preinstallation manual diamond™ e-1000 series oem lasers

Preinstallation ManualDIAMOND™ E-1000 SeriesOEM Lasers

5100 Patrick Henry DriveSanta Clara, CA 95054

Diamond E-1000 Series OEM Lasers Preinstallation Manual

This document is copyrighted with all rights reserved. Under copyrightlaws, this document may not be copied in whole or in part, or reproducedin any other media, without the express written permission of Coherent,Inc. (Coherent). Permitted copies must carry the same proprietary andcopyright notices as were affixed to the original. This exception does notallow copies—whether or not sold—to be made for others; however, all thematerial purchased may be sold, given, or loaned to another person.Under the law, “copying” includes translation into another language.

Coherent, the Coherent Logo, DIAMOND and LabMax are registeredtrademarks of Coherent, Inc.

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 USA:

Should you experience any difficulties with your laser or need anytechnical information, please visit our Web site www.Coherent.com.Should you need further assistance, please contact Coherent TechnicalSupport via e-mail [email protected] or telephone,1-800-367-7890 (1-408-764-4557 outside the U.S.). Please be ready toprovide model and laser head serial number of your laser system as wellas the description of the problem and any corrective steps attempted to thesupport engineer responding to your request.

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

Outside the USA:

If you are located outside the U.S., please visit www.Coherent.com fortechnical assistance, or phone your local Service Representative. ServiceRepresentative phone 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


mailto:[email protected]



TABLE OF CONTENTS

Preface ................................................................................................................................ viiU.S. Export Control Laws Compliance .............................................................................. viiSymbols Used in This Manual and on the Laser System .................................................. viiiPre-installation Checklist ....................................................................................................... 1

Confirm Laser Environment ......................................................................................... 4Operation in Humid Environments...................................................................... 4

Receive and Inspect ...................................................................................................... 5Laser Installation Area.................................................................................................. 6

Service Access ..................................................................................................... 6Mounting Feet...................................................................................................... 7

Laser System Cooling................................................................................................... 8Coolant Temperature............................................................................................ 9Coolant Filtering .................................................................................................. 9Coolant Composition ......................................................................................... 10Freeze/Burst Protection...................................................................................... 10Flow Direction ................................................................................................... 12Chiller Electrical Supply.................................................................................... 13Electrical Disconnect ......................................................................................... 13

Laser System Purge Gas ............................................................................................. 14Delivery System Purge Gas ............................................................................... 14Guidelines for Use of Compressed Air for Purge.............................................. 15

DC Power Supply ....................................................................................................... 17DC Power Supply Electrical Service ................................................................. 17Electrical Disconnect ......................................................................................... 17Mains Power Cord ............................................................................................. 18

Beam Delivery System ............................................................................................... 18Shutter ................................................................................................................ 18Accessory Coupler ............................................................................................. 18Purge .................................................................................................................. 18Optical Isolation................................................................................................. 19

Laser Control, Measurement &Diagnostic ................................................................. 19External Interlock Circuit .................................................................................. 19Laser Power Measurement................................................................................. 20

Laser Safety ................................................................................................................ 20Installation ........................................................................................................................... 21

Required Tools ............................................................................................................ 21Required Parts and Equipment ................................................................................... 22Facility Preparation..................................................................................................... 24Unpacking and Inspection .......................................................................................... 24Unpacking Instructions ............................................................................................... 25Mount the Laser System ............................................................................................. 35

Alternate Mounting Orientations ....................................................................... 38Vertical Mounting ....................................................................................................... 38

iii


Mount the DC Power Supply...................................................................................... 42Laser Head Indicators and Connections ..................................................................... 42Optics Purge Connection ............................................................................................ 44Set-up Purge................................................................................................................ 44Connect Coolant Lines................................................................................................ 44Connect Electrical Cables ........................................................................................... 46Remove Output Aperture Cover ................................................................................. 47Mounting Accessories to Laser Aperture ................................................................... 48Controller Connection................................................................................................. 48

E-1000 Series HTTP and TCP Server ................................................................................. 49Introduction................................................................................................................. 49Initial Connection and Configuration ......................................................................... 50

Connections ....................................................................................................... 50Client Configuration .......................................................................................... 51

Testing the Connection Using PING........................................................................... 54HTTP Information and Diagnostic Pages ................................................................... 55

Home Page......................................................................................................... 55System Data/Info Page....................................................................................... 56Clock and Diagnostics Page .............................................................................. 57FAQ.................................................................................................................... 58

Java Applet ................................................................................................................. 58Java Runtime Configuration .............................................................................. 58Opening a Socket ............................................................................................... 61Diagnostics Elements......................................................................................... 61Control Elements ............................................................................................... 62

Extended Diagnostics Pages ....................................................................................... 62Onboard Time Page ........................................................................................... 63EEPROM Maintenance...................................................................................... 64Rolling Buffer .................................................................................................... 65System Monitoring Applet................................................................................. 66

TCP Client Connections ............................................................................................. 68Connection Requirements.................................................................................. 68API Available..................................................................................................... 69Using Pueblo TCP Client................................................................................... 70Command Line Interface Details ....................................................................... 72

Generating a Log File ................................................................................................. 74Interpreting the Raw Data from an E-1000 Series Log File ....................................... 76

CAN Node Addresses ........................................................................................ 83CAN Data Page Contents: ................................................................................. 84

iv

LIST OF ILLUSTRATIONS

1. Coolant Flow Diagram........................................................................................................ 82. Coolant Flow to Laser System.......................................................................................... 123. Electrical Disconnect Switch (with Fuse Protection) ....................................................... 134. Purge Gas Diagram ........................................................................................................... 155. Purge Filter/Dryer Panel Assembly (optional) ................................................................. 166. Electrical Disconnect Switch (with Fuse Protection) ....................................................... 177. Removing Crate Cover ..................................................................................................... 258. Top Cover Removed ......................................................................................................... 269. Unstrapping the System .................................................................................................... 2710. Exposing the Eye-bolt Holes ............................................................................................ 2811. Installation of Eye-bolts.................................................................................................... 2912. Removing Spreader from Crate ........................................................................................ 3013. Attaching Eye-bolts to Spreader Bar ................................................................................ 3114. Cutting Top of Moisture Seal Bag .................................................................................... 3215. Lifting the DIAMOND E-1000 Series.............................................................................. 3316. Place Laser System on Cart .............................................................................................. 3417. RF Power Supply System Cable ....................................................................................... 3418. DIAMOND E-1000 Series System Installation in OEM Equipment ............................... 3619. Vertical Mounting Eye-bolt Positions (Beam Up) ............................................................ 3920. Vertical Mounting Eye-bolt Positions (Beam Down) ....................................................... 4021. Vertical Mounting Illustration........................................................................................... 4122. E-1000 Series Interface Connectors ................................................................................. 4223. RF Power Supply DC Input Terminal Fasteners............................................................... 4624. Output Aperture Cover ..................................................................................................... 4725. DIAMOND E-1000 Series Output End View................................................................... 4826. IP Address Change (On System Data Screen).................................................................. 5027. Network Connections Screen............................................................................................ 5128. Local Area Connection Properties Screen ........................................................................ 5229. Internet Protocol (TCP/IP) Properties Screen................................................................... 5330. Ping Screen ....................................................................................................................... 5431. Welcome Screen................................................................................................................ 5532. System Data Screen .......................................................................................................... 5633. Onboard Diagnostics Screen............................................................................................. 5734. Java Control Panel Screen ................................................................................................ 5935. Java Applet Cache Viewer Screen .................................................................................... 6036. E-1000 Series Laser Ethernet Control Applet .................................................................. 6137. Diagnostics Main Menu.................................................................................................... 6238. Onboard Time ................................................................................................................... 6339. EEPROM Maintenance..................................................................................................... 6440. Rolling Buffer ................................................................................................................... 6541. System Monitoring Applet................................................................................................ 6642. QuickConnect ................................................................................................................... 7043. QuickConnect Response ................................................................................................... 70

v


LIST OF TABLES

1. Pre-installation Checklist .................................................................................................... 22. Recommended Coolant for E-1000 Series Lasers ............................................................ 103. Parts and Equipment Required for Installation................................................................. 224. E-1000 Series Head Indicators and Connectors ............................................................... 435. Get Commands (available at any time)............................................................................. 726. Set Commands .................................................................................................................. 737. Special Commands (available at any time)....................................................................... 738. FPGA Status Byte Codes .................................................................................................. 819. CAN FAULT CODES....................................................................................................... 82

vi

Preface This manual provides facilities preparation information and installa-tion instructions for the DIAMOND™ E-1000 Series lasers – OEMversion.

Complete product information is contained in the DIAMONDE-1000 Series OEM Lasers Operator’s Manual, part number1192674.

Thoroughly review the Operator’s Manual, especially the lasersafety section, prior to operating the E-1000 Series OEM laser.

Read this Preinstallation Manual carefully before installing thelaser. Special attention must be given to the material in theSafety section.

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

Use of the system in a manner other than that described withinthis manual may impair the protection provided by the system.

U.S. Export Control Laws Compliance

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

Export and re-export of lasers manufactured by Coherent are subjectto the U.S. Export Administration Regulations administered by theDepartment of Commerce, Bureau of Export Administration.

The applicable restrictions vary depending on the specific productinvolved, intended application, and the product destination. In somecases, an individual validated export license is required from theU.S. Department of Commerce prior to resale or re-export of certainproducts. If you are uncertain about the obligations imposed by U.S.law, obtain clarification from Coherent.

vii


Symbols Used in This Manual and on the Laser System

This symbol is intended to alert the operator to the presence ofdangerous voltages associated with the laser that may be of suffi-cient magnitude to constitute a risk of electric shock.

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 identifies direct current electric potential.

This symbol identifies electrical ground.

viii

UTILITY REQUIREMENTSAND SYSTEM INSTALLATION

Before installation, it is essential that the customer read thismanual thoroughly. It is important that the user becomefamiliar with all aspects of the installation and operation of theE-1000 Series laser system, including and specifically the infor-mation contained in Section Two: Laser Safety of the operator’smanual.

Pre-installation Checklist

In order to perform a smooth integration of the laser system into atool or installation at a customer site, it is necessary to prepare inadvance. A pre-installation checklist outlining the general require-ments is provided in Table 1.

1

DIAMOND E-1000 Series OEM Lasers Preinstallation Manual

Table 1. Pre-installation Checklist

ACTIVITY GENERAL REQUIREMENTS REFERENCE(S)

Confirm Laser Environment

[ ] Temperature and Humidity in specification[ ] Cleanliness[ ] Vibration[ ] Ventilated space

“Confirm Laser Environment” on page 4

“Operation in Humid Environ-ments” on page 4

Receive and Inspect

[ ] Area is clean and sufficiently large enough to uncrate laser

[ ] Forklift or pallet jack capable of moving the fully loaded crate (320 kg/705 lbs.)

[ ] Forklift or hoist capable of lifting the 173 kg (381 lbs.) laser off the shipping pallet

[ ] Cart capable of moving 173 kg (381 lbs.) laser to installation area

“Receive and Inspect” on page 5

“Unpacking Instructions” on page 25

LaserInstallation Area

[ ] Clear path to the installation site[ ] Forklift or hoist capable of lifting the 173 kg

(381 lbs.) laser plus lifting hardware into tool[ ] Laser head mounting area prepared (lift access,

mounting feet installed, able to support 173 kg (381 lbs.) laser system plus weight of cables, hoses, output aperture accessories, etc.)

[ ] Service access provided[ ] All connections reach laser head

“Laser Installation Area” on page 6

“Mount the Laser System” on page 35

Laser System Cooling

[ ] Chiller installed and operational (loop test OK)[ ] Coolant is a mixture of water and corrosion

inhibitor[ ] 30 µm particle filter installed at laser head inlet[ ] Shut-off valves installed (optional, recommended)[ ] 5/8” ID or greater hose between the laser and chiller[ ] Required flow rate, temperature set point and

temperature stability capability verified

“Laser System Cooling” on page 8

“Coolant Composition” on page 10

Table 1-2 on page 1-8 in the oper-ator’s manual

Laser System Purge Gas

[ ] N2 or filters installed to provide clean, dry air[ ] Shut-off valve installed (optional, recommended)[ ] Output fitting installed to accept 1/4” OD tubing[ ] Clean, flexible 1/4” OD tubing to connect purge gas

supply to laser head

“Laser System Purge Gas” on page 14

“Purge Gas Filter Panel Assembly” on page C-2 in the operator’s manual

2

DC Power Supply

[ ] Rack w/shelf, bench or frame (mounting) prepared[ ] Electrical circuit with circuit breaker/fuse and elec-

trical disconnect ready[ ] Mains input (electrical disconnect to power supply)

power cable ready[ ] Cooling water system, supply and return lines and

fittings ready (for liquid-cooled DC power supplies only)

OEM Product Literature (external document(s))

“DC Power Supply” on page 17

Appendix C: Accessories and Options in the operator’s manual

Beam Delivery System

[ ] Beam delivery system purge gas ready[ ] Optical Isolator installed (if cutting/marking reflec-

tive material)[ ] External optical beam delivery system meets optical

specifications

“Beam Delivery System” on page 18

Laser Control, Measurement and Diagnostic

[ ] If using a Coherent E-Series Remote Controller, controller is available

[ ] If monitoring laser diagnostics with a personal computer via network cable, a computer Ethernet cross-over cable is required

[ ] For 3rd party controller, see OEM documentation[ ] Interlocks installed[ ] Suitable Power Meter and Detector Head available

“Laser Control, Measurement&Diagnostic” on page 19 andSection Four: Control Interfacesin the operator's manual

DIAMOND E-Series OEM/Indus-trial Laser Remote Controller Operator’s Manual, part number 1153591 (external document)

“Power Meters and Sensors” on page C-1 in the operator’s manual

Laser Safety

[ ] Laser Safety Officer (LSO) identified (recom-mended)

[ ] Laser Safety Training completed[ ] Laser Controlled Area established[ ] Personal Protective Equipment (laser safety

eyewear) available

“Laser Safety” on page 20

Section Two: Laser Safety in the operator’s manual

Table 1. Pre-installation Checklist (Continued)

ACTIVITY GENERAL REQUIREMENTS REFERENCE(S)

3


Confirm Laser Environment

The laser must be installed and operated in a temperature andhumidity-controlled environment. The operating temperature mustbe 5 – 45ºC (41 – 113ºF). The humidity must be 5 – 95%,non-condensing, for the laser system coolant inlet temperature.Operating altitude must be <2,000 m (6,600 ft.).

Additionally, the laser environment should be clean and free ofair-borne particles, and mounted such that vibrations are withinspecification. If possible, create a “clean” area for the laser andinitial beam delivery optics and a “dirty” area for the final beamdelivery system and work piece.

Since the laser and/or associated beam delivery systems may benitrogen purged and the cutting/marking processes generally createnoxious fumes, make sure to provide adequate ventilation for alloperators in the area.

Operation in Humid Environments

The cooling fluid of the E-1000 Series lasers can condense moisturefrom the air when the temperature of the cooling fluid is at or belowthe dew point of the air.

The system must not operate in a condensing environment sincethis condition will lead to catastrophic failure in both the laserhead and the RF power supply. Doing so will void the warranty.It is the responsibility of the customer to ensure an E-1000 Serieslaser system is never operated in a condensing environment.Failed laser heads and RF power supplies must be returned tothe factory for repair.

Condensation may form on any component surface when the surfacetemperature is at or below the dew point of the air. The typicalcondition that leads to condensation is warm, humid weathercombined with fluid that is cooler than the surroundings.

High risk conditions which are likely to lead to condensation are:

• Operating the laser in a room that is not air conditioned in highhumidity environments

• Using cooling fluid that is not temperature controlled

• Leaving the cooling fluid system on when the laser is not oper-ating for extended time periods

Risk of Condensation: The information required to determine if thecooling fluid temperature will lead to condensation is:

• Room temperature

4

• Relative humidity

Since weather conditions change, these factors need to beperiodically checked especially in spring, summer or wet seasons. Inenvironments that are air conditioned, Coherent recommends settingthe cooling fluid temperature to 23°C (73.4°F). For environmentsthat are not air conditioned, Coherent recommends that the coolingfluid temperature be increased to the air temperature to avoidcondensation in humid climates, but no higher than 26ºC (78.8ºF)and not less than 20ºC (68ºF).

Receive and Inspect

The E-1000 Series laser system packaging has been designed forrobust shipment. Upon receiving the system, inspect the outside ofall containers immediately to ensure no damage occurred duringtransit. If there appears to be visible damage (holes in the containers,fluid damage, crushing etc.), immediately notify Coherent and arepresentative of the carrier. Request that a representative of thefreight company be present when unpacking the contents.

Keep the original shipping containers and packing materials fortransporting the E-1000 Series laser system from one location toanother. If the system is to be returned to Coherent for repair, itmust be transported in the original shipping container.

The containers may appear in good condition, but the contents maybe damaged. Inspect all major components as they are unpacked.Unpacking procedure instructions are found in “Installation” onpage 21.

To unpack the laser system, at least two people and the followingtools will be required:

• Scissors or a package cutting knife

• 8” adjustable wrench

• Large Pliers (may be required to loosen 2 wing-nuts)

• Forklift or jack able to lift and move at least 320 kg (705 lbs.)- total weight of a fully loaded shipping crate

• Hoist capable of lifting the 173 kg (381 lbs.) laser system outof the crate

• Cart capable of supporting and transporting the 173 kg(381 lbs.) laser system to the installation area

5


While in transit, the shipping container and its contents may beexposed to cold temperatures. To prevent condensation fromdeveloping on and within the laser system, move the crate to alocation near the installation area and allow it to acclimatebefore unpacking the laser.

Laser Installation Area

It is assumed that the laser will be integrated into a laser cutting ormarking tool designed and manufactured by a third party. Becauseeach system installation is unique, only general guidelines will bediscussed.

Service Access It is highly recommended that the system integrator followCoherent’s recommendation for laser orientation with respect toservice access within the customer’s equipment (see Figure 18a“Laser Head Mounting Dimensions”).

If placing the laser inside a cabinet or enclosure, make sure to designsufficient access to all lifting and mounting points. Additionally,make sure to provide adequate service clearance at the rear (inter-face connectors), the front (coupling to beam delivery system), topand sides (to remove covers for service access), and above andaround the RF power supply module, as the RFPS module is fieldreplaceable.

• Mount the laser system with the RFPS module readily acces-sible through service access panels.

• Provide easy access to all electrical and signal connections.

• Provide easy access to cooling and purge connections.

Providing the recommended service access will provide ease andspeed of service and repair of the E-1000 Series laser system.

Also, consider the interface/connection point locations at the rearend of the laser system and the length of cables, hoses and tubing,including service loops, when placing the DC power supply, chillerand control system.

6

Mounting Feet Since all E-1000 Series laser beams are precisely aligned with refer-ence to three kinematic mounting feet, it is recommended that laserintegrators utilize this mounting feature. Refer to the mechanicaldrawing in Figure 18.

Because beam pointing is virtually identical for all lasers referencedto these feet, re-alignment of delivery system optics, in the event ofa laser replacement, will greatly be minimized if aligned to the refer-ence position. Since the laser is precisely aligned to these mountingfeatures, a laser can be replaced with minimal or potentially nodelivery system re-alignment.

7


Laser System Cooling

The E-1000 Series laser head and the RF power supply require acontinuous flow of constant temperature cooling fluid. Because theproperties of the cooling fluid are important for laser performance,ensure that the conditions remain within the tolerance limits listed inTable 1-2 on page 1-8 (operator’s manual) at all times.

A closed-loop cooling system (chiller) should be used to obtainconsistent, stable laser performance. The chiller must be able toremove up to 20 kW of heat, plus an additional 2 kW if theliquid-cooled DC power supply option is used. The coolant compo-sition for the closed-loop chiller is described in the followingsection.

A typical flow diagram is shown in Figure 1. The delivery systemand/or laser power detector may be connected in parallel auxiliaryloops as long as they do not reduce the required flow to the laser, orthey may be cooled by a separate chiller.

If using the optional liquid-cooled power supply, it is to beconnected in series after the laser system. The liquid-cooled powersupply must be installed with the provided bypass loop to maintainthe high flow required by the laser (as the power supply alone willrestrict the flow).

Figure 1. Coolant Flow Diagram

��

��

��

��

��

��

�� !!�"��#��

��

��

��

�� $� ��%�

&�'

()*

&�'

*+,-�.�� &��/��

��

�� '��

/ ��0

�)�� 11�� 1��%)�.�� 2��

��

8

Coolant Temperature At the laser head, the inlet temperature of the cooling fluid shouldalways be above the dew point to prevent condensation from devel-oping inside the laser head or RF power supply.

Coolant Filtering To prevent accumulation of debris in the cooling system, the coolantshould be filtered at the inlet to the laser system. Coherent recom-mends the use of a particle filter that traps particles larger than30 µm in diameter, unless specified by the chiller manufacturer touse a finer filter.

A coolant kit is provided with each laser system, which contains ¾”NPT to Male GHT (Garden Hose Thread) and ¾” NPT to FemaleGHT fittings. This permits the use of off-the-shelf garden hose toconnect the laser system to the chiller system. In general, Coherentrecommends the use of hose with an ID of 5/8” (16mm) or greater tominimize the pressure drop from the chiller to the laser system. Hosefittings and clamps to connect hoses to the chiller are not included.Do not exceed the maximum hose length specified by the chillermanufacturer.

Shut-off valves on the supply and return lines are recommended tofacilitate maintenance to the cooling system filters and laser system.

9


Coolant Composition The recommended coolant composition is a mixture of cleandistilled or de-ionized water and OPTISHIELD® Plus, a lowtoxicity, corrosion inhibitor. OPTISHIELD Plus is available fromOptiTemp, Inc. and can be shipped worldwide. Contact informationis provided in Table 2.

The required mixture is a 10% solution of OPTISHIELD Plus anddistilled or de-ionized water (Example: 1 liter of OPTISHIELD Plusinto 9 liters of distilled water). Contact OptiTemp for detailed waterquality recommendations and for complete product information.

To prevent damage to the laser head and RF power supply,never operate the E-1000 Series liquid-cooled laser usinguntreated tap, distilled or de-ionized water as a coolant. Thelaser contains materials which will suffer corrosion damagewhen exposed to water without corrosion inhibitors. Corrosioncaused by improperly treated coolant voids the warranty.

It is important to add the right amount of corrosion inhibitor in thecoolant mix. Too much may result in poor cooling performance andtoo little will result in reduced protection against corrosion. Levelslower than the recommended amount may also encourage microbialgrowth, which can result in fouling and blockage of the coolingsystem. Also, only use fresh, clean coolant mix (OptiTemprecommends that the coolant be drained and replaced annually).

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 E-1000 Series laser system(or separate laser head or RF power supply components) should

Table 2. Recommended Coolant for E-1000 Series Lasers

PRODUCTNAME

MANUFACTURER’SNAME & CONTACT

INFORMATION

HEATTRANSFER

FLUIDTYPE

REQUIREDHEAT

TRANSFERFLUID

CONTENT

FREEZINGBURST

PROTECTION

OPTISHIELD® Plus

OptiTemp, Inc.www.optitemp.comUS/Canada(231) 946-2931

Corrosion Inhibited Water

10% Solution in WaterDoes not reduce water freezing point!

10

never be stored or transported unless the coolant has beencompletely removed by using a compressed air supply to blow outall coolant passages.

Never store or ship a complete E-1000 Series laser system orlaser head or RF power supply (or liquid-cooled DC powersupply, optional) with coolant installed, as the coolant mayfreeze and cause permanent internal damage. Always removethe coolant prior to storage or shipment by using a compressedair supply to blow out all coolant passages. Plug or cap coolantinlet and outlet fittings after draining to prevent residual coolantleaks during storage or shipment. Damage to the laser duringstorage or shipment, as a result of failure to remove coolant andplug the inlet and outlet fittings after coolant removal, is specif-ically excluded from the product warranty.

11


Flow Direction At the laser system, the flow direction must be as follows: coolant isto flow to the laser head first, then out to the RF power supply beforebeing returned. Do not reverse flow direction or split the flow intotwo separate parallel circuits at the laser system. Refer to Figure 2.

Figure 2. Coolant Flow to Laser System

��

��

��

��

3�4/

��

3�4/

��

��

3�4/

�� )5�� !��6

�� )�� 7��!��)

�� )�8�/8��1�9�� 1)

��

��

�� ).!�� :�� #��$�� !��!� �� 1�� !� ��)

��

84�

./

�4��;

�4��;

�4��;

<&�'

()*

<&�'

% =

<&�'

()*

��

3�4/

�4��;

��

��

�� $�� ).�� :�� !� �� 1)

��

84�

./ <&�'

% =

<&�'

>�6

��

3�4/

�4��;

$��9��2�� )

��

��

�� )5�� !��6

�� 84�

./��

3�4/

�4��;

12

If any other components are included in the cooling loop (e.g. DCpower supply, as shown in Figure 1), they must not reduce thecoolant flow to the laser head, and any heat absorbing/generatingcomponents must come after the laser system.

Chiller Electrical Supply

A large industrial chiller normally requires a 230 or 480 VAC,3-phase electrical supply with its own circuit breaker or fuse protec-tion and an electrical disconnect. Refer to the chiller manufacturer’sinstallation guide for electrical requirements and installation instruc-tions.

Electrical Disconnect It is recommended that the chiller have a main power disconnect toelectrically isolate it from mains power for maintenance and service.Consult a qualified electrician to select and install this hardware. Atypical disconnect switch with fuse protection is shown in Figure 3.

Figure 3. Electrical Disconnect Switch (with Fuse Protection)

8�� 9�?��8/

��

�%

�=

�3

��@

�%@

�=@

�3

�./3 �85�

�8'�5�.�.�;3�3��.�5��.��.$4�.8/�5/3�

TO CHILLER

13


Laser System Purge Gas

The use of specified purge gas will extend the life and reduce costof ownership of the E-1000 Series laser systems.

The quality of the purge gas is extremely important factor for troublefree operation of the laser. The preferred purge gas is nitrogenwith a purity of 99.95%.

E-1000 Series lasers are used in a wide range of material processingwhich often has by-products of dust, smoke, fumes, oil and variousgases. These by-products can cause contamination of the laser headoptics as well as the beam delivery optics and electronic compo-nents. Contamination will severely degrade the system performanceand can lead to damage or failure of sensitive components.

Passing a purge gas through the laser head and RF power supply canprevent component damage by creating an internal positive pres-sure. Also under some conditions of high humidity, the laser beamcan be distorted by optical absorption of the laser beam by fluidvapor. This effect can be totally eliminated by use of a proper gaspurge.

Delivery System Purge Gas

Purge gas is brought to the laser system and split by a Tee into twopaths, one to the laser head and the other to the RF power supply.

The purge gas fills the RF power supply and slowly leaks out ofsmall gaps between enclosure covers. The gas purge to the laser headexits primarily via the beam output aperture. While this is theprimary exit path for the purge gas, small gaps in the interfacesbetween the component comprising the protective housing result inadditional purge exit paths. Therefore the user should not rely onpurge gas exiting the beam output aperture to provide purge gas tothe user's beam delivery optics. A separate purge should be used forexternal beam delivery optics.

Threaded holes in the output end plate provide a convenient meansto connect the user's beam delivery optics while maintaining a gasseal at this interface.

Do not rely on purge gas exiting the beam output aperture topurge the external beam delivery optics. A separate purge lineshould be used to purge the external beam delivery optics.

14

If a shared purge gas supply is directed to both the laser system andthe beam delivery system, make certain the supply and supply lineis properly sized to provide an adequate flow rate to the laser system.

Other inert gases such as argon (Ar) must not be used. Use ofinert gases will result in damage to the RF power supply andassociated matching network components. Only nitrogen asdescribed above or compressed air as described below should beused as a purge gas.

Guidelines for Use of Compressed Air for Purge

If nitrogen is not available, the alternative is clean, dry, oil-freecompressed air. Compressed air is available in many facilities buttypically is contaminated with water and oil vapors. The purityrequirements for the compressed air are:

1. Filtered to remove particles larger than 1 micron.

2. Dried so that dew point is 10°C (18°F) lower than the inletcooling fluid temperature to the E-1000 Series laser.

3. Oil free to better than 99.995%.

Recommended purge gas configurations are shown in Figure 4.

Figure 4. Purge Gas Diagram

��

��

5�� 1��

��

��

A

� %

=B

�

�� !!�"��#�%

=

A

(

/��

� ��

,

, ��#��1

� �� !��

5!�� 9

��

� %

� ��

* (

*

B

15


A pre-assembled filter panel (see Figure 5) designed to provideclean, dry air (CDA) is available that contains items 4, 5 and 6shown in Figure 4. The output is attached to a Tee that splits theCDA to the laser and delivery systems (if no separate purge gas lineis provided to the delivery system). Install flow regulators on alllines to establish and monitor proper flow rates. Use only Teflontape to seal all connections, and provide drain tubing at the vent ofeach auto drain (on the coalescing filters).

For additional information on the Purge Filter/Dryer PanelAssembly, refer to the “Purge Gas Filter Panel Assembly” onpage C-2 in the operator’s manual.

It is the responsibility of the customer to provide purge gas ofeither nitrogen or compressed air that meets the specificationsstated above, and clean flexible tubing to carry the purge gas.Failure to comply with these specifications will void thewarranty and the customer is responsible for all cost of repair ordamage to the laser.

Figure 5. Purge Filter/Dryer Panel Assembly (optional)

Coherent P/N:

CT Components P/N:

1166836

600218COH

(860) [email protected]

16

See “Preventive Maintenance” on page 6 1 in Section Six:Maintenance and Troubleshooting in the operator’s manual for theroutine maintenance required for the purge gas filters.

DC Power Supply Coherent has qualified the DC power supplies listed in Appendix C:Accessories and Options in the operator’s manual for use with theE-1000 Series laser systems. These DC power supply recommenda-tions include both air-cooled and liquid-cooled options. Theair-cooled type requires proper ventilation, while the liquid-cooledtype requires a continuous supply of liquid coolant. Both typesrequire an electrical disconnect to reset faults and to provide adisconnection for service.

Coherent can provide the DC power cables that connect the DCpower supply output to the +48 VDC and 48 VDC return terminalson the RF power supply.

DC Power Supply Electrical Service

Consult the instruction manual provided by the DC power supplymanufacturer for electrical service requirements. Also, consult localelectrical codes to determine the current rating for fuses or circuitbreakers for the electrical service to the power supply.

Electrical Disconnect Both supplies require an electrical disconnect to reset faults and toprovide a disconnect for service. Coherent recommends that a mainpower disconnect (to the DC power supply) be located in the sameroom as the laser system. Consult a qualified electrician to select andinstall this hardware. Refer to Figure 6.

Figure 6. Electrical Disconnect Switch (with Fuse Protection)

8�� 9�?��8/

��

�%

�=

�3

��@

�%@

�=@

�3

�./3 �85�

�8'�5�.�.�;3�3��.�5��.��.$4�.8/�5/3�

TO DC POWER SUPPLY

17


Mains Power Cord The integrator must provide the AC mains cable of suitable size(gauge) for the chosen length and current carrying requirement.Depending upon local electrical code, the power cord may need tobe hard-wired into a junction box or electrical disconnect switch, ormay be connected to mating plug and receptacle. Consult a qualifiedelectrician and wire to local electrical code.

Beam Delivery System

The beam delivery system is typically designed and built by thesystem integrator.

Verify that the beam delivery system is designed for the E-1000Series laser beam specifications: wavelength, beam diameter, powerdensity, divergence, output beam height (with respect to base-plateor mounting ball), mirror cooling, etc.

Shutter If the laser is equipped with the optional internal shutter assembly, ared (visible) aiming laser is provided whenever 48 VDC is on andthe shutter is closed. This aiming beam serves as a visual indicatorof the process beam path, and can be used to align the beam deliverysystem. This optional internal shutter is intended to be a safetydevice - it is not to be used as a process shutter.

If the optional internal shutter assembly is not installed, it is recom-mended to provide an external safety shutter or beam block near thelaser aperture to prevent laser exposure when servicing the deliverysystem. Make sure the beam block is made of suitable material tosafely trap and dissipate the laser power.

Accessory Coupler The laser head output aperture provides accommodation for a50 mm (2”) OD beam tube to couple to the laser head. Enclosing thebeam within gas-purged metallic tubes is a safe and recommendedmethod of transmitting the beam from the laser head to the workpiece.

Purge Providing a constant flow of purge gas to the delivery optics isrecommended to keep optical surfaces clean and moisture free. Ifsharing a purge gas supply between the laser and deliver system,make certain that the laser system purge gas flow rate is maintainedat the specified volume. See “Laser System Purge Gas” on page 14.

18

If cutting or marking reflective materials, an optical isolatormust be installed between the laser and the process material toprevent work piece reflections from returning to the laser head.

Optical Isolation An Optical Isolator must be installed between the laser and theprocess material if cutting or marking reflective materials to preventwork piece surface reflections from returning to the laser head.

Coherent has qualified the optical isolators listed in Appendix C:Accessories and Options in the operator’s manual for use with theE-1000 Series laser systems.

Laser Control, Measurement &Diagnostic

There are several methods of controlling and monitoring the laser.Some offer limited control, while others allow total control.Depending upon the end-user application, one or a combination ofmethods may be employed.

• Built-in Java Applet running on a PC

• Coherent E-Series Remote Controller (optional)

• Java Applet + Coherent Remote Controller

• TCP/IP via LAN/Internet Connection and TCP Client Soft-ware

• 3rd Party/Customer Designed Controller (Real-time controlinterface)

Laser control methods are discussed in Section Four: Control Inter-faces in the operator’s manual. Please consult with Coherent’sApplications Department to determine which control method is bestsuited to requirements, schedule and budget.

External Interlock Circuit

Regardless of which control method is used, the laser requires thatan external interlock (user supplied) be satisfied (closed) for opera-tion. It is highly recommended to incorporate a serial interlock loopconsisting of switch contacts on all service access doors and panels,and interlock switches or light curtains on all material access gatesand doors.

19


Laser Power Measurement

To accurately measure delivered laser power, a calibrated opticalpower meter (detector head plus display console) is necessary.Liquid (water) cooling is generally required for the detector head atE-1000 Series power levels. Make sure to provide adequate coolingfor the detector head.

Coherent manufactures a wide range of power meters (displayconsoles and sensor heads). Refer to Appendix C: Accessories andOptions in the operator’s manual for recommended measurementtools.

Laser Safety Safety First! Read and understand the contents of Section Two:Laser Safety in the operator’s manual. Accidents can generally bereduced or eliminated by following all recommended safety guide-lines.

Coherent recommends that each facility appoint and train a LaserSafety Officer (LSO) responsible for overseeing all aspects of lasersafety.

Design systems with safety in mind. Use engineering controls suchas: enclosed beam paths, interlocked covers, and safety shutters.

Designate a laser controlled area and keep all untrained andnon-essential personnel out. Provide beam blocks, light shieldsand/or curtains, as required, to establish a controlled area.

Insist that all operators and maintenance personnel receive propertraining (and re-training) in laser and electrical safety. Require allpersonnel to have appropriate Personal Protective Equipment (PPE),especially laser safety eyewear suited to the laser in use and the jobat hand.

20

Installation The installation procedure consists of performing the followingsteps:

1. Prepare facility (all items on the Pre-installation Checklist aresatisfied)

2. Receive and unpacking the shipment.

Allow the laser system temperature to equilibrate.

Remove laser, DC power supply, loose parts and accessoriesfrom shipping crates.

Inspect system components.

3. Mount the laser system and the DC power supply.

4. Connect optics purge gas line and perform a laser system purge(mandatory).

5. Connecting coolant lines and perform a leak check.

6. Connect the electrical cables.

7. Remove the output aperture cover and mount output accesso-ries (couple beam delivery system to laser head).

8. Connect a laser controller.

Required Tools To following tools will be required to unpack and install the lasersystem:

• Scissors or a package cutting knife

• Forklift or jack to lift 320 kg (705 lbs.) - the weight of a fullyloaded shipping crate

• A hoist capable of lifting at least 173 kg (381 lbs.) - the weightof the laser system

• A cart capable of supporting and transporting at least 173 kg(381 lbs.) - the weight of the laser system

• Metric hex wrench set (Allen keys)

• 1/4” flat-blade (–) screw driver

• #1 Phillips (+) screw driver

• Roll of 1/2” wide Teflon tape (included in coolant filter kit)

• 9/16” open end wrench (or 8” adjustable wrench)

• 3/4” open end wrench (or 8” adjustable wrench)

• Common hand tools

21


Required Parts and Equipment

Table 3 lists parts and equipment required to perform the installa-tion. Note that some items are supplied with the laser system whileothers must be obtained locally.

Table 3. Parts and Equipment Required for Installation

ITEM QUANTITY PURPOSEINCLUDED W/LASER SYSTEM

+48 VDC power supply 1 Provides +48 VDC power to the RF power supply and the laser head. No

AC power cord for DC power supply 1 Connects AC electrical supply to DC power supply

input No

Electrical disconnect for DC power supply 1

Disconnects power cord (to DC power supply)from AC electrical supply; can be matingplug/receptacle (if allowed by local code), or panelmounted disconnect

No

DC power supply cables

4each 3 m (10 ft.) in

length

48 VDC cablesQty 4, 3/0 AWG cables (2 red & 2 black - eachcolor to be connected in parallel)Transmits 48 volts to RF power supply.

No

Mounting bolts/feet3 feet, 3 bolts

and 3 washers

The Coherent supplied mounting feet & bolts usedto secure the E-1000 Series.• Mounting Kit (P/N 1174342)• Bolts: M8 X 75 mm length (high strength

steel) torque to 23.7 N·m (210 lb-in)Customer must prepare the mounting surface and

supply hardware to mount the feet to themounting surface (refer Figure 18c)

Yes

Liquid-cooling System/Chiller 1

Provides temperature regulated liquid coolant tolaser system (and to optional liquid-cooled DCpower supply)

No

Coolant filter 1 Filters particle from coolant - 30 micron or better No

Hose fittings 1 3/4” male NPT to male GHT (garden hose thread) Yes

Hose fittings 1 3/4” male NPT to female GHT (garden hosethread) Yes

Coolant hoses as requiredProvides coolant to the laser head and RF powersupply (and to optional liquid-cooled DC powersupply). 5/8” ID or greater hose is recommended

No

Coolant Amount varies

The heat transfer medium used to remove heatfrom the laser system; consists of a mixture ofdistilled (or de-ionized) water and corrosion inhib-itor

No

22

Corrosion inhibitor Amount varies

Prevents corrosion of metal parts in contact withthe coolant No

Purge Gas(Regulated Supply)

1Used to displace atmosphere of air within the laserhead and the RF power supply; typically N2 orclean, dry air (CDA).

No

Purge Gas FilterN/A if using N2; required if using CDA

Removes water vapor, oil and particulates fromcompressed air; see Appendix C: Accessories andOptions in the operator’s manual

No

Purge Gas tubing(between laser head and RF power supply)

1 piece

A short length of 1/4 inch (6 mm) OD Teflon, poly-ethylene or polypropylene tubing to connect thepurge gas line between the laser head and RFpower supply

Yes

Tee 1 1/4 inch (6 mm) OD Tee for splitting the purge gastubing at the laser head and RF power supply Yes

Purge Gas tubing(between purge gas supply and laser system)

as required1/4 inch (6 mm) OD Teflon, polyethylene or poly-propylene tubing to connect the purge gas supply tothe laser head

No

Table 3. Parts and Equipment Required for Installation (Continued)

ITEM QUANTITY PURPOSEINCLUDED W/LASER SYSTEM

23


Facility Preparation

Prepare the facility (installation site) as described in Table 1 onpage 2.

Unpacking and Inspection

The E-1000 Series laser system packaging has been designed forrobust shipment. Upon receiving the system, inspect the outside ofall containers immediately for damage that may have occurredduring transit. If there appears to be visible damage (holes incontainers, fluid damage, crushing, etc.), immediately notifyCoherent and a representative of the carrier. Request that a represen-tative of the freight company be present when unpacking thecontents.

Keep the original shipping crates, lifting hardware and packingmaterials for shipping the E-1000 Series laser system from onelocation to another. If the system is to be returned to Coherentfor repair, it must be in the original shipping container.

Carefully unpack the crate in a clean, dry area. Inspect all majorcomponents as they are unpacked.

The E-1000 Series laser system is not designed to be lifted orcarried by hand. Always lift, move and place the laser usingequipment approved for lifting and properly rated for theweights listed. To avoid personal injury, never place any bodyparts below a lifted or suspended laser.

24

Unpacking Instructions

1. Unlock all six (6) clasps of the top cover (Figure 7).

Figure 7. Removing Crate Cover

25


2. Lift up and pull off to remove top the top cover (Figure 8).

Figure 8. Top Cover Removed

26

3. Un-strap the system by releasing both (2) ratchet straptie-downs (Figure 9).

4. Locate the two eye-bolts (lifting eye-bolt, M6,20 mm ID X 36 mm OD, zinc plated steel) included in theuser documents bag (bag not shown).

STOP! Before proceeding, allow enough time for the laser toreach room temperature, especially when transported duringthe winter months, before cutting the moisture seal bag.

V

Figure 9. Unstrapping the System

27


5. At the center of each end, carefully cut through the moistureseal bag as shown in Figure 10. Peel away the moisture sealbag and the bubble wrap underneath to expose the eye-boltholes.

Figure 10. Exposing the Eye-bolt Holes

28

6. Fully turn all threads of the eye-bolts into the holes at the topof each end of the laser system (Figure 11).

Figure 11. Installation of Eye-bolts

29


7. Loosen and remove the wing nuts (2 places) that secure thespreader bar to the inside of the crate, then pull the spreader baroff of the bolts and lift it up (Figure 12).

Figure 12. Removing Spreader from Crate

30

When originally shipped, the wooden spreader bar and associ-ated lifting hardware were inspected to be in good condition.Always inspect the lifting components before use. Do not use anycomponent that is rusted, rotted or broken.

8. Place the spreader bar on top of the laser system with theshackles toward the eye-bolts. Shackle the eye-bolts to thespreader bar as shown in Figure 13. Fully thread the shacklepin and tighten the pin with a pliers or wrench.

Figure 13. Attaching Eye-bolts to Spreader Bar

31


9. Cut the moisture seal bag along the groove between the laserhead and RF power supply from eye-bolt to eye-bolt, then cutacross the bag top at both ends (Figure 14).

Figure 14. Cutting Top of Moisture Seal Bag

32

Steps 10 through 15 involve lifting and suspending a heavyobject (the laser system). Only use approved lifting equipmentrated for the load. Wear appropriate safety shoes or protectiveshoe covers. Always keep hands and body parts out from undera suspended load.

10. Secure the spreader bar to a hoist capable of lifting 173 kg(381 lbs.). Carefully lift the laser system straight up, removethe moisture seal bag (Figure 15).

Figure 15. Lifting the DIAMOND E-1000 Series

33


11. Place the laser system on a cart capable of supporting andtransporting 173 kg (381 lbs.) (Figure 16).

12. Locate and remove the sealed plastic bag containing the RFpower supply system cable (Figure 17).

Figure 16. Place Laser System on Cart

Figure 17. RF Power Supply System Cable

34

13. Using the necessary lifting equipment, carefully set the lasersystem on a clean and flat surface, such as an optical table.

14. Remove the spreader bar and return it to the shipping crate.

15. Remove the eye-bolts from the top holes and store for futureuse.

Mount the Laser System

The integrated laser system has provisions for stress free kinematicmounting.

A protective cover is mounted to protect the beam output aperture ofthe laser during shipment. This must be removed before mountingthe laser as it blocks access to one of the mounting holes.

Mount the laser using mounting feet as shown in Figure 18d. TheM8 x 75 mounting bolts must be torqued to 23.7 N·m (210 lb.-in.).Do not over torque these mounting bolts. Doing so will distort themounting feet.

Torque specification for the M8 X 75 mounting bolts is 23.7 N·m(210 lb.-in.). Do not over torque. Over torquing will damagemounting feet.

See Figure 18a, b, c & d.

35


a. Laser Head

b. RF Power Supply

Figure 18. DIAMOND E-1000 Series System Installation in OEM Equipment

��

��

��

�� !

��

��"

�� #��

��

��

��

��

��#��

��

��

�"��

��

�$ �� %��

&�� !

��"�"�

��

��

��

�$��"�"��"��$��"�� %��

�$��"�"��%��"�

"��

��"��

��"��

��

��

��

��

��"�

��"��

36

c. Interface Mounting Dimensions

d. Mounting Foot Detail

Figure 18. DIAMOND E-1000 Series System Installation in OEM Equipment (Continued)

��

� ��

��""�"�

��

��""

�'�

��

�'�

(��)��

(��

��*��

��

��

��

��$��$��)�"%�� %�

��

��&��

��#��

Dimensions in mm [in.]

�$��%��$�� #� �'�� !+� ��,�!��%��

�$��%��$�� #�!+� ��,�!��%�� %��

�$��"�� #��

37


Alternate Mounting Orientations

The laser head can be mounted in any orientation. If mountedvertically with the beam tube up, ensure no dust or other particulatesfall into the output aperture during installation.

Customers mounting the laser in a 'non-horizontal' feet downconfiguration are responsible for properly supporting the laserduring installation (and de-installation). Great care must betaken that the laser (173 kg/381 lbs.) plus weight of hoses, cablesand externally mounted accessories is supported withoutdamage to the laser structure. The top eye-bolts cannot be usedfor vertical installation.

Vertical Mounting For “beam up” vertical mounting, refer to Figure 19. For “beamdown” vertical mounting, refer to Figure 20.

Do not use the top eye-bolt locations (previously used for liftingthe laser system out of the crate) for a vertical lift!

1. Fully install the eye-bolts into the screw holes.

38

Figure 19. Vertical Mounting Eye-bolt Positions (Beam Up)

1

Install eye-bolt in upper hole

Remove Phillips head (+) screwfrom base

Install eye-bolt in lower hole

1

2

3

2

3

39


2. Securely connect appropriate slings or chains to the eye-boltsand spreader bar. Chains/slings must be vertical when underload. See Figure 21.

The eyebolts with hex nuts and shackle can be removed from theprovided spreader bar and installed on the user suppliedvertical lifting spreader bar.

Figure 20. Vertical Mounting Eye-bolt Positions (Beam Down)

1

Install eye-bolt in upper hole

Remove Phillips head (+) screwfrom base

Install eye-bolt in lower hole

1

2

3

2 3

40

If lifting laser in the Beam Up position, take extreme care toprotect the interface connections from damage as the laser istilted from horizontal!

3. Carefully lift the laser system while preventing the free endfrom moving around.

Figure 21. Vertical Mounting Illustration

��

��

��

��

��!"��!��"��#��#��

"��#��#��#��

��#�$��!"��!��"��#��#��

41


Mount the DC Power Supply

Refer to the information provided in Appendix C: Accessories andOptions in the operator’s manual for mounting information.

Since the DC power cables (available from Coherent) are 3 m(10 ft.) in length, position the power supply output terminals withinreach of the RF power supply input terminals. Refer to Figure 22 forRF power supply connection points.

Laser Head Indicators and Connections

Refer to Figure 22 and Table 4 for the location and description of thelaser head indicators and connections.

Figure 22. E-1000 Series Interface Connectors

�� +�"

� �%��

�$��+��

��+��$ ��'�+��

��&�� +��#��

�� +�� #��#�

�+��

�� +��

�!��-�� !��

�)��

��& � �

(��

��!��

42

Table 4. E-1000 Series Head Indicators and Connectors

CALL-OUT DESCRIPTION FUNCTION

1 Coolant (inlet)

Connection for the cooling fluid hose that supplies coolant from thecoolant source.

2Embedded Control/Diagnostic (interface connector)

LAN connector for control, diagnostics and troubleshooting.

3 DCPS/Auxiliary I/O(connector)

DB-15 connector provides for an auxiliary 48 VDC input to permitoperation of control/diagnostic electronics without application of main48 VDC power supply and reserved I/O to support advanced controloptions.

4 Extended I/O (connector)

DB25 connector that provides extended capability (including shuttercontrol and additional fault signals).

5 Shutter LED LED illuminates when the (optional) internal shutter is open.

6 Real Time I/O(control connector)

DB25 connector that supplies control and input modulation signals fromthe user to the RF power supply and supplies status information from thelaser system.

7 Power Indicator LEDs

LEDs illuminate when 48 VDC is applied to the RFPS terminals andwhen the Connector Cable (Item 9) is connected.

8 48 VDC (+) (terminal)

Connects +48 VDC from the DC power supply to the RF power supply.Use a 3/4” wrench. Apply 190 lb.-in. (21.4 N·m) torque to nut supplied.

9 Laser to RFPSconnector cable Connector cable provides internal laser head to RFPS signals.

10 48 VDC Return (–)(terminal)

Connects the RF power supply ground to the DC power supply. Use a9/16” wrench. Apply 190 lb.-in. (21.4 N·m) torque to nut supplied.

11

FWD & REFL Power Monitor (BNC connectors on RF Power Supply)

For service use only.

12 Coolant(outlet)

Connection for the cooling fluid hose. Cooling fluid travels from the laserhead through the RF power supply and out to the drain.

13 Nitrogen Purge (inlet)

Provides for gas purge of the laser head and RF power supply. Requires1/4 inch (6.3 mm) OD Teflon, polyethylene or polypropylene tubing.Nitrogen is the preferred purge gas. Refer to “Installation” on page 21 foradditional information on purging the laser head.Note that the purge line on the laser head has a small filter (internal). Thisfilter protects the laser optics from any particles that are generated as aresult of connecting the purge gas tubing to the laser head. If customersupplied purge meets required specifications, this internal filter shouldlast a lifetime.

43


Optics Purge Connection

Locate the 1/4 inch Tee provided with the laser system at the purgeinput on the laser head. The Tee splits the purge line directing somepurge gas to the RF power supply.

Use 1/4 in. (6 mm) OD clean polyethylene, polypropylene or Teflontubing and insert it into the Tee. Fully insert the tubing (until itbottoms out), then give it a slight pull and verify that the tube is heldin place.

The purge gas at this input must meet the requirements discussedearlier in this chapter.

Set-up Purge Set-up purge is required in order to eliminate moisture from thesystem prior to use. This is required even though the systempackaging is designed to ship the laser in a ‘dry condition’. Note thatsystem purge is required whenever the system has been off for anextended period of time without purge.

1. Connect the tubing to the Tee as described “Optics PurgeConnection”. Refer to Figure 22 for the purge gas line connec-tion point.

2. Purge the laser system with nitrogen or clean, dry air for aminimum of two hours.

Failure to purge the system leaves the system at substantial riskof optics failure. Guidelines for system purge gas are found in“Delivery System Purge Gas” on page 14.

Connect Coolant Lines

Connect the fittings and coolant lines to the laser system, with theparticle filter connected to the inlet coolant line near the laser head.Connection points are shown in Figure 22. Use Teflon tape onfittings. Observe the coolant flow direction shown in Figure 2.

The recommended coolant source is a closed-loop cooling system.Coolant composition must meet the requirements stated in “CoolantComposition” on page 10. Refer to “Laser System Cooling” onpage 8 and “Installation” on page 21 for additional information.

The recommended hose for coolant consists of a 5/8 inch (16 mm)minimum ID hoses up to 15 m (50 ft.) total.

44

After connecting the water hoses, verify that there are no water leaksas follows:

• Close supply and return valves, then turn the chiller on.

• Open the valve in the water return (drain) line.

• Slowly open the valve in the water supply line.

• With the water supply pressure and water line differential pres-sure in accordance with Table 1-2 on page 1-8 (in the oper-ator’s manual), check all connections for leaks.

45


Connect Electrical Cables

1. Connect the short interface cable between the laser head (J14 -Laser to RFPS) and the RF power supply (J1 - RFPS to Laser).Tighten the jack screws.

Never connect or disconnect the laser to RFPS connector cablewhen the laser is powered on. Wait at least 2 minutes afterpower is turned off before connecting or disconnecting the cable.

2. Connect all four DC power cables between the DC powersupply and the RF power supply.

Refer to the DC power supply manufacturer’s instructions forterminal identification, recommended fasteners and torquespecifications for connections at the DC power supply.

On the RF power supply, fasten the cables as shown inFigure 23.

At the RFPS, place the protective terminal boots over the redcable ends before fastening the cables.

Use the RED cables for the “+48 VDC” positive (+) connec-tions, and the BLACK cables for the “48V Return” negative(–) connections.

Apply 190 lb.-in. (21.4 N·m) torque to both supplied hex nuts.

Figure 23. RF Power Supply DC Input Terminal Fasteners

��8C3�4��;

DA,"��

A,"��3�4/

�3'./5��

�� ?��

� % =

� % ��C��C�� E�/��=

��

46

Shut off the electrical power source before connecting the mainspower cord. Consult a qualified electrician to make the mainpower connection.

3. Connect the AC power cord to the DC power supply. Refer tothe power supply manufacturer’s instructions for terminalidentification, recommended fasteners and torque specifica-tions.

Remove Output Aperture Cover

Before attaching an optical isolator or other beam delivery compo-nents and before operating the laser, remove the output aperturecover. To remove the aperture cover, loosen the two thumbscrews.Set the cover aside for re-installation at future shipments.

Failure to remove the output aperture cover before operation(and lasing on the cover) will cause permanent damage to opticalsurfaces inside the laser head.

Figure 24. Output Aperture Cover

Remove for OperationInstall for Storage & Transportation

47


Mounting Accessories to Laser Aperture

The E-1000 Series lasers have provisions for the customer to mountoptics/accessories via the laser front plate. The following provisionsmust be followed:

• Accessory mount maximum load: 2.3 kg (5 lbs.) at 254 mm(10 in.) or equivalent.

• The customer must provide a continuation of optical purgethrough the added components using a separate purge line.

Controller Connection

Install and connect the controller cable(s) to the laser.

Figure 25. DIAMOND E-1000 Series Output End View

��

��

��'��#��$� ��,#�� &��.�� $��$��)�"%��

��

��

��

��

��"��

��

��#�� Dimensions in mm [in.]

Beam Center

48

EMBEDDED CONTROL AND DIAGNOSTICS

E-1000 Series HTTP and TCP Server

Introduction The E-1000 Series Control Electronics have embedded control andintegrated sensors that allow remote monitoring of the E-1000Series system status via TCP/IP over Ethernet. The system iscapable of serving HTTP (web) pages to a client via a local areanetwork (LAN) or by direct connection using a crossover cable.Using the LAN connection, it is possible to interrogate or control anE-1000 Series system remotely via the Internet. As every end-user isslightly different, the details of enabling Internet access are left tothe end user. Check with the network administrators for strategiesthat make the most sense in your organization.

In addition, the E-1000 Series can serve a Java Applet that canmonitor the E-1000 Series operation (live) or perform simple controlof the E-1000 Series. This functionality allows operation of theE-1000 Series with only a computer, a network interface card (NIC)and a web browser compatible with HTTP and Java.

The next few subsections will:

• Illustrate a simple connection to the E-1000 Series.

• Test the connection using the ping utility.

• Go over the various pages available to the connectedclient.

• Go into a few advanced connection schemes.

49


Initial Connection and Configuration

Connections Using an Ethernet crossover cable, connect the computer's NetworkInterface Card port to the Ethernet port on the E-1000 Series.

The default IP address for every E-1000 Series is 169.254.12.13. Adifferent IP address may be assigned by the user, and a system datapage is provided to allow the end-user to do this. See Figure 26. If adifferent IP address is required, it is recommended to connect locallyand change the IP address before connecting to a LAN. Localconnection instructions are given in the following section.

Figure 26. IP Address Change (On System Data Screen)

50

Client Configuration The next few illustrations are geared towards clients runningMicrosoft Windows Operating Systems but most modern operatingsystems are very similar. Begin by navigating to the Control Panel(START -> CONTROL PANEL). Double click on NETWORKCONNECTIONS to get to the Network Connections screen(Figure 27).

Figure 27. Network Connections Screen

51


Double click on LOCAL AREA CONNECTION to get to the LocalArea Connection Properties screen (Figure 28).

Figure 28. Local Area Connection Properties Screen

52

In the General tab, scroll down the pane and Double Click onINTERNET PROTOCOL (TCP/IP). This will open the InternetProtocol (TCP/IP) Properties screen (Figure 29).

Select “Use the following IP address:” and enter the numbersexactly as they appear in the Figure 29. When done, dismiss all theopen windows by selecting OK. The E-1000 Series is now ready tobe connected.

Once the DC connections to the E-1000 Series have been verified,apply +48 VDC to the laser before proceeding with the nextsections.

Figure 29. Internet Protocol (TCP/IP) Properties Screen

53


Connection to the E-1000 Series can still be obtained, evenwithout the necessary permissions. Simply connect the Ethernetcrossover cable as above and turn on the +48 VDC powersupply. The operating system in the computer will attempt toobtain an IP address from the E-1000 Series. Since the E-1000Series does not have a DHCP server, the computer will selfassign an IP address (APIPA) that should be within the pool thatincludes the default E-1000 Series IP address (169.254.x.x). Thisprocedure can take a bit longer but a message will appear whenthe connection is ready with limited or no connectivity.

Testing the Connection Using PING

Start the Windows PING utility by selecting START->RUN…

Next, type CMD to bring up the Command Prompt.

Type ping 169.254.12.13 and press ENTER.

The following screen should be displayed after a few moments.

This IP address is the default address for the E-1000 Series. Thefollowing sections will explain how this IP address can be changedand how connection to the LAN can be achieved. But first, the pagesavailable to clients will be described.

Figure 30. Ping Screen

54

HTTP Information and Diagnostic Pages

Home Page Open the computers web browser (Microsoft Internet Explorer inthis case) and type the following URL:

http://169.254.12.13

The following screen (Figure 31) will be displayed:

This is the home page for the E-1000 Series Web Server. Navigationto all the other client services is available with links from here. Thebottom third of the page has these links.

Figure 31. Welcome Screen

55


System Data/Info Page

This page (Figure 32) provides general system data. In addition,there is a utility to change the IP address of the system. Coherentrecommends that the system be first used with its default IP address.

Figure 32. System Data Screen

56

Clock and Diagnostics Page

System operation diagnostics are provided on this page (Figure 33):

This screen logs the total system run time (+48 VDC ON) and theenabled run time (System Enable asserted). All the times describedon this page now and in the future will be in theDays:Hours:Minutes:Seconds format. The system will also keeptrack of time that both the LASER and RFPS spend above thewarning temperature. This along with a count of warning tempera-ture threshold crossings will provide some insight into the usage ofthe DIAMOND E-1000 Series system.

The lower part of this page has System Warning and Fault informa-tion. The customer will have to navigate to this page in order todetermine what condition is causing a System Warning.

Figure 33. Onboard Diagnostics Screen

57


FAQ This page (not shown) will keep a list of Frequently Asked Ques-tions for users of the E-1000 Series system. In addition, the Coherentweb site can be reached from any E-1000 Series web page via a linkat the bottom (Note: LAN connection is necessary for the link towork).

Java Applet

Java Runtime Configuration

Before using the JAVA applet, the JAVA runtime engine (JRE) mustbe installed on the client. A link to the download web page isprovided on the E-1000 Series home page. The system needs version1.4.2 or later. Once JRE is downloaded and installed, disable thecache for the E-1000 Series JAVA applet to run properly. This onlyneeds to be done once. Again, launch the Windows Control Panel(START->CONTROL PANEL). Next, double click on Java to bringup the JAVA CONTROL PANEL. The look of this panel haschanged from version to version. Consult the documentation to findout how to disable the cache. In this version (1.5.0), on theGENERAL tab at the bottom of the page in the Temporary InternetSettings. Press the SETTINGS button:

58

Figure 34. Java Control Panel Screen

59


Next, press the VIEW APPLETS… button.

In the bottom left corner, uncheck ENABLE CACHING. Dismiss allopened windows by pressing OK.

Note that if there is a running instance of the web browser whendoing the JAVA configuration, it must be closed before proceeding.In other words, close all instances of Internet Explorer beforecontinuing with the JAVA applet.

Figure 35. Java Applet Cache Viewer Screen

60

Opening a Socket Start the Java Client after reopening a client connection to theE-1000 Series. See the sections above if not already running anactive client. After several seconds, the following screen (Figure 36)will be displayed:

To begin using this tool, click the OPEN SOCKET button to open aTCP connection to the E-1000 Series system.

Diagnostics Elements The bottom left section is devoted to visual diagnostic indicators.Faults are kept apart from interlock and general system status indi-cators. Serious faults are indicated in RED and warnings are indi-cated in yellow. Temperature is indicated in the center of the applet.RF power is shown underneath the temperature. The activitywindow will track all faults and system messages with a timestamp.

Figure 36. E-1000 Series Laser Ethernet Control Applet

61


Control Elements The right hand portion of the applet is devoted to controlling theE-1000 Series. Note that control this way is only available if theEthernet Control Input is asserted on the Extended I/O Connector(refer to Section Four: Control Interfaces in the operator’s manual).Shutter control is also available from this applet. To control the laser,press LASER ENABLE and then RF ENABLE. Slowly slide theDUTY CYCLE slider to the right and LASER POWER indicated inWatts should be seen.

Extended Diagnostics Pages

Access to these pages is password protected. From any web page,press the Diagnostics link. At the bottom of this page (Figure 37)enter the password in the text field provided and press the SUBMITkey. Access to the Extended Diagnostics pages is now possible.

Figure 37. Diagnostics Main Menu

62

Onboard Time Page This page (Figure 38) reports the current time reported by the batterybacked up onboard real time clock:

Provisions are also provided at the bottom of this page to reset thetime and date. Please be very careful how you enter the new time anddate values.

Figure 38. Onboard Time

63


EEPROM Maintenance

Several non-volatile system parameters can be cleared from this webpage (Figure 39). To do so select the appropriate section and clickSUBMIT.

System Enabled Time as well as RFPS Time in Warning Temp isexplained in the Diagnostics web page, above.

The Rolling Buffer Pointer Location is reserved for logging faultdata to EEPROM. Since the log is a rolling buffer, the last used loca-tion is also saved to EEPROM. Use this option to clear the last loca-tion to the base location.

Figure 39. EEPROM Maintenance

64

Rolling Buffer This web page (Figure 40) provides a time-stamped log of systemfaults. Currently, the buffer is only eight entries deep. The ninthentry will overwrite the first and so on.

Figure 40. Rolling Buffer

65


System Monitoring Applet

This applet adds the ability to monitor system status more closely. Itintercepts the CAN bus traffic internal to the E-1000 Series andparses it into this display. Operation starts by opening a socketexactly as the previous applet, above. Fault status and Activity Logis also provided. Please note that the screen shots provided inFigure 41 were taken during a test case condition and does notreflect the nominal values present in an actual system.

With “RFPS 1 to 5” Tab Selected

Figure 41. System Monitoring Applet

66

With “RFPS 6 to 10” Tab Selected

Figure 41. System Monitoring Applet (Continued)

67


TCP Client Connections

In addition to the functionality introduced above, there are a fewmore options available to users. Since web pages and JAVA appletsare suitable only for a ‘human to machine’ interface, we have alsoprovided some limited ‘machine to machine’ functionality. A usercan use any TCP client software to open a TCP socket to theDIAMOND E-1000 Series.

Connection Requirements

Any TCP client software or firmware can communicate with theE-1000 Series. However, only one socket to port 5000 is allowed atthis time. Simply open a socket to the IP address of the E-1000Series using port 5000. When done, close this socket.

With “Laser and OSC/DRV” Tab Selected

Figure 41. System Monitoring Applet (Continued)

68

API Available Commands to the E-1000 Series follow the standard ‘GET’ and‘SET’ protocol. For example, to get the temperature of the LASERhead the user or client software would type ‘glt’ and press return orconcatenate the end of line character (\n\r). The E-1000 Series wouldreturn the temperature in degrees Celsius. See end of document forcommand summary and structure. Some commands also requireadditional parameters to work properly. For instance, set shutteropen also requires a ‘1’ for true or a ‘0’ for false. So, to open theshutter the user or client software would need to send ‘sso 1\n\r’.‘grp’ and ‘gfp’ optionally require additional parameters. Issuing‘gfp’ without parameters will return total forward power in 10s ofWatts. However, adding an integer from 1 to 5 (inclusive) will givethe forward power of that particular RFPS in 10s of Watts.

69


Using Pueblo TCP Client

A very easy to use TCP client is Pueblo. Pueblo is available fromhttp://pueblo.sourceforge.net/pueblo/. Download and install thePueblo application. Launch Pueblo, and using the QuickConnectfeature, type in the IP and port of 5000 as shown in Figure 42:

Type commands and receive responses directly (Figure 43).

Figure 42. QuickConnect

Figure 43. QuickConnect Response

70

This page intentionally left blank.

71


Command Line Interface Details

Table 5. Get Commands (available at any time)

COMMAND DEFINITION PARAMETERS RETURNS

grt Get RFPS temperature none RFPS maximum temperature in degrees Celsius

glt Get LASER temperature none Laser maximum temperature in degrees Celsius

gfp Get forward power none, 1-4

RFPS peak forward power in 10s of watts. No parameters returns the total forward peak power. gfp 1 returns peak forward power for amp #1 in 10s of watts

grp Get reflected power none, 1-4

RFPS peak reflected power in 10s of watts. No parameters returns the total reflected peak power. grp 1 returns peak reflected power for amp #1 in 10s of watts.

gms Get modulation strength none Modulation on percentage in percent

gmd Get modulation direction none 1 if RFPS is being modulated and 0 if the RFPS is not modulating

gsn Get serial number none Serial number of system in decimal. This number is related to the MAC, see above.

glp Get LASER power none LASER optical power in watts

gcs Get CAN status none 1 if no CAN bus is detected and 0 if CAN is functioning normally

gso Get shutter open none 1 if shutter is open and 0 if shutter is closed.

gsf Get system frequency none Modulation frequency in kHz

72

Ethernet Control must be enabled via the Expanded InputOutput Interface Connector for Set Commands to become effec-tive.

Table 6. Set Commands

COMMAND DEFINITION & PURPOSE PARAMETERS RETURNS

sms

Set modulation strength

Sets modulation on percentage in percent.

integers (1-100), default is 1 CRLF

smd

Set modulation direction

This command should be used to toggle the laser on and off

1 to set modulation on and 0 to set modulation off CRLF

sme

Set modulation enable

This command should be used to enable the system prior to opera-tion

1 to enable and 0 to disable CRLF

sso

Set shutter open

This command is used to open and close the shutter

1 to open and 0 to close CRLF

ssfSet system frequency

Sets modulation frequency in kHzintegers (10-100), default is 25 CRLF

Table 7. Special Commands (available at any time)

COMMAND DEFINITION PARAMETERS RETURNS

log start/stop transmission of log file data none

A data stream from the system including fault status with timestamp and CAN traffic.

73


Example sequence for turning on the DIAMOND E-1000 Series viaTCP:

1. Turn on power with Ethernet crossover cable connected.

2. Wait for the IP address assignment to occur.

3. Start a TCP Client.

4. Open socket.

5. Type ‘sme 1’ to enable the system.

6. Type ‘ssf x’ to set a modulation frequency (replace x with thedesired frequency in kHz).

7. Type ‘sms x’ to set the modulation strength (replace x with thedesired on percentage).

8. Check that safe operation of the LASER is possible!

9. Type ‘smd 1’ to turn on the LASER.

10. Verify the LASER is operating by typing ‘glp’.

Generating a Log File

In order to retrieve the log file from a running E-1000 Series system,use a TCP client software that allows buffering. For demonstrationpurposes in this manual the Pueblo/UE will be used for this exampleand is available at: http://pueblo.sourceforge.net/pueblo/.

To generate a log file using Pueblo, perform the following steps:

1. Find the IP address of the unit to be logged (default laser IPaddress is 169.254.12.13).

2. Connect a PC with the Pueblo application to the laser.

3. Configure the PC network adapter card to use static IP address169.254.12.12, with subnet mask 255.255.0.0.

4. Launch the Pueblo application.

5. From the Worlds tab, select QuickConnect. Enter the laser IPaddress and port 5000. See Figure 42. The port used to openthe TCP socket is 5000; only one TCP port can be opened atone time. Press “Connect.”

6. From the Pueblo command line, select File->Log to a File.Click on “Log to a File” and note a check mark at this line.

7. A new “Save As” dialog box will open. Choose an appropriatepath/folder for the log file, then create a file name using thelaser serial number and date (serialnumber_DDMMYY).Leave the extension .txt and press “Save”.

74

8. From the Pueblo window, type LOG (or log, case does notmatter) followed by a return to start the logging function. Thelogging function will begin and the following data will appearapproximately once a second (example data shown).

225421192008096|000|000|000|001|000|000|021032|000|000|005|105|019|000|048065|000|000|000|000|021|000|048066|000|000|000|000|021|000|048067|000|000|000|000|021|000|048068|000|000|000|000|021|001|049069|000|000|000|000|021|000|048096|000|001|021|024|030|006|047032|000|000|005|105|019|000|048065|000|000|000|000|021|000|048066|000|000|000|000|021|000|048067|000|000|000|000|021|000|048068|000|000|000|000|021|001|049069|000|000|000|000|021|000|048070|000|000|000|000|021|000|048071|000|000|000|000|021|000|048072|000|000|000|000|021|000|048073|000|000|000|000|021|001|049074|000|000|000|000|021|000|048096|000|002|020|021|020|019|021

9. Allow approximately 15 minutes worth of data to be logged.During the log time, command the laser to perform a sequencethat is causing a problem, generates a fault or where perfor-mance is in question.

10. At the end of the logging period, type LOG (or log), followedby a return to stop the logging function.

11. From the Pueblo command line, select File->Log to a File andnote the check mark should disappear. This will “write” thelogged data to the file serialnumber_DDMMYY.txt.

75


Interpreting the Raw Data from an E-1000 Series Log File

Before interpreting the data from this actual file, two types of datamust be discussed.

The following is the first type and is a time stamped entry showingthe FPGA status:

225421192008

The first 6 digits encode the time of day. The format is SSMMHH.The number for each is logged in decimal but must be converted tohex to get the BCD information. In the entry above:

Seconds are 22 decimal or 16 hexMinutes are 54 decimal or 36 hexHours are 21 decimal or 15 hex

So, the time of this entry is 15:36:16 or 3:36PM

The next 3 digits (192) are the decimal representation of the firstFPGA status byte. The last 3 digits (008) are the decimal represen-tation of the second FPGA status byte. See Table 8 on page 81describing the bit wise representation of this information. Thesetypes of codes are only recorded when there is a change in the FPGAstatus bytes. They do not occur as often as the next type of log entry.

The second type of log entry is the CAN message received from thevarious CAN nodes:

096|000|000|000|001|000|000|021

The format is as follows:

CAN node address | Fault Code | Data Page | Data 3 | Data 4 | Data5| Data 6 | Data 7

In the above entry:

CAN node address = 096Fault Code = 000Data Page = 000Data 3 = 000Data 4 = 001Data 5 = 000Data 6 = 000Data 7 = 021

See “CAN Node Addresses” on page 83 and “CAN Data PageContents:” on page 84 for a listing of the various address types, faultcodes and data pages.

76

Now continuing with the interpretation:

032|000|000|005|105|019|000|048CAN node address = 032 (OSC/DRV)Fault Code = 000 (No Faults)Data Page = 000 (Data Page 0)Data 3 = 005 (Coolant Temp In in °C)Data 4 = 105 (Coolant Temp Out in °C)Data 5 = 019 (Highest Temp on

Assembly in °C)Data 6 = 000 (DC Current in Amps)Data 7 = 048 (DC Voltage in Volts)

065|000|000|000|000|021|000|048CAN node address = 065 (RFPA1)Fault Code = 000 (No Faults)Data Page = 000 (Data Page 0)Data 3 = 000 (Peak Forward Power in

10s of Watts)Data 4 = 000 (Peak Reflected Power

in 10s of Watts)Data 5 = 021 (Highest Temp on Assembly)Data 6 = 000 (DC Current)Data 7 = 048 (DC Voltage)

066|000|000|000|000|021|000|048067|000|000|000|000|021|000|048068|000|000|000|000|021|001|049069|000|000|000|000|021|000|048070|000|000|000|000|021|000|048071|000|000|000|000|021|000|048072|000|000|000|000|021|000|048073|000|000|000|000|021|000|048074|000|000|000|000|021|000|048

These 9, above from the next 9 RFPA assemblies.

096|000|001|021|024|030|006|047CAN node address = 096 (LASER)Fault Code = 000 (No Faults)Data Page = 001 (Data Page 1)Data 3 = 021 (Thermistor 6 in °C)Data 4 = 024 (Ambient Temperature in° C)Data 5 = 030 (Humidity)Data 6 = 006 (Dew Point in °C)Data 7 = 047 (DC Voltage in Volts)

032|000|000|005|105|019|000|048Data 3 and Data 4 will always be 005 and 105 until pilot

77


065|000|000|000|000|021|000|048066|000|000|000|000|021|000|048067|000|000|000|000|021|000|048068|000|000|000|000|021|001|049069|000|000|000|000|021|000|048070|000|000|000|000|021|000|048071|000|000|000|000|021|000|048072|000|000|000|000|021|000|048073|000|000|000|000|021|000|048074|000|000|000|000|021|000|048

RF is still off. No forward, reflected or current

096|000|002|020|021|020|019|021CAN node address = 096 (LASER)Fault Code = 000 (No Faults)Data Page = 002 (Data Page 2)Data 3 = 020 (Thermistor 1 in °C)Data 4 = 021 (Thermistor 2 in °C)Data 5 = 020 (Thermistor 3 in °C)Data 6 = 019 (Thermistor 4 in °C)Data 7 = 021 (Thermistor 5 in °C)

032|000|000|005|105|019|000|048065|000|000|000|000|021|000|048066|000|000|000|000|021|000|048067|000|000|000|000|021|000|048068|000|000|000|000|021|001|049069|000|000|000|000|021|000|048070|000|000|000|000|021|000|048071|000|000|000|000|021|000|048072|000|000|000|000|021|000|048073|000|000|000|000|021|000|048074|000|000|000|000|021|000|048

No changes on RF or OSC/DRV096|000|000|000|002|000|000|021

CAN node address = 096 (LASER)Fault Code = 000 (No Faults)Data Page = 000 (Data Page 0)Data 3 = 000 (Optical Power in Watts,

multiply by 256….Data 4 = 002 ….and add to this byte for

total optical power)Data 5 = 000 (Bit wise Faults Byte 0)Data 6 = 000 (Bit wise Faults Byte 1)Data 7 = 021 (Highest Temp on Assembly)

78

Skipping down to the action….

065|000|000|255|011|021|002|048066|000|000|255|011|021|002|048067|000|000|255|009|021|002|048 -RF now fired up, must be low

duty since only 2 ampssso 1

068|000|000|255|018|021|003|048165521208004 -15:37:10,

FPGA reports shutter open069|000|000|255|010|021|002|048070|000|000|255|009|021|002|048071|000|000|255|010|021|002|048072|000|000|255|011|021|002|048073|000|000|255|011|021|002|048074|000|000|255|010|021|002|048096|000|000|000|048|000|000|021 -48 Optical Watts032|000|000|005|105|244|000|048065|000|000|255|011|021|002|048066|000|000|255|011|021|002|048067|000|000|255|009|022|002|048068|000|000|255|018|021|003|048069|000|000|255|000|021|002|048070|000|000|255|009|021|002|048071|000|000|255|010|021|002|048072|000|000|255|011|022|002|048073|000|000|255|011|021|003|048074|000|000|255|010|021|002|048096|000|001|021|024|030|006|047032|000|000|005|105|244|000|048065|000|000|255|011|021|002|048066|000|000|255|011|021|002|048067|000|000|255|009|022|002|048068|000|000|255|014|022|002|048365521242004 -15:37:24, FPGA reports a

General andSystem Fault (latched)

069|000|000|255|000|022|001|048070|000|000|255|009|021|002|048071|000|000|255|010|021|002|048072|000|000|255|011|021|002|048073|000|000|255|011|021|002|048074|000|000|255|010|021|002|048

79


096|004|002|020|021|020|019|008 -LASER node reports tempfault, Thermistor 5 at 8°C

395521178000 -15:37:27, FPGA reports+24 Disabled

032|000|000|005|105|244|000|048065|000|000|241|000|022|001|048 -RF power falling off066|000|000|195|000|021|000|048067|000|000|240|000|022|000|048068|000|000|112|000|022|001|049069|000|000|141|000|022|000|048070|000|000|201|009|021|002|048071|000|000|198|010|021|002|048072|000|000|157|011|021|002|048073|000|000|174|011|021|002|048074|000|000|190|010|021|002|048515521176000 -15:37:33, FPGA reports

General Fault cleared096|004|002|020|021|020|019|021 -Laser node still not clear032|000|000|005|105|244|000|048065|000|000|020|000|021|000|048066|000|000|010|000|021|000|048067|000|000|103|000|022|000|048068|000|000|000|000|022|001|049069|000|000|018|000|021|000|048070|000|000|001|000|021|002|048071|000|000|012|000|021|002|048072|000|000|004|000|021|002|048073|000|000|000|000|021|002|048074|000|000|001|000|021|002|048096|000|002|020|021|020|019|021 -No faults reported by any

nodes however, user musttoggle the Enable line torestart the system.

80

Table 8. FPGA Status Byte Codes

RTIO_ENABLE_STATUS (1ST BYTE)

INTERLOCK FLAG

SHUTTER INTERLOCK FLAG

SYSTEM FAULT

SYSTEM ENABLE

ETHERNET CONTROL

TEMPERATURE FAULT

GENERAL FAULT

SHUTTER FAULT

DECIMAL HEX

0 0 0 1 0 0 0 0 16 0x10

1 0 0 0 0 0 0 0 128 0x80

1 0 0 1 0 0 0 0 144 0x90

1 0 1 1 0 0 0 0 176 0xB0

1 0 1 1 0 0 1 0 178 0xB2

1 1 0 0 0 0 0 0 192 0xC0

1 1 0 0 0 0 1 0 194 0xC2

1 1 0 0 1 0 0 0 200 0xC8

1 1 0 1 0 0 0 0 208 0xD0

1 1 1 1 0 0 0 0 240 0xF0

1 1 1 1 0 0 0 1 241 0xF1

1 1 1 1 0 0 1 0 242 0xF2

RTIO_FPGA_STATUS (2ND BYTE, MODULATING FAULTS)

NOT USED NOT USEDNOT USED

SIMMERSHUTTER POSITION*

SHUTTER COMMAND**

DUTY CYCLE

VSWR DECIMAL HEX

0 0 0 0 0 0 0 1 1 0x01

0 0 0 0 0 0 1 0 2 0x02

0 0 0 0 0 0 1 1 3 0x03

0 0 0 0 0 1 0 0 4 0x04

0 0 0 0 0 1 0 1 5 0x05

0 0 0 0 0 1 1 1 7 0x07

0 0 0 0 1 0 0 0 8 0x08

0 0 0 0 1 0 0 1 9 0x09

0 0 0 1 0 0 0 0 16 0x10

*High is closed, Low is open or opening**High is commanding to open

81


The following is provided for information only.

Table 9. CAN FAULT CODES

NAME CODE (HEX - $XX) DESCRIPTION

No Fault 0 No Faults Detected - Reset Faults State

NODE FAULTS (0X01-0X7F)

RFPS SWR 0x01 RF SWR exceeds maximum

Shutter Interlock 0x02 Shutter Interlock Open

Shutter Transition 0x03 Shutter Transition Failure

Node Temperature 0x04 Node Temperature Out of Range

Node Dew Point 0x05 Node Dew Point Out of Range

Reserved 0x06 Reserved

+48V Power Supply 0x07 +48V DCPS Out of Range

+5V Power Supply 0x08 +5V DCPS Out of Range

I2C Communication 0x09 I2C Communication Failure

Microcomputer EEPROM 0x0A = 10 Microcomputer EEPROM Failure

Microcomputer RAM 0x0B = 11 Microcomputer RAM Failure

Microcomputer Memory 0x0C = 12 Microcomputer Program memory checksum failure.

Microcomputer ADC 0x0D = 13 Microcomputer ADC Failure

Reserved 0x0E = 14 Reserved

+48V DCPS Current 0x0F = 15 +48V DCPS Current fault

COMMUNICATION AND MESSAGE FAULTS (0X80 - 0XFF)

NFOR (RS-232 noise, framing, overrun error) 0x80 Serial Comm Character Reception Fault

RS-232 Time-out 0x81 Serial Comm Message Time-out

Bad RS-232 Header 0x82 Bad Serial Comm Message Header Character

Bad RS-232 Footer 0x83 Bad Serial Comm Message Footer Character

Bad Checksum 0x84 Bad Serial Comm Message Checksum

Command Sequence 0x85 Improper Command Sequence

Bad Command 0x86 Illegal or Invalid Node Command

82

CAN Node Addresses 032 = OSC/DRV065 = RFPA1066 = RFPA2067 = RFPA3068 = RFPA4069 = RFPA5070 = RFPA6071 = RFPA7072 = RFPA8073 = RFPA9074 = RFPA10096 = LASER

Command Parameter 0x87 Remote Command Parameter Invalid or Out of Range

Bad Message 0x88 Illegal or Invalid Node Message

Node Reset Completed 0x89 Node has completed a local reset

Reflash Command ACK 0xAA Acknowledgement of Command

Reflash Image CRC Fail 0xAB CRC of Image Space Failed

Reflash Application CRC Fail 0xAC CRC of Application Space Failed

Reflash Stuck in Boot-loader 0xAD Node cannot leave boot code space

Table 9. CAN FAULT CODES (Continued)

NAME CODE (HEX - $XX) DESCRIPTION

83


CAN Data Page Contents:

Byte 2 - 7 - Data message

• RFPA Message 0Byte 2 - Message type - 0x00Byte 3 - Output forward powerByte 4 - Output reflected powerByte 5 - Highest temperatureByte 6 - RFPA currentByte 7 - Vdd voltage

• RFPA Message 1Byte 2 - Message type - 0x01Byte 3 - BLF #1 TemperatureByte 4 - BLF #2 TemperatureByte 5 - BLF #3 TemperatureByte 6 - BLF #4 TemperatureByte 7 - RFPA current

• RF Exciter Message 0Byte 2 - Message type - 0x00Byte 3 - Coolant Temperature InByte 4 - Coolant Temperature OutByte 5 - Highest TemperatureByte 6 - DC CurrentByte 7 - Vdd voltage

• RF Exciter Message 1Byte 2 - Message type - 0x01Byte 3 - BLF #1 TemperatureByte 4 - BLF #2 TemperatureByte 5 - Temperature 3 - binary, 1°C resolutionByte 6 - Temperature 4 - binary, 1°C resolutionByte 7 - Dew Point

• Laser Head Message 0Byte 2 - Message type - 0x00Byte 3 - Optical Power High ByteByte 4 - Optical Power Low ByteOptical power reading is 10 bits, right justifiedByte 5 - Boolean Fault 0 - “1” - Fault, “0” Safe

Bit 0 - Flow Bit 1 - 48V Monitor

Fault when V< 42V or V> 53VBit 2 - ReservedBit 3 - 5V Monitor

Fault when V<4.75V or V>5.25VBit 4 - Dew Point

Fault when Dew Point < AmbientTemperature - 5°C margin

Bit 5 - Spare

84

Bit 6 - SpareBit 7 - Spare

Byte 6 - Boolean Fault 0 - “1” - Fault, “0” SafeBit 0 - Thermistor 0

Fault when T<10°C or T >50°CBit 1 - Thermistor 1





Fault when T<10°C or T >50°CBit 6 - Spare - set to 0Bit 7 - Spare - set to 0

Byte 7 - Highest temperature

• Laser Head Message 1Byte 2 - Message type - 0x01Byte 3 - Temperature 6 - binary, 1°C resolutionByte 4 - Ambient Temperature - binary, 1°C resolutionByte 5 - HumidityByte 6 - Dew PointByte 7 - Reserved

• Laser Head Message 2Byte 2 - Message type - 0x02Byte 3 - Temperature 1 - binary, 1°C resolutionByte 4 - Temperature 2 - binary, 1°C resolutionByte 5 - Temperature 3 - binary, 1°C resolutionByte 6 - Temperature 4 - binary, 1°C resolutionByte 7 - Temperature 5 - binary, 1°C resolution

85


86

DIAMOND™ E-1000 Series OEM Laser System Preinstallation Manual© Coherent, Inc., 01/2011 (RoHS), Printed in the U.S.A.Coherent P/N: 1173344, Rev. AA

preinstallation manual diamond™ e-1000 series oem lasers

Documents