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DIAMOND C-55 Liquid-CooledOEM LaserPreinstallation Manual

Preinstallation ManualDIAMOND C-55 Liquid-CooledOEM Laser

1280 Blue Hills AvenueBloomfield, CT 06002

DIAMOND C-55 Liquid-Cooled OEM Laser Preinstallation Manual

This document is copyrighted with All Rights Reserved. Under copyrightlaws, this document must not be copied in full or in part, or reproduced byany other media, without the express written permission of Coherent, Inc.(Coherent). Permitted copies must have the same proprietary andcopyright notices as were attached to the original. This exception does notpermit copies—whether or not sold—to be made for others; however, allthe material purchased can be sold, given, or loaned to another person.Under the law, “copying” includes translation into another language.

Coherent and the Coherent Logo are trademarks or registered trademarksof Coherent, Inc. All other trademarks or registered trademarks are theproperty of their respective owners.

Patents referenced in this manual are active when the manual is printed.For a list of current patents, see www.coherent.com/company/patents.

Every effort has been made to ensure that the data given in this documentis accurate. The information, figures, tables, specifications, part numbers,and schematics contained herein are subject to change without notice.Coherent makes no warranty or representation, either expressed orimplied, with respect to this document. In no event will Coherent be liablefor any direct, indirect, special, incidental, or consequential damagesresulting from any defects in its documentation.

Technical Support

In the U.S.:

Should you experience any difficulties with your laser or need anytechnical information, please go to our web site www.coherent.com.Should you need further assistance, please contact Coherent TechnicalSupport by e-mail [email protected] or telephone,1-800-367-7890 (1-408-764-4557 outside the U.S.). Please be prepared tosupply the model and laser head serial number of your laser system alsothe description of the problem and any attempted corrective steps to theProduct Support Engineer responding to your request.

Telephone coverage is available Monday through Friday (except U.S.holidays and company shutdowns). Inquiries received outside of normaloffice hours will be captured by our automatic answering system and willbe quickly returned the next business day.

Outside the U.S.:

If you are located outside the U.S., please visit www.coherent.com fortechnical assistance, or contact your local Service Representative. ServiceRepresentative telephone numbers and addresses can be found on theCoherent web site.

Coherent provides telephone and web-based technical assistance as aservice to its customers and assumes no liability thereby for any injury ordamage that may occur contemporaneous with such services. Under nocircumstances do these support services affect the terms of any warrantyagreement between Coherent and the buyer. Operation of any Coherentlaser with any of its interlocks defeated is always at the operator's own risk.

ii

http://www.coherent.com

http://www.Coherent.com


mailto:[email protected]

https://www.coherent.com/company/patents

Table of Contents

TABLE OF CONTENTS

Signal Words and Symbols in This Manual......................................................................... viSignal Words ............................................................................................................... viSymbols ..................................................................................................................... vii

Preface ............................................................................................................................... viiiExport Control Laws Compliance ..................................................................................... viiiNotice Concerning Regulatory Status of Diamond Series Lasers ....................................... ixNotice Concerning Warranty ............................................................................................... ix

Section One: Laser Safety ......................................................................................... 1-1Hazards ............................................................................................................................... 1-1

Optical Safety ............................................................................................................ 1-2Recommended Precautions and Guidelines...................................................... 1-2Laser Safety Eyewear ....................................................................................... 1-3Viewing Distance .............................................................................................. 1-4

Electrical Safety ......................................................................................................... 1-4RF Power Module ............................................................................................. 1-4

Laser Head ................................................................................................................. 1-5Recommended Precautions and Guidelines...................................................... 1-5

Laser Safety Requirements ................................................................................................. 1-6Laser Classification.................................................................................................... 1-6Protective Housing..................................................................................................... 1-6Protective Covers (Safety Interlocks) ........................................................................ 1-7

Compliance to Standards Relevant to CE Mark ................................................................. 1-7Environmental Compliance ................................................................................................ 1-8

RoHS Compliance ..................................................................................................... 1-8China-RoHS Compliance .......................................................................................... 1-8EU REACH................................................................................................................ 1-8Waste Electrical and Electronic Equipment (WEEE)................................................ 1-9

Labeling ............................................................................................................................ 1-10Sources of Additional Information ................................................................................... 1-14

Laser Safety Standard .............................................................................................. 1-14Publications and Guidelines..................................................................................... 1-14Equipment and Training........................................................................................... 1-14

Section Two: Description and Specifications ................................................ 2-1Introduction......................................................................................................................... 2-1Purpose of This Manual ...................................................................................................... 2-1Specifications and Input Requirements .............................................................................. 2-2Hardware Overview............................................................................................................ 2-2

DC Input Power ......................................................................................................... 2-2Cooling Requirements ........................................................................................................ 2-2

Comparison of Liquid-Cooling & Air-Cooling (Reference) ..................................... 2-3Liquid-Cooling Option of the C-55 ........................................................................... 2-3

iii


Laser Head .......................................................................................................................... 2-4RF Power Module ............................................................................................................... 2-4Specifications, Configuration, and Facility Requirements ................................................. 2-5

Section Three: Utility Requirements and System Installation ........... 3-1Introduction......................................................................................................................... 3-1Unpacking and Inspection .................................................................................................. 3-1

Verifying Delivery ..................................................................................................... 3-1Protective Shipping Tape ........................................................................................... 3-2

Tape Removal ................................................................................................... 3-2Safety Issues in Laser Installation ...................................................................................... 3-3Mechanical Mounting ......................................................................................................... 3-4

C-55 Mounting Considerations.................................................................................. 3-5Liquid-Cooling.................................................................................................................... 3-5

Cooling System Layout ............................................................................................. 3-6Re-Circulation and Coolant Flow Interlock Switch .................................................. 3-6Signal Interface .......................................................................................................... 3-6Thermal Shutdown Switch......................................................................................... 3-6Mounting Orientation ................................................................................................ 3-7AC Power Relay ........................................................................................................ 3-7Condensation of Water Vapor .................................................................................... 3-7Coolant Fittings on Laser System.............................................................................. 3-8Cooling Capacity ....................................................................................................... 3-9Coolant Filtering ........................................................................................................ 3-9Coolant Composition ................................................................................................. 3-9

Freeze/Burst Protection................................................................................... 3-10Alternative Coolant Composition ............................................................................ 3-11Freeze/Burst Protection............................................................................................ 3-13Coolant Flow Rate and Pressure .............................................................................. 3-13Pressure Drop........................................................................................................... 3-14Materials Used in Cooling Systems......................................................................... 3-14

Electrical Power Connection ............................................................................................ 3-14DC Power Supply Requirements ............................................................................. 3-16

DC Power Supply Cabling Requirements ...................................................... 3-16Control Signal Connection................................................................................................ 3-16Beam Propagation............................................................................................................. 3-17

iv

Table of Contents

LIST OF ILLUSTRATIONS

1-1. Nominal Ocular Hazard Distance (NOHD)for indicated conditions calculated per ANSI Z136.1-2007 ...................................... 1-4

1-2. Waste Electrical and Electronic Equipment Label........................................................... 1-91-3. Location of Safety Labels .............................................................................................. 1-10

2-1. C-55 Liquid-Cooled Laser ............................................................................................... 2-1

3-1. Protective Shipping Tape ................................................................................................. 3-23-2. C-55 Liquid-cooled Laser Dimensions............................................................................ 3-43-3. Recommended Liquid-Cooling System Functional Block Diagram ............................... 3-53-4. C-55 Liquid-Cooling Connections................................................................................... 3-83-5. Water Circuits - Untreated and Treated ......................................................................... 3-103-6. Electrical Connections to C-55 ...................................................................................... 3-153-7. Beam Diameter vs. Distance From Laser Head............................................................. 3-17

LIST OF TABLES

2-1. Comparison: The Benefits of Liquid-Cooling vs. Air-Cooling Methods ........................ 2-32-2. C-55 Liquid-Cooled Configuration and Facility Requirements ...................................... 2-5

3-1. Recommended Coolant for C-55 Lasers.......................................................................... 3-93-2. Propylene Glycol-Based Heat Transfer Fluids for C-55 Lasers .................................... 3-113-3. Ethylene Glycol-Based Heat Transfer Fluids for C-55 Lasers ...................................... 3-11

v


Signal Words and Symbols in This Manual

This documentation may contain sections in which particularhazards are defined or special attention is drawn to particularconditions. These sections are indicated with signal words inaccordance with ANSI Z-535.6 and safety symbols (pictorial hazardalerts) in accordance with ANSI Z-535.3 and ISO 7010.

Signal Words Four signal words are used in this documentation: DANGER,WARNING, CAUTION and NOTICE.

The signal words DANGER, WARNING and CAUTIONdesignate the degree or level of hazard when there is the risk ofinjury:

DANGER!Indicates a hazardous situation that, if not avoided, will result indeath or serious injury. This signal word is to be limited to themost extreme situations.

WARNING!Indicates a hazardous situation that, if not avoided, could resultin death or serious injury.

CAUTION!Indicates a hazardous situation that, if not avoided, could resultin minor or moderate injury.

The signal word “NOTICE” is used when there is the risk ofproperty damage:

NOTICE!Indicates information considered important, but not hazard-related.

Messages relating to hazards that could result in both personal injuryand property damage are considered safety messages and not prop-erty damage messages.

vi

Preface

Symbols The signal words DANGER, WARNING, and CAUTION arealways emphasized with a safety symbol that indicates a specialhazard, regardless of the hazard level:

This symbol is intended to alert the operator to the presence ofimportant operating and maintenance instructions.

This symbol is intended to alert the operator to the danger ofexposure to hazardous visible and invisible laser radiation.

This symbol is intended to alert the operator to the presence ofdangerous voltages within the product enclosure that may be ofsufficient magnitude to constitute a risk of electric shock.

This symbol is intended to alert the operator to the danger ofElectro-Static Discharge (ESD) susceptibility.

This symbol is intended to alert the operator to the danger ofcrushing injury.

This symbol is intended to alert the operator to the danger of alifting hazard.

vii


Preface This is the Preinstallation Manual for the DIAMOND C-55Liquid-Cooled OEM/Industrial carbon dioxide (CO2) laser manu-factured by Coherent. These lasers are OEM systems; they aredesigned as components which are to be inserted by the originalequipment manufacturer (OEM) prior to delivery to the end user.Coherent strongly recommends that the user readSection One: Laser Safety, before operating the laser.

WARNING!Use of controls or adjustments or performance of proceduresother than those specified in this manual may result inhazardous radiation exposure.

Export Control Laws Compliance

It is the policy of Coherent to comply strictly with U.S. exportcontrol laws.

Export and re-export of lasers manufactured by Coherent are subjectto U.S. Export Administration Regulations, which are administeredby the Commerce Department. In addition, shipments of certaincomponents are regulated by the State Department under theInternational Traffic in Arms Regulations.

The applicable restrictions vary depending on the specific productinvolved and its destination. In some cases, U.S. law requires thatU.S. Government approval be obtained prior to resale, export orre-export of certain articles. When there is uncertainty about theobligations imposed by U.S. law, clarification must be obtainedfrom Coherent or an appropriate U.S. Government agency.

Products manufactured in the European Union, Singapore,Malaysia, Thailand: These commodities, technology, or software aresubject to local export regulations and local laws. Diversion contraryto local law is prohibited. The use, sale, re-export, or re-transferdirectly or indirectly in any prohibited activities are strictlyprohibited.

viii

Preface

Notice Concerning Regulatory Status of DIAMOND Series Lasers

This laser component does not include all safety features that arerequired by the United States Food and Drug Administration (FDA),Center for Devices and Radiological Health (CDRH) in lasersystems sold to end users. It is sold solely to qualified manufacturerswho in their end product, supply interlocks, indicators, and otherrequired 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 thismanual, may void the warranty.

ix


x

Laser Safety

SECTION ONE: LASER SAFETY

This user information is in compliance with the following stan-dards for Light-Emitting Products IEC 60825-1 / EN 60825-1“Safety of laser products - Part 1: Equipment classification andrequirements” 21 CFR Title 21 Chapter 1, Subchapter J,Part 1040 “Performance standards for light-emitting products”.

WARNING!LASER RADIATION - AVOID EYE OR SKIN EXPOSURETO DIRECT OR SCATTERED RADIATION CLASS 4 LASERPRODUCT!

WARNING!Use of controls or adjustments or performance of proceduresother than those specified herein may result in hazardousradiation exposure.

This laser safety section must be reviewed thoroughly prior tooperating the C-55. Safety instructions presented throughout thismanual must be followed carefully.

Hazards Hazards associated with lasers generally fall into the followingcategories:

• Biological hazards from exposure to laser radiation that maydamage the eyes or skin

• Electrical hazards generated in the laser power supply orassociated circuits

• Chemical hazards resulting from contact of the laser beamwith volatile or flammable substances, or released as a resultof laser material processing

The above list is not intended to be exhaustive. Anyone operatingthe laser must consider the interaction of the laser system with itsspecific working environment to identify potential hazards.

1 - 1


Optical Safety Laser light, because of its optical qualities, poses safety hazards notassociated with light from conventional light sources. The safe useof lasers requires all operators, and everyone near the laser system,to be aware of the dangers involved. Users must be familiar with theinstrument and the properties of coherent, intense beams of light.

The safety precautions listed below are to be read and observed byanyone working with or near the laser. At all times, ensure that allpersonnel who operate, maintain or service the laser are protectedfrom accidental or unnecessary exposure to laser radiationexceeding the accessible emission limits defined in the laser safetystandards.

WARNING!Direct eye contact with the output beam from the laser maycause serious eye injury and possible blindness.

The greatest concern when using a laser is eye safety. In addition tothe main beam, there are often many smaller beams present atvarious angles near the laser system. These beams are formed byspecular reflections of the main beam at polished surfaces such aslenses or beamsplitters. While weaker than the main beam, suchbeams may still be sufficiently intense to cause eye damage.

Laser beams are powerful enough to burn skin, clothing, orcombustible materials, even at some distance. They can ignitevolatile substances such as alcohol, gasoline, ether, and othersolvents, and can damage light-sensitive elements in video cameras,photomultipliers, and photodiodes. The user is advised to follow thecontrol measures below.

Recommended Precautions and Guidelines

1. Observe all safety precautions in this preinstallation manuals.

2. Always wear appropriate eyewear for protection against thespecific wavelengths and laser energy being generated. See“Laser Safety Eyewear” on page 1-3. for additional informa-tion.

3. Avoid wearing watches, jewelry, or other objects that mayreflect or scatter the laser beam.

4. Stay aware of the laser beam path, particularly when externaloptics are used to steer the beam.

5. Provide enclosures for beam paths whenever possible.

6. Use appropriate energy-absorbing targets for beam blocking.

1 - 2

Laser Safety

7. Block the beam before applying tools such as Allen wrenchesor ball drivers to external optics.

8. Limit access to the laser to trained and qualified users who arefamiliar with laser safety practices. When not in use, lasersshould be shut down completely and made off-limits to unau-thorized personnel.

9. Terminate the laser beam with a light-absorbing material.Laser light can remain collimated over long distances andtherefore presents a potential hazard if not confined. It is goodpractice to operate the laser in an enclosed room.

10. Post laser warning signs in the area of the laser beam to alertthose present.

11. Exercise extreme caution when using solvents in the area ofthe laser.

12. Never look directly into the laser light source or at scatteredlaser light from any reflective surface, even when wearinglaser safety eyewear. Never sight down the beam.

13. Set up the laser so that the beam height is either well below orwell above eye level.

14. Avoid direct exposure to the laser light. Laser beams can easilycause flesh burns or ignite clothing.

15. Advise all those working with or near the laser of these precau-tions.

Laser Safety Eyewear Always wear appropriate laser safety eyewear for protection againstthe specific wavelengths and laser energy being generated. Theappropriate eye protection can be calculated as defined in the “EN207 Personal eye protection equipment - Filters and eye-protectorsagainst laser radiation (laser eye-protectors)”, in other national orinternational standards (e.g. ANSI, ACGIH, or OSHA) or as definedin national safety requirements. Anyone working with or near theC-55 laser must wear laser safety eyewear with an OD rating 5 eyeprotection.

CAUTION!Laser safety eyewear protects the user from accidental exposureto laser radiation by blocking light at the laser wavelengths.However, laser safety eyewear may also prevent the operatorfrom seeing the beam or the beam spot. Exercise extremecaution even while wearing safety glasses.

1 - 3


Viewing Distance The C-55 laser produces optical power levels that are dangerous to theeyes and skin if exposed directly or indirectly. These products mustbe operated only with proper eye and skin protection at all times.Never view directly emitted or scattered radiation with unprotectedeyes. When viewing the laser during operation, the operator mustmaintain the Nominal Ocular Hazard Distance (NOHD) between thelaser or scattered radiation and the operator's eyes. Figure 1-1summarizes the NOHD for the power range of the C-55 for directviewing of the collimated beam along with two other common config-urations. The NOHD in Figure 1-1 is based on the Maximum Permis-sible Exposure (MPE = 0.1 W/cm2) level for each power condition asspecified in ANSI Z136.1 and IEC 60825-1.

Electrical Safety

RF Power Module The C-55 RF power module requires only 48 VDC input voltage.This voltage and other voltages derived within this laser can be lethal.Every portion of the electrical system should be treated as if it wereat a dangerous voltage level.

Figure 1-1. Nominal Ocular Hazard Distance (NOHD)for indicated conditions calculated per ANSI Z136.1-2007

0.01

0.10

1.00

10.00

100.00

0 10 20 30 40 50 60Nom

inal

Ocu

lar H

azar

d Di

stan

ce (m

eter

s)

Laser Power (W)

Nominal Ocular Hazard Distance

Raw Beam straight out of the laser Di use (Lamber an) Re ec onFocused Beam - 100 um diameter spot

1 - 4

Laser Safety

Laser Head High voltages are present in the laser head when the power is on.There are no serviceable parts or optics within the laser head. Do notremove any covers or make any adjustments to any screw.

DANGER!To avoid potentially fatal electrical shock hazards fromelectrical equipment, follow all applicable electrical codes suchas (in the U.S.) the National Electrical Code.

Recommended Precautions and Guidelines

The following precautions must be observed by everyone whenworking with potentially hazardous electrical circuitry:

DANGER!When working with electrical power systems, the rules for elec-trical safety must be strictly followed. Failure to do so couldresult in the exposure to lethal levels of electricity.

1. Disconnect main power lines before working on any electricalequipment when it is not necessary for the equipment to beoperating.

2. Do not short or ground the power supply output. Protectionagainst possible hazards requires proper connection of theground terminal on the power cable, and an adequate externalground. Check these connections at the time of installation,and periodically thereafter.

3. Never work on electrical equipment unless there is anotherperson nearby who is familiar with the operation and hazardsof the equipment, and who is competent to administer first aid.

4. Always use approved, insulated tools.

When possible, keep one hand away from the equipment to reducethe danger of current flowing through the body if a live circuit istouched accidentally.

1 - 5


Laser Safety Requirements

This laser does not conform to the United States Governmentrequirements for laser safety. In the United States, it is theresponsibility of the buyer that the product sold to the end usercomplies with all laser safety requirements prior to resale. Theselaser safety requirements are contained in 21 CFR, Sub Chapter Jand are administered by the Center for Devices and RadiologicalHealth (CDRH).

Integrators who incorporate a C-55 laser into other products thatthey introduce into United States commerce are defined in the lawas manufacturers who are thus required to manufacture their prod-ucts to conform to the Federal standard, certify them, and submitproduct reports to the CDRH.

The text of this federal standard is available from the U.S. Govern-ment Printing Office Bookstore located in most major cities in theU.S. as well as Washington, D.C. A report detailing how the laserproduct complies with the Federal standard is required before theproduct is shipped. The form of this report is covered in a pamphletentitled: Compliance Guide for Laser Products, HHS PublicationFDA 86-8260. This pamphlet is available at no cost from:

U.S. Food and Drug AdministrationCenter for Devices and Radiological HealthDocument Mail Center – WO66-G60910903 New Hampshire AvenueSilver Spring, MD 20993-0002www.fda.gov

For jurisdictions outside of the United States, it is the responsibilityof the buyer of this laser device to ensure that it meets the local lasersafety requirements.

Laser Classification

Governmental standards and requirements specify that the lasermust be classified according to the output power or energy and thelaser wavelength. The C-55 is classified as Class 4 based on 21 CFR,Subchapter J, Part 1040, section 1040.10 (c) and/orIEC/EN 60825-1, Clause 5. In this manual, the classification will bereferred to as Class 4.

Protective Housing

The laser head is enclosed in a protective housing that preventshuman access to radiation in excess of the limits of Class radiationas specified in the 21CFR, Part 1040 Section 1040.10 (f)(1) andEN 60825-1/IEC 60825-1 Clause 6.2 except for the output beam,which is Class 4.

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http://www.fda.gov

Laser Safety

Protective Covers(Safety Interlocks)

The RF power module and laser head covers are not interlocked.These covers should never be removed. There are no user-service-able components inside.

WARNING!Use of controls or adjustments, or performance of proceduresother than those specified herein, may result in hazardousradiation exposure.

DANGER!To avoid potentially fatal electrical shock hazards from elec-trical equipment, follow all applicable electrical codes such as(in the U.S.) the National Electrical Code.

Compliance to Standards Relevant to CE Mark

C-55 lasers are OEM products, and are sold as components for inte-gration into complete laser systems by a system integrator. Theseproducts are tested and CE Marked as independent products. Forspecific details regarding what applicable compliance directives andstandards the products have been tested to, please refer to the Decla-ration of Conformity which is available upon request from Coherent,per contact information on page ii of this manual.

Compliance to applicable standards for a particular laser tool incor-porating C-55 lasers must be demonstrated by the manufacturer ofthe complete system. The primary issue for the system integrator isto design covers, shielding, grounding, routing of electrical cableassemblies, and control elements with the proper safety features sothat during subsequent testing the system meets the appropriate stan-dards.

Coherent recommends the following guidelines to control theamount of radiated interference:

• Use high quality cables and connectors for all electricalconnections

• Verify grounding of cable shields, generally at both endsof the cable

1 - 7


Environmental Compliance

RoHS Compliance The RoHS directive restricts the use of certain hazardous substancesin electrical and electronic equipment. Coherent can provide RoHScertification upon request for products requiring adherence to theRoHS Directive.

Compliance of this laser with the EMC requirements is certified bythe CE mark. For more information about the CE mark see “Compli-ance to Standards Relevant to CE Mark” on page 1-7.

China-RoHSCompliance

Coherent products supplied by Coherent are in conformity withapplicable requirements of China's “Management Methods”,commonly referred to as China-RoHS, and associated standards andapplies to the production, sale, and import of products in the People'sRepublic of China.

The China RoHS Hazardous Materials Substance Table is located inthe shipping document packet shipped with the product (or lasersystem).

EU REACH Coherent products are classified as “articles” according to EUREACH definition as follows:

Article means an object which during production is given a specialshape, surface or design which determines its function to a greaterdegree than its chemical composition. (REACH, Article 3(3))

Articles as defined by REACH regulations are exempt from registra-tion as long as they are not intended to release a chemical substance.

To the best of our knowledge, all Coherent product meet the defini-tion of “article” according to REACH.

In addition, to the best of our knowledge, Coherent products do notcontain any substances of very high concern (SVHC) above thethreshold limit included in the REACH SVHC list updated which isupdate every six month. The full SVHC list is available on-line athttps://echa.europa.eu/candidate-list-table.

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https://echa.europa.eu/candidate-list-table

Laser Safety

Waste Electrical and Electronic Equipment (WEEE)

The European Waste Electrical and Electronic Equipment (WEEE)Directive (2012/19/EU) is represented by a crossed-out garbagecontainer label. The purpose of this directive is to minimize thedisposal of WEEE as unsorted municipal waste and to facilitate itsseparate collection.

The WEEE Directive applies to this product and any peripheralsmarked with this symbol. Do not dispose of these products asunsorted municipal waste. Contract the local distributor forprocedures for recycling this equipment.

Figure 1-2. Waste Electrical and Electronic Equipment Label

1 - 9


Labeling Figure 1-3 shows the positions of all the labels located on the C-55laser.

TOP VIEW

SIDE VIEWS

Figure 1-3. Location of Safety Labels (Sheet 1 of 4)

4

1

6

3

33

3 2

3 3

3 3

1 - 10

Laser Safety

FRONT VIEW BACK VIEW

BOTTOM VIEW


6 3

5

3

8

7

9

1 - 11


1. IDENTIFICATION LABEL

2. DANGER OF LASER RADIATION LABEL

3. TAMPER PROOF LABEL

4. VOLTAGE WARNING LABEL


PATENT: www.coherent.com/patent

1280 BLUE HILLS AVE, BLOOMFIELD, CT 06002

THIS PRODUCT IS INTENDED FOR USE SOLELY AS A COMPONENT OF AN OEMPRODUCT AND DOES NOT COMPLY WITH CDRH PERFORMANCE STANDARDS,21 CFR SUBCHAPTER J, IF OPERATED AS A STAND-ALONE INSTRUMENT.

MODEL: XXXXXX XXXXXX XXXXXX

PART: XXXXXXX REV: XXMFD / 20XX-XX-XX

SERIAL: XXXXXXXXXXXXX XXXXXX

MADE IN THAILAND

YYYY-MM-DD

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Laser Safety

5. WARNING APERTURE LABEL

6. QC APPROVAL LABEL

7. COOLANT SUPPLY LABEL

8. COOLANT RETURN LABEL

9. COOLANT WARNING


1 - 13


Sources of Additional Information

The following are sources for additional information on laser safetystandards and safety equipment and training.

Laser Safety Standard

American National Standard for Safe Use of LasersANSI Z136 SeriesAmerican National Standards Institute (ANSI)www.ansi.org

Performance standards for light-emitting products21 CFR Title 21 Chapter 1, Subchapter J, Part 1040U.S. Food and Drug Administrationwww.fda.gov

Publications and Guidelines

International Electrotechnical Commission (IEC)www.iec.ch

A Guide for Control of Laser HazardsAmerican Conference of Governmentaland Industrial Hygienists (ACGIH)www.acgih.org

Laser Safety GuideLaser Institute of Americawww.lia.org

Equipment and Training

Laser Focus Buyer’s GuideLaser Focus Worldwww.laserfocusworld.com

Photonics Spectra Buyer’s GuidePhotonics Spectrawww.photonics.com

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http://www.ansi.org

http://www.fda.gov

http://www.fda.gov

http://www.iec.ch

http://www.iec.ch

http://www.acgih.org

http://www.acgih.org

http://www.lia.org

http://www.lia.org

http://www.laserfocusworld.com

http://www.photonics.com

http://www.photonics.com

Description and Specifications

SECTION TWO: DESCRIPTION AND SPECIFICATIONS

Introduction In this section, specifications and characteristics of the C-55 laserwill be discussed. Characteristics to be discussed includemechanical, thermal, electrical, and optical interfaces; andenvironmental requirements and limitations.

The C-55 laser is a sealed-off, RF-excited CO2 laser, capable ofcontinuous wave (CW) or modulated operation. From the lasersafety point of view, this laser is considered to be a component andmust be integrated into a system by a qualified original equipmentmanufacturer (OEM) prior to delivery to the end user. See “LaserSafety Requirements” on page 1-6 for a complete discussion of lasersafety issues.

Purpose of This Manual

This manual is designed to assist the original equipmentmanufacturer (OEM) during the integration of the C-55 OEM laser.It contains information on the performance and operation of the laseras well as installation and control methods.

Figure 2-1. C-55 Liquid-Cooled Laser
2 - 1


Specifications and Input Requirements

Table 2-2 on page 2-5 provides specifications, configurations, andfacility requirements for C-55 lasers. Refer to the data sheet (avail-able online at www.coherent.com) for power input specificationsand requirements.

Figure 2-1 illustrates the baseline configuration (i.e., without anyoptional hardware additions or deletions) of the C-55 laser. Eachlaser system consists of a laser head assembly and an integratedradio frequency (RF) power supply. The RF power module converts48 VDC electrical power to radio frequency power.

Connection of the customer-supplied DC power supply to the C-55is via a barrier strip with screw terminals on the RF power module.These terminals should also be used for the connection of wires forremote voltage sensing. Such sensing is recommended to control thevoltage at the input to the RF power module more precisely.

Hardware Overview

The C-55 laser is a waveguide, carbon dioxide (CO2) laser. RFelectric fields provided by the RF power module excite the CO2 gasmixture. The standard configurations of this laser operate atwavelengths between 9 µm and 11 µm in the infrared region of theelectromagnetic spectrum.

DC Input Power DC input power is provided by the user through customer-suppliedbus wiring, which goes to the RF power module. The RF powermodule converts this DC electrical power into RF power, which isused to excite the gas in the laser head. The DC power supplyrequirements are discussed in detail in “DC Power SupplyRequirements” on page 3-16.

Cooling Requirements

Total heat dissipation for the laser is specified in Table 2-2. The laserhead typically dissipates 650 W from its base surface while the RFpower module typically dissipates 350 W, for a total typical heatdissipation of 1,000W (maximum total heat dissipation is 1,230 W).The C-55 must be provided adequate cooling to keep the laser oper-ating temperature within acceptable limits. The cooling method thatis used must not induce stresses that will result in misalignment ofthe laser resonator.

2 - 2



Comparison of Liquid-Cooling & Air-Cooling (Reference)

Liquid-cooling and air-cooling each have distinct advantages.Table 2-1 describes the factors to be taken into consideration whenchoosing a cooling system for a laser module.

Consideration should also be taken if condensable vapors arepresent and to take suitable measures to purge sensitive areas, suchas optical surfaces, with a suitable gas.

Liquid-Cooling Option of the C-55

Installation requirements related to the liquid-cooling option of theC-55 laser are discussed in detail in the section titled“Liquid-Cooling” on page 3-5. This section is a quick overviewonly. Figure 3-2 shows the recommended connection from thecustomer-supplied refrigerated recirculator to the C-55 laser system.

Coherent recommends that the coolant water flowing from thecustomer-supplied refrigerated recirculator flow to the laser head,and then to the RF power module. Refer to Figure 3-2 on page 3-4.A customer provided flow switch or interlock device must beinstalled in the cooling water return line to detect the presence ofcooling water at the required flow rate, and to shut down the laser ifadequate coolant flow is not present.

NOTICE!To avoid damage to the laser, never operate the laser without asupply of cooling water meeting the requirements indicated inTable 2-2 or (alternatively) adequate air-cooling.

Table 2-1. Comparison: The Benefits of Liquid-Cooling vs. Air-Cooling Methods

LIQUID-COOLING AIR-COOLING

• Offers the highest process stability• Can yield the most compact arrangement• Suitable for applications in which the ambient air

temperature exceeds 40ºC• Better for applications in which the ambient air is

laden with particulates• Easier to make a hermetically sealed system

• Low in cost• Low in complexity• Low service requirements• Easier to install

2 - 3


Laser Head The laser head takes RF input power and converts some of it to laserradiation. The rest of the RF input power is exhausted as waste heat.For the C-55 liquid-cooled laser, this waste heat is exhausted into thecooling water that flows through the laser head. The laser headconsists of the folded optical waveguide resonator, the all-metal gasenvelope structure, and RF power module. Infrared laser radiation isemitted from the optical aperture. Pictures and dimensions drawingsfor the C-55 liquid-cooled laser is shown in Figure 2-1 on page 2-1and Figure 3-2 on page 3-4.

RF Power Module

The C-55 RF power module converts DC input power to RF energy,which is sent to the laser head. Heat from the RF power module isexhausted into the liquid-cooling water. An RJ-45-type connector isused to control the laser system. All of the user interfaces (DC powercooling water, and signal interface) are on one panel of the RF powermodule.

2 - 4


Specifications, Configuration, and Facility Requirements

Table 2-2 describes the configuration and facility requirements forC-55 lasers. Detailed specifications are provided on the laser datasheet (available online at www.coherent.com) and in the test reportprovided with each laser.

Table 2-2. C-55 Liquid-Cooled Configuration and Facility Requirements

PARAMETER VALUE

Weight 9.5 kg (21.0 lbs.)

Dimensions (LxWxH)1 579.6 x 92.5 x 104.1 mm(22.82 x 3.64 x 4.1 in.)1

Input Power2 48 VDC, 20 A

Cooling Liquid

Heat Dissipation (W) < 1200

Maximum Case Temperature < 60ºC (140ºF)

Operating Environment

Temperature 5 to 40ºC (41 to 104ºF)

Altitude < 2,000 m (6,500 ft.)

Humidity Non-condensing

Shipping/Storage Environment - 10 to 60ºC (14 to 140ºF), non-condensing

Coolant De-ionized or distilled water with Corrosion Inhibitor*

Coolant Flow Rate > 3.8 lpm (1.0 gpm)

Maximum Coolant Pressure 3.2 bar (46 psig)

Coolant Temperature 15 to 30ºC (59 to 86ºF)

1Optional fans add 1 A.2The overall height dimension is taller for the Dual Chillplate version of this item.*See Section Three: Utility Requirements and System Installation for recommended corrosion inhibitors.

2 - 5



2 - 6

Utility Requirements and System Installation

SECTION THREE: UTILITY REQUIREMENTS AND SYSTEM INSTALLATION

Introduction This section covers unpacking and installation of the C-55 lasers.Detailed operating instructions are given in Section Four: LaserOperation.

Unpacking and Inspection

Before unpacking the laser components, inspect the shipping cartonfor evidence of rough handling and note any damage. If damage tothe shipping carton is evident, request the carrier’s agent be presentwhen the unit is unpacked. Inform the shipping carrier and Coherentof any evidence of damage in shipment. The Buyer and its shippingcarrier are responsible for any damage which occurs duringshipment.

Verifying Delivery The shipping container contains the following:

• Laser head and integral RF power module

• Final Test Sheet

• Manual packet containing the CD

If any items are missing, report this to Coherent immediately.

3 - 1


Protective Shipping Tape

The front of the C-55 laser head is protected by a blue adhesive filmor tape (see Figure 3-1). This tape is designed to protect the opticsduring shipping and must be removed prior to operating the laser.

NOTICE!To avoid damage, the blue protective tape must be removedBEFORE operating the laser.

Tape Removal To remove the protective tape:

1. Pinch one corner of the tape between the thumb and indexfingers.

2. Gently pull the tape off of the laser.

3. Discard the tape and do not place the tape anywhere near or onthe laser.

Figure 3-1. Protective Shipping Tape

3 - 2


Safety Issues in Laser Installation

Installation of the C-55 laser must comply with all applicableelectrical safety and laser safety laws and regulations. ReviewSection One: Laser Safety for important information relating tosafety.

The negative (return) side of the DC input connection to the C-55 RFpower module is connected internally to the chassis. The user mustassure that the system into which the C-55 is built protects againstthe possibility that the C-55 laser head or RF power module chassiscould be at a hazardous voltage and that personnel could be exposedto these voltages.

DANGER!To avoid potentially fatal electrical shock hazards from elec-trical equipment, be sure to follow all applicable electrical codessuch as (in the U.S.) the National Electrical Code.

The laser must be secured properly to avoid the possibility of thelaser shifting unexpectedly during operation, creating a hazardouscondition. The location of the output beam of the C-55 laser head isshown in Figure 3-2. The laser output is emitted from the apertureshown in the referenced figures and propagates within a full coneangle up to 5º. The acceptance angle of the system aperture mustintercept all of the output of the laser.

It is also extremely important to understand the direction,divergence, and magnitude of all reflections that will occur fromoptical surfaces. Infrared (IR) beams, such as those from C-55lasers, can also be located with commercially available IR screens,such as those produced by Macken Instruments, Inc. [tel.(707) 566-2110]. Coherent recommends that all beam propagationpaths be enclosed and that personnel operating the laser be qualifiedoptical technicians who are familiar with this type of hardware.

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Mechanical Mounting

The dimensions for the C-55 laser head are shown in Figure 3-2.Mechanical mounting of the C-55 laser head must result in no distor-tion or stress to the laser head in any way. Otherwise, optical align-ment and power stability could be adversely affected.

Figure 3-2. C-55 Liquid-cooled Laser Dimensions

92.5 mm (3.6 in.)

Beam Output

BeamOutput

20.6 mm(0.8 in.)

102.4 mm(4.0 in.)

40.6 mm(1.6 in.)

14.2 mm(0.6 in.)

64 mm(2.5 in.)

30.6 mm(1.2 in.)

12.5 mm(0.5 in.) 12.5 mm

(0.5 in.)

38.2 mm(1.5 in.)

23.4 mm(0.9 in.)

63.6 mm(2.5 in.)

40 mm(1.6 in.)20 mm

(0.8 in.)17.7 mm(0.7 in.)

486.3 mm (19.1 in.)

476 mm (18.7 in.)

575.3 mm (22.6 in.)

537.1 mm (21.2 in.)

7.9 mm(0.3 in.)

27.18 ±0.51 mm(1.07 ±0.02 in.)

29.1 ±0.51 mm(1.15 ±0.02 in.)

10X M411.4 mm (0.5 in.)

Both Sides

4X M415.2 mm(0.6 in.)

Grounding Post

Coolant ReturnØ 6mm OD

Coolant SupplyØ 6mm OD

DC PowerConnector

ControlConnector,RJ45

3 - 4


C-55 Mounting Considerations

Certain aspects of specific customer applications may precludeabsolute interchangeability of laser heads. For example, for certainapplications, the sensitivity of the application to optical beampointing errors may require external optical realignment after thelaser head is replaced in the customer’s integrated system.Depending on the method of mounting and the sensitivity of theintegrated customer system to beam pointing errors, even removinga laser head from the customer’s system, then replacing the samelaser head back into the customer’s system may require externaloptical realignment. This external alignment would be arepositioning of the head itself or adjustment of beam deliverymirrors (positions and angle). Consult Coherent if there is anyquestion about such interchangeability issues.

Coherent recommends use of the optional brackets (part number1101-12-0016 for a set of 4) that are designed for mounting the lasersafely without inducing any stress onto the laser. Care must be takennot to induce stress onto the laser head, as optical mis-alignment ofthe laser resonator can occur, which would require the laser to bereturned to Coherent for service. A mechanical drawing for thisbracket is provided in Appendix A. Coherent strongly encouragesuse of this bracket or a similar design in order to accommodatetemperature changes in operation while providing secure mounting.

Liquid-Cooling The C-55 liquid-cooled laser is cooled by means of liquid coolant.The cooling system, external to the laser head and the RF powermodule, is the responsibility of and must be supplied by the user. Aschematic of the recommended configuration of the cooling systemis shown in Figure 3-3.

Figure 3-3. Recommended Liquid-Cooling System Functional Block Diagram

Laser System*

Those items marked with * are supplied by Coherent®

AC power AC power cable*

Coolant

ElectronicController

AC PowerRelay

CoolantFilter

FlowInterlock

Switch

CoolantRefrigeratedRecirculator

DC

3 - 5


Cooling System Layout

By connecting the laser head and the RF power module in series, asingle interlock will protect the laser system.

Following the flow of coolant from the refrigerated recirculator, thelaser head is the first element reached by the coolant after it leavesthe recirculator. This assures that the laser head receives thelowest-temperature coolant available.

To prevent inadvertent operation of the laser without adequatecoolant, an interlock must be provided so that laser operation ishalted. Refer to coolant requirements in Table 2-2 on page 2-5.

Re-Circulation and Coolant Flow Interlock Switch

The coolant flow switch should be the last element traversed by thecoolant before it returns to the refrigerated recirculator “return” line.This assures that the flow switch verifies that coolant is flowingthrough the laser system. The flow switch must not be placed in anyother position. The interlock, which is tripped when the coolantswitch indicates no flow or low flow, cuts off AC power to the DCpower supply to prevent the system from overheating.

Signal Interface The signal interface in the laser interlock system may be used to turnthe laser off when the coolant interlock is breached. With thisapproach, the laser is commanded to shut down via the signalinterface, in the event that the coolant interlock system detects acoolant fault. Coherent recommends that both Modulation Input andControl Enable be commanded to the OFF state when the coolantinterlock system detects a coolant fault. These signals are listed inTable 4-1 on page 4-1 and described in subsections ofSection Four: Laser Operation.

Thermal Shutdown Switch

The C-55 laser has a thermal protection switch that protects thesystem at case temperatures over 80ºC. Coherent recommends,however, that the OEM install sensors that detect coolant flow andshuts the laser down in the event of loss of coolant.

The system also provides a high temperature warning. This warningis used to alert the user to the need of maintenance in order to returnthe cooling system performance back to normal, full coolingcapacity. Failure to take action regarding the temperature warningwill result in poorer product performance (outside specifications)and lesser product life time.

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Mounting Orientation

Coolant leaks are unlikely if coolant connections are properly made.However, it is advisable to take precautions to avoid damage in theevent of leaks in the cooling system. One such precaution is toarrange cooling lines and connections such that coolant leaks wouldnot result in coolant coming into contact with sensitive electronicequipment and components.

AC Power Relay The recommended AC power relay used to cut mains to the DCpower supply, in the event of cooling system failure, can also be usedas part of the laser safety interlock system. Similarly, if the signalinterface is used to shut down the laser when there is a coolingsystem fault, the signal interface can be used to shut down the laserin the event that there is a breach of a safety interlock. The design ofthe interlock controls must be in compliance with applicable safetystandards, including those described in Section One: Laser Safety.

Condensation of Water Vapor

If the coolant temperature is below the dew point of the ambient air,water will condense out of the air onto the outside of the laser head,and onto the outside surface and internal surfaces of the RF powermodule. Condensation can damage the output optical element of thelaser head when the laser is turned on, and could damage internalcomponents of the RF power module if power is applied whilecondensate is present.

NOTICE!To avoid damaging the system, never allow the coolant tempera-ture to fall below the dew point of the ambient air. Turn thecoolant flow off if the laser will be off or stored for an extendedperiod of time in humid conditions.

If necessary, the laser system can operate with coolant temperaturesslightly below the dew point of the ambient air. This requires specialprocedures to be followed, such as shutting off the coolant flow atall times when the laser is not producing laser output. ContactCoherent Product Support for more information about this optionbefore attempting to operate the system in ambient air below the dewpoint.

3 - 7


NOTICE!To avoid possible damage to the laser head, never attempt tochange the coolant fittings at the locations where the coolantenters the laser head. If the fittings must be changed for anyreason, return the laser head to Coherent to be serviced byCoherent technicians.

Coolant Fittings on Laser System

The C-55 liquid-cooled laser has 6 mm. O.D. tubing for the connec-tion interface. The user must supply an appropriate compressionfitting to make the connection with the rest of the user’s system.

Figure 3-4. C-55 Liquid-Cooling Connections

C-55 Lase r

Coolant supply

Coolant return

3 - 8


Cooling Capacity The cooling system must have sufficient capacity to maintain thecoolant temperature at the outlet of the refrigerated recirculatorwithin the range given in Table 2-2. With the laser operating at itsmaximum output power, the cooling system must dissipate up to1,230W. See Section Five: Maintenance and Troubleshooting formaintenance and replacement requirements for the coolant.

Coolant Filtering Coherent recommends that the user incorporate coolant filtering inthe coolant supply line to avoid the accumulation of debris in thecooling system, as shown in Figure 3-4. The filter should trapparticles larger than 30 µm to 50 µm in size, unless specifiedotherwise by the manufacturer of the refrigerated recirculator.

Coolant Composition

The recommended coolant composition is a mixture of cleandistilled or deionized water containing a low toxicity corrosioninhibitor. Coherent has tested two different solutions that willprevent corrosion within the laser coolant circuit.

These are described in Table 3-1:

Table 3-1. Recommended Coolant for C-55 Lasers

PRODUCT NAME

MANUFACTURERS NAME

AND CONTACT

HEAT TRANSFER

FLUID TYPE

REQUIRED HEAT

TRANSFER FLUID

CONTENT

FREEZING BURST

PROTECTION

OTHERPRECAUTIONS

Optishield OptiTemp. Inc.www.optitemp.comUS/Canada231-946-2931

Corrosion Inhibited Water

10% solution in water

Does not reduce the water freezing point

Use may be restricted in geographical locations outside the US

WT1000 Nalco Inc.www.nalco.comUS630-305-1000

Corrosion Inhibited Water

2500 ppm in water (2.5 mL per liter of water)

Does not reduce the water freezing point

Use may be restricted in geographicallocations outside the US

3 - 9

http://www.optitemp.com

http://www.nalco.com


Figure 3-5 shows system components from water circuits treatedwith inhibitor and a water circuit without inhibitor.

Freeze/Burst Protection

The recommended coolant mixture does not provide freezeprotection; therefore the coolant temperature must be maintainedabove the freezing point of water. Since lower temperatures mayoccur during shipment and storage, the C-55 should never be storedor transported unless the coolant has been completely removed byusing a compressed air supply to blow out all coolant passages.

NOTICE!Never store or ship a C-55 with coolant installed, as the coolantmay freeze and cause permanent internal damage. Alwaysremove the coolant prior to storage or shipment by using acompressed air supply to blow out all coolant passages. Plug orcap coolant inlet and outlet fittings after draining to preventresidual coolant leaks during storage or shipment. Damage tothe laser during storage or shipment, as a result of failure toremove coolant and plug the inlet and outlet fittings aftercoolant removal, is specifically excluded from the productwarranty.

Untreated Water Circuit Treated Water Circuit

Figure 3-5. Water Circuits - Untreated and Treated

3 - 10


Alternative Coolant Composition

An alternative coolant composition is a mixture of water andDOWFROST, a low toxicity, corrosion inhibited, propylene glycolbased heat transfer fluid available from The Dow ChemicalCompany. Because this fluid consists of propylene glycol andnon-toxic corrosion inhibitors, the legal and regulatory restrictionson its use and disposal are less demanding than is the case for fluidscontaining ethylene glycol. The required mixture is 25% to 30%DOWFROST by volume, with the balance consisting of water. Inaddition to DOWFROST, alternative propylene glycol based heattransfer fluids may also be used, as indicated in Table 3-2. In addi-tion, for those applications where the user determines that the highertoxicity of an ethylene glycol based heat transfer fluid is acceptable,the fluids indicated in Table 3-3 may be used.

Table 3-2. Propylene Glycol-Based Heat Transfer Fluids for C-55 Lasers

PRODUCT NAME

MANUFACTURER’S NAME AND

TELEPHONE NUMBER

SUGGESTED DISTRIBUTOR AND

CONTACTINFORMATION

HEAT TRANSFER

FLUID TYPE

2REQUIRED HEAT

TRANSFERRED FLUID

CONTENT IN COOLANT

ASSURED BURST

PROTECTION

1DOWFROST orDOWCAL N

The Dow Chemical CompanyU.S./Canada:1-800-447-4369Europe: +31 20691 6268 Elsewhere:1-517-832-1556

U.S.: Hubbard-Hall,1-203-756-5521www.hubbardhall.comor: S/C Industries, Inc.1-800-675-4785

Inhibited propylene glycol

25 vol% to30 vol%

- 18°C (0°F)

1DOWCAL N is a Dow Chemical product functionally equivalent to DOWFROST. DOWCAL N is available primarily in Europe, and DOWFROST is available primarily in the U.S. and Canada.2The balance of the coolant consists of water with low mineral content.

Table 3-3. Ethylene Glycol-Based Heat Transfer Fluids for C-55 Lasers

PRODUCT NAME

MANUFACTURER’S NAME AND

TELEPHONENUMBER

SUGGESTED DISTRIBUTOR AND

CONTACTINFORMATION

HEAT TRANSFER FLUID

TYPE

1REQUIRED HEAT

TRANSFERRED FLUID

CONTENT IN COOLANT

ASSURED BURST

PROTECTION

DOWTHERM SR-1

The Dow Chemical CompanyU.S./Canada:1-800-447-4369Europe:+31 20691 6268Elsewhere:1-517-832-1556

U.S.:Hubbard-Hall,1-203-756-5521www.hubbardhall.com

Inhibited ethylene glycol

30 vol% to35 vol%

- 27°C (-17°F)

1The balance of the coolant consists of water with low mineral content.

3 - 11

www.hubbardhall.com

www.hubbardhall.com


Coherent has found that to be safe, distilled water is highly recom-mended as the dilution water component of the coolant mix. Recom-mended guidelines on dilution water quality are as follows:

• Chlorides and sulfates in dilution water less than 25 ppm

• Total hardness as calcium carbonate less than 100 ppm

The manufacturers listed in Table 3-2 and Table 3-3 offer predilutedmixtures. The water dilutions indicated in these tables are appro-priate only for the undiluted product in each case.

See Section Five: Maintenance and Troubleshooting in the oper-ator’s manual for maintenance and replacement requirements for thecoolant.

NOTICE!To prevent damage to the laser, never operate any C-55 liquidcooled laser using only ordinary water, such as tap water ordeionized water, as a coolant. These lasers contain materialswhich will suffer corrosion damage when exposed to plain waterwithout corrosion inhibitors. Corrosion caused by impropercoolant voids the warranty.

It is important to neither use too much, nor too little corrosion inhib-ited glycol in the coolant mix. Too much glycol will result in poorcooling performance, and possibly overheating of parts of the lasersystem. Too little glycol will result in reduced protection againstcorrosion, freezing, and bursting. Glycol fluid levels lower than therecommended amount may also encourage microbial growth, whichcan result in fouling and blockage of the cooling system.

3 - 12


Freeze/Burst Protection

With the recommended alternative coolant mixes, burst protection isassured down to a temperature of - 18°C (0°F) for the propyleneglycol based fluids (Table 3-2) and to - 27°C (- 17°F) for theethylene glycol based fluids (Table 3-3). Since lower temperaturesmay occur during shipment and storage, C-55 lasers should never beshipped or stored unless the coolant has been drained. And it isstrongly suggested that the coolant within cooling lines of the lasersystem components be blown out with dry air or Nitrogen.

NOTICE!To avoid damage, never ship or store any C-55 laser containingcoolant if it is possible it will be exposed to temperatures belowthe freezing point of the coolant during such shipment orstorage. Plug or cap coolant inlet and outlet to prevent coolantleaks during shipment or storage.

Coolant Flow Rate and Pressure

Requirements on coolant flow rate are listed in Table 2-2 onpage 2-5. To prevent damage to the laser head or the RF powermodule, the gauge pressure of the coolant at the laser head and at theRF power module must not exceed 100 psig (i.e. the gauge pressure− the difference between the absolute pressure of the coolant and theabsolute pressure of the ambient air − must not exceed 7 kg/cm2, or690 kPa). Note that the gauge pressure at the laser system includesthe effect of the gravitational pressure change if the refrigeratedrecirculator is mounted much higher than the laser system.

NOTICE!Exceeding the maximum allowed gauge pressure in the laserhead or RF power module, even for a short period of time, maycause irreversible damage and result in permanent coolantleaks.

Depending on the customer’s overall cooling system design,portions of the cooling system, other than the laser head and the RFpower module, may limit the maximum-allowed gauge pressure ofthe coolant to a lower pressure than the value noted above for thelaser head and the RF power module.

3 - 13


Pressure Drop The pressure drop from the coolant outlet to the coolant inlet of therefrigerated recirculator will depend on many factors, including:

• Flow rate

• Temperature

• Length and inside diameter of coolant hoses andconnections

• Coolant composition

To achieve the minimum flow rates given in Table 2-2 on page 2-5,provide a pressure drop of no more than 35 psi (2.5 kg/cm2) betweencoolant inlet and coolant outlet of the laser. In addition, there is somepressure drop in the cooling lines, which depends primarily on thediameter and length of these lines.

The selected arrangement, once configured, should be checked foradequate flow within the specified pressure limits.

Materials Used in Cooling Systems

Although the coolant mix recommended above will control corro-sion in the cooling system to some degree, certain materials must beavoided to further reduce corrosion problems. In particular, galva-nized steel must be avoided in all user-supplied cooling systemcomponents which come into contact with the coolant because zincwill react with the corrosion inhibitor.

In general, corrosion problems in the cooling system will be mini-mized if only aluminum, stainless steel, nickel plated brass, andplastic materials come into contact with the coolant

Electrical Power Connection

The C-55 laser requires 48 VDC input power. This power is carriedfrom the power source to the system through the terminal block onthe C-55. The maximum current required is 25A.

The negative (return) side of the DC input connection to the C-55 RFpower module is connected internally to the chassis. The user mustassure that the system into which the C-55 is built protects againstthe possibility that the C-55 chassis could be at a hazardous voltageand that personnel could be exposed to these voltages.

DANGER!To avoid potentially fatal electrical shock hazards fromelectrical equipment, be sure to follow all applicable electricalcodes such as (in the U.S.) the National Electrical Code.

3 - 14


Coherent strongly recommends that the user review the precautionsdescribed in Section Two: Laser Safety regarding electrical safetybefore using the C-55 laser. It is the user’s responsibility to providecircuit breakers and/or fusing of the AC power source, in accordancewith all applicable laws and regulations.

Note: Pin #1 of RJ45 control interface is on the left as viewed.

Connect leads to the user-supplied power source last after other connection are made.

Figure 3-6. Electrical Connections to C-55

Negative PowerConnection

Positive PowerConnection

RJ45 Connection

Connect to RJ45 jack(8) pins

C-55 Laser

Coolant return

Coolant supply

Terminal block screwsare for securing thepower source leads

to the laser

DC POWER SUPPLYNEGATIVE LEADS

DC POWER SUPPLYPOSTIVE LEADS

3 - 15


DC Power Supply Requirements

The following are the requirements for the customer-supplied DCpower supplies:

DC Power Supply Cabling Requirements Coherent strongly recommends the use of remote voltage

sense/regulation at the C-55. This requires a 4-wire cable(2 supply currents and 2 voltage senses).

The following requirement minimizes the voltage loss from supplyto C-55:

Control Signal Connection

Electrical control of the C-55 laser is achieved via an RJ-45connector built into the system. The signals carried on each of thepins are indicated in Table 4-1 on page 4-1. Details about controllingthe laser through the signal interface are discussed inSection Four: Laser Operation.

DC Voltage: 48 VDC measured at the terminals

Peak Current: 35A for a minimum of 1 ms with a maximum voltage drop of 1.5V

Regulation: <±2%Regulation Sensing: Remote at loadRipple and Noise: <1% p-p (20 MHz BW limit)Overload and ShortCircuit Protect: Automatic Recovery

WIRE LENGTH (IN METERS) AWG0-2 2 x 17 or 14

2-3 2 x 15 or 12

3-5 2 x 13 or 10

Note: Typically, doubling the wire at a given length will reduce the AWG by 3.

3 - 16


NOTICE!Coherent highly recommends use of shielded interface cables.The interface cable shield must connect to the chassis ground ofthe controller. In addition to proper shielding, this shieldprovides a secondary connection for the signal ground (Pin 8).

A floating ground connection (use of un-shielded interface cableor no return path between the host control electronics and thelaser) can present an unsafe condition and result in unstable orunexpected operation of the laser. This condition can arise whenthe control signal ground connection (Pin 8) is lost and theControl Enable (Pin 7) and Modulation Input (Pin 1) remainhigh. Therefore, Coherent strongly recommends that a secondsafety ground be provided either via a shielded control cable orcommon potential chassis mounting between the laser head andthe control electronics.

Beam Propagation

The true waveguide structure of the C-55 delivers a 1.8 mm 1/e2

diameter beam with a 7.5 mrad 1/e2 full angle divergence. Thetypical beam diameter as a function of distance from the laser isshown in Figure 3-7.

Figure 3-7. Beam Diameter vs. Distance From Laser Head

Beam Diameter vs. Z

0.00

2.00

4.00

6.00

8.00

10.00

12.00

14.00

16.00

0 500 1000 1500 2000 2500

DIAMOND C-55 Beam Diameter (1/e2) in mm vs. Distance from Laser Head

3 - 17


3 - 18

*1430074 AG*DIAMOND C-55 Liquid-Cooled OEM Laser Preinstallation Manual© Coherent Inc., June 2018 (RoHS), printed in the USA and ThailandPart No. 1430074 Rev. AG

DIAMOND C-55 Liquid-Cooled OEM Laser Preinstallation Manual© Coherent Inc., June 2018 (RoHS), printed in the USA and ThailandPart No. 1430074 Rev. AG

*1430074 AG*

diamond c-55 liquid-cooled oem laser · diamond c-55 liquid-cooled oem laser preinstallation manual...

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