Operator’s Manual GEM Series OEM/Industrial Lasers GEM-100™ Air Cooled
1280 Blue Hills Avenue Bloomfield, Connecticut 06002-1301 Telephone: (800) 367-7890
GEM-100 Air Cooled Laser Operator’s Manual This document is copyrighted with all rights reserved. Under the copyright laws, this document may not be copied in whole or in part or reproduced in any other media without the express written permission of Coherent, Inc. Permitted copies must carry the same proprietary and copyright notices as were affixed to the original. This exception does not allow copies to be made for others, whether or not sold, but all the material purchased may be sold, given or loaned to another person. Under the law, copying includes translation into another language. Coherent, Coherent/DEOS, the Coherent Logo, GEM-25, GEM-30, GEM-50, GEM-60, GEM-100, GEM-200PC, GEM-Q400. GEM-Q3000, and PC-1 Controller are registered trademarks of Coherent, Inc. DOWFROST, DOWTHERM, and DOWCAL are registered trademarks of The Dow Chemical Company. UCARTHERM is a registered trademark of Union Carbide Corporation. Pipe Saver is a registered trademark of Virginia KMP Corp. Teflon is a registered trademark of E. I. du Pont de Nemours and Company. Every effort has been made to ensure that the data given in this document is accurate. The information, figures, tables, specifications and schematics contained herein are subject to change without notice. Coherent makes no warranty or representation, either expressed or implied with respect to this document. In no event will Coherent be liable for any direct, indirect, special, incidental or consequential damages resulting from any defects in its documentation. Technical Support In the US: Should you experience any difficulties with your laser or need any technical information, please visit our web site www.coherentinc.com. Additional support can be obtained by contacting our Technical Support Hotline at 800-367-7890 or E-mail (
[email protected]). Telephone coverage is available Monday through Friday (except U.S. holidays). If you call outside our office hours, your call will be taken by our answering system and will be returned when the office reopens. If there are technical difficulties with your laser that cannot be resolved by support mechanisms outlined above, please E-mail or telephone Coherent Technical Support with a description of the problem and the corrective steps attempted. When communicating with our Technical Support Group, through the web or telephone, the model and Laser Head serial number of your laser system will be required by the Support Engineer responding to your request. Outside the US: If you are located outside the US visit our web site for technical assistance or contact, by phone, our local Service Representative. Representative phone numbers and addresses can be found on the Coherent web site, www.coherentinc.com. Coherent provides telephone and web technical assistance as a service to its customers and assumes no liability thereby for any injury or damage that may occur contemporaneous with such services. These support services do not affect, under any circumstances, the terms of any warranty agreement between Coherent and the buyer. Operation of any Coherent laser with any of its interlocks defeated is always at the operator's own risk.
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Table of Contents
TABLE OF CONTENTS Preface ........................................................................................................................... vii U.S. Export Control Laws Compliance ......................................................................... vii Notice Concerning Regulatory Status of GEM Series Lasers ....................................... vii Notice Concerning Warranty ......................................................................................... vii Symbols Used in This Manual...................................................................................... viii
Section One: Description and Specifications........................................... 1-1 Introduction................................................................................................................... 1-1 Purpose of This Manual ................................................................................................ 1-1 Variations in Hardware Configuration ......................................................................... 1-2 RF Cable Lengths ................................................................................................ 1-2 Specifications and Input Requirements ........................................................................ 1-2 Hardware Overview ...................................................................................................... 1-3 DC Input Power ................................................................................................... 1-3 Cooling Requirements .................................................................................................. 1-3 Comparison of Air-Cooling and Liquid-Cooling (Reference) ............................ 1-3 Laser Head .................................................................................................................... 1-4 RF Power Supply .......................................................................................................... 1-4 Compatibility and Interchangeability .................................................................. 1-5
Section Two: Laser Safety .................................................................................. 2-1 Optical Safety ............................................................................................................... 2-1 Electrical Safety ............................................................................................................ 2-3 Laser Head ........................................................................................................... 2-3 Laser Safety Requirements ........................................................................................... 2-3 Safety Interlocks .................................................................................................. 2-4 Radiated Emission Compliance .................................................................................... 2-4 Interference Potential of the System .................................................................... 2-4 Compliance to Standards Relevant to CE Mark ........................................................... 2-4 Location of Safety Labels ............................................................................................. 2-5 Certifications of Compliance ........................................................................................ 2-8
Section Three: Utility Requirements and System Installation..... 3-1 Unpacking and Inspection ............................................................................................ 3-1 Verifying Delivery ............................................................................................... 3-1 Checking Delivered Items ................................................................................... 3-1 Safety Issues in Laser Installation ................................................................................ 3-2 Mechanical Mounting ................................................................................................... 3-2 Mounting Considerations for Laser Heads .......................................................... 3-5 Mounting Considerations for the RF Power Supply............................................ 3-5 Ambient Air Cleanliness...................................................................................... 3-5 Air Cooling ................................................................................................................... 3-5 Air Flow ............................................................................................................... 3-6 iii
GEM-100 Air Cooled Laser Operator’s Manual Signal Interface .................................................................................................... 3-6 Over Temperature Interlock Switch .................................................................... 3-6 DC Power Relay .................................................................................................. 3-6 Electrical Power Connection ........................................................................................ 3-7 DC Power Supply Requirements ......................................................................... 3-8 Control Signal Connection............................................................................................ 3-8 RF Power Supply Connection....................................................................................... 3-8 Coaxial Cable....................................................................................................... 3-8 Cable Connections and Torque............................................................................ 3-9
Section Four: Laser Operation ........................................................................ 4-1 Signal Interface Connectors.......................................................................................... 4-1 Operating Modes........................................................................................................... 4-1 Typical Waveform ............................................................................................... 4-1 CW Mode............................................................................................................. 4-1 Gated CW Mode .................................................................................................. 4-3 Variable Output Power Capability; Pulsewidth Variation................................... 4-3 Optical Pulse Shape .................................................................................... 4-3 Complex Modulation Waveforms ....................................................................... 4-4 Varying the Pulsewidth............................................................................... 4-4 Protection from Unacceptable Inputs ......................................................... 4-4 Turning On the Laser .................................................................................................... 4-4 Electronic Control......................................................................................................... 4-5 Electronic Signals Required to Turn On the Laser .............................................. 4-5 Modulation Select ....................................................................................... 4-5 Start-up Sequence ....................................................................................... 4-5 Response Times of Laser to Modulation, and Power Supply Enable.................. 4-6 Signals Used for Fault Detection ......................................................................... 4-6 VSWR Faults During Initial Turn-on .................................................................. 4-7
Section Five: Maintenance and Troubleshooting ................................. 5-1 Maintenance.................................................................................................................. 5-1 Cleanliness of Output Optical Element ............................................................... 5-1 Troubleshooting ............................................................................................................ 5-1 Connectors and Cables......................................................................................... 5-1 DC Power and Voltage ........................................................................................ 5-2 Control Inputs ...................................................................................................... 5-2 VSWR Fault Indicator ......................................................................................... 5-2 Over Temperature Shutdown............................................................................... 5-2 CW Mode............................................................................................................. 5-2 Visualizing ........................................................................................................... 5-3 Voltages ............................................................................................................... 5-3 Output Beam ........................................................................................................ 5-3
Parts List ........................................................................................................................ A-1
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Table of Contents
Warranty .........................................................................................................................B-1 GEM Series Laser Warranty.........................................................................................B-1 Conditions of Warranty ................................................................................................B-1 Responsibilities of the Buyer ........................................................................................B-1 Limitations of Warranty................................................................................................B-2
Glossary ............................................................................................................... Glossary-1 Packing Procedure ....................................................................................................C-1 For Liquid Cooled Lasers/ RF Power Supplies ............................................................C-1 For All Laser Heads ......................................................................................................C-1 For All RF Power Supplies ...........................................................................................C-2 Shipping Instructions ....................................................................................................C-2 RMA Form Instructions................................................................................................C-2
Index ........................................................................................................................... Index-1
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GEM-100 Air Cooled Laser Operator’s Manual
LIST OF ILLUSTRATIONS 1-1 1-2 1-3
GEM-100 Air Cooled Laser System.......................................................................... 1-1 GEM-100 Air Cooled Laser Head ............................................................................. 1-4 D-1000 Air Cooled RF Power Supply ....................................................................... 1-5
2-1 2-2
Location of Safety Labels .......................................................................................... 2-5 Declaration of Conformity......................................................................................... 2-8
3-1 3-2 3-3
GEM-100 Air Cooled Laser Head Dimensions ......................................................... 3-3 D-1000 W Air Cooled RF Power Supply Dimensions .............................................. 3-4 Electrical Connections to D-1000 RF Power Supply ................................................ 3-7
4-1 4-2
RF Input Waveform and Laser Output Waveform .................................................... 4-3 Fault Detection Circuit............................................................................................... 4-6
5-1
GEM-100 Voltage Chart............................................................................................ 5-4
LIST OF TABLES 1-1
Specifications and Input Requirements for GEM-100 Lasers ................................... 1-6
4-1
Signal Interface Description and Connector Pinout .................................................. 4-2
A-1 A-2
GEM-100 (100 Watts) Laser System - Typical Configurations ............................... A-1 GEM-100 (100 Watts) Laser Component Part Numbers.......................................... A-1
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Preface
Preface
This is the Operator’s Manual for the GEM-100™ Air Cooled OEM/Industrial carbon dioxide (CO2) lasers manufactured by Coherent/DEOS®. These lasers are OEM systems, they are designed as components which are to be inserted by the original equipment manufacturer (OEM) prior to delivery to the end user. It is strongly recommended that the user read Section Two, Laser Safety, before operating the laser.
Caution — use of controls or adjustments or performance of procedures other than those specified in this manual may result in hazardous radiation exposure.
U.S. Export Control Laws Compliance
It is the policy of Coherent/DEOS to comply strictly with the U.S. export control laws. Export and re-export of lasers manufactured by Coherent/DEOS are subject to the U.S. Export Administration Regulations administered by the Department of Commerce, Bureau of Export Administration. The applicable restrictions vary depending on the specific product involved, intended application, and the product destination. In some cases, an individual validated export license is required from the U.S. Department of Commerce prior to resale or re-export of certain products. If you are uncertain about the obligations imposed by U.S. law, obtain clarification from Coherent/DEOS.
Notice Concerning Regulatory Status of GEM Series Lasers
This laser component does not include all safety features that are required by the United States Food and Drug Administration (FDA), Center for Devices and Radiological Health (CDRH) in laser systems sold to end users. It is sold solely to qualified manufacturers who in their end product, supply interlocks, indicators, and other required safety features, in full compliance with 21 CFR 1040, Subchapter J and/or other applicable national and local regulations.
Notice Concerning Warranty
Operation or handling of this laser component, inconsistent with this manual, may void the warranty.
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GEM-100 Air Cooled Laser Operator’s Manual
Symbols Used in This Manual This symbol is intended to alert the operator to the presence of dangerous voltages associated with the laser that may be of sufficient magnitude to constitute a risk of electric shock.
This symbol is intended to alert the operator to the presence of important operating and maintenance instructions.
This symbol is intended to alert the operator to the danger of exposure to hazardous visible and invisible laser radiation.
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Description and Specifications
SECTION ONE: DESCRIPTION AND SPECIFICATIONS Introduction
In this section, specifications and characteristics of the GEM-100 laser will be discussed. Characteristics to be discussed include mechanical, thermal, electrical, and optical interfaces; and environmental requirements and limitations. The GEM-100 laser is a sealed-off, RF excited CO2 laser capable of CW or modulated operation. From the laser safety point of view, this laser is considered a component and must be integrated into a system by a qualified original equipment manufacturer (OEM) prior to delivery to the end user. See Section Two for a complete discussion of laser safety issues.
Purpose of This Manual
This manual is designed to assist the original equipment manufacturer during the integration or the GEM-100 OEM laser. It contains information on the performance and operation of the laser as well as installation and control methods.
Figure 1-1. GEM-100 Air Cooled Laser System 1-1
GEM-100 Air Cooled Laser Operator’s Manual
Variations in Hardware Configuration
For each GEM-100 laser there are a number of variations in the configuration of hardware delivered to customers. These variations are due to the following factors:
•
Customers can also select among several options in the length of the RF power cable which connects the RF power supply to the laser head. These optional extender cables, if selected by the customer, are added to the short RF cable which comes with every GEM-100.
Do not operate any GEM-100 laser head with any RF power supply other than the Coherent/DEOS® Model D-1000 RF power supply. Any operation of an GEM-100 laser head with an RF power supply other than the Model D-1000 will void the Coherent/DEOS® warranty. Do not under any circumstances modify the RF cable.
RF Cable Lengths
There are several options regarding the length of the cable which connects the RF power supply to the laser head. The RF cable options are described in the section entitled RF Power Supply Connection. For part numbers please check the section titled Parts List in this manual.
Specifications and Input Requirements
Figure 1-1 provides specifications, and requirements for power inputs, for the Model GEM-100 laser. Figure 1-1 illustrates the baseline configurations (i.e., without any optional hardware additions or deletions) of the GEM-100 laser. Each laser system consists of a laser head assembly, a radio frequency (RF) power supply, and a coaxial cable for connecting the RF power supply to the laser head. The RF power supply converts 48-50 VDC, ≤50 A power to radio frequency power. Connection of the customer-supplied DC power supply to the Coherent/DEOS® supplied Model D-1000 RF power supply is through a barrier strip with screw terminals on the RF power supply. The barrier strip includes terminals for connection of wires for remote voltage sensing. Such sensing is recommended to better control the voltage at the input to the RF power supply.
1-2
Description and Specifications
Hardware Overview
The GEM-100 laser is a waveguide carbon dioxide (CO2) laser. RF electric fields provided by the RF power supply are delivered to the laser head through the special connecting coaxial cable. The RF electrical field excites the CO2 gas mixture. The standard configuration of this laser operates at a wavelength near 10.6 µm in the infrared region of the electromagnetic spectrum.
DC Input Power
DC input power is provided by the user through customer-supplied bus wiring, which goes to the RF power supply. The RF power supply converts this DC electrical power into RF power which is used to excite the gas in the laser head.
Cooling Requirements
Total heat dissipation for the laser head and RF power supply is specified in Table 1-1. The laser head typically dissipates 1200 W from its base surface while the RF power supply typically dissipates 800 W, for a total typical heat dissipation of 2000 W (maximum total heat dissipation is 2400 W). The GEM-100 must be provided adequate cooling to keep the laser operating temperature within acceptable limits. The cooling method that is used must not induce stresses that will result in misalignment of the laser resonator. The heat sinks which are included in the air cooled GEM-100 are designed so that the assembled structure remains free of excessive stress. Installation requirements related to cooling of the air-cooling version of the GEM-100 laser are discussed in detail in Section Three in the subsection entitled Air Cooling.
Comparison of Air-Cooling and Liquid-Cooling (Reference)
Air cooling has some distinct advantages relative to liquid cooling. It is low in cost, low in complexity, and has low service requirements. The air-cooling option is easier to install. Liquid-cooling, on the other hand, can yield the most compact arrangement and is generally more suitable for applications in which the ambient air temperature exceeds 40ºC and/or the ambient air is heavily laden with particulates. One should also consider if condensable vapors are present and take suitable measures to purge sensitive areas such as optical surfaces with a suitable gas. It is generally easier to make a hermetically sealed system using a liquid-cooling approach rather than an air-cooling one. Applications which require the highest process stability will also yield better results if the temperature is controlled with a liquid based cooling system.
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GEM-100 Air Cooled Laser Operator’s Manual
To avoid damage to the laser head and the RF power supply, never operate the laser without adequate air cooling.
Laser Head
The laser head takes RF input power and converts some of it to laser radiation. The rest of the RF input power is exhausted as waste heat. For the GEM-100 air cooled laser, the waste heat is exhausted into the ambient air. The laser head consists of the folded optical waveguide resonator, the all-metal gas envelope structure, the RF matching network, and a type-N RF power connector. Infrared laser radiation is emitted from the optical aperture. Pictures and dimensions drawings for the GEM-100 air cooled laser is shown in Figure 1-2 and Figure 3-1.
Figure 1-2. GEM-100 Air Cooled Laser Head
RF Power Supply
The Model D-1000 RF power supply converts DC input power to RF energy which is sent through the RF cable to the laser head. Heat from the RF power supply is exhausted into the surrounding air. A male 15-pin D type connector built into the RF power supply, is used to control the laser system. All the user interfaces (DC power and signal interface) are on one panel of the RF power supply.
1-4
Description and Specifications The GEM-100 laser head requires approximately 1000 W of CW RF input power in CW Mode. A picture of the 1000 W RF power supply (D-1000) for the GEM-100 air cooled laser is shown in Figure 1-3. The corresponding dimensions is shown in Figure 3-2.
Figure 1-3. D-1000 Air Cooled RF Power Supply
Compatibility and Interchangeability
Any two GEM-100 laser heads can be interchanged (except as noted in the section entitled Mounting Considerations for Laser Heads). Similarly, any two GEM-100 RF power supplies can be interchanged.
To avoid possible damage to the laser head and the RF power supply, use only the Model D-1000 RF power supply with the GEM-100 laser head.
1-5
GEM-100 Air Cooled Laser Operator’s Manual Table 1-1. Specifications and Input Requirements for GEM-100 Lasers CHARACTERISTIC
SPECIFIED VALUE
COMMENTS
Wavelength
10.6 µm
Lines near 10P20 line of 12C16O2
1CW
≥100 W
De-rate power by 1% per ºC for laser head temperatures above 25ºC.
Output Power
Power Stability
< ±5%
Mode
>98% TEM00
Beam Size
3.8 ± 0.4 mm
At 1/e2 diameter at exit aperture
Beam Divergence
