DOMAILLE ENGINEERING OptiSaber OS7000S User manual

OS7000S
OptiSaberTM Laser Cleaver
User’s Guide

Table of Contents
OptiSaber™ Laser Cleaver
OS7000S
User’s Guide
Welcome.................................................................................1
Overview ................................................................................1
Safety and Environment .......................................................2
Safety.............................................................................2
Environmental Effects.......................................................4
Safety Systems and Radiation..............................................5
Radiation Fields and Path ..................................................5
Levels of Radiation ...........................................................5
Collateral Radiation ..........................................................6
Protective Housing ...........................................................6
Safety Interlocks..............................................................6
Getting Started.......................................................................7
Unpacking & Setup...........................................................7
Parts and Functions................................................................8
Back...............................................................................8
Laser Diagram .................................................................9
Front..............................................................................9
Laser Operation ....................................................................11
Startup.........................................................................11
Operating the Laser ........................................................11
Cut Length Adjustments..................................................12
Laser Shut Down ..................................................................13
Laser Maintenance................................................................14
Daily.............................................................................14
Monthly.........................................................................15
Troubleshooting ....................................................................16
Service & Support ................................................................17
 TechnicalSpecications...................................................17
CE Notice and Standards.................................................18
Limited Warranty..................................................................19
Product Summary.................................................................20
Printing History
January 2016
© Copyright 2015 by Domaille Engineering LLC
© Copyright 2015 OpTek, Ltd 2015

Welcome
Congratulations on selecting the OptiSaber™ OS7000S designed for
lasercleavingofsingleopticalbersassembledinvariousconnector
types such as LC, SC, SMA, FC and ST.
This User’s Guide will assist you in the setup, operation, and
maintenance of the OS7000S laser cleaver to maximize the use and
life of the equipment.
Overview
The OptiSaber™ Laser Cleaving System is designed to address
theneedtoefcientlycleavealargevolumeofconnectorswhile
reducing operating time, costs, and increasing yield. Eliminates
cracking or chipping associated with mechanical cleaving.
TheOptiSaber™OS7000Sallowsyoutolasercleavesingleber
connectorsfastandaccuratelywhilesavingcriticaloorspace.
Operators can initiate the cleave cycle by using a hand or foot
switch for easy activation.
Our quick change adapter inserts all provide accurate orientation
from the ferrule to the end face for easy and precise loading. The
OptiSaber™ includes a removable thumbwheel to set cleave length
in increments of approximately 10 microns for accurate cleaving.
12
Safety & Environmental Effects
Safety
Laser Safety
The machine operates as a Class 1 (i.e. inherently safe) laser
product system. Although incorporating a Class 4 laser, the machine
is rendered inherently safe by the whole system design that is
protected by access restrictions and mechanical interlocks. It is built
to meet requirements of 21 CFR 1040. 10 and EN 60825-1 provided
safety interlocks are not defeated.
Under no circumstances should the machine be
operated with safety interlocks over-ridden unless
under the supervision of a responsible person
suitablyqualiedinlasersafety.
The warning signs that are used on the system are shown in
the Safety Warning labels section of this User’s Guide.
Safety Warning and Identication Labels
The OptiSaber™ is a Class 1 laser system but incorporates a Class
4 laser from which the user is protected by a light-tight protective
housing.

3
Mechanical Safety
There are no user accessible moving parts.
Under no circumstances should the machine be operated
with safety interlocks over-ridden unless under the
supervisionofaresponsiblepersonsuitablyqualied
in laser safety.
The machine includes low power moving parts required for scanning
the laser beam during processing. These parts are located within
the protective housing and therefore not accessible during normal
operations.
Electrical safety
The machine complies with all relevant American, UK and European
electrical safety standards. All external panels require a tool for
removal. Main voltage components are further shielded once external
panels are removed. There are no High Voltage circuits accessible in
the laser unit protective housing. The machine is fully EMC tested and
certied.Thisincludestestingatlightindustriallevelsforemissions,
and at industrial levels for susceptibility.
Fume & Extract
Laserprocessingofmaterialsgeneratesnedustandvaporparticles.
The nature, composition and volume of these debris will be dependent
on the material being processed and the laser parameters being
used. The machine is intended for processing silica and epoxy
adhesiveassociatedwithberopticalconnectors,butDomailledoes
not have control over what materials are introduced into the laser
unit. Consequently, Domaille cannot take responsibility for the fumes
and particulates produced. It is the responsibility of the customer to
4
ensure that adequate measures are taken to ensure the safe handling
of fumes and particulates. To comply with safety regulations the
extraction unit used with the machine must be operating correctly
andconnectedwiththesuppliedexiblehosetotheextracthose
connection.
The machine should not be operated without a suitable
and correctly functioning extract unit attached. It is
the responsibility of the user to ensure that the
extracted fumes and debris are handled safely and
responsibly, and that the suitable safety documentation is prepared, in
accordance with local legislation and regulations.
Domaille takes no responsibility for the collection or treatment of the
processing fumes, or for the subsequent exhaust of the processed
fume. Domaille shall not be responsible for damage or failure due
to build-up of contamination caused by inadequate extraction or
operation without a correctly operating extract unit.
Environmental Effects
It is Domaille’s policy to produce machines that have a positive
overall environmental effect. In the case of the OptiSaber™, positive
effects will result from subsequent improvements in performance
andyieldoftheultimateberopticalproductthatthislaserunitwill
allow. Negative environmental effects could result from machining of
hazardous or toxic materials and it is strongly recommended that the
user ensure that the handling of any process by-products be controlled
to minimize any negative effect on the environment as a whole.
Connection to Utilities & Environment
The laser unit is designed to operate in a clean environment, free from
substantial sources of vibration and shock.

Safety Systems & Radiation
Thissectioncoversthespecicsafetysystemsincorporatedintothis
laser unit that are designed to protect the user from harmful radiation.
This radiation, its paths and levels of intensity are described in detail
along with all protective housings and interlock devices.
There is no human access to laser radiation during
normal operation or maintenance of the machine.
Radiation Fields & Path
Protective housings and interlocks completely cover and protect
humans from the laser beam in normal operation and maintenance.
The beams are only accessible with the covers removed and/or the
interlocks defeated. No beam attenuators or scanners are present.
Levels of Radiation
The laser sources are described in the table below. The beam
described is only accessible with the covers open while servicing
the machine.
56
The parameters listed in the table are the maximum values that are
possible for the laser to produce, even under fault conditions.
Collateral Radiation
Collateral radiation generated by the process is minimized to very
safelevels.Signicantcollateralradiationisnotnormallyproduced
from this machine during operation or maintenance. Measurements
of collateral radiation are described below. The interlocked protective
housing meets Class 1 laser safety standards. It was constructed light
tight with material which is opaque to the laser radiation and capable
ofwithstandingthisradiationforanindeniteperiod.
• In operation: No collateral radiation is present in normal operation.
If the laser is triggered when there is no connector in the tooling to
be machined, the maximum collateral radiation measured at the
loading port is six times below the MPE/AEL limit.
• In maintenance: No collateral radiation is present.
Protective Housing
The protective housing is an integral part of the laser unit and its
operation, serving to prevent unnecessary human access to laser
radiation.
The housing completely protects the user from laser beam access.
There are no user serviceable parts in this machine.
Safety Interlocks
Mechanical safety interlocks are an integral part of the machine
design. They have been installed in the appropriate places to ensure
that no human access to the laser beam is possible during operation
and maintenance.
Parameter CO2 Laser (IR)
Wavelength 10.55-10.63μm
Average Power <50W
Output Power Stability <5%
Operating Frequency & Duty Cycle 0-25kHz & 0-100%

7
Getting Started
Unpacking & Setup
NOTE: Your OptiSaber™ Laser will arrive in a shipping case while the
Extract Unit and accessories will ship in a separate box.
1. Remove all loose components from the shipping case.
2. Carefully lift the OptiSaber™ and power supply out of the shipping
case on to a robust surface. Remove the plastic bag from around
the laser unit.
3. Remove Extract Unit and accessories from the second shipping box.
4. Inspect the laser for any damage that may have occurred
in shipping.
5. Start the setup by connecting Extraction Hose to top of Extract Unit
bypushingrmlyintotting.
6. Assemble other end of the hose to the back of OptiSaber™. Position
hose clamp no more than an half inch from end of hose. Using a
slotted screwdriver, tighten hose clamp screw.
7. Attach Activation Switch cable to the port labeled “Switch” located
on the back of laser cleaver.
8. Optional monitor may be connected to the port labeled “Monitor”.
9. Connect each power cord into the Extract Unit and Power Supply.
10. Lastly, plug the other end of each power cord into the appropriate
outlet (120/240 volt).
Trigger switch connection
Air Filter
Power cord hard wired to
the power supply
BNC output for the
monitor
Connection for the
extraction hose
Foot or hand switch available, initiates cut cycle
Power cord provides electricity from power supply
to laser unit
BNC port for OPTIONAL monitor
Keeps air particles from entering laser
Interface between laser unit and extract hose
1
2
3
4
5
Trigger switch connection
BNC output for the monitor
1
3
Air Filter
Power cord hard
wired to the
power supply
Connection for
the extraction hose
5
2
4
8
Parts and Functions

Laser Unit
Locking Screw
Ready Lights
Power Supply
Monitor (optional)
Adapter Insert
Extract Unit
Thumbwheel
Access Door
OS7000S laser unit
Easily change between SC, LC, SMA, FC, ST and
ferruleonlycongurations
Necessary for operation, removes shards, fumes, and
keeps laser unit cool
Allows for adjustment of cleave length
Tighten or loosen to adjust thumbwheel
Alerts operator when laser is ready
Hardwired to laser
OPTIONAL monitor to provide visual support while
laser cleaving
Allows access to cleaning bottom of adapter
1
2
3
4
5
6
7
8
9
Laser Unit
Ready Lights
Power Supply
Extract Unit
Monitor (optional)
Adapter Insert
1
6
9
2
7
8
Access Door
Locking Screw
Thumbwheel
4
5
3
910

Laser Operation
Standard Startup Procedure
Due to a small amount of laser output on startup it is recommended
that no ferrules are loaded in the OptiSaber™ at this point.
IMPORTANT: an Extract Unit must always be connected and working
when the module is in use. Failure to do so will void the warranty.
1. The fume Extract Unit must be turned on using the “GREEN” button
on unit.
2. To start the laser unit, connect the power
cord to the power outlet. If your power cord is
equipped with a “YELLOW” GFCI plug, you MUST
push the reset button on the plug to supply
power to the machine.
3. Turn on the switch on the power supply module.
4. If monitor is being used, plug into power outlet and turn on.
NOTE: Black selector switch located on
the back of extract unit must be set to 0.
Operating the Laser
To begin operations, set dial on
Extract unit between 75% -100%
based on ambient temperature.
When the machine has been switched on all cycle lights illuminate,
thenthefaultandlaseremissionLEDswillash“BLUE”and“WHITE”
respectively as the laser warms up. A single “GREEN” LED on the top
panel will indicate that the unit is ready.
Cleavingsinglebercanbedoneinafewsimplesteps.
1. The ferrules must be free of epoxy
contamination on the side and
excess epoxy on the end.
2. Select desired adapter insert and
snap in to position.
11
3. Insert the connector or ferrule to be cleaved into the adapter.
4.Verifyberisintactbeforeinitiatingcycle.
5. Press “RED” button on hand held switch or
foot pedal to initiate laser cleaving cycle.
6. Wait for audible chime to signal completion
of cycle, approximately 2-3 seconds.
7. Remove the ferrule from the adapter.
Once desired lot has been laser cleaved, move to polishing operations
usingDomailleEngineeringopticalpolishingmachinesandxtures.
Cut Length Adjustments
The OptiSaber comes pre-set with a long cleave length and will have
to be reduced accordingly depending on connector type. Each line
graduation on the thumbwheel represents an approximate 10um
adjustment.
Adjusting this length can be done in a few simple steps.
1. Loosen the locking screw- located directly above the thumbwheel.
2. Rotate adjustment wheel to achieve desired cleave length.
Turningtotheleftwillshortentheberlength.Toachievea
longer cut length, rotate the adjustment wheel to the right.
3. Tighten locking screw to secure thumbwheel.
12

Laser Shut Down
The following procedure should be used to shut down the OptiSaber™
OS7000S.
1. Turn off power supply module switch.
2. Using green button, turn off Extract Unit.
3. For additional security, unplug electrical cords from power outlets.
Always ensure that any hazard has been removed before
the machine is restarted. Staff of a suitable level of
responsibility and training should be involved in the
decision to restart following emergency shutdown.
13
Laser Maintenance
Proper care and handling of the laser unit, power supply, and extract
unitiscriticaltomaintainingefcientoperation.Ifthelaserunitor
components are damaged in any way, contact Domaille Engineering.
There are no serviceable parts inside the laser unit. Do not remove
sealed screws. Evidence of tampering will void warranty.
Daily or More Often as Required
1. Ensure correct operation of the extract and cooling system.
2. Ensure fans on laser, power supply, and extract unit remain
unobstructed.
3.CheckExtractUnitlter.Ifcleaningorchangeisneeded,
follow instructions in Extract Unit manual.
4. Clean Adapter Unit and adapters as needed following
instructions below.
Cleaning Adapter Unit
Before any maintenance is to be performed, the OptiSaber™ must be
properly powered down and unplugged from all power sources.
1. Throughtout the day clean the adapter by removing if from the
adapter unit and cleaing the top and bottom side.
2. While the adapter is out of adapter unit, clean the top side of the
adapter by inserting the cleaning brush to clear debris from
inside adapter.
3. Occasionally, the bottom of the adapter and
the top surface of damage control stop will
need to be cleaned.
There is a door on the front of the OptiSaber™
to enable the user to clean the bottom of the
adapter. When the door is open, there is a
physicalblock to prevent laser radiation from
exiting the machine.
14

Step 1: Remove the screw for the cleaning door using a 2.5mm Allen
wrench.
Step 2: Pull out and rotate the door clockwise to open.
Step 3: Clean bottom of the adapter with a small angled cleaning
brush. Replacement brushes can be ordered from Domaille
Engineering please contact our customer service.
Monthly
Inspectfanltersonthebackofthelaser,powersupply,andextract
unit. Vacuum to clean or remove and clean with compressed air.
Troubleshooting
A red warning light indicates an operating fault in the laser unit. The
user should follow the standard shut down procedure (page 13) to
power off the OptiSaber™ and contact Domaille Engineering to report
the fault.
Repeating Fault Beep Repeating Fault Beep Remedy
1 short One or both of the two
cover switches is open
Check cleaning access door
to ensure it is closed
2 short Laser internal temperature
is above 50°C or laser
error
Refer to over temperature
section below
3 short Scanner plate is above
50°C
Refer to over temperature
section below
4 short Air Temperature inside the
laser unit is above 50°C
Refer to over temperature
section below
5 short Laser voltage error feed-
back from laser
Contact Domaille
1 long, 1 short Start Button Fault Start button may be stuck,
check switch operation
2 long, 1 short Laser Not Ready Restart Laser
2 long, 2 short Opto-sensor not broken by
scan arm
Restart laser; Contact
Domaille
Over Temperature
The laser can go over temperature when the ambient temperature
is above 86°F (30°C). Follow shut-down procedure to allow the laser
unit to cool (page 13).
Ensure the vacuum hose seal is tight and properly extracting the
warm air from the laser. Increase extraction unit power to 100%.
Ferrule difcult to insert
Most likely the side of the ferrule is contaminated with epoxy or the
insert needs cleaning from buildup. Clean insert (page 14) and
ensure your ferrules are free from epoxy on the side.
15 16