

not use the Laser and contact SPI Lasers immediately.

Failure to do so may result in electrical shock and damage to the

Laser.

7.5.1 Base plate

The Laser must be operated with a source of chilled water as specified in Section 11.3. The

base plate has two cooling circuits. They are terminated with approximately 30mm of 10mm

diameter copper pipe protruding from four positions on the front panel. The two circuits must

be connected in parallel, with flows in directions as shown in Figure 12. Hoses must be routed,

observing the specified bend radius, so that any leaking cooling water will be kept away from

the Laser, and provision must be made to shut down the Laser and shut off the cooling water

flow when a leak is detected.

De-ionized water is not permitted in the cooling circuit to prevent corrosion.

Cooling water connections must be made and checked for leaks before making electrical

connections and powering up the Laser. To avoid potential water ingress the electrical

connectors should be capped while checking for leaks.

If an external coolant leak occurs and water comes into contact with any of the electrical

connectors, allow the Laser to dry completely before operating. If coolant is allowed to enter

the Laser enclosure, do not use the Laser and contact SPI Lasers immediately.

Figure 12 Cooling Water Connections

7.5.2 PIPA-Q Optical Connector

It is essential that the PIPA-Q optical connector is adequately cooled with a source of clean,

chilled water in accordance with the specifications listed in Section 11.3.2. Operating the






37

PIPA-Q optical connector without an adequate flow of cooling water may result in catastrophic

damage.

The inlet and outlet water connections are SMC MS-5HLH-6 type miniature hose elbows

suitable for 6mm LLDPE or polyurethane tubing.

7.5.3 Cooling Water Fittings

The Laser is not supplied with water fittings. SPI Lasers recommends that the widely available

push-on John Guest ‘Speedfit’ water connections are used to connect the cooling circuit to the

chilled water supply. Ensure that the pipes are clean before adding the connections and that

the correct locking clips are used. John Guest part numbers are given in Table 4.

Table 4 Water Tubing and Fittings

Description John Guest Part Number Illustration

10mm Equal Elbow PM0310E

10mm Equal Straight

Connector PM0410E

10mm Locking Clip PM1810R

10mm Plug PM0810R

10mm LLDPE Tubing (for

base plate) PE-1007-100M-*

6mm LLDPE Tubing (for

optical connector) PE-0604-0100M-*






38

Description John Guest Part Number Illustration

10mm Equal Elbow PEM0310W

Description SMC Part Number Illustration

10mm polyurethane tubing

(for base plate) TU1065**-**

6mm polyurethane tubing

(for optical connector) TU0604**-**

Description Essentra Item Code Illustration

End Cap FCWA-0095-013

When using ‘Speedfit’ the water connection should be made as follows:

Cut the tube square and remove burrs and sharp edges. Ensure the outside diameter

is free of score marks. Push the tube into the fitting, to the tube stop.

Push the locking clip onto the fitting behind the collet.

Pull on the tube to check it is secure. Test the system before use.

To disconnect the water connection:

Ensure the system is depressurised and drained.

Remove the locking clip.

Push the collet square against the fitting. With the collet held in this position the tube

can be removed.

If this Laser is to be transported to a new location, returned to SPI Lasers or placed in storage

the PSU must be turned off and disconnected first, and then once the chiller has been

disconnected both the Laser and the optical connector must be drained of all coolant and

blown through with compressed air.






39

7.6 Electrical Connections

CAUTION: This PRISM Fiber Laser must be grounded for safety

and to comply with regional electrical codes.

Failure to do so may result in electric shock and incorrect operation

of the Laser.

For safe operation of this Laser the electrical connections given in the following sections need

to be made. All electrical connections should use cables of the shortest practical length.

Before making electrical connections and powering up the Laser, the cooling water

connections must be made and checked for leaks with the electrical connectors protected

from water splashes. For safety, the Laser must be connected to an external protective

earthing system before any other electrical connections are made. The Laser is not ‘hot

pluggable’: all electrical connectors must be mated and secured in place before power is

applied.

All figures in this section indicate the pin positions when looking at the connector on the rear

panel of the Laser.

To operate this Laser two power connections and a control connection, which can be serial

(RS-232, RS-485 or CAN bus) or analogue and logic, must be made.

The connectors, mounted on the rear panel of the Laser as shown in Figure 13, are:

Bus bars – DC Pump Diode Supply

This is the DC power input to the pump diodes. Further details of the power supply

requirements are given in Section 11.3.1.

37-way D-type male connector – User Interface

This connector carries the main analogue and logic connections to the laser, and the

CAN bus serial interface.

It is used to enable, control and monitor the laser.

The FCMS circuit in the BDO is made available this connector. It must be monitored by

an external safety rated circuit provided by the Laser Integrator.

9-way D-Type male connector – serial interfaces

RS-232 and RS-485 serial interfaces.

The connector positions on the rear panel are shown in Figure 13, in which the head of the

arrow indicates pin 1. Table 5 give references to the sections in which the pinout and details of

the signals on each connector are given.






40

Figure 13 Electrical Connections and Status Indicators

Table 5 Electrical Interface Connections

№ Function Connector Description Reference

Section

1 Protective Conductor (Earth)

Terminal

M5 female thread 7.6.1

2 Pump Diode PSU +V Bus Bar with two eyes for M8 bolts 7.6.2

3 Pump Diode PSU -V Bus Bar with two eyes for M8 bolts 7.6.2

4 User Interface 37-way D-type male connector 7.6.3

5 RS-232 and RS-485 9-way D-Type male connector 7.6.4






41

7.6.1 Protective Conductor (Earth) Terminal

Figure 14 Star Earthing Configuration

For safe operation of the Laser, to comply with regional electrical codes, and to reduce the

possibility of interference in the control and monitoring electronics the Laser, 24V DC Auxiliary

PSU, laser integrator digital and analogue control circuits and pump diode PSU must be

correctly grounded.

A star arrangement, as shown in Figure 14, is essential. The star is connected to the negative

terminals of the 24V DC Auxiliary PSU, the pump diode PSU and to the protective conductor

terminal of the Laser. The Laser’s protective conductor terminal is an M5 threaded hole and

requires a fixing torque of 4Nm. The Pump Diode PSU and 24V DC Auxiliary PSU must be

sited as close as possible to the Fiber Laser to minimise the connecting cable lengths. The

connections to the 24V DC Auxiliary PSU and the pump diode PSU should be made as close

to the PSUs as possible.






42

The protective conductor shall support the maximum short-circuit current of the pump diode

PSU.

7.6.2 Pump Diode PSU

The principal power source for the Laser is the pump diode PSU. Connection to the Laser is

made using the two bus bars on the back panel of the Laser. The positive bus bar is on the left

and the negative bus bar is on the right when looking at the back panel, and they are identified

+V and –V as shown in Figure 13.

Connection to the bus bars is made as shown in Figure 15 using an M8x16 screw, two flat

washers, a spring washer and a nut for each bus bar. The nut should be tightened to a torque

of 12Nm to 13Nm.

Figure 15 Bus Bar Connection

The remote sense connections of the PSU should also be connected to the bus bars.






43

7.6.3 User Interface

Figure 16 User Interface Connector

The connector is a 37-way D-type male connector and has

connections for the auxiliary power supply

connections for the alignment laser power supply (if alignment laser fitted)

logic inputs and outputs

analogue inputs and outputs

FCMS connections

The pinout and functions of the connections are given in Table 6. A fully screened, high quality

cable should be used. SPI Lasers recommends a cable from the L-com series CSMN37.

Most of the logic connections are set up for operation with 24V PLC controllers. Logic lines are

set HIGH by applying a voltage in the range 5.0 to 24.0V and set LOW by applying a voltage

in the range 0.0 to 4.0V. These logic levels are illustrated in Figure 17. Logic outputs have the

voltage level of the auxiliary power supply.






44

Figure 17 PLC Logic Levels

An alternative Modulate input is set up for TTL logic levels to allow faster modulation. This

input is set HIGH by applying a voltage in the range 2.0 to 5.0V and set LOW by applying a

voltage in the range 0.0 to 0.8V, as illustrated in Figure 18. The two Modulate inputs are OR’d

internally.

Figure 18 TTL Logic Levels






45

Table 6 Pinout of User Interface Connector

Pin

№

Connection

Name Type Function Level/Tolerance

1 Alignment

Laser

Power The alignment laser (if fitted) is

powered from this connection, not

from the auxiliary power supply. It is

turned on by applying 24V and turned

off by removing 24V.

24V ±10%, 50mA

2 Enable Input When Enable is set HIGH the Laser

goes into the Ready state if there are

no alarms.

PLC (Figure 17)

3 Modulate

TTL

Input When Enable is set HIGH, Modulate

switches the laser power between the

powers set by Power Set (Modulate

HIGH) and Simmer Set3 (Modulate

LOW).

TTL (Figure 18)

4 Modulate

PLC

Input When Enable is set HIGH, Modulate

switches the laser power between the

powers set by Power Set (Modulate

HIGH) and Simmer Set3 (Modulate

LOW).

PLC (Figure 17)

5 Low Power

Mode

Enable

Input Set HIGH to enable low power mode PLC (Figure 17)

6 Alarm Reset Input Set HIGH to clear alarms that do not

require a service engineer. Alarms will

only reset if the fault condition is no

longer present.

PLC (Figure 17).

Alarms are reset

on a rising edge.

7 Reserved Input Do not connect -

8 Reserved Input Do not connect -

9 Alarm

Indicator

Output HIGH if an alarm is present. Auxiliary power

supply level.

10 Warning

Indicator

Output HIGH if a warning is present. Auxiliary power

supply level.

3 Simmer Set can only be adjusted through the serial interface.






46

Pin

№

Connection


11 Ready Output HIGH indicates that the laser is ready

to emit.

Auxiliary power

supply level.

12 Emitting Output HIGH indicates that the laser is

emitting. Note that if Power Set is

small or zero, power may not be

emitted.

Auxiliary power

supply level.

13 Status 1 Output Status bit. LSB Auxiliary power

supply level.

14 Status 2 Output Status bit Auxiliary power

supply level.


supply level.


supply level.

17 Status 5 Output Status bit. MSB Auxiliary power

supply level.

18 Auxiliary

Power

Supply +ve

Power +24V to power control and monitoring

electronics

24V ±5%, 500mA

19 Auxiliary

Power

Supply +ve

Power +24V to power control and monitoring

electronics

24V ±5%, 500mA

20 Reserved Output Do not connect -


22 Reserved I/O Do not connect -

23 Reserved I/O Do not connect -

24 Ground Ground - -

25 Power Set Input -

Analogue

0-10V differential analogue input to

set the power level.

0-10V with

respect to pin 26.

26 Analogue

Input Ground

Ground - -







47

Pin

№

Connection


28 Output

Power

Monitor

Output -

Analogue

A voltage proportional to the output

power of the Laser. Nominally 10V at

rated power.

0-15V

29 Back

Reflected

Power

Monitor

Output -

Analogue

A voltage indicative of the back

reflected power of the Laser.

Nominally 10V at rated power in the

absence of back reflection. Not

present on bare fiber units

0-15V


31 FCMS

Monitoring

Pin 1

Analogue Connection to the BDO fiber continuity

monitoring system (FCMS)

-


33 FCMS

Monitoring

Pin 2

Analogue Connection to the BDO fiber continuity

monitoring system (FCMS)

-


35 FCMS

Monitoring

Pin 3

Analogue Not used -

36 Auxiliary

Power

Supply -ve

Power 0V -

37 Auxiliary

Power

Supply -ve

Power 0V -






48

7.6.4 RS-232 and RS-485

Figure 19 RS-232 and RS-485 Connector

Pin 1 of the RS-232 and RS-485 connector is indicated in Figure 19 and the connections are

given in Table 7. When connecting using RS-232 a three wire cable must be used. When

connecting to a standard computer serial port with RS-232, pins 2 and 3 must be crossed over

at the computer end. Note that no connection should be made to pins 6 to 9 when using RS-

232 and no connection should be made to pins 2 and 3 when using RS-485.

For operation of the RS-232 and RS-485 interfaces refer to the redPOWER PRISM Fiber

Laser Serial interface Manual SM-S00482 or redPOWER PRISM Fiber Laser GUI Manual

SM-S00483.

Table 7 RS-232 and RS-485 Control

Pin № Connection Name I/O Description

1 Ground - Ground

2 RS-232 Rx I RS-232 receive

3 RS-232 Tx O RS-232 transmit

4 Not connected - -

5 Ground - Ground

6 RS-485 Rx + I RS-485 receive (differential)

7 RS-485 Rx - I

8 RS-485 Tx - O RS-485 transmit (differential)

9 RS-485 Tx + O

The RS-485 interface may be used in differential mode or, by connecting pin 6 to pin 9 and pin

7 to pin 8 it can be configured as a two-wire bus, but in this case care must be taken to ensure

that the Laser’s responses are allowed to complete before a new command is transmitted

from the controlling device, as the transmit and receive data will use the same connections.






49

7.6.5 Connection to Interlock and Emergency Stop System

WARNING: The PRISM Fiber Laser does not control the pump

power supply and has no safety function to de-energise or control

the pump diodes or the output power.

Failure to provide external safety systems may result in exposure to

harmful levels of radiation.

It is the responsibility of the Laser Integrator to provide an integrator safety circuit, constructed

from components approved to the relevant standards, to make certain that electrical power is

removed to ensure laser safety. It is understood that this will be done in a manner certified to

the required national and international laws, rules, statutes and standards. This safety circuit

must only allow the Laser to be enabled when the industrial laser machine into which the

Laser is incorporated is in a state safe for laser emission. It must disable the Laser to make

the industrial laser machine safe both as required in normal operation and after activation of

the emergency stop system.

With appropriate monitoring of the FCMS, a fiber break or cable severance, an unmated

connector or optical connector over temperature condition can be detected and used to shut

down the Laser. The monitoring and shut down circuits are not included in the Laser.

The integrator safety circuit must include the FCMS such that if there is no continuity between

the FCMS pins, 33 and 35, on the user interface connector (see Section 7.6.3.) the Laser is

disabled and the industrial laser machine is put in a safe state.

The resistance of the circuit depends on the BDO length and is minimum 3, typically 4.5 and

maximum 6 ohms per metre. The circuit is insulated from earth (ground) and is only suitable

for SELV circuits, maximum 25V AC or 60V DC. The minimum recommended voltage is 5V

and minimum current is 10mA, to ensure reliable operation of the temperature switches. The

maximum permissible current is 50mA.

All applicable safety requirements for the intended market must be met prior to allowing the

Laser to enter service as part of an integrated laser system.

7.7 Routing the Beam Delivery Optic

CAUTION: If damage to the conduit or optical connector is

suspected, stop using the PRISM Fiber Laser and contact SPI

Lasers immediately.

Failure to do so may result in exposure to harmful levels of

radiation.

BDOs and their optical connectors are precision parts.

Avoid contamination and mechanical stress when handling.






50

Avoid shocks and impacts on optical connectors.

Avoid pulling, twisting and over-bending of the conduit.

Beam delivery optics are less robust than electrical cables, although superficially they look

similar. If BDOs are treated and handled as electrical cables, they will fail prematurely. BDO

replacement can be both time-consuming and expensive.

Avoid kinking and twisting the conduit by unrolling the coil, rather than pulling it straight.

If the BDO is led through openings, the openings must be sufficiently large that the optical

connector with protective cap can be led through without applying any force.

In static applications (where BDO and process head do not move):

The BDO may be routed alongside power, water or control cables provided these do

not impose stresses or strains on the conduit.

The conduit must not be bent tighter than the minimum bend radius at any point along

the route. (Refer to Table 26.)

The maximum tensile loading must not be exceeded. (Refer to Table 26.)

The conduit must be supported at points along its length, at intervals no greater than

3m, to prevent gross movements under its own weight during the production

sequence.

At the support points, the conduit must be held using mechanical parts which prevent

bends tighter than the minimum bend radius and which do not apply a compressive

force on the conduit.

The external surface of the conduit must be prevented from rubbing or abrading at

support points or on any other parts in the workstation (e.g. jigs, fixtures, production

parts, workstation walls, floors, robot parts).

In dynamic applications (where BDO and process head move), additionally:

The BDO must be routed separately from power, water and control cables.

The BDO must be held off the floor and routed along a path so that the conduit is not

bent tighter than the minimum bend radius at any point along its length all through the

production sequence.

The conduit must never be pulled tight at any point along its length during the

production sequence.

If a balancer is used, tie the conduit to the rope of the balancer so that:

o the rope takes the tensile loading and not the optical connector.

o the conduit has sufficient slack for all kinds of robot motions without bending

below the minimum bend radius.






51

Acceleration and deceleration of the BDO and process head must be kept to a

minimum consistent with achieving process cycle time.

At BDO installation and periodically during operation (e.g. once per shift), a dry run of

the production sequence should be made. The BDO motion should be checked to

ensure that the routing still complies with the points of good practice above.

7.8 Connecting the PIPA-Q Optical Connector to the Process Head

CAUTION: The protective cap placed on the optical connector is

intended to protect the connector from contamination during

shipping and when the PRISM Fiber Laser is not in use for

extended periods, and to prevent the FCMS circuit from being

accidentally closed. It MUST NOT be treated as a beam stop.

Operating the Laser with the protective cap in place may result in

damage to the Laser. In addition, due to the elevated temperatures

associated with operating the Laser at high power with the

protective cap in place, contact may lead to personal injury.

CAUTION: The protective tape attached to the optical connector is

intended to protect the connector from contamination during

shipping.

Operating the PRISM Fiber Laser with the protective tape in place

may result in damage to the Laser.

Each optical connector change incurs the risk of contaminating or damaging the connector.

Therefore optical connectors should only be changed when required and the local

environment should be as clean and dust free as possible to avoid introducing debris into the

process head.

The protective cap and protective tape must only be removed after the BDO is routed and

immediately before the optical connector is inserted into the process head. Remove the

protective cap slowly holding the optical connector downwards to avoid contamination settling

on the window.

Do not grease optical connectors

Keep the optical connector facing downwards when uncovered and not installed.

Do not touch the window

The optical connector must not be subjected to forces caused by dropping, impacting or

collision with heavy objects.

Optical connectors must be inspected, and cleaned if necessary, before being reinserted. See

Section 9.3.






52

The PIPA-Q optical connector should be installed as follows:

Carefully route the BDO following the instructions given in Section 7.4.

Carefully clean any dust or debris away from the receiver of the process head, taking

care that nothing gets into the receiver.

Position the process head so that the receiver for the optical connector is horizontal.

Remove the sealing plug from the receiver.

Figure 20 PIPA-Q with Protective Cap

Remove the protective cap, shown in Figure 20, from the optical connector. It can be

pulled straight off.

Figure 21 Connector Before Removal of Protective Tape

Remove the protective tape, shown in Figure 21, from the connector.

Inspect the connector for contamination using suitable magnification and illumination,

and clean if necessary following the instructions in Section 9.3.






53

Figure 22 Red Dots Aligned

Install the optical connector into the process head, collimating optics or adapter using

the 2-step bayonet fitting on the front of the connector. Ensure the red dot on the

optical connector is aligned with the two red dots on the receiver (refer to Figure 22).

Locking Step 1:

Fully insert the optical connector (Figure 23) and turn the locking sleeve through about

a tenth of a turn in a clockwise direction.

Locking Step 2:

Pull the sleeve out by 2mm.

While in the pulled-out position rotate the locking sleeve until hand tight.

Tighten by hand only.

Figure 23 Connector Inserted into Receiver






54

7.9 Removing PIPA-Q Optical Connector from the Process Head

Each optical connector change incurs the risk of contaminating or damaging the connector.

Therefore optical connectors should only be changed when required and the local

environment should be as clean and dust free as possible to avoid introducing debris into the

process head.

Using clean, dry compressed air or nitrogen, blow away any dust from the area where the

optical connector enters the process tool.

Using a clean cloth or tissue, wipe down the area where the optical connector enters the

process tool to remove the last traces of dust or debris.

Remove the PIPA-Q optical connector from the process head using the 2-step process.

Unlocking Step 1:

Pull the locking sleeve out by 2mm.

Unlocking Step 2:

Turn the locking sleeve through about a tenth of a turn in an anticlockwise direction

and remove the optical connector.

Immediately after the optical connector is removed the protective cap must be refitted. The

process head receiver should also be plugged to prevent dust entry.






55

8 Operating Instructions

WARNING: Follow the procedures and instructions described in the

following section.

Failure to do so may lead to harmful radiation exposure resulting in

personal injury and damage to the equipment.

This section describes the operation of the PRISM Fiber Laser. Before proceeding refer to all

relevant sections in these Instructions for Use covering safety, environmental and electrical

specifications, component inspection and Laser installation.

In this section the names of electrical connections are given in bold. Logic lines are set HIGH

as described in Section 7.6.3

8.1 Before Operation 8.1.1 Risk Assessment and Checks

Carry out and implement a risk assessment covering personnel and the environment

appropriate to the installation and operation of the integrated laser system.

Ensure that Lasers with bare fiber output are spliced to the appropriate SPI High

Power Combiner Module.

Ensure that the FCMS is correctly connected to the safety circuit.

Ensure that the protective cap and protective tape are removed from the optical

connector.

Ensure that the optical connector is securely mounted.

Ensure that the beam is directed towards the work piece, power meter or appropriate

beam dump.

Ensure all laser safety precautions are adhered to.

Ensure a supply of chilled water is connected to the base plate in accordance with

Section 7.5.

Ensure a supply of chilled water is connected to the optical connector in accordance

with Section 11.3.

Ensure the electrical connections are made in accordance with Section 7.6.






56

8.1.2 User Training

All Users must be officially trained and authorised within their respective organisations. They

must also be fully conversant with the following:

Laser hazards, safety procedures and correct use of related safety equipment.

Hazards related to the use of Lasers for materials processing, prescribed safety

procedures and related equipment.

The contents of these Instructions for Use, and therefore the safety provisions in it.

8.2 Modes of Operation

The Laser has three modes of operation: continuous wave (CW), analogue modulation and

digital modulation. The mode of operation is controlled by the use of the Modulate logic input

and Power Set and Simmer Set levels. (Note that Simmer Set has a default value of 0% and

can only be set using a serial interface.) When Modulate is set HIGH the output power is

determined by the level set on the Power Set input, and when Modulate is set LOW the

output power is determined by the Simmer Set level.

To generate an arbitrary output (analogue modulation mode) Modulate should be set HIGH

and the arbitrary signal applied to the Power Set input. To switch rapidly between power

levels set by the Power Set and Simmer Set inputs (digital modulation mode) a logic signal

should be applied to the Modulate input.

Note that if Power Set is zero and Simmer Set is not zero, power will be emitted when

Modulate is LOW and not when Modulate is HIGH.

8.2.1 CW Mode

The output level is set by Power Set. In this mode Modulate should be set to logic HIGH. In

addition Simmer Set should be set to 0%.

8.2.2 Analogue Modulation Mode

In this mode the output of the Laser can be continuously varied using Power Set.

This mode should be used when pulse shaping and direct analogue control are required.

The power is set to that requested by Power Set when Modulate is set HIGH. If Modulate is

LOW the output power is set to that requested by Simmer Set.






57

8.2.3 Digital Modulation Mode

In this mode the Laser switches between the two power levels set by Power Set and Simmer

Set. The power is set to that requested by Power Set when Modulate is set HIGH. When

Modulate is LOW the output power is set to that requested by Simmer Set.

8.2.4 Low Power Mode

Low power mode allows the laser to operate down to significantly lower average power levels

than are possible in normal mode while still maintaining stable operation. When low power

mode is enabled the maximum power available is limited to approximately 300W and stable

operation is possible down to approximately 30W. Low power mode should be used whenever

the power required is less than 300W for improved stability and avoidance of spurious output

failure alarms.

Low power mode can be used at any time with CW, analogue modulation and digital

modulation operation by setting Low Power Mode Enable HIGH.

8.2.5 Use of Simmer Set

In digital modulation mode the Laser switches between the two power levels set by Power Set

and Simmer Set. If the power level set by Simmer Set is 0%, then the first pulse in a train

may be different from subsequent ones. This first pulse non-uniformity is a well known

phenomenon which occurs when power is demanded after a period of no power, for example

when using single shots or gated pulse trains. The degree of non-uniformity is dependent on

the power, modulation frequency and duty cycle, and becomes increasingly significant at

lower powers, frequencies and duty cycles. The turn-on delay of the laser can also be

minimized using this feature. By setting Simmer Set to an empirically determined optimum

value the laser can be held just below threshold to ensure that the first pulse turns on as

quickly as the subsequent pulses and has the same energy.

Simmer Set can be adjusted from 0% to 100% which corresponds to 0% to about 20% of

rated power. A Simmer Set value of 20% is suggested as starting point for the optimisation. If

there is appreciable power when Modulate is set LOW then Simmer Set should be reduced.

If non uniformity is present, and there is no appreciable power when Modulate is set LOW,

then increase Simmer Set.

Note that if Simmer Set is not set to 0%, power will be emitted by the Laser when Modulate is

set LOW and Enable is set HIGH.






58

8.3 Turning the Laser On and Off

CAUTION: If Simmer Set is not set to 0%, power will be emitted by

the Laser when Modulate is set LOW and Enable is set HIGH.

8.3.1 Enabling the Laser

Power should be applied to the Laser in the following sequence:

1. 24V DC Auxiliary PSU. The ‘Run’ status indicator will show green.

2. Allow the 24V DC Auxiliary PSU to stabilise

3. Pump Diode PSU

4. Allow the Pump Diode PSU to stabilise

To enable the Laser

5. Set Enable HIGH

The Laser will respond with HIGH on Ready and the ‘Emission’ status indicator will show

yellow. This will only occur if there are no alarms present. Alarm conditions are described in

Section 8.5.

The Laser is now enabled and power can be requested using the Power Set and Modulate

inputs. A third control, Simmer Set, can be set using the serial interface.

The two modulate inputs, Modulate TTL and Modulate PLC, are OR’d together and are not

distinguished in the following sections.






59

8.3.2 Operating in CW Mode

Figure 24 Timing Diagram for CW Operation

1. Enable the Laser

2. If using a serial interface, set Simmer Set to 0%

3. Set the power required by applying a voltage to Power Set. The voltage should be

between 500mV and 10.0V corresponding to output powers between approximately

5% and 100% of rated power

4. Set Modulate HIGH

If the Laser has enabled correctly then Emitting will go HIGH and the ‘Emission’ status

indicator will show yellow.






60

8.3.3 Operating in Analogue Modulation Mode

Figure 25 Timing Diagram for Operation in Analogue Modulation Mode

In this mode the output of the Laser can be continuously varied using Power Set.

This mode should be used when pulse shaping and direct analogue control is required.

1. Enable the Laser

2. If using a serial interface, set Simmer Set to 0%

3. Set Power Set to 0V

4. Set Modulate HIGH

5. Set Enable HIGH

If the Laser has enabled correctly then Emitting will go HIGH and the ‘Emission’ status


Set the power required by applying a variable voltage to Power Set. The voltage should be

between 500mV and 10.0V corresponding to output powers between approximately 5% and

100% of rated power.

8.3.4 Operation in Digital Modulation Mode

In this mode the Laser switches between the two power levels set by Power Set and Simmer

Set. The power is set to that requested by Power Set when Modulate is set HIGH. When

Modulate is LOW the output power is set to that requested by Simmer Set.






61

1. Enable the Laser

2. Set Modulate LOW

3. Set the power required when Modulate is LOW by setting Simmer Set using a serial

interface. Refer to Section 8.2.5 for the use of Simmer Set

4. Set the power required when Modulate is HIGH by applying a fixed voltage to Power

Set. The voltage should be between 500mV and 10.0V corresponding to output

powers between approximately 5% and 100% of rated power

5. Set Enable High

If the Laser has enabled correctly then Emitting will be set HIGH and the ‘Emission’ status


Apply arbitrary logic pulse train to Modulate.

Figure 26 Timing Diagram for Operation in Digital Modulation Mode

8.3.5 Turning the Laser Off

To turn the Laser off:

1. Set Enable LOW

2. Set Modulate LOW

3. Set Power Set to 0V

4. Set Simmer Set to 0%






62

The Laser will respond with LOW on Ready and Emitting, and the ‘Emission’ status indicator

will turn off. Note that Emitting will remain high for 200ms after Modulate goes low.

Remove power from the Laser in the following sequence:

1. Ensure that Enable, Modulate and Power Set are set to 0V and discharged

2. Turn off the Pump Diode PSU

3. Allow the Pump Diode PSU to discharge

4. Turn off the 24V DC Auxiliary PSU

5. Allow the 24V DC Auxiliary PSU to discharge

8.4 Turning the Alignment Laser On and Off

The alignment laser (if fitted) is turned on by applying 24V to pin 1 of the User Interface

connector. It is powered from this connection, not from the auxiliary power supply. It cannot be

turned on and off over the serial interface.

In Integrated Laser Systems in which several Lasers are combined together, the total

alignment laser power may exceed the AEL for Class 2 of IEC/EN 60825-1 if the individual

alignment lasers in some or all of the Lasers are turned on. This implementation facilitates

compliance of the Integrated Laser System to IEC/EN 60825-1 as a hardware connection is

necessary.

To determine whether an alignment laser is fitted refer to Section 5.5.

8.5 Monitoring, Alarms and Diagnostics

The state of the laser can be determined by monitoring the five status lines, pins 13 to 17 on

the user interface connector. The status should be monitored so that appropriate action can

be taken in the event of an alarm. Alarms and warnings are also indicated by the ‘Alarm

Warning’ status indicator on the rear panel. This indicator shows steady red when a warning is

present and flashing red when an alarm is present.

The states of the five status lines form a five bit word, with Status 1 the least significant bit and

Status 5 the most significant bit. Each of the 32 values and its meaning is given in Table 8.

Table 8 Meaning of Status Words

Value Meaning Action

0 Emitting (Modulation and Enable HIGH,

driver voltage present, no alarms)

Normal operation

1 Idle (Enable HIGH, driver voltage present,

no alarms)

Normal operation

2 Not Armed (Enable LOW, no alarms) Normal operation






63


3 Enable Line Cycle Required Cycle Enable LOW then HIGH to enable

the Laser

4 Alarm: Laser Temperature The Laser is too hot or too cold. Check

that cooling water within the specified

temperature range is flowing at a flow

rate within the specified range. Allow the

laser to reach operating temperature

before restarting.

5 Alarm: Over Temperature Switch The Laser is too hot. Check that cooling

water within the specified temperature

range is flowing at a flow rate within the

specified range. Allow the laser to reach

operating temperature before restarting.

6 Alarm: Memory Corruption Contact SPI Lasers.

7 Alarm: Aux Power Supply Voltage Low Check that the auxiliary power supply

voltage is set within the specified range

8 Alarm: Reserved -

9 Alarm: Optical Failure Detected Refer to Section 8.5.1.

This function is not implemented on

Lasers with bare fiber output

10 Alarm: Reserved -

11 Alarm: Reserved -

12 Alarm: Humidity The humidity within Laser is too high and

there is a risk that condensation may

occur. Try increasing the cooling water

temperature to a higher temperature

within the specified range. Run the

cooling water at this temperature until

the alarm clears before restarting.

13 Alarm: Internal Communication Failure Communication failure can occur when

operating in a electrically very noisy

environment. Address any sources of

electrical noise, then clear the alarm. If it

persists, contact SPI Lasers.

14 Alarm: Unexpected Emission Detected Contact SPI Lasers.






64


15 Alarm: Driver Negative Power Supply

Failure

This alarm may occur with the Aux

Power Supply Voltage Low alarm. If so,

check that the auxiliary power supply

voltage is set within the specified range.

If the alarm occurs alone, it indicates a

possible electronics fault. Contact SPI

Lasers.

16 Alarm: PLC Output Driver Fault The output driver circuitry has

overheated. Ensure that the User

Interface Connector is connected

correctly, and that high voltages are not

being applied or high currents being

drawn. Allow the Laser to reach

operating temperature before restarting.

17-31 Reserved for future use -

8.5.1 Conditional Reset of Optical Failure Detected Alarm

WARNING: Observe all laser safety precautions before starting the

reset sequence.

Failure to do so may result in exposure to hazardous radiation.

An Optical Failure Detected alarm will be asserted and the Laser shut down if the internal

power monitoring system detects an inappropriate optical output in response to Power Set

and Modulate signals. The alarm can only be cleared using the serial interface.

Operating the Laser at very low average powers (outside the specified operating range) may

trigger a false Optical Failure Detected alarm. To confirm whether the alarm is a true

condition, a command can be used to perform a conditional reset. Refer to the redPOWER

PRISM Fiber Laser Serial interface Manual SM-S00482 for the Clear Optical Failure Detected

command and responses.

If the reset routine is unsuccessful after the first attempt contact SPI Lasers immediately for

advice.

To reset the Optical Failure Detected alarm:

Ensure the beam delivery optic is securely mounted, pointing towards a suitable beam

dump and the protective cap has been removed.

Ensure the pump diode PSU is connected and turned on.






65

Set modulate HIGH.

Send the Clear Optical Failure Detected command.

If the response is Alarm Cleared, confirm that reset procedure is successful.

The laser is now reset and ready for continued operation.

If the reset procedure is NOT successful contact SPI Lasers immediately for advice.

8.6 Laser Control Using PrismView

For instruction in the use of the PrismView graphical user interface to control the Laser refer to

redPOWER PRISM Fiber Laser GUI Manual SM-S00483.

8.7 Serial Control of the Laser

For the full command set refer to PRISM Fiber Laser Serial interface Manual SM-S00482.






66

9 Maintenance

WARNING: Never attempt to modify internal or external

components not covered in this section.

Doing so may lead to serious personal injury, performance

degradation and premature failure.

The PRISM Fiber Laser is designed to be maintenance free. There are no parts or mechanical

items within the Laser that require replacement during the specified operating life of the Laser.

However periodic inspection of the Laser is recommended.

9.1 Periodic Inspection

The items listed below should be inspected periodically for damage which may affect the safe

operation of the Laser. The frequency of the inspection will depend on the environment in

which the Laser is installed.

The enclosure

The conduit

The optical connector

The electrical connections

The water connections and hoses

It is important that cooling water connections and hoses are regularly inspected and

maintained in order to reduce the possibility of leakage or external component failure.

Refer to Sections 7.5 for instructions regarding water cooling connection and disconnection

from the Laser.

9.2 General Cleaning

CAUTION: Do not operate the PRISM Fiber Laser if any of the

hazard warning labels are missing or damaged such that they

cannot be read properly.

Occasionally, the outside of the Laser may require cleaning to assure full and clear visibility of

the warning labels. Before cleaning disconnect the Laser from the power supplies. Clean only

with a clean damp cloth and if any labels become displaced contact SPI Lasers immediately

for replacements.






67

9.3 Maintenance of Optics

WARNING: Isolate all electrical supplies to ensure that inadvertent

operation of the Laser cannot take place.

CAUTION: To reduce window contamination, fit the protective cap

when the Laser is not used for prolonged periods of time and when

the Laser is being transported or stored.

CAUTION: Never attempt to use an abrasive material to remove

contamination. Do not use any cleaning agents other than those

specified in this document.

9.3.1 General

The cleanliness of all optical surfaces is critically important. Contamination in the optical path

from environmental dirt or dust, or finger grease from incorrect handling must be avoided as

the contamination will be burned into the optical surfaces causing permanent damage.

Before leaving the factory SPI Lasers inspects all optical surfaces using an automated system

to identify contamination consistently.

Before being exposed to high power, optical connector windows should be inspected,

preferably with a magnifying aid, and cleaned if any contamination is observed.

If the window on the optical connector is damaged, or too dirty to clean, a replacement window

kit and window is available to order from SPI Lasers. The kit contains a replacement window

assembly and the tools necessary to change it. Note that the window assembly is a

consumable item and is not covered by the laser warranty.

The Laser should never be operated without the window in place.

Table 9 Replacement Window Kit and Replacement Window

Part Number Description

PT-K00232 PIPA-Q Replacement Window Kit






68

Part Number Description

The kit contains

PIPA-Q Window Assembly

PIPA-Q Window Assembly Spanner

PIPA-Q Window Access Tool

PS-A01683 PIPA-Q Window Assembly

9.3.2 Cleaning the Optical Connector Window

Figure 27 PIPA-Q Window Assembly

First try to remove any surface contamination from the window using a clean air blower. Never

use general "shop floor" or other unknown air sources as these can contain significant

amounts of lubricating oil which will add to the contamination. Always wear gloves to avoid

further contamination.

If contamination is still present after air blowing, it is recommended that the protective sleeve

is removed and the window is cleaned with IPA (isopropyl alcohol, propan-2-ol) as described

below. If this is unsuccessful then the window will need to be replaced as described in Section

9.3.3.






69

Figure 28 Removing Sleeve

1. Secure the PIPA-Q optical connector

2. Use the PIPA-Q Window Access Tool to hook into the hole in the sleeve. Turn the

sleeve to loosen. If necessary use the PIPA-Q Window Assembly Spanner (wrench) to

hold the window.

3. Unscrew and remove the sleeve by hand. Take care not to touch the window surface.

4. Inspect the exposed window for further contamination or damage. If any debris or dust

particles are present blow away with clean air.

5. If the window requires further cleaning then use soft lens cleaning paper specifically

designed for cleaning optical surfaces with IPA.

a. Place a sheet of lens cleaning paper on top of the window.

Figure 29 Placing Lens Cleaning Paper on top of the Window

b. Drip a single drop of isopropyl alcohol on the lens paper above the window.






70

Figure 30 Wetting the Lens Paper

c. Drag the lens paper across the surface of the window until the surface is

completely dry. Do not rub or scratch the surface. For each cleaning process

use a new, clean tissue. In some instances, it may not be possible to remove

particles. Generally this indicates that the coating is damaged or scratched and

so the window must be replaced.

Figure 31 Cleaning the Window

d. Visually inspect the window for cleanliness using a strong light and inspect the

surface at a slight angle to improve visibility. Carefully replace the sleeve.

9.3.3 Replacing the Window

Removal of the protective window should be conducted in a clean environment to reduce the

possibility of dust particles being deposited onto the exposed window and internal surfaces.

Prepare the replacement window assembly and keep it in the dust free packaging.

1. Secure the PIPA-Q optical connector horizontally to reduce the risk of dust settling on

the internal surfaces.






71

Figure 32 Removing Window

2. Use the PIPA-Q Window Assembly Spanner (wrench) to loosen the window assembly.

3. Unscrew and remove the window assembly by hand. Take care

not to touch the internal surfaces of the optical connector.

to ensure that contamination is not deposited on the internal surfaces of the optical

connector.

not to let the window assembly touch the exposed end of the delivery fiber as it is

removed.

4. Take the new window assembly from the packaging and screw on to the optical

connector by hand. Take care

not to touch the window or the internal surfaces of the optical connector.

to ensure that contamination is not deposited on the window or the internal surfaces of

the optical connector.

not to let the window assembly touch the exposed end of the delivery fiber as it is

replaced.

5. Gently tighten the window assembly using the PIPA-Q Window Assembly Spanner.






72

10 Disposal

At end of life, this Laser should be separately collected from unsorted waste with a view to

meeting the recovery and recycling targets specified in the appropriate national regulations

implementing the WEEE Directive on waste electrical and electronic equipment (WEEE) for a

product of its class.






73

11 Specifications

The following section describes the operating and performance specifications of the PRISM

Fiber Laser. Included are details of the utilities required for installation and operation. Before

attempting to install or integrate the Laser, please read this section to ensure all requirements

are understood.

11.1 Operating Conditions

This Laser is designed for indoor use and to be safe when operated within the environmental

conditions given in Table 10 and at the pump diode supply voltage given in Table 12.

Table 10 Environmental Operating Conditions

Parameter Value Units

Temperature (Operating)4 5 – 45 °C

Humidity (Operating)4 5 – 85 (non-condensing) % RH

Altitude <2500 m

This Laser is sealed against dust and water ingress to IP52 to BS EN 60529:1992+A2:2013

with the exception of the electrical connectors which are rated IP50. The laser integrator

should ensure that when installed the Laser is not exposed to water.

Note that auxiliary equipment is required to operate the Laser. The environmental operating

conditions of the additional equipment must be observed.

This Laser should not be installed in a corrosive atmosphere.

This Laser should not be exposed to high levels of optical radiation, for instance laser

radiation from materials processing.

Water must not be allowed to condense on or in the Laser. It is therefore important to use a

cooling water temperature appropriate to the local humidity. The solid lines in Figure 33 cover

the permitted cooling water temperatures for the Laser5 and can be used to determine if the

atmosphere is condensing. For example, if the ambient air temperature is 25°C and the

relative humidity is 40% then there will be no condensation for any cooling water temperature

in the specified range as the condition is below the 18°C cooling water curve. However, if the

4 Refer to Figure 33 for a chart showing the relationship between relative humidity, ambient air temperature and

cooling water temperature for non-condensing operation

5 The maximum cooling water temperature for 2kW Lasers is 25°C






74

ambient air temperature is 30°C and the relative humidity is 80% then the cooling water

temperature should be above 26°C, and preferably 30°C, to prevent condensation.

Figure 33 Environmental Conditions for Non-Condensing Operation

Water must not be allowed to condense on or in the optics. The dashed and solid lines in

Figure 33 cover the permitted cooling water temperatures for the PIPA-Q optical connector

and can be used to determine if the atmosphere is condensing. For example, if the ambient air

temperature is 25°C and the relative humidity is 40% then there will be no condensation for

any cooling water temperature in the specified range as the condition is below the 15°C

cooling water curve. However, if the ambient air temperature is 35°C and the relative humidity

is 80% then the cooling water temperature should be 35°C to prevent condensation.






75

11.2 Non-Operating Conditions

Table 11 Non-Operating Conditions


Temperature (Storage)6 0 to +70 °C

Humidity (Storage) 0 – 95 (non-condensing) % RH

11.3 Utility Requirements 11.3.1 Electrical Requirement

The Laser is electrically powered. Electrical power for the pump diodes is provided by an

external DC power supply and power for the internal electronics is provided by a DC auxiliary

power supply.

Table 12 Electrical Requirements

Parameter Min Typ Max Units Notes

Pump Diode Supply Voltage 48 - 51 V DC

Pump Diode

Operating Current

300W - 21 28 A

500W - 32 42 A

750W - 53 70 A

1000W - 63 84 A

1500W - 95 126 A

2000W - 126 168 A

Auxiliary PSU 22.8 25.2 V DC 0.5A Rated

An appropriately certified7 DC power supply which is adequately protected is required to

power the pump diodes in the Laser.

Table 13 gives the output requirements of a suitable PSU.

6 Below 2°C the cooling circuit must be drained to prevent freezing

7 Preferably, the power supply should be certified against at least the requirements of IEC 60950 2

nd edition

amendment A1 by a Nationally Recognised Testing Laboratory






76

Table 13 Power Supply Output Capability Requirements

Parameter Min Max Units Notes

Voltage Adjustment

Range

48 51 V DC

Output

Current

300W 28 A

500W 42 A

750W 70 A

1000W 84 A

1500W 126 A

2000W 168 A

Output Load Regulation - 0.5 % 10% to 90% load variation

Output Line Regulation - 0.5 % ±10% input variation

Output Ripple and Noise - 0.5 % 20MHz measurement bandwidth

At full load, nominal input voltage

Power supply to be able to energise

≥4,000µF of load capacitance under

direct on-line load power application (cold

start)

Hold Up Time 5 - ms At full load, nominal input voltage

Transient Response - 0.5 % The input current can change from zero

to maximum in less than 5µs. If the PSU

cannot respond fast enough additional

capacitive support will be required to

ensure that the output power is

maintained over the first few milliseconds.

Stability - 0.5 % Over time and temperature

To ensure compliance with IEC/EN 6101060204-1 Safety requirements for electrical

equipment for measurement, control and laboratory use – Part 1: General Requirements, an

external switch or circuit breaker and external overcurrent protection device should be fitted.

Use of an inappropriate pump diode power supply will invalidate the warranty on the Laser.

Further information can be provided by request from SPI Lasers.

A power supply capable of providing 0.5A at 24V DC which is appropriately approved and

protected is required to power the control and monitoring circuits in the Laser.






77

11.3.2 Cooling Water Requirements

The Laser requires water cooling. The base plate within the body of the laser has a dual water

cooling circuit. The PIPA-Q optical connector has a separate water cooling circuit.

Requirements for the cooling water are given in Table 14. Permitted temperature ranges and

required flow rates, together with other parameters, for the base plate and PIPA-Q optical

connector are given in Table 15 and Table 17.

Table 14 Cooling Water Requirements

Parameter Min Max Units

Appearance Clear and without sediment -

Particle size - 100 μm

Hardness (mg CaCO3 per litre) - 300 mg/l

Electrical conductivity at 25°C 22 2200 μScm-1

pH 6.5 9.0 -

Drinkable tap water is likely to meet these requirements, and water meeting the requirements

of VDI3803, Appendix B, Table B3 does.

When designing the water cooling system, the Laser Integrator should consider that:

deionised water is not permitted in the cooling circuit as the generally high levels of

dissolved O2 and CO2 in deionised water cause corrosion.

as the cooling circuit of the base plate is copper and the internal surfaces of the

PIPA-Q optical connector are nickel-plated and stainless steel, aluminium and plain

carbon or low alloy steels should not be used as galvanic corrosion may occur.

Galvanic corrosion occurs if materials with widely different electrochemical potentials

are used. Stainless steel and insulating materials (polymers) may be used.

the temperatures specified for the cooling water may sustain bacterial growth. Bacterial

growth may reduce both the flow rate and the efficiency of heat transfer as well as

being a health hazard.

hard water (water that has high mineral content) may cause scaling in the cooling

circuit reducing both the flow rate and the efficiency of heat transfer.

pre-treated water and additives for prevention of corrosion, scaling and microbial

growth are available commercially, for example from NALCO and Optishield.

where there is a need to protect the cooling water from freezing, inhibited ethylene

glycol (ethane-1,2-diol) may be added to it. SPI recommends a concentration of 25%






78

by volume to protect against freezing to -10°C with a minimal drop in thermal

performance while also providing corrosion protection and serving as a bactericide.

additives may reduce the heat capacity of the water. The flow rate must be increased

to compensate. Refer to the manufacturers’ instructions and safety information for the

use of additives.

Table 15 Cooling Requirements (Base Plate)


Cooling Water

Temperature

18 30 ºC For most efficient operation the cooling

water temperature should be between 18ºC

and 22ºC It is important that condensation

will not occur. Refer to Section 11.1. Cooling Water

Temperature. 2000W

Lasers

18 25 ºC

Input Pressure - 6 bar

Flow Rate 10 l/min/kW The total flow through both pipes. At 25°C

water temperature. The minimum flow rate

for different inlet water temperature and

rated powers is given by Figure 34.

Pressure Drop Long

Module

- 2.5 bar

Pressure Drop Short

Module

- 2.0 bar






79

Figure 34 Minimum Flow Rate against Inlet Water Temperature

Table 16 Required Chiller Capacity

Rated Power 300W 500W 750W 1000W 1500W 2000W Units

Chiller Capacity 900 1500 2250 3000 4500 6000 W

Table 17 Cooling Requirements (PIPA-Q Optical Connector)


Cooling Water

Temperature

15 35 ºC It is important that condensation will not occur.

Refer to Section 11.1.

Input Pressure - 6 bar

Flow Rate 0.5 2 l/min/kW At 20°C water temperature.

Pressure Drop 1.6 5 bar

Chiller Capacity 0.5 - kW






80

11.4 Optical Specifications 11.4.1 General Laser Optical Specifications

Table 18 General Laser Optical Specifications


Rated Output Power (CW, EOL)8 2000 W

1500 W

1000 W

750 W

500 W

300 W

Electro-optical Conversion Efficiency (Typical) 33% %

Modes of Operation

CW

Analogue modulation

Digital modulation

-

Polarisation Random -

Central Emission Wavelength 1068 - 1082 nm

Emission Bandwidth (FWHM) ≤10 nm

Output Power Range (CW)9 10 - 100 %

Minimum CW output power for stable operation when

operating in XPR mode 30 W

Alignment Laser Emission Wavelength 630 – 680 nm

Maximum Output Power 1.0 mW

Rise Time10 5 µs

Fall Time11 6 µs

8 Rated output power for variants with bare fiber is increased by 4%

9 For stable operation at percentage of rated output power

10 10%-90% rated power, 20kHz modulation frequency, 50% duty cycle

11 90%-10% rated power, 20kHz modulation frequency, 50% duty cycle






81

The maximum modulation bandwidth in both analogue and digital modes varies with the set

output power of the Laser, not with the rated output power. Figure 35 shows the maximum

modulation bandwidth as a function of set power.

Figure 35 Modulation Bandwidth as a Function of Set Power

The maximum modulation bandwidths for PRISM Module Fiber Lasers with different rated

powers are therefore as given in Table 19.

Table 19 Maximum Modulation Bandwidth


Modulation

Bandwidth

300W 0 40 kHz

500W 0 50 kHz

750W 0 50 kHz

1000W 0 50 kHz

1500W 0 50 kHz

2000W 0 50 kHz

11.4.2 Optical Output – PIPA-Q Optical Connector

The tables below give the properties of the output beam for single mode and multimode

(50µm, 100µm and 300µm core diameter) fibers.






82

Table 20 Single Mode Optical Specification

Parameter Value Units Notes

Mode Field

Diameter 18 µm -

M2 1.1 ±0.1 -

Beam Divergence 82 mrad Full angle

2nd moment of area

Beam Divergence ≤140 mrad Full angle

99.5% power enclosed

Table 21 Multimode Optical Specifications: 50µm Fiber


Core diameter 50 µm Nominal

BPP 2.1 mm.mrad

Beam Divergence 170 mrad Full angle

2nd moment of area

Beam Divergence ≤280 mrad Full angle



Parameter Value

Standard

Beam Quality

Value

Enhanced

Beam Quality

Units Notes

Core diameter 100 100 µm Nominal

BPP 4.5 3.3 mm.mrad

Beam Divergence 180 130

mrad Full angle

2nd moment of area

Beam Divergence ≤280 ≤240

mrad Full angle




Core diameter 300 µm Nominal






83


BPP 13 mm.mrad

Beam Divergence 175

mrad Full angle

2nd moment of area

Beam Divergence ≤300

mrad Full angle


11.4.3 Optical Output – Bare Fiber Beam Delivery

Information on the output fiber of Lasers with bare fiber beam delivery can be provided by

request from SPI Lasers.

11.5 Mechanical Specifications 11.5.1 Overall Dimensions

PRISM Module Fiber Lasers come in two lengths depending on the rated power. The

mechanical specifications are given in Table 24 and Table 25.

Table 24 Mechanical Specifications – Short Modules


Rated Powers 300, 500, 750, 1000 W Except those Lasers with 2 as the last

digit of the order code. See Table 3.

Dimensions W445 x D550 x H88 mm Excluding bus bars and handles.

Figure 36 and Figure 37.

Mass 26 kg

Water Connectors Ø10mm copper pipe -






84

Figure 36 Outline Drawing – Short Module






85

Figure 37 Mounting Locations – Short Module

Table 25 Mechanical Specification – Long Modules


Rated Powers 1500, 2000 W And those Lasers with 2 as the last digit

of the order code. See Table 3.

Dimensions W445 x D702 x H88 mm Excluding bus bars and handles.

See Figure 38 and Figure 39

Mass 38 kg

Water Connectors Ø10mm copper pipe -






86

Figure 38 Outline Drawing – Long Module






87

Figure 39 Mounting Locations – Long Module

11.5.2 Optical Output – PIPA-Q Optical Connector

Figure 40 PIPA-Q Optical connector

Table 26 Mechanical Specifications – PIPA-Q Optical Connector

Parameter Units Value

Connector Length mm 126.5

Connector Diameter mm 34.0

Cable Diameter mm 11.9

Cable Material (External) - Anti-abrasion polyurethane (yellow)

Minimum Bend Radius mm 150






88

Figure 41 Outline Drawing – PIPA-Q Beam Delivery Optic

The PIPA-Q connector is provided with two contacts which must be short-circuited to complete

the integrity circuit. Generally the receiver on the process head, beam switch etc into which

the connector is inserted will perform this function so ensuring that the integrity circuit cannot

be closed until the connector is correctly installed. The contacts must not be connected to

ground.






89

11.5.3 Optical Output - Bare Fiber

Figure 42 Outline Drawing – Bare Fiber Output

Note that with bare fiber the conduit exits normal to the front panel, as shown in Figure 42,

rather than parallel, as for a BDO, as shown in Figure 2.

Table 27 Bare Fiber Output Interface

Parameter Units Specification

Bulkhead

fittings - -

Adaptaflex straight conduit fitting. Part

number SP10/PG7/A.

A 12.6mm clearance hole is required to

mount the fitting, which can be secured with

the nut provided.

Conduit

Type - Adaptaflex SP10 conduit. Part number

SP10/BL

Material - Galvanised steel core conduit coated in PVC

Outer Diameter mm 10


Orange

tube Material -

Kevlar reinforced LSZH polymer tubing with

FEP inner tube

PTFE tube Material - PTFE






90

Parameter Units Specification

Fiber

Fiber Specifications

SF21-0042 -

Further information can be provided by

request from SPI Lasers







91

12 General Information

12.1 Trade Marks

The SPI Lasers logo, SPI, GTWave, redPOWER, and redENERGY are trademarks

(registered or applied for) of SPI Lasers in at least one of the United States of America, the

United Kingdom, the European Community, China, and in various other territories throughout

the world. All other trademarks are the property of their registered owners.

12.2 Licensing

This Laser carries no licence by IMRA America, Inc. for pulsed operation less than 100ps.

12.3 Software

Any software forming part of this equipment should be used only for the purpose for which it

was supplied by SPI Lasers. No changes, modifications or copies (except for producing a

necessary back-up copy) shall be undertaken by the User.

SPI Lasers accepts no responsibility for equipment malfunction resulting from any of the

above actions.

12.4 Warranties

SPI Lasers makes no warranties, expressed or implied, including and without limitation

warranties as to merchantability or fitness for a particular purpose except as expressly set

forth in the standard Terms and Conditions of sale.

12.5 Copyright

Copyright SPI Lasers. All rights reserved. You may not reproduce, transmit, store in a retrieval

system or adapt this publication, in any form or by any means, without the prior written

permission of SPI Lasers, except as allowed under applicable copyright laws. The information

contained herein is confidential and is the property of SPI Lasers. No part may be reproduced,

disclosed or used except as authorised by contract or other written permission. The copyright

and the foregoing restriction on reproduction and use extend to all media in which the

information may be embodied.






92

12.6 Changes

These Instructions for Use are supplied without liability for errors or omissions. SPI Lasers

reserves the right to change the information and specifications contained in these Instructions

for Use without prior notice.






93

13 Contact Information

Table 28 Contact Information

UK Head Office and

Manufacturing

Facility

US Corporate Office China Office Korea Office

SPI Lasers UK

Limited SPI Lasers LLC

SPI Lasers

(Shanghai) Co., Ltd.

SPI Lasers Korea

Ltd.

6 Wellington Park

Hedge End

Southampton

SO30 2QU

UK

4000 Burton Drive

Santa Clara

CA 95054

USA

Room 108, Building 3

No. 7 Guiqing Road

Caohejing Hi-tech

Park

Shanghai 200233

China

A-1201 DAEBANG

TRIPLAON Business

Tower

1682 Jungsan-dong

Ilsandong-gu

Goyang-si

Gyeonggi-do

Republic of Korea

Tel: +44 (0)1489

779696

Tel: +1 408 454 1169 Tel: +86 (0) 21 6171

9470

Tel: +82 31 926 7580

Customer Services

[email protected]

Tel: +44 (0)1489 779696 - Option 5

Company Web Site

www.spilasers.com

Product Support

[email protected]

Tel: +44 (0)1489 779696 - Option 2

[email protected]

Contact your local office number

Or contact your local distributor.

http://www.spilasers.com/

mailto:[email protected]






94

14 Customer Service

In the unlikely event that the Laser requires attention outside the scope of the maintenance

requirements as detailed in Section 9, contact SPI Lasers for advice on further on-site fault

diagnosis and/or return of the Laser. Contact information is given in Section13.

When contacting SPI Lasers, please have the following information at hand:

The order code.

The serial number.

The number of accumulated laser hours.

Typical operating parameters.

Any other relevant information (e.g. fault codes and descriptions) that would assist in

fault diagnosis.

If the Laser requires fault-diagnosis or servicing or is to be returned to SPI Lasers, it is the

system integrator’s responsibility to remove the Laser from the integrated laser system and

make it safe and, if the Laser is to be returned to SPI Lasers, to ensure that all relevant return

documentation is in place before shipment. Details of documentation requirements and copies

can be obtained where required from SPI Lasers.

The Laser must be drained of all coolant and the end caps fitted to all pipes prior to shipment.

If the Laser is shipped without the end caps fitted then any residual coolant will escape during

transit and may cause permanent damage.

Pack the Laser in the original packaging and include all original accessories and

documentation as detailed in the original inventory. The correct and original packaging should

be used to prevent damage in transit. If all or part of the original packaging is unavailable,

contact SPI Lasers for replacement items. Please take time to complete all return

documentation, which can be obtained from SPI Lasers. Accurate details, diagnosis and

comments in the documentation reduce turnaround time for repair at SPI Lasers.

On request, SPI Lasers will supply a report detailing faults found and repairs carried out

necessary to return the Laser to full operational specification.

redPOWER 300W to 2.0kW Module Fiber Lasers Instructions ... · 7.8 Connecting the PIPA-Q Optical...

Documents

Transcript of redPOWER 300W to 2.0kW Module Fiber Lasers Instructions ... · 7.8 Connecting the PIPA-Q Optical...