Iradion Infinity Series User manual

92-3005
MADEinUSA
OPERATOR’S MANUAL
Infinity Series
CO2Laser: Models 155 through 1512
www.Iradion.com

92-3005 2
Table of Contents
Table of Contents........................................................................2
Hazard Information......................................................................3
Terms......................................................................................................3
General Hazards..........................................................................4
Infinity Series Label Locations ..................................................6
Laser Safety.................................................................................7
Other Hazards..............................................................................7
Declaration of Conformity..............Error! Bookmark not defined.
Introduction .................................................................................8
CDRH..........................................................................................10
Available Safety Features.........................................................10
System Overview ......................................................................11
Quick Start Connection Guide.................................................12
Power Cable, All Lasers........................................................................ 12
Connector (RJ-45), All Lasers ............................................................... 12
Connector (HD-15), Lasers Shipped AFTER January 1, 2016............... 13
Connector (HD-15), Lasers Shipped BEFORE January 1, 2016............ 14
Nominal Operating Voltages.................................................................. 15
“F” Type Lasers..................................................................................... 15
“W” Type Lasers.................................................................................... 15
Operation of Unit.......................................................................16
Tickle Pulse........................................................................................... 17
Laser Command Signals....................................................................... 18
System Test.......................................................................................... 19
Laser Indicator Lights............................................................................ 19
Water Cooled Laser Connections.......................................................... 20
Condensation........................................................................................ 22
Iradion RS232 Com Test Software...........................................23
Mechanical Outline ...................................................................24
Specifications, 10.2µm and 10.6µm.........................................25
Specifications, 9.3µm................................................................26
Troubleshooting........................................................................27

3
Hazard Information
Hazard information includes terms, symbols, and instructions used 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.

4
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. CO2laser 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 CO2radiation 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.
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) Z136.1-2007 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 EN60825.1-2007,
Safety of Laser Products.

5
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 Z136.1-2007, 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.

6
Label Locations

7
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 Z136.1-2007 at all times
when actively lasing.
Always wear approved Laser Safety Glasses with a minimum OD (Optical Density) 4.27 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.

8
Declaration of Conformity
In accordance with ISO / IEC 17050-2:2004
We,
Manufacturers Name: Iradion Laser, Inc.
Manufacturers Address: One Technology Drive
Uxbridge, MA 01569
USA
Hereby declare under our sole responsibility that the following equipment:
Product Name: Infinity
Model Number: 15XX
Conforms to the following Directive(s) and Standard(s):
Applicable Standard(s):
IEC 60825-1, 3rd Ed., 2014 Safety 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:
Starting at serial number 2190 (Decimal)
Corporate Officer:

9
Declaration of Conformity
The European Union has established requirements for Restriction of Hazardous Substances (RoHS) in
all Electrical and Electronic Equipment (EEE). On 4 June 2015, the EU commission has published a
new Directive (EU) 2015/863 to amend Annex II to EU RoHS 2 (Directive 2011/65/EU) to add the
following 4 phthalates onto the list of restricted substances.
Bis(2-Ethylhexyl) phthalate (DEHP): max 0.1%;
Benzyl butyl phthalate (BBP): max 0.1%;
Dibutyl phthalate (DBP): max 0.1%;
Diisobutyl phthalate (DIBP): max 0.1%.
We, Manufacturers Name: Iradion Laser, Inc.
Manufacturers Address: One Technology Drive
Uxbridge, MA 01569
USA
Certify that to its knowledge that the products listed below conform to the requirements of the European
Union’s Restriction on Use of Hazardous Substances in EEE RoHS II Directive (EU) 2015/863 to
amend Annex II to EU RoHS 2 (Directive 2011/65/EU) which may or may not include exemption in the
directive.
Product Name: Infinity Model Number: 15XX
To comply with RoHS II, all CE marked products require a Declaration of Conformity (DoC) and that a
technical file be made available upon request. For finished EEE where Iradion Laser, Inc. is the legal
manufacturer, Iradion will provide the CoC and the technical documentation. Iradion will make available
part-specific Certificates of Compliance demonstrating compliance to the banned substances of RoHS
II.
10 hazardous substances will now be restricted in EEE under EU RoHS 2.
Cadmium(Cd): 0.01%
Mercury: 0.1%
Lead(Pb) : 0.1%
Hexavalent chromium (Cr6+) : 0.1%
Polybrominated biphenyls (PBB): 0.1 %;
Polybrominated diphenyl ethers (PBDE): 0.1 %
Bis(2-Ethylhexyl) phthalate (DEHP): 0.1% (added in 2015);
Benzyl butyl phthalate (BBP): 0.1% (added in 2015);
Dibutyl phthalate (DBP): 0.1% (added in 2015);
Diisobutyl phthalate (DIBP): 0.1% (added in 2015)
Based on our own internal analyses, vendor supplied analyses, and/or material certifications of the raw
materials used in the manufacture of Iradion Laser, Inc. We declare the products listed above, starting
at serial number 8000 (decimal), comply with and conform to RoHS regulations.
Corporate Officer:

10
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 rear panel interface:
Interlock Upon contact closure, allows the system to operate. An open
connection will prohibit 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.

11
System Overview
Iradion CO2lasers are rated from 50 to 120Watts. They can be overpowered to up to 180 Watts,
and they all integrate RFPA and cooling in one package. Two connectors in the rear provide the
interface to control signals, power, and returns diagnostic signals and faults signals. Connector
pins and associated electronics are protected against static ESD damage. DC power is applied
to the one meter power cord.
Caution
There are no user-serviceable parts under the cover. The RF cover must be removed
according to procedure; otherwise, 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 the skin if touched.
Caution
The lasers are waveguide lasers with a “slab” unstable optical resonator. The resulting
elliptical beam is corrected by a cylindrical lens in the black extension tube mounted to
the faceplate. This assembly is exactly positioned so that the beam direction is close to
the original elliptical beam. Removal of the cylindrical lens assembly will result in the loss
of this original alignment and will require a procedure for replacement.
Caution
The optical intensity at the cylindrical lens is VERY high (>6000W/cm2).
Any contamination to the optical surface could cause runaway destruction of the lens.
Do NOT burn materials close to the lens or leave fingerprints on the lens.
Caution
The cylindrical lens comes with a pink plastic cap that covers the lens for protection.
Remove this cap before applying DC power. Firing the laser through the cap WILL
cause permanent damage to the lens.

12
Quick Start Connection Guide
There are two connectors 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, All Lasers
Designation
Pin
Description
Comment
Black
-
Power Ground
10 gauge wire to power supply Ground
Red
-
Power VDC positive
connection
10 gauge wire to power supply
Connector (RJ-45), All Lasers
Designation
Pin
Description
Comment
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.

13
Connector (HD-15), Lasers Shipped AFTER January 1, 2016
NOTE: 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 9)
HD-15 Pin
4
Modulation High In*
TTL signal relative to pin 3. (Page
9)
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. (Page 10)
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.
(Page 9)
HD-15 Pin
9
Reflected Monitor Out 1
Signal use optional.
HD-15 Pin
10
Forward Monitor Out 2
Not Used.
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
Not Used.
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.
*The laser may be modulated at up to 140 KHz.

14
Connector (HD-15), Lasers Shipped BEFORE January 1, 2016
NOTE: 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 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*
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. 12V at 25mA, 470Ω series resistor.
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. 12V at 25mA, 470Ω series resistor.
HD-15 Pin
8
Forward RF monitor
output
Signal use optional. (Page 9)
HD-15 Pin
9
Reflected RF monitor
out
Signal use optional.
HD-15 Pin
10
Ground
System Ground.
HD-15 Pin
11
Lase LED drive pin
Signal to drive an LED directly with grounded
cathode. 12V at 120mA, 100Ω series resistor.
HD-15 Pin
12
Ground
System Ground.
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. 12V at 25mA, 470Ω series resistor.
*The laser may be modulated at up to 140 KHz.

15
Caution
This unit is provided with a 1-meter length of cable for DC power. If the wire is extended
in length, #10 wire must be used. Do not add more than 1 meter additional wire unless
it is heavier than #10. Power supply regulation should be greater than ±2% and ripple
no greater than 400 mV. No damage can occur to the laser if the DC voltage is in the
range of 0 to 50 Volts; however, the laser will only operate at the specified voltage.
Check your power supply before attachment and adjust it to the specified voltage. The
software will not allow more than ≈± 2 Volts variation including line drops at high current
settings. If output becomes intermittent and the fault light flashes on and off, the
voltage drop on the power cable may be too large or the power supply may be
bad. If the fault light lights up on power up, check the power supply voltage
setting.
Nominal Operating Voltages
Model Number:
155
155 9.3
156
156 9.3
158
1510
1512
DC Voltage:
36V
45V
40V
50V
45V
50V
50V
“F” Type Lasers
Current production lasers are marked, for example, as 156F. These lasers are designed to
control fan operation internally based on the operating temperature. The fan will start operating
at 32°C or higher and will stop at 30°C or lower. This fan function is enabled via commands sent
over the RS 232 lines. If the fans do not start when power is applied, this means that the fan
function is disabled. If fans do not start with power up, this does not indicate fan malfunction!
Factory fresh lasers are always shipped with the fan function disabled. See the Iradion LCC
Comm Protocol_v1.5 for information on communicating with the laser control card.
“W” Type Lasers
Water cooled lasers require water connections before operation. See “Other Connection Details”
below. Water cooled lasers cannot detect water flow. If the laser is operated without water flow,
a fault will occur due to overheating after several minutes (depending on the operating duty).
Damage will not occur.

16
Operation of Unit
1. Mount the laser in a manner such that the beam will strike a target capable of absorbing
up to 180 Watts of power. Make sure that the airflow openings are clear of any
obstructions.
2. Confirm that the signal connections to the laser are secure and tight. Make sure that
the power supply is correctly adjusted and is capable of delivering a minimum of the
rated amps plus 2 amps margin.
3. Connect the laser power leads to DC, Red + using at least 10-gauge wire. The power
supply can affect laser performance! Use a high-quality, well-regulated supply.
4. Power up the DC supply. The fans should start. (The “F” fan option, when programed,
will not start the fans until the laser reaches a preset temperature.)
5. Make sure the "INTERLOCK" switch is down or off, or the interlock line is ungrounded.
6. The Key Switch line must be toggled from off to on to arm the laser. If the switch is
closed when power is applied, turn it off and then on. There will be a 6 second delay
before the green "READY" light lights up. (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.
7. When the system arms to "READY", if the tickle is being applied, the "LASE" light
should also light up when the interlock is enabled. The "LASE" light will get brighter as
the power increases; this is normal.
8. The “Mod 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. 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
reach up to 200 KHz. NOTE: OEM lasers may be shipped with the tickle function
disabled. In this case, the user must provide the correct tickle protocol at all
times.
9. Make sure there is enough cool air available to dump the heat! Do not obstruct the air
flow in any way or modify the fans. The laser should not be near heaters or other heat
sources that increase the ambient fan inlet temperature.

17
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_v1.5 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. There is an adjustable pulse stretcher within the
laser control board 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 increases due to software settings or deliberate measures, there is
a danger of unintended laser emission.
NOTE: If the user desires to control the sub-threshold tickle within the external host
control software, Iradion can 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.

18
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, pins 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:

19
System Test
The operation of the laser is possible after the above connections are completed. To test the
laser, apply power and the tickle command signal. If the software settings require a key switch,
toggle it off and on. After about 6 seconds, the system will be 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. The
signals monitored with LEDs are:
LASER READY
Lights up when the laser controller is ready for operation.
OVERTEMP
Lights up when the RFPA is getting too hot. Faults at Temp limit.
FAULT
Lights up when the controller is in a Fault state.
LASE LED
Lights up whenever signals are delivered to the RFPA FET bias.
POWER
Lights up whenever DC power is applied.
INTERLOCK
Lights up when the interlock switch is closed.
Laser Indicator Lights
Cooling Temp Lights Faults
Air 55˚C 60˚C
Water 35˚C 40˚C

20
Water Cooled Laser Connections
The 15XXWlasers require water cooling connections. The rear plate of these lasers is pictured
below:
Cooling Specifications:
Flow Rate
3.78 –7.56 liters/minute
Water Temp
Non-Condensing, 18˚C to 24˚C
Inlet Pressure
413kPa
Hardness
<250mg/liter
Heat Load
>1.5kW
pH
6 to 8
Particulate Size
<200 microns