Iradion Infinity Series User manual

www.iradion.com
Iradion Laser, Inc.
51 Industrial Dr.
N. Smithfield, RI 02896
[phone]
92-3026 Rev. A
MADEinUSA
OPERATOR’S MANUAL
Infinity Series
CO2Laser: Model 1625

ii
Table of Contents
Hazard Information......................................................................1
Terms.......................................................................................................... 1
General Hazards ..........................................................................2
Infinity Series Label Locations...................................................4
Laser Safety..................................................................................6
Other Hazards ..............................................................................6
Declaration of Conformity...........................................................7
Introduction..................................................................................8
CDRH.............................................................................................8
Available Safety Features...........................................................8
System Overview.........................................................................9
Specifications.............................................................................11
Mechanical Outline, Laser ........................................................12
Mounting.....................................................................................13
Electrical Connections, Laser ..................................................14
“W” Type Lasers ....................................................................................... 16
Operation of Unit .......................................................................16
Tickle Pulse............................................................................................... 17
Laser Command Signals.......................................................................... 18
System Test.............................................................................................. 19
Laser Indicator Lights............................................................................... 19
Indicator Lights Details............................................................................. 20
Beam Expanders and Other First Optical Surfaces...............21
Water Cooled Laser Connections............................................22
Cooling Specifications.............................................................................. 23
Water Filter ............................................................................................... 23
Setting the Flow Rate............................................................................... 23
Condensation............................................................................................ 24
The 1625 Power Supply and Air Pump Unit............................25
Electrical Ratings...................................................................................... 25
Environmental Conditions ........................................................................ 25
Mechanical Outline................................................................................... 27

iii
Connecting the Power Supply and Air Pump........................................... 28
Power Supply and Air Pump Service....................................................... 29
Serviceable Parts...................................................................................... 30
Air Ventilation............................................................................................ 30
Troubleshooting ........................................................................31
Directional Coupler:.................................................................................. 31

1
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.

2
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.
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.

3
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.

4
Infinity Series Label Locations

5

6
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.
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.
IEC 60825-1
MPE (Maximum Permissible Exposure) = 1.00e-
1
NOHD (Nominal Ocular Hazard Distance) =
1.68e+2

7
Declaration of Conformity
In accordance with ISO / IEC 17050-2:2004
We,
Manufacturers Name: Iradion Laser, Inc.
Manufacturers Address: 51 Industrial Drive
North Smithfield, RI 02896
USA
Hereby declare under our sole responsibility that the following equipment:
Product Name: Infinity
Model Number: 1625
Conforms to the following Directive(s) and Standard(s):
Applicable Standard(s):
IEC 60825-1, 3rd Ed., 2014Safety of Laser Products
EN 55011:2009/A1:2010 Group 2 Class A ISM emissions requirements (EU)
EN 61000-6-4:2007 Emissions requirements for heavy industrial
environments - Generic
EN 61000-6-2:2005 Immunity for heavy industrial environments - Generic
Serial Number Range:
5000 dec.
Corporate Officer:
Date
11 May, 2016

8
Introduction
This guide provides the basic information needed to operate an Iradion 1625 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 needs to 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 the safety features are available, and
the user is expected to apply them and fully comply with all CDRH requirements.
Available Safety Features
The following safety features are available as electronic signals on the rear panel
interface:
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

9
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 1625 CO2laser is rated at 250W and includes 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, the
1625 depends on the flow of water to stay cool. For that reason, the 1625 monitors the
actual flow rate of water and will fault below or above specified limits. (See section on
cooling.)
The 1625 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 1625 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 1625 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.

10
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.
The output aperture comes covered by a clearly marked dust
guard that must be removed before use. Firing the laser
through the cover WILLcause permanent destruction of the
laser.

11
THE FOLLOWING SECTIONS MUST BE REVIEWED BEFORE
ANY ATTEMPT IS MADE TO POWER UP THE UNIT!
Specifications

12
Mechanical Outline, Laser

13
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.

14
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
Pin
Description
Comment
Black
-
Power Ground
6 gauge welding wire
Red
-
Power VDC positive
connection
6 gauge welding wire
Screw torque should equal 3 Nm.
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.
HD-15 Pin
1
CTL TXD
RS 232 program line
HD-15 Pin
2
CTL RXD
RS 232 program line
HD-15 Pin
3
Modulation Low In
This line grounded or
driven independently
for command line
isolation. (Page 9)
HD-15 Pin
4
Modulation High In
(up to 150KHz)
TTL signal relative to
pin 3. (Page 9)
HD-15 Pin
5
Ready LED drive pin
Signal to drive an LED
directly with grounded
cathode.
HD-15 Pin
6
Key Switch in
Ground this line
through key switch to
arm laser. (page 10)
HD-15 Pin
7
Fault LED drive pin
Signal to drive an LED
directly with grounded
cathode.
HD-15 Pin
8
Forward RF monitor 1
output
Signal use optional
(page 9)
HD-15 Pin
9
Reflected RF monitor 1
Signal use optional
HD-15 Pin
10
Forward RF monitor 2
Signal use optional

15
HD-15 Pin
11
Lase LED drive pin
Signal to drive an LED
directly with grounded
cathode.
HD-15 Pin
12
Reflected RF monitor 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.
Connector (RJ-45)
RJ-45
1
Modulation High in
TTL relative to GND
or Pin 6. (Page 9)
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 9)
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
not allow more than ≈± 1 Volt 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.

16
“W” Type Lasers
Water cooled lasers require ½ inch plastic hose water connections before operation.
See “Other Connection Details” below. 1625 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.
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.

17
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 1625 requires a water chiller capable of cooling a 3000 Watt
load.
Tickle Pulse
Iradion has chosen to follow the industry convention and make provision for the
inclusion of a “tickle pulse” function to keep the laser lit during down time. The intent of
the tickle pulse is to improve the pulse-to-pulse consistency and timing relative to firing
commands received from the control electronics. This function may be disabled if
required by the customer. If disabled, there is no signal processing done to incoming
commands to fire. Adjustments to the signal processing can be made via the RS232
interface covered in the Iradion LCC Comm Protocol document.
The laser command line (modulation high) requires a 1 to 3 Sec pulse repeated at 200
Sec intervals when there is no output commanded. Within the laser control board,
there is an adjustable pulse stretcher that is set to just below the threshold of the laser
producing light, assuming the implied 5000 Hz tickle rate.
Warning
If the tickle rate becomes higher due to software settings or deliberate measures,
there is a danger of unintended laser emission.
If the user desires to control the sub threshold tickle within the external host control
software, Iradion will set the tickle stretch to 0 Sec upon request before shipping. This
would be required if, for example, the software required a tickle rate greater than 5000
Hz.
Generally, all OEM lasers are shipped with the Pulse Stretch set to 0µS.
Setting the pulse stretch to greater than 0µS will limit the maximum pulse frequency and
alter the linearity of the laser response to PWM duty.