GSi JK300HP User manual

JK300HP/JK300P/JK125P
Nd: YAG Industrial Laser
Pre-installation and User Manual
GSI Group - Laser Division
Cosford Lane, Swift Valley
Rugby, Warwickshire, CV21 1QN
England
Telephone: [phone]
Fax: [phone]
www.gsig.com
Petitioners Canadian Solar Inc. and Canadian Solar (USA) Inc.
Ex. 1025, p. Cover

GSI Group - Laser Division
JK300HP/JK300P/JK125P
Pre-installation and User Manual Issue 2.0
Page ii Part No: 1EA300E01
Intentionally blank
Petitioners Canadian Solar Inc. and Canadian Solar (USA) Inc.
Ex. 1025, p. ii

GSI Group - Laser Division
JK300HP/JK300P/JK125P
Issue 2.0 Pre-installation and User Manual
Part No: 1EA300E01 Page iii
Acceptance Sheet
The acceptance of this shipment by the Transport Company at GSI Group - Laser Divisions
plant is an acknowledgement that it was properly packed and handed over in good condition.
The Transport Company that delivers this shipment to your premises is responsible for its
safe delivery.
If the shipment has been made Free Carrier (FCA) GSI Group - Laser Divisions and is
damaged externally, undertake the following actions:
•The delivery person must note the nature and extent of the damages on the freight bill.
•Notify the office of the Transport Company that delivered the shipment and request
that the shipment be inspected.
•File a claim for damages with the Transport Company immediately.
•Retain all packing material until the shipment is inspected and the claim is settled.
If the shipment has been made FCA - Rugby – Packed and is damaged internally, undertake
the following actions:
1. File a claim for damages with the Transport Company immediately.
2. Retain all packing material until the shipment is inspected and the claim is settled.
3. If the shipment has been made FCA - Rugby - Packed and shortages have occurred,
undertake the following actions:
4. If the shipment delivered to you is not in agreement with the quantity of containers
shown on your receipt, accept it only after such shortages have been noted on the
freight bill or bill of loading. File a claim immediately with the Transport Company
responsible for shipment delivery.
5. Please contact GSI Group - Laser Division if you have any questions on arrival of a
shipment made FCA - Rugby - Packed.
6. GSI Group - Laser Division accepts no responsibility for shipments made FCA -
Rugby - Packed which are damaged or lost in transit. Claims for loss or damage
must not be deducted from the invoice value, or payment withheld, awaiting
adjustment or settlement of such claims.
If shipment has been made Carriage, Insurance and Freight (CIF) destination and
damages or shortages have occurred:
7. Notify us immediately by telephone or fax upon arrival of the shipment and carry out
all procedures outlined above, except for those relating to the filing of claims. All
documents resulting from these procedures must be mailed to GSI Group - Laser
Division, Cosford Lane, Rugby, Warwickshire, CV21 1QN, England.
Petitioners Canadian Solar Inc. and Canadian Solar (USA) Inc.
Ex. 1025, p. iii

GSI Group - Laser Division
JK300HP/JK300P/JK125P
Pre-installation and User Manual Issue 2.0
Page iv Part No: 1EA300E01
Intentionally blank
Petitioners Canadian Solar Inc. and Canadian Solar (USA) Inc.
Ex. 1025, p. iv

GSI Group - Laser Division
JK300HP/JK300P/JK125P
Issue 2.0 Pre-installation and User Manual
Part No: 1EA300E01 Page v
Document Approval
Issue Author Approved for Issue Date
1.0 Terry Cutmore
2.0 Terry Cutmore
SOFTWARE DISCLAIMER
Any software forming part of this equipment should be used only for the purpose for which it was
supplied by GSI Group - Laser Division. No changes, modifications or copies (except for producing a
necessary back-up copy) shall be undertaken by the User.
GSI Group - Laser Division accepts no responsibility for equipment malfunction resulting from any of
the above actions.
SAFETY WARNING
It is of the utmost importance that the Safety Section of this manual is read and fully understood
before any attempt is made to operate the equipment or undertake any actions which might
necessitate removal of any parts from the equipment.
© 2005 GSI Group. All rights reserved.
The information contained herein is confidential and is the property of GSI Group - Laser Division.
This manual is supplied without liability for errors or omissions. No part may be reproduced, disclosed
or used except as authorised by contract or other written permission. The copyright and the foregoing
restriction on reproduction and use extend to all media in which the information may be embodied.
Petitioners Canadian Solar Inc. and Canadian Solar (USA) Inc.
Ex. 1025, p. v

GSI Group - Laser Division
JK300HP/JK300P/JK125P
Pre-installation and User Manual Issue 2.0
Page vi Part No: 1EA300E01
Intentionally blank
Petitioners Canadian Solar Inc. and Canadian Solar (USA) Inc.
Ex. 1025, p. vi

GSI Group - Laser Division
JK300HP/JK300P/JK125P
Issue 2.0 Pre-installation and User Manual
Part No: 1EA300E01 Page vii
Table of Contents
1. General Information...................................................................................................... 3
1.1 Class of Laser ..................................................................................................... 3
1.2 Intended Users.................................................................................................... 3
1.3 Documentation .................................................................................................... 3
1.3.1 Safety Paragraphs ................................................................................ 3
1.4 Table of Definitions ............................................................................................. 4
1.5 After Sales Support ............................................................................................. 7
1.6 CE Mark Information ........................................................................................... 7
1.7 The JK300HP/JK300P/JK125P Series Laser ..................................................... 8
1.7.1 Main Assemblies ................................................................................... 8
1.7.2 Control System and Local Controller .................................................... 9
1.7.3 Machine Interface.................................................................................. 9
1.7.4 Ancillaries.............................................................................................. 9
1.8 Technical Specification ..................................................................................... 10
1.9 Safety Interlocks................................................................................................ 14
1.9.1 Customer Remote Interlocks............................................................... 14
1.9.2 Shutter Interlocks (Beampath Interlocks) ............................................ 14
1.10 Laser Power Delivery ........................................................................................ 15
1.11 Operating Parameters....................................................................................... 17
1.11.1 Changing Parameters ......................................................................... 17
1.11.2 Parameter Set Selection ..................................................................... 19
1.12 Laser Outputs.................................................................................................... 19
1.13 Operating Guidelines ........................................................................................ 19
1.14 Processing Considerations ............................................................................... 19
1.15 Fibre Optic Handling ......................................................................................... 20
1.15.1 Description .......................................................................................... 20
1.15.2 Unpacking Fibre Optic Cable .............................................................. 20
1.15.3 Fibre Installation.................................................................................. 21
1.15.4 Minimum Bend Radii ........................................................................... 21
1.15.5 Fibre Optic Termination....................................................................... 22
1.15.6 Fibre Routing....................................................................................... 22
1.15.7 Fibre Removal..................................................................................... 22
2. Safety........................................................................................................................... 23
2.1 Laser Classification ........................................................................................... 23
2.2 Laser Radiation Hazards................................................................................... 25
2.3 Control Measures.............................................................................................. 25
2.4 Electrical Safety ................................................................................................ 27
2.5 Environmental Hazards..................................................................................... 28
2.5.1 Fire ...................................................................................................... 28
2.5.2 Fume ................................................................................................... 29
2.5.3 Compressed Gases ............................................................................ 30
2.5.4 Solvents .............................................................................................. 30
2.6 Conditions of Use.............................................................................................. 31
2.6.1 Approved Materials ............................................................................. 31
2.6.2 Approved Process............................................................................... 31
2.6.3 Approved Conditions........................................................................... 31
2.6.4 Due Authorisation................................................................................ 32
2.7 Safety Control System ...................................................................................... 33
2.7.1 Safety Category .................................................................................. 33
Petitioners Canadian Solar Inc. and Canadian Solar (USA) Inc.
Ex. 1025, p. vii

GSI Group - Laser Division
JK300HP/JK300P/JK125P
Pre-installation and User Manual Issue 2.0
Page viii Part No: 1EA300E01
2.7.2 Safety Compliance .............................................................................. 33
2.7.3 Safety Labelling................................................................................... 33
2.7.4 Safety Features................................................................................... 36
2.7.5 Remote Interlock Connector ............................................................... 36
2.7.6 Workstation Interlock........................................................................... 37
2.8 Training ............................................................................................................. 38
2.9 Personal Protective Equipment......................................................................... 38
2.9.1 Eye Protection..................................................................................... 38
2.10 Manual Handling ............................................................................................... 38
2.10.1 Manual Handling Requirements.......................................................... 38
3. Pre-installation............................................................................................................ 39
3.1 Location of Laser System.................................................................................. 39
3.2 General Arrangement........................................................................................ 40
3.2.1 Dimensions and Weight ...................................................................... 40
3.3 Site Preparation ................................................................................................ 41
3.3.1 Electrical Supply Requirements .......................................................... 41
3.3.2 Cooling Water Supply ......................................................................... 41
3.3.3 Gas Supply.......................................................................................... 43
3.3.4 Fume Control ...................................................................................... 43
3.4 Environmental Conditions ................................................................................. 44
3.4.1 Temperature and Humidity.................................................................. 44
3.4.2 Degree of Protection given by Enclosure............................................ 44
3.5 Electromagnetic Compatibility........................................................................... 44
3.6 Transportation ................................................................................................... 44
3.7 Electrical Connections....................................................................................... 45
3.7.1 Connection Panel................................................................................ 45
3.7.2 PL601 - Customer Interlocks............................................................... 45
3.7.3 PL602 – Workstation Interlocks .......................................................... 45
3.7.4 SK603 – Basic Machine (M/C) Interface ............................................. 46
3.7.5 SK604 – Full M/C Interface - I/O card 1 (Optional) ............................. 52
3.7.6 SK605 – Full M/C Interface - I/O card 2 (Optional) ............................. 53
3.8 Fibre Route Planning ........................................................................................ 54
3.9 Installation Consumables .................................................................................. 54
3.10 Pre-installation Checks ..................................................................................... 55
4. Installation................................................................................................................... 57
4.1 Equipment Warranty ......................................................................................... 57
4.2 Installation Procedure ....................................................................................... 57
4.3 Installation Toolkit ............................................................................................. 58
4.4 Fibre Optic Handling ......................................................................................... 58
4.5 Installation Procedures...................................................................................... 58
4.6 Certification ....................................................................................................... 58
5. De-Commissioning ..................................................................................................... 59
5.1 Disconnect Power Supply ................................................................................. 59
5.2 Connector Removal .......................................................................................... 59
5.3 Disconnect External Water Supply.................................................................... 60
5.4 Drain Internal Cooling System .......................................................................... 60
5.5 Fibre Removal................................................................................................... 61
5.6 Re-packaging .................................................................................................... 61
6. Laser Operation .......................................................................................................... 63
6.1 Overview ........................................................................................................... 63
6.2 Laser Start-up ................................................................................................... 63
6.3 Laser Shut-down ............................................................................................... 63
Petitioners Canadian Solar Inc. and Canadian Solar (USA) Inc.
Ex. 1025, p. viii

GSI Group - Laser Division
JK300HP/JK300P/JK125P
Issue 2.0 Pre-installation and User Manual
Part No: 1EA300E01 Page ix
6.4 Emergency Shutdown ....................................................................................... 63
6.5 Keys .................................................................................................................. 64
6.5.1 General ............................................................................................... 64
6.5.2 Control Keys........................................................................................ 64
6.5.3 Navigation Keys .................................................................................. 64
6.5.4 Function Keys ..................................................................................... 64
6.5.5 Value Keys .......................................................................................... 64
6.5.6 Editing Keys ........................................................................................ 64
6.5.7 Status Bar ........................................................................................... 65
6.5.8 Local warnings .................................................................................... 65
6.6 WELCOME screen............................................................................................ 65
6.6.1 Function .............................................................................................. 65
6.6.2 Entry.................................................................................................... 66
6.6.3 Exit ...................................................................................................... 66
6.6.4 {Laser Descr) {Laser Type} {s/w} ...................................................... 66
6.7 MAIN screen ..................................................................................................... 66
6.7.1 Function .............................................................................................. 66
6.7.2 Entry/Exit............................................................................................. 66
6.7.3 ‘Operate’.............................................................................................. 66
6.7.4 ‘Setup’ ................................................................................................. 66
6.7.5 ‘Alarm/Warnings’ ................................................................................. 66
6.7.6 ‘System’............................................................................................... 66
6.7.7 Status Bar ........................................................................................... 66
6.8 OPERATE screen ............................................................................................. 66
6.8.1 Function .............................................................................................. 66
6.8.2 Entry/Exit............................................................................................. 67
6.8.3 Status Bar ........................................................................................... 67
6.9 SETUP screen .................................................................................................. 67
6.9.1 Function .............................................................................................. 67
6.9.2 Entry/Exit............................................................................................. 67
6.9.3 Status Bar ........................................................................................... 68
6.10 MODIFY SHAPE screens ................................................................................. 68
6.10.1 Function .............................................................................................. 68
6.10.2 Entry/Exit............................................................................................. 68
6.10.3 Title ..................................................................................................... 68
6.11 Energy MONITOR screen ................................................................................. 69
6.11.1 Function .............................................................................................. 69
6.11.2 Entry/Exit............................................................................................. 69
6.11.3 Status Bar ........................................................................................... 69
6.12 SYSTEM screen................................................................................................ 70
6.12.1 Function .............................................................................................. 70
6.12.2 Entry/Exit............................................................................................. 70
6.13 ALARM / WARNINGS screen ........................................................................... 70
6.13.1 Function .............................................................................................. 70
6.13.2 Entry/Exit............................................................................................. 70
6.13.3 Display ................................................................................................ 70
6.13.4 Alarm/Warning .................................................................................... 71
7. Alarm and Warning Handling .................................................................................... 73
7.1 Alarm and Warning Display............................................................................... 73
7.2 Alarms For Generic Control System ................................................................. 73
7.3 System Level Alarms (Zone 1).......................................................................... 73
7.3.1 Alarm 1n01 : Communications Error ................................................... 73
7.3.2 Alarm 1n02 : Serial Communications Fault......................................... 74
Petitioners Canadian Solar Inc. and Canadian Solar (USA) Inc.
Ex. 1025, p. ix

GSI Group - Laser Division
JK300HP/JK300P/JK125P
Pre-installation and User Manual Issue 2.0
Page x Part No: 1EA300E01
7.3.3 Alarm 1n03 : No Laser Type Configured............................................. 74
7.3.4 Alarm 1n04 : Laser Control Card Communication Fault...................... 74
7.3.5 Alarm 1n05 : Pulse Generator Card Communication Fault................. 74
7.3.6 Alarm 1n06 : Interlock Module Communication Fault.......................... 74
7.3.7 Alarm 1n07 : Software Error................................................................ 75
7.3.8 Alarm 1n08 : Safety Relay Out Fault................................................... 75
7.3.9 Alarm 1n09 : Safety Relay In Fault ..................................................... 75
7.3.10 Alarm 1n10 : Safety Relay Not Detected. .......................................... 75
7.3.11 Alarm 1n11 : Emission Indicator Timeout .......................................... 75
7.3.12 Alarm 1n12 : Laser Type Not Recognised By The Laser Control
Network .............................................................................................. 76
7.3.13 Alarm 1n13 : LCC DSP Communications Fault................................... 76
7.3.14 Alarm 1n14 : Unexpected power down ............................................... 76
7.4 Interlock Alarms (Zone 2).................................................................................. 76
7.4.1 Alarm 2n01 : Interlock Chain Input 1 Fault.......................................... 76
7.4.2 Alarm 2n02 : Interlock Chain Input 2 Fault.......................................... 77
7.4.3 Alarm 2n03 : Interlock Chain Input 3 Fault.......................................... 77
7.4.4 Alarm 2n04 : Interlock Chain Input 4 Fault.......................................... 77
7.4.5 Alarm 2n05 : Interlock Chain Input 5 Fault.......................................... 77
7.4.6 Alarm 2n06 : Interlock Chain Input 6 Fault.......................................... 78
7.4.7 Alarm 2n07 : Interlock Chain Input 7 Fault.......................................... 78
7.4.8 Alarm 2n08 : Interlock Chain Input 8 Fault.......................................... 78
7.4.9 Alarm 2n09 : Interlock Chain Input 9 Fault.......................................... 78
7.4.10 Alarm 2n10 : Interlock Chain Input 10 Fault........................................ 79
7.4.11 Alarm 2n11 : Interlock Chain Input 11 Fault........................................ 79
7.4.12 Alarm 2n12 : Interlock Chain Input 12 Fault........................................ 79
7.4.13 Alarm 2n13 : Interlock Chain Input 13 Fault........................................ 79
7.4.14 Alarm 2n14 : Interlock Chain Input 14 Fault........................................ 80
7.4.15 Alarm 2n15 : Interlock Chain Input 15 Fault........................................ 80
7.4.16 Alarm 2n16 : Interlock Chain Input 16 Fault........................................ 81
7.4.17 Alarm 2n17 : Interlock Chain Input 17 Fault........................................ 81
7.4.18 Alarm 2n18 : Interlock Chain Input 18 Fault........................................ 82
7.4.19 Alarm 2n19 : Interlock Chain Input 19 Fault........................................ 82
7.4.20 Alarm 2n20 : Interlock Chain Input 20 Fault........................................ 83
7.4.21 Alarm 2n21 : Interlock Chain Input 21 Fault........................................ 83
7.4.22 Alarm 2n22 : Interlock Chain Input 22 Fault........................................ 83
7.4.23 Alarm 2n23 : Interlock Chain Input 23 Fault........................................ 83
7.4.24 Alarm 2n24 : Interlock Chain Input 24 Fault........................................ 84
7.4.25 Alarm 2n25 : Interlock Chain Input 25 Fault........................................ 84
7.4.26 Alarm 2n26 : Interlock Chain Input 26 Fault........................................ 84
7.4.27 Alarm 2n27 : Interlock Chain Input 27 Fault........................................ 84
7.4.28 Alarm 2n28 : Interlock Chain Input 28 Fault........................................ 84
7.4.29 Alarm 2n29 : Interlock Chain Input 29 Fault........................................ 85
7.4.30 Alarm 2n30 : Interlock Chain Input 30 Fault........................................ 85
7.4.31 Alarm 2n31 : Interlock Chain Input 31 Fault........................................ 85
7.4.32 Alarm 2n32 : Interlock Chain Input 32 Fault........................................ 85
7.5 Cooler Alarms (Zone 3)..................................................................................... 85
7.5.1 Alarm 3n01 : Cooler Module communication fault .............................. 85
7.5.2 Alarm 3n02 : No Pump On Response................................................. 86
7.5.3 Alarm 3n03: Low Coolant Level .......................................................... 86
7.5.4 Alarm 3n04: Over Temperature Switch............................................... 86
7.5.5 Alarm 3n05: Cooler Module Relay Fault ............................................. 86
7.5.6 Alarm 3n06: Cooler Module Relay Overload Fault.............................. 87
7.5.7 Alarm 3n07: Low temperature fault ..................................................... 87
Petitioners Canadian Solar Inc. and Canadian Solar (USA) Inc.
Ex. 1025, p. x

GSI Group - Laser Division
JK300HP/JK300P/JK125P
Issue 2.0 Pre-installation and User Manual
Part No: 1EA300E01 Page xi
7.5.8 Alarm 3n08: High temperature fault .................................................... 87
7.5.9 Alarm 3n09: Very High temperature fault............................................ 87
7.5.10 Alarm 3n10: High Conductivity fault .................................................... 88
7.5.11 Alarm 3n11: Low Coolant Flow ........................................................... 88
7.5.12 Alarm 3n12: High Coolant Flow .......................................................... 88
7.5.13 Alarm 3n13: Temperature Sensor Fault.............................................. 88
7.5.14 Alarm 3n14: Conductivity Sensor Fault............................................... 89
7.6 Power Supply Alarms (Zone 4) ......................................................................... 89
7.6.1 Alarm 4n01 : Power Supply Module communication fault................... 89
7.6.2 Alarm 4n02 : Power Supply Software Error ........................................ 89
7.6.3 Alarm 4n03 : Power Supply Negative 15 Volt Fault ........................... 89
7.6.4 Alarm 4n04 : Power Supply Fan Fault ................................................ 89
7.6.5 Alarm 4n05 : Power Supply Over Temperature .................................. 90
7.6.6 Alarm 4n06 : Power Supply Contactor In Fault ................................... 90
7.6.7 Alarm 4n07 : Power Supply Failed to initialise .................................... 90
7.6.8 Alarm 4n08 : Power Supply Contactor In Timeout .............................. 90
7.6.9 Alarm 4n09 : Power Supply Failed To Simmer .................................. 90
7.6.10 Alarm 4n10 : Power Supply Failed To Simmer Timeout ..................... 91
7.6.11 Alarm 4n11 : Power Supply Simmer Under Power Fault. ................... 91
7.6.12 Alarm 4n12 : Power Supply Simmer Over Power Fault ...................... 91
7.6.13 Alarm 4n13 : Power Supply Failed To Enable ................................... 91
7.6.14 Alarm 4n14 : Power Supply Limit Fault .............................................. 91
7.6.15 Alarm 4n15 : Power Supply IGBT Fault .............................................. 92
7.6.16 Alarm 4n16 : Power Supply Earth Fault .............................................. 92
7.6.17 Alarm 4n17 : Power Supply Input Voltage Loss.................................. 92
7.6.18 Alarm 4n18 : Power Supply Contactor Out Fault ................................ 92
7.6.19 Alarm 4n19 : Power Supply Shutdown During Operation ................... 92
7.6.20 Alarm 4n20 : Power Supply Contactor Out Timeout ........................... 93
7.6.21 Alarm 4n21 : Power Supply Residual Voltage Fault ........................... 93
7.7 Shutter Alarms (Zone 5).................................................................................... 93
7.7.1 Alarm 5n01 : Shutter communication fault .......................................... 93
7.7.2 Alarm 5n02 : Shutter Initialisation Failure ........................................... 93
7.7.3 Alarm 5n03 : Shutter Configuration Failure......................................... 94
7.7.4 Alarm 5n05 : Shutter Emergency Stop Fault....................................... 94
7.7.5 Alarm 5n06 : Shutter Close Fault ........................................................ 94
7.8 Machine Interface Alarms (Zone 6)................................................................... 94
7.9 Warning Number Allocation .............................................................................. 95
7.10 System Level Warnings (Zone 1)...................................................................... 95
7.10.1 Warning 1n01 : Serial Link Buffer Overflow ........................................ 95
7.10.2 Warning 1n02 : Laser Control Card Communications Overflow.......... 95
7.10.3 Warning 1n03 : Incorrect packet data ................................................. 95
7.10.4 Warning 1n04 : Data Over Range....................................................... 95
7.10.5 Warning 1n05 : Shutter Communications Timeout ............................. 96
7.10.6 Warning 1n06 : Sector Over Range .................................................... 96
7.10.7 Warning 1n07 : Operating Envelope Over Range............................... 96
7.10.8 Warning 1n08 : High Output Trip ........................................................ 96
7.10.9 Warning 1n09 : Low Output Trip ......................................................... 96
7.10.10 Warning 1n10 : Shot Limit Exceeded.................................................. 96
7.10.11 Warning 1n11 : Shutter Multi Pulse External Trigger Timeout ............ 96
7.10.12 Warning 1n12 : Shutter Multi shot or Single shot not allowed while
laser is off ........................................................................................... 97
7.11 Cooler Warnings (Zone 3)................................................................................. 97
7.11.1 Warning 3n01 : Low Temperature...................................................... 97
7.11.2 Warning 3n02 : High Temperature..................................................... 97
Petitioners Canadian Solar Inc. and Canadian Solar (USA) Inc.
Ex. 1025, p. xi

GSI Group - Laser Division
JK300HP/JK300P/JK125P
Pre-installation and User Manual Issue 2.0
Page xii Part No: 1EA300E01
7.11.3 Warning 3n03 : Low Flow................................................................... 97
7.11.4 Warning 3n04 : High Flow.................................................................. 97
7.11.5 Warning 3n05 : High Conductivity...................................................... 97
7.12 Power Supply Warnings (Zone 4) ..................................................................... 97
7.12.1 Warning 4n01 : Disabled..................................................................... 97
7.12.2 Warning 4n02 : Dumping Current ....................................................... 98
7.12.3 Warning 4n03 : Dump Resistors Cooling ........................................... 98
7.13 Shutter Warnings (Zone 5)................................................................................ 98
7.13.1 Warning 5n01 : Fibre Temperature .................................................... 98
7.13.2 Warning 5n02 : Shutter Temperature................................................. 98
7.13.3 Warning 5n03 : FCMS........................................................................ 98
7.13.4 Warning 5n04 : External Work Chamber Doors................................. 98
7.13.5 Warning 5n05 : Close......................................................................... 98
7.13.6 Warning 5n06 : Open ......................................................................... 98
7.13.7 Warning 5n07 : Shutter Switch Feedback Error................................. 99
7.13.8 Warning 5n08 : Energy Share Configuration Fail............................... 99
7.13.9 Warning 5n09 : Datum Failure ........................................................... 99
7.13.10 Warning 5n10 : External Work Chamber Doors Open ....................... 99
8. Optimisation.............................................................................................................. 101
8.1 Introduction ..................................................................................................... 101
8.2 Initial Set-up .................................................................................................... 101
8.3 Rear Mirror Tuning .......................................................................................... 102
8.4 Focus Head Setup .......................................................................................... 104
8.5 External Power Control (EPC) Set-up............................................................. 105
8.5.1 Set Up Procedure:............................................................................. 105
9. User Maintenance ..................................................................................................... 107
9.1 Introduction ..................................................................................................... 107
9.2 User Maintenance Tasks ................................................................................ 108
9.3 General Inspection .......................................................................................... 109
9.4 Coolant Replenishment................................................................................... 110
9.4.1 Materials............................................................................................ 110
9.4.2 Draining Procedure ........................................................................... 110
9.4.3 Filling Procedure ............................................................................... 112
9.5 Filter Replacement Procedure ........................................................................ 114
9.6 De-ioniser Replacement Procedure ................................................................ 116
9.7 Coolant Pump Replacement ........................................................................... 118
9.7.1 Materials............................................................................................ 118
9.7.2 Removal Procedure .......................................................................... 118
9.7.3 Installation Procedure ....................................................................... 120
9.8 Arc-lamp Replacement.................................................................................... 123
9.8.1 Materials............................................................................................ 123
9.8.2 Replacement Procedure ................................................................... 124
9.8.3 Installation Procedure ....................................................................... 126
9.9 PIPA Fibre Optic Cable Replacement............................................................. 130
9.9.1 Materials............................................................................................ 130
9.9.2 Removal Procedure .......................................................................... 130
9.9.3 Installation Procedure ....................................................................... 132
9.9.4 Fibre Output Termination Replacement Procedure .......................... 134
9.9.5 Alignment Procedure......................................................................... 136
9.10 Cover Slide Replacement Procedure.............................................................. 138
9.10.1 Materials............................................................................................ 138
9.10.2 Removal Procedure .......................................................................... 138
9.10.3 Cleaning and Installation Procedure ................................................. 140
Petitioners Canadian Solar Inc. and Canadian Solar (USA) Inc.
Ex. 1025, p. xii

GSI Group - Laser Division
JK300HP/JK300P/JK125P
Issue 2.0 Pre-installation and User Manual
Part No: 1EA300E01 Page xiii
9.11 Focus lens cell Replacement Procedure......................................................... 142
9.11.1 Materials............................................................................................ 142
9.11.2 Replacement Procedure ................................................................... 142
9.11.3 Cleaning Procedure .......................................................................... 144
9.12 Focus Lens Replacement Procedure.............................................................. 146
9.12.1 Materials............................................................................................ 146
9.12.2 Removal Procedure .......................................................................... 146
9.12.3 Installation Procedure ....................................................................... 148
9.13 Surge Suppressor Replacement Procedure ................................................... 150
9.13.1 Materials............................................................................................ 150
9.14 Bulb Replacement Procedure ......................................................................... 152
9.14.1 Materials............................................................................................ 152
9.15 Bendlock Assembly......................................................................................... 153
9.15.1 Assembly Instructions ....................................................................... 153
9.16 Pointing Diode Replacement........................................................................... 154
9.16.1 Materials............................................................................................ 154
9.16.2 Replacement Procedure ................................................................... 154
9.16.3 Alignment Procedure......................................................................... 156
10. Laser Processing...................................................................................................... 159
10.1 Overview ......................................................................................................... 159
10.2 Welding with Pulsed Lasers ............................................................................ 159
10.2.1 Pulse energy ..................................................................................... 160
10.2.2 Peak Power....................................................................................... 160
10.2.3 Pulse frequency and overlap............................................................. 160
10.3 Welding in Continuous Wave Mode ................................................................ 161
10.4 Welding in Modulation Mode........................................................................... 161
10.5 Jigs and Fixtures ............................................................................................. 162
10.6 Shielding Gas.................................................................................................. 162
10.7 Fume and Spatter Control............................................................................... 163
10.8 Material Welding ............................................................................................. 164
10.9 Cutting in CW Mode ........................................................................................ 164
10.10 Cutting in Modulation Mode ............................................................................ 165
10.11 Cutting Fixtures ............................................................................................... 165
10.12 Cutting Assist Gas........................................................................................... 165
10.13 Inert Assist Gases ........................................................................................... 165
10.14 Cutting Different Materials............................................................................... 166
10.15 Process Preparation........................................................................................ 166
10.15.1 Choice of Focused Spot Size............................................................ 166
10.15.2 Part/Focus Position ........................................................................... 166
10.15.3 Weld Shape, Cut Width and Joint Strength....................................... 166
10.15.4 Cover Slide Damage ......................................................................... 167
10.15.5 Processing Access............................................................................ 167
10.15.6 Finding Focus.................................................................................... 167
10.15.7 Welding ............................................................................................. 167
10.15.8 Cutting............................................................................................... 169
10.16 Optimisation .................................................................................................... 170
10.16.1 Use of Ramp Up and Ramp Down.................................................... 170
10.17 Record Keeping .............................................................................................. 170
11. Spares........................................................................................................................ 171
Petitioners Canadian Solar Inc. and Canadian Solar (USA) Inc.
Ex. 1025, p. xiii

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JK300HP/JK300P/JK125P
Pre-installation and User Manual Issue 2.0
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Petitioners Canadian Solar Inc. and Canadian Solar (USA) Inc.
Ex. 1025, p. xiv

GSI Group - Laser Division
JK300HP/JK300P/JK125P
Issue 2.0 Pre-installation and User Manual
Part No: 1EA300E01 Page 1 of 172
Introduction to GSI Group - Laser Division
GSI Group - Laser Division is a worldwide technology company specialising in the
development, production and support of lasers and laser-based systems. The Company
organisation includes manufacturing operations located in North America and Europe along
with a network of support centres.
GSI Group - Laser Division offers a complete range of lasers that cover applications in
sectors including electronics, aerospace, automotive, advanced manufacturing, packaging
and advanced research.
GSI Group - Laser Division collaborates with customers to develop laser systems that
increase productivity, solve manufacturing problems and meet the requirements of leading-
edge research.
Petitioners Canadian Solar Inc. and Canadian Solar (USA) Inc.
Ex. 1025, p. 1

GSI Group - Laser Division
JK300HP/JK300P/JK125P
Pre-installation and User Manual Issue 2.0
Page 2 of 172 Part No: 1EA300E01
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Petitioners Canadian Solar Inc. and Canadian Solar (USA) Inc.
Ex. 1025, p. 2

GSI Group - Laser Division
JK300HP/JK300P/JK125P
Issue 2.0 Pre-installation and User Manual
Part No: 1EA300E01 Page 3 of 172
1. General Information
1.1 Class of Laser
The JK300HP/JK300P/JK125P Series Laser is a Class 4 (IV) Laser system. Refer to
Section 2 – Safety for information on Laser radiation hazards and safety precautions in a
Class 4 (IV) environment.
1.2 Intended Users
All operators using this Laser equipment must be officially trained and authorised. They must
also be fully conversant with the following:
• Laser hazards, safety procedures and correct use of related safety equipment.
• Hazards related to the use of Lasers for materials processing, prescribed safety
procedures and related equipment.
• The contents of this manual, and therefore the related safety provisions prescribed for
the safe installation of the equipment.
Authorised Personnel are classified as Engineers who have attended official GSI Group -
Laser Division Training Courses and have been certified as competent.
1.3 Documentation
The JK300HP/JK300P/JK125P Series Laser is supplied with a Pre-installation and User
Manual.
The Manual provides information on Pre-installation requirements, Installation Procedures,
De-Commissioning Procedures and user information.
The Pre-installation section specifies site preparation and the interfaces that need to be in
place prior to Laser delivery.
The Installation section provides information and the procedures necessary for installation
and commissioning and decommissioning.
The User Manual section provides information on the Operating Procedures, Routine
Maintenance to Level 1 and Fault Diagnosis.
1.3.1 Safety Paragraphs
Throughout the documentation ‘WARNING’, ‘CAUTION’ and ‘Note’ paragraphs appear. It is
the responsibility and duty of all personnel who operate and maintain this equipment to fully
understand the WARNING, CAUTION and Note procedures in order to reduce or eliminate
hazards.
WARNING
WARNING TEXT MUST BE OBSERVED TO PREVENT PERSONAL INJURY
TO YOURSELF AND OTHERS.
CAUTION
Caution text must be observed to prevent possible damage or destruction to
equipment or loss of operational effectiveness.
Note Note text must be observed for essential and effective operating procedures and conditions.
Petitioners Canadian Solar Inc. and Canadian Solar (USA) Inc.
Ex. 1025, p. 3

GSI Group - Laser Division
JK300HP/JK300P/JK125P
Pre-installation and User Manual Issue 2.0
Page 4 of 172 Part No: 1EA300E01
1.4 Table of Definitions
Name Definition
Aperture An opening in the protective housing of a Laser enclosure or Laser unit
through which Laser radiation is emitted.
Assist Gas Gas that is fed to the beam focus at the workpiece to assist the cutting
process. See Shielding Gas.
BCD Binary Coded Decimal.
Beam Divergence
Laser beam diameter increases with increasing distance from the Laser
owing to beam divergence (i.e. spread). It is expressed as the angle (mrad)
the beam diameter increases per unit distance (mm).
Beam divergence can be used to predict the minimum beam diameter
achieved by focusing the beam with a lens.
Beam Dump A device used to absorb beam energy when not required.
BET Beam Expanding Telescope.
Beam Focus The location beyond a focusing lens at which the beam diameter reaches a
minimum value or focal point.
Beam Tube
A length of metal or PTFE (Teflon) tube located between component
assemblies in the beam path. Prevents human access to the Laser beam
and the ingress of dust.
The Beam Tube is also known as the Gaiter.
Beam Path
Laser light directed to the workstation via a Shutter, Fibre and Focus Head.
Multiple fibres can be accommodated in Timeshare and Energy Share
configurations. See Timesharing and Energy Sharing.
Beam Stop A device that stops a Laser beam path.
Beam Quality Beam quality is defined using beam radius and half angle divergence and
relates to 86.5% of enclosed power (ISO 11146).
Continuous Wave Laser operating and continuously emitting radiation over periods of time
greater than or equal to 0.25 seconds.
Depth of Focus
When a lens focuses a Laser beam to a small diameter, the Depth of
Focus is that distance along the lens axis over which the beam may still be
considered focused. Depth of Focus is defined as the axial distance over
which the beam diameter is no more than 10% larger than the minimum
diameter at the beam focal point.
Energy Sharing The ability to share the laser beam down more than one fibre at the same
time. See Beam Path.
Eyewear
Personal Protective eyewear that prevents Laser radiation reaching the
eye directly. Laser safety eyewear reduces the incident light to a safe
level, provided it is used correctly.
Fume Airborne grit, particles, smoke, dust, vapours and gases generated by
Laser processing of materials.
Graphical User
Interface (GUI)
Graphical User Interface. The software for this interface between the
Operator and the Laser System is called LaserviewTM SE. The LaserviewTM
SE software can be run on either a Personal Computer (PC) or on an
Industrial Touch Screen Computer. See also the Universal Front Panel
(UFP).
Intensity
Beam intensity is strictly the power per unit area (Wcm2) of beam cross-
section. Intensity is also energy density - the energy per unit area of beam
cross-section.
Invisible Light outside the visible wavelength range 400 to 700nm.
Petitioners Canadian Solar Inc. and Canadian Solar (USA) Inc.
Ex. 1025, p. 4

GSI Group - Laser Division
JK300HP/JK300P/JK125P
Issue 2.0 Pre-installation and User Manual
Part No: 1EA300E01 Page 5 of 172
Name Definition
Laser Controlled
Area
A work area controlled and supervised to protect personnel from Laser
hazards.
Laser Safety Officer Person knowledgeable in the evaluation and control of Laser hazards and
has responsibility for overseeing control of Laser hazards.
LASER Acronym: Light Amplification by the Stimulated Emission of Radiation.
Laser Resonator
An optical assembly that provides feedback for light emerging from the
Laser rod (thus enabling oscillation) and allows extraction of light to
provide the output beam.
The resonator may include additional components to tailor the
characteristics of the Laser beam - for example, beam divergence,
polarisation or monochromaticity.
Light Spectrum
Invisible light of longer wavelength than red light (700nm).
Invisible light of shorter wavelength than violet light (400nm).
Visible light in the wavelength range of 400 to 700nm.
Local Control Laser is operated and monitored via the control console (PC or GUI).
LSD Least Significant Digit.
Machine Interface Facility that allows an external controlling device such as a PLC to control
and monitor the Laser.
MSD Most Significant Digit.
Nd: YAG
Nd Neodymium:
Doping to provide 1064nm wavelength of the beam.
YAG Yttrium Aluminium Garnet.
The host crystal contained in the Laser Head.
Parameter Update
Strobe The signal that is used to send information into the Laser.
Parameter Change
Acknowledge The signal that is used to acknowledge receipt of information by the Laser.
Remote Control Laser is operated and monitored via the Machine Interface.
Simmer
Simmer current (or simmer arc) is a current, which is arranged to flow in
the Arc-lamp after the lamp has been triggered (i.e. the impedance of the
gas inside the lamp has been broken down).
Simmering a lamp allows a quicker, more efficient response to current
pulses and avoids the need to trigger the lamp before every Laser pulse.
Sinking A term used to describe interface signals where current flows into the
Signal Driver in the True state. No current flows in the False state.
Sourcing A term used to describe interface signals where current flows out of the
Signal Driver in the True state. No current flows in the False state.
Petitioners Canadian Solar Inc. and Canadian Solar (USA) Inc.
Ex. 1025, p. 5

GSI Group - Laser Division
JK300HP/JK300P/JK125P
Pre-installation and User Manual Issue 2.0
Page 6 of 172 Part No: 1EA300E01
Name Definition
Spot Size
There are two possible interpretations of this phrase and care must be
exercised. Spot size can represent:
The actual diameter of the beam focus at the surface of the workpiece,
based on knowledge of the Laser beam characteristics and the parameters
of the optical focusing system.
The diameter of a spot weld or drilled hole or the width of a seam weld or
cut.
Generally, spot size is interpreted according to the first definition.
The Formula for calculating spot size is as follows:
Focussed Spot Diameter =
Fibre diameter x Focal length of Focus Lens
Focal length of Recollimating Lens
This assumes aberration free lenses.
Shielding Gas Gas that is fed to the beam focus at the workpiece during welding to
exclude atmospheric oxygen. This prevents oxidisation of the weld.
Ready Status of equipment during periods of inactivity.
Timesharing The ability to switch Laser power between different workstations by
selecting a different beam path. See Beam Path.
Universal Front
Panel (UFP) The touch screen fitted to the laser cabinet. See GUI.
The following convention is used throughout this manual
• 0 = signal False.
• 1 = signal True.
Petitioners Canadian Solar Inc. and Canadian Solar (USA) Inc.
Ex. 1025, p. 6