Iradion D200 User manual

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OPERATOR’S MANUAL
Destiny Series
CERAMICORE® CO2Laser: Models D200 & D250
http://www.iradionlaser.com

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Table of Contents
OPERATOR’S MANUAL.............................................................................. 2
Table of Contents........................................................................................ 3
Hazard Information ..................................................................................... 4
Terms...................................................................................................................4
General Hazards.......................................................................................... 4
General Hazards.......................................................................................... 5
Other Hazards.............................................................................................. 5
Infinity Series Label Locations.................................................................. 6
Laser Safety................................................................................................. 7
Declaration of Conformity.......................................................................... 8
Declaration of Conformity.......................................................................... 9
Introduction ............................................................................................... 10
CDRH.......................................................................................................... 10
Available Safety Features ........................................................................ 10
System Overview ...................................................................................... 11
Technical Drawings .................................................................................. 13
Mounting.................................................................................................... 14
Specifications............................................................................................ 15
Electrical Connections, Laser ................................................................. 16
“W” Type Lasers ................................................................................................17
Operation of Unit....................................................................................... 18
Tickle Pulse........................................................................................................19
Laser Command Signals ...................................................................................19
System Test.......................................................................................................20
Laser Indicator Lights ........................................................................................21
G = CPLD (Complex Programmable Logic Device) failure................... 21
Beam Expanders and Other First Optical Surfaces.............................. 22
Cooling Specifications .......................................................................................24
Water Filter.........................................................................................................24
Setting the Flow Rate ........................................................................................24
Condensation.....................................................................................................25
The D200/D250 Power Supply and Air Pump Unit................................. 26
Electrical Ratings...............................................................................................26
Environmental Conditions..................................................................................26
The D200/D250 Power Supply and Air Pump Unit................................. 27
Mechanical Outline ............................................................................................28
Connecting the Power Supply and Air Pump....................................................29
Power Supply and Air Pump Service.................................................................30
Serviceable Parts...............................................................................................31
Air Ventilation.....................................................................................................31
Directional Coupler: ...........................................................................................31
Troubleshooting........................................................................................ 32

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Hazard Information
Hazard information includes terms, symbols, and instructions used either in this manual or on
the equipment to alert both operating and service personnel to the recommended precautions in
the care, use, and handling of Class 4 laser equipment.
Terms
Certain terms are used throughout the manual or on the equipment labels. Please familiarize
yourself with their definitions and significance.
Danger Imminent hazards which, if not avoided, will result in death or serious
injury.
Warning Potential hazards which, if not avoided, could result in death or serious
injury.
Caution Potential hazards or unsafe practices which, if not avoided, may result in
minor or moderate injury.
General Hazards
Danger - Serious Personal Injury
This Class 4 laser product emits invisible infrared laser radiation at 10.6µm.
Do not allow laser radiation to enter the eye by viewing direct or reflected laser energy.
CO2 laser radiation can be reflected from metallic objects even though the surface is
darkened. Direct or diffuse laser radiation can inflict severe corneal injuries leading to
permanent eye damage or blindness. All personnel must wear eye protection suitable for
10.6µm CO2 radiation when in the same area as an exposed laser beam. Eyewear protects
against scattered energy but is not intended to protect against direct viewing of the beam.
Never look directly into the laser output aperture or view scattered laser reflections from
metallic surfaces even when wearing goggles. Instant blindness can occur.
This laser presents a particular danger due to its very high-power density. The optical
intensity at the output window is VERY high (>8500W/cm2).
Enclose the beam path whenever possible. Exposure to direct or diffuse CO2 laser
radiation can seriously burn human or animal tissue, which may cause permanent damage
This product is not intended for use in explosive, or potentially explosive, atmospheres.

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General Hazards
Warning –Serious Personal Injury
U.S. customers should refer to and follow the laser safety precaution described in
the American Nation Standards Institute (ANSI) Z136.1-2014 document, Safe Use of
Lasers. Procedures listed in this Standard include the appointment of a Laser
Safety Officer (LSO), Operation of the product in an area of limited access by
trained personnel, servicing of equipment only by trained and authorized
personnel, and posting of signs warning of the potential hazards.
European customers should appoint a Laser Safety Officer (LSO) who should refer
to and follow the laser safety precautions described in EN60825.1-2014 Safety of
Laser Products.
Warning –Serious Personal Injury
Materials processing with a laser can generate air contaminates such as vapors,
fumes, and/or particles that may be noxious, toxic, or even fatal. Material Safety
Data Sheets (MSDS) for materials being processed should be thoroughly evaluated
and the adequacy of provisions for fume extraction, filtering, and venting should
be carefully considered. Review the following reference for further information:
ANSI Z136.1-2014, Safe Use of Lasers
Warning –Serious Personal Injury
The use of controls or adjustments, or performance of procedures other than those
specified herein may result in hazardous radiation exposure.
Other Hazards
The following hazards are typical for this product family when incorporated for intended use: (A)
risk of injury when lifting or moving the unit; (B) risk of exposure to hazardous laser energy
through unauthorized removal of access panels, doors, or protective barriers; (C) risk of
exposure to hazardous laser energy and injury due to failure of personnel to use proper eye
protection and/or failure to adhere to applicable laser safety procedures; (D) risk of exposure to
hazardous or lethal voltages through unauthorized removal of covers, doors, or access panels;
(E) risk of exposure and/or interference from radio-frequency (RF) electro-magnetic energy
through unauthorized removal of covers, doors, or access panels; (F) generation of hazardous
air contaminants that may be noxious, toxic, or even fatal.

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Infinity Series Label Locations

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Laser Safety
To prevent exposure to direct or scattered laser radiation, follow all safety precautions specified
throughout this manual and exercise safe operating practices per ANSI Z136.1-2014 at all times
when actively lasing.
Always wear approved Laser Safety glasses with a minimum OD (Optical Density) 4.494 for a
wavelength of 10.6µm.
A CO2laser is capable of igniting most materials under the proper conditions. Never operate the
laser in the presence of flammable or explosive materials, gases, liquids, or vapors.
**NOTICE**
The output aperture comes covered by a clearly marked dust guard that
must be removed before use. Firing the laser through the cover WILL
cause permanent destruction of the laser.
IEC 60825-1
MPE (Maximum Permissible Exposure) = 1.00e-1
NOHD (Nominal Ocular Hazard Distance) = 1.68e+2

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Declaration of Conformity
When integrating Iradion’s Destiny Series Lasers, the Buyer and/or integrator of the end
system is responsible for meeting all applicable Standards to obtain the CE mark. To aid in this
compliance process, Iradion’s testing program has demonstrated that Infinity-Series lasers
comply with the relevant requirements of 2014/30/EU, the Electromagnetic Compatibility
Directive, as summarized in the table below.
Table 1. European Union Directives.
Applicable Standards / Norms
2014/30/EU
Electromagnetic Compatibility Directive
2006/95/EC
Low Voltage Directive
2015/836/EU
RoHS Directive
EN 61010-1-2010
Safety Requirements for Electrical Equipment for Measurement,
Control, and Laboratory Use - Part 1: General Requirements
EN 61000-6-4:2007
EN 61000-6-4:2007
Radiated Emissions Group 1, Class A
Conducted Emissions Group 1, Class A
EN 61000-6-2:2005
EN 61000-6-2:2005
EN 61000-6-2:2005
EN 61000-6-2:2005
Electrostatic Discharge Immunity
RF Electromagnetic Field Immunity
Electrical Fast Transient/Burst Immunity
Conducted RF Disturbances Immunity
After a laser or laser processing system has met the requirements of all applicable EU
Directives, the product can bear the official compliance mark of the European Union as a
Declaration of Conformity.
After a laser or laser processing system has met the requirements of all applicable EU
Directives, the product can bear the official compliance mark of the European Union as shown
in the figure below and a Declaration of Conformity is provided for the compliant component.

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Declaration of Conformity
in accordance with ISO / IEC 17050‐2:2010
Manufacturer’s Name:
Manufacturer’s
Address:
Iradion Laser, Inc.,
One Technology Drive
Uxbridge, MA 01569 U.S.A.
Hereby declare under our sole responsibility that the following equipment:
Product Name:
Model Number:
Destiny Series
D200 & D250
Conforms to the following Directive(s) and Standard(s):
Applicable Directive(s):
2014/30/EU
2014/35/EU
2011/65/EU
Electromagnetic Compatibility Directive
Low Voltage Directive
RoHS Directive
Applicable Standard(s):
EN 61010‐1:2010
EN 60825‐1‐2:2007
EN 61000‐6‐4:2007
EN 61000‐6‐4:2007
EN 61000‐6‐2:2005
EN 61000‐6‐2:2005
EN 61000‐6‐2:2005
EN 61000‐6‐2:2005
Safety Requirements for Electrical Equipment for Measurement,
Control, and Laboratory Use ‐Part 1: General Requirements
Safety of Laser Products
Radiated Emissions, Group 1, Class A
Conducted Emissions, Group 1, Class A
Electrostatic Discharge Immunity
RF Electronic Fields Immunity
Electrical Fast Transient/Burst Immunity
Conducted RF Disturbances Immunity
*Lasers are not subject to EN 60825‐1:2014, Safety of Laser Products. Buyers of laser
products are solely responsible for meeting applicable Directives and Standards for CE
compliance and marking, since the final product will itself be subject to this standard.
Corporate Officer:
Philippe Brak, President/CEO
Date: 7/30/2020
MADE IN THE U.S.A

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Introduction
This guide provides the basic information needed to operate an Iradion Laser. This laser is
designed for use while integrated within a system and is not designed to meet CDRH
requirements as a stand-alone product. As such, the user must be aware of certain
requirements before use.
CDRH
This is an OEM laser component that has been designed for integration into a functioning laser
system. As a stand-alone device, it cannot be turned on and therefore does not incorporate all
of the safety features required by the Center for Devices and Radiological Health (CDRH).
Provisions for the incorporation of these safety features are available, and it is expected that the
user will apply them and fully comply with all CDRH requirements.
Available Safety Features
The following safety features are available as electronic signals on the laser’s HD-15 control connector:
Interlock
Upon contact closure, allows the system to operate.
An open connection will disallow the laser from firing.
Key switch
Upon contact closure, allows the laser to fire after
imposing a 5-second delay. (Key switch function is
program version dependent.)
Power up in Fault
Requires the key switch to be cycled. (Program
version dependent.)
Lase signal
Output signal indicating the laser is firing.
Fault signal
Output signal indicating the malfunction of an internal
component or the electronics.
Indicator lights
DC Power, Temp Warning, Interlock, Fault, Ready,
Lase

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System Overview
This Iradion laser is a waveguide laser with a “slab” unstable optical resonator. The beam is
corrected by a patented internal correction scheme to generate a nearly round beam.
The Iradion D200 CO2laser is rated at 200W and the D250 is rated at 250W. These lasers
include an integrated RFPA and separate power supply/air supply in 2 packages. Connectors
in the rear provide the interface to control signals, power, water, air and returns diagnostic
signals and faults signals. Connector pins and associated electronics are protected against
static ESD damage. DC power and filtered air is supplied from a separate unit designed to
maintain the proper voltage, current and airflow to avoid system faults.
Because this laser is small with a low thermal mass, it becomes overheated internally in only
60 seconds without cooling. Although it does have a thermal protect function, these lasers
depend on the flow of water to stay cool. For that reason, the D200/D250 monitors the actual
flow rate of water and will fault below or above specified limits. (See section on cooling.)
The D200/D250 also includes airflow monitoring and will fault if the airflow is too high or low.
Because the exact regulation of house air can be difficult, the D200/D250 comes with a
specially configured air pump and filters. Internal sensor settings ensure that the laser will
operate without faults when fed from this pump. This laser will not operate without an air
source. (See section on air flow.)
The D200/D250 also includes an RS232 interface to allow monitoring of the settings and flows.
Iradion can provide a special Windows™based application that reports parameters including
water and air flow as well as the voltage, temperature, fault codes, serial number and other
parameters.
This Iradion laser is class IV laser product that can burn skin, start fires and generate smoke.
Proper smoke evacuation may be required. A proper target or backstop must be provided.
This model can exceed 300 Watts of power under normal operation.

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Caution
There are no user serviceable parts under the cover. Removal of the RF cover must be
done according to a procedure or damage could occur. (The RF cover edges are RF
sealed to the top heat sink, which makes it very difficult to slide off the cover.) The laser
may not operate properly without the cover in place. There are dangerous RF voltages
under the cover that will cause serious RF burns to skin if touched.
Caution
There are no user serviceable parts in the AC Power Supply.
Caution
The optical intensity at the output window is VERY high (>8500W/cm2). Any
contamination to the window surface could cause runaway destruction. To protect the
window, Iradion provides a power supply unit that includes a long-life air pump and
filters to bathe the window in clean filtered air. Do NOT burn materials close to the
laser. The flow of air may not be enough to overcome the explosive vaporization of
objects near the output aperture.
**NOTICE**
The output aperture comes covered by a clearly marked dust
guard that must be removed before use. Firing the laser through
the cover WILL cause permanent destruction of the laser.
THE FOLLOWING SECTIONS MUST BE REVIEWED BEFORE ANY
ATTEMPT IS MADE TO POWER UP THE UNIT!

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Technical Drawings

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Mounting
On the bottom of the laser there are 22 mounting holes provided (4mm x 9mm deep).
The laser must be mounted on three (3) points so that no stress is imparted to the
structure. The mounting holes are provided so the user can select 3 holes or 3 sets of
holes to attach mounting pads. The mounting pads must create a minimal space under
the laser.
The simplest mounting would be with three (3) spherical washers using two (2) of the holes in
the front corners and one (1) in the center rear. For increased mounting strength, a cluster of
three or four holes in a corner can be used to attach a mounting bracket of the user’s design.
Three of these mounting brackets would make up the 3-point mounting. This might be a better
solution for situations in which the laser is mounted to a gantry that imparts accelerations to
the laser with associated high stresses at the mounting points.

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Specifications
Destiny
Model
D200
D250
Nominal Power
200 W
250 W
Beam Quality
M2 ≤1.2
M² ≤1.2
Beam Ellipticity
< 1.2:1
< 1.2:1
Beam Diameter, 1/e2 @ 0 m
2.5 ±0.5 mm
2.5 ± 0.5 mm
Beam Divergence (full angle)
6 ± 1 mrad
6 ± 1 mrad
Wavelength
10.6 µm, 10.2 µm
10.6 µm, 10.2 µm
Rise Time
<75 µs
<75 µs
Power Stability*, Water
< ± 4%
< ± 5%
Polarization
Vertical to the mounting plate
Vertical to mounting plate
Cooling
Water
Water
Input power / Heat Load
2340 W
2640 W
Input Voltage, Current
45 V / 52 A
48 V / 55 A
Frequency Range
0.1 - 140 kHz
0.1 -140 kHz
Operating Temperature
5˚C - 40˚C / 40˚F - 104˚F
5˚C - 40˚C / 40˚F - 104˚F
Operating Humidity
Non-Condensing
Non-Condensing
Shipping Temperature
-10˚C - 60˚C / 14˚F - 140˚F
-10˚C - 60˚C / 14˚F - 140˚F
Weight
24.6 kg / 52 lbs.
24.6 kg / 52 lbs.
Dimensions L x W x H
684 x 196 mm x 99 mm
684 x 196 mm x 99 mm
*Power Stability is measured after 5 minutes ofwarmup.
Iradionfollows a policy of continuous product improvement. All specifications are subject to change without notice.

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Electrical Connections, Laser
There are two signal connectors and two power terminals on the rear of the laser available for
operation of the laser. The 15 pin “D” connector contains all the available connections for
operation. The RJ-45 connector contains a basic set of connections.
Power Cable Connections
Designation
Description
Comment
Black
Power Ground
6-gauge welding wire
Red
Power VDC positive connection
6-gauge welding wire
Screw torque should equal 3 Nm.
DO NOT ROTATE THE CONNECTOR’s MAIN MOUNTING NUT
AS INTERNALL DAMAGE MAY OCCUR.
Connector (HD-15 pin “D”) *
*The use of standard Video cables with a HD 15 pin connector is not permitted when
interfacing to this connector.
Designation
Pin
Description
Comment
HD-15 Pin
1
CTL TXD
RS 232 Transmit.
HD-15 Pin
2
CTL RXD
RS 232 Receive.
HD-15 Pin
3
Modulation Low In
This line grounded or driven independently for
command line isolation. (Page 19)
HD-15 Pin
4
Modulation High In*
TTL signal relative to pin 3.
(Page19)
HD-15 Pin
5
Ready LED Drive
Signal to drive an LED directly with grounded
cathode. 5V @ 33mA, 150Ω series resistor.
HD-15 Pin
6
Key Switch in
Ground this line through key switch to arm laser.
HD-15 Pin
7
Fault LED drive pin
Signal to drive an LED directly with grounded
cathode. 5V @ 33mA, 150Ω series resistor.
HD-15 Pin
8
Forward Monitor Out 1
Signal use optional.
HD-15 Pin
9
Reflected Monitor Out 1
Signal use optional.
HD-15 Pin
10
Forward Monitor Out 2
Signal use optional.
HD-15 Pin
11
Lase LED drive pin
Signal to drive an LED directly with grounded
cathode. 5V @ 33mA, 150Ω series resistor.
HD-15 Pin
12
Reflected Monitor Out 2
Signal use optional.
HD-15 Pin
13
Interlock signal
Ground this line through switch to enable laser.
HD-15 Pin
14
Ground
System Ground.
HD-15 Pin
15
Temperature Warning LED
drive pin
Signal to drive an LED directly with grounded
cathode. 5V @ 33mA, 150Ω series resistor.
BLACK
RED

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Connector (RJ-45)
RJ-45
1
Modulation High in
TTL relative to GND or Pin 6.
(Page 19)
RJ-45
2
Fault LED drive pin
Grounded Cathode
RJ-45
3
Interlock
Grounded Interlock will enable
laser.
RJ-45
4
CTL TXD
RS232 Comm line
RJ-45
5
CTL RXD
RS232 Comm line
RJ-45
6
Modulation low in
This line grounded or driven
independently for command line
isolation. (Page 19)
RJ-45
7
Ground
System GND
RJ-45
8
Ground
System GND
Note: This unit is provided with a 1-meter length of 6-gauge welding cable for DC power. If the
wire is extended in length, it must be of 6 gauge or heavier and must be able to carry 60 Amps
with no more than 0.5 Volts drop. Avoid adding more than 1 meter of additional wire unless it
is heavier than #6. This laser is provided with prewired power supplies that are set to 50Volts.
Do not attempt to adjust the voltage of either power supply! No damage can occur to the laser
if the DC voltage is in the range of 0 to 50 Volts; however, the laser will operate only at the
specified voltage. The software will allow for -2/+1.5 Voltage variation including line drops at
high current settings. If output becomes intermittent and the fault lamp flashes on and
off, the voltage drop on the power cable may be too large or the power supply
connections may be bad. If the fault lamp lights up on power up, check the power
supply voltage.
“W” Type Lasers
Water cooled lasers require ½ inch plastic hose water connections before operation. See
“Other Connection Details” below. D200/D250 water cooled lasers detect water flow. If the
laser is operated without water flow or if the laser is not receiving enough water, a fault will
occur (see fault light chart). If the flow is too high, the pressure may exceed the maximum limit
of 60 psi and a fault will occur. Flow rates exceeding 4 gallons/min. are not recommended or
needed. If the water flow becomes too high or too low, there will be a 10 second delay before
the water fault occurs.

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Operation of Unit
1. Mount the laser in a manner such that the beam will strike a target capable of absorbing
>300 watts of power. Make sure that the aperture is clear of obstruction. See pages 14
and 15 for the power supply connections. Remove the aperture cover.
2. Confirm that the signal connections to the laser are secure and tight. Make sure that
the power supply unit is correctly connected, including the blue air hose. Make sure the
inner desiccant and outer air filters are in place. (The desiccant filter must be changed
every 300 to 700 hours of operation depending on the humidity.) Make sure that the
water connections are in place and the water flow direction is correct.
3. Connect the laser power leads to power supply terminals, Red (+) and Black (-) using at
least 6-gauge wire. Be careful not to over-tighten the 7/16” bolt on the (+) connection at
the laser. This connection is part of an RF feed-through filter and can be damaged.
4. Make sure the "INTERLOCK" is off or the interlock line is ungrounded.
5. Start the water flow. Make sure that the water is flowing out of the flow turbine
assembly.
6. Power up the DC supply. Check that the fault light is off and the ready light is on. Wait
20 seconds. If the ready light is still on after 20 seconds, then the air and water flow is
within the proper range.
7. If the Key Switch function is enabled, this line must be toggled from off to on to arm the
laser. If the switch is closed when power is applied, then turn it off and then on. There
will be a 6 second delay before the green "READY" light lights. This switch must be
toggled to arm the system after power up. (NOTE: This function depends on the
software version and programing. OEM lasers are shipped without this function.)
8. When the system arms to "READY" and the interlock line is closed, the "LASE" light
might also light faintly if the tickle is being applied. The "LASE" light will get brighter as
the power (PWM duty) increases. This is normal.
oIf a tickle signal is being used, the “Modulation Hi” connection to the laser
requires that the command signal contain a tickle pulse of 1 to 3 S at 5,000 Hz
when the laser is not being commanded to fire. The laser control card can be
programed to stretch incoming pulses up to 10µS. This allows the tickle signal to
be adjusted to just under the threshold of lasing. (See Tickle Pulse section)
Tickle rates of greater than 5,000 Hz will result in dangerous conditions (possible
unexpected low-level emissions). When the laser is being commanded, the
modulation rate can be up to 150 KHz. (NOTE: OEM lasers are shipped with
the pulse stretch function disabled. In this case, the user must provide the
correct tickle protocol at all times.)
oMake sure there is enough water-cooling capacity available to dump the heat.
The D250 requires a water chiller capable of cooling a 3000-Watt load.

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Tickle Pulse
This option is supplied by the customer, Iradion DOES NOT supply the tickle pulse inside the
laser.
Laser Command Signals
During laser bench testing, it is recommended that command signals be generated from an
Iradion Laser Controller or properly programed pulse generator. These units can provide the
tickle pulse and drive signals needed to test and operate the laser properly. Alternatively, most
motion control software packages are designed to provide the proper pulse protocol.
The Modulation pins on both the “D” connector, pin 3 (low) and 4 (high), and the RJ-45, pins
1 (high) and 6 (low), are designed to allow either floating or grounded input modes.
Both the High and Low pins should be used in either case. A software setting made
through the RS232 interface will either ground Modulation Low or leave it floating. Factory
setting is set to ground Modulation Low.
It is possible to use the Modulation High pin only if the Modulation Low pin is grounded by
software settings or by a physical wire, however, depending on the ground integrity of the host
system and level of ground noise this may not be the best solution.
The diagram below shows the circuit of the modulation input interface:

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System Test
The operation of the laser is possible after the above connections are completed. To test the
laser, apply DC power (and the tickle command signal if desired). If the software settings
require a key switch, toggle it off and on. After about 6 seconds the system is armed.
The interlock connections must be closed to operate the system.
Fault conditions can be detected by viewing the LED indicators on the rear of the laser. Water
and airflow faults take 20 seconds to indicate a fault. The signals monitored with LEDs are:
LASER READY
Lights (cw) when the laser controller is ready for operation
OVERTEMP
Lights (cw) when the RFPA is getting too hot*
FAULT
Lights (or blinks) when the controller is in a Fault state
LASE LED
Lights with varying brightness whenever RF power is generated
POWER
Lights (cw) whenever DC power is applied
INTERLOCK
Lights (cw) when the interlock switch is closed
WATER FLOW
Fault (cw) and Temp blink when too low or high flow rate
AIR FLOW
Fault blinks and Temp cw when air is out of range
*The D200/D250 is water cooled and therefore the Overtemp light should never light up;
however, if the cooling water gets hot enough this light will come on and the laser will fault.

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Laser Indicator Lights
The following chart is provided for clarity and is specific to the D250 water cooled laser:
RED
FAULT
off
On
on
blink
on
blink
blink
YELLOW
WARN
on
On
off
on
blink
blink
off
Condition:
A
B
C
D
E
F
G
A = Getting hot warning, but no-fault condition.
B = System faults: too hot/water too hot.
C = System fault: over/under voltage, other faults.
D = No air flow (system in continuous fault)
E = No or low water flow, too much water flow/pressure (system in continuous fault)
F = In the D250 configuration, this state is not allowed.
G = CPLD (Complex Programmable Logic Device) failure
Note: A blinking red light is the same level of fault as a solid red light.