Lumina Power LDD-3000 User manual

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USER MANUAL
LDD-3000 CW Laser Diode Driver

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Table of Contents
Product Overview 3
Explanation of Symbols 4
Theory of Operation 5
LDD-3000 Specifications 8
LDD-3000 Interface 9
Optional RS-232 Protocol 10
Installation and Operation 12
Tables and Figures
Figure 1 LDD-3000 Block Diagram 7
Table 1 LDD-3000 Specification Overview 8
Table 2 LDD-3000 Interface Pinout 9
Figure 2 LDD-3000 Interface Schematic 11
Figure 3LDD-3000 Input/Output Connections 12
Table 3LDD-3000 AC Input Requirements 13
Figure 4 LDD-3000 Outline Drawing 15

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Product Overview
The LDD-3000 laser diode driver is intended for OEM laser applications using high power diode
lasers. It has been designed to be integrated into systems for maximum performance at a cost far
below traditional laboratory and scientific diode laser drivers.
The LDD-3000 utilizes a proprietary low loss, high frequency power factor correction circuit which
keeps power factor above 0.98. Power factor corrected power supplies use up to 30% less input
current and meet stringent IEC harmonic requirements. The output inverter is a state-of-the-art zero
voltage switching (ZVS) inverter with permits very high frequency power conversion with minimum
losses.
As a diode laser driver, the LDD-3000 power supply acts as a current source and delivers constant
current based on the input program signal, Iprogram(+), which is normally 0-10V. An optional RS-
232 interface is available. All units are configured with a maximum current and maximum voltage
capability, depending on the user’s requirements. LDD-3000 will deliver current, as programmed,
into any load, providing the voltage requirements of that load do not exceed the maximum rated
voltage of the unit. When the required compliance voltage is higher then the maximum rated output
voltage of the unit, the unit will limit output current.

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Explanation of Symbols
Hazard:
This equipment produces high voltages
which can be fatal. Only service personnel of Lumina
Power, Inc. are qualified to service this equipment.
High Voltage Present.
This power supply produces
lethal high voltages. Only service personnel of Lumina
Power, Inc., are qualified to service this equipment.
Only qualified service personnel are permitted to install
this power supply.

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LDD-3000 Diode Driver Theory of Operation
(Refer to Figure 1)
The LDD-3000 has been designed specifically for the OEM high power CW laser diode systems. OEM
power supplies for the laser diode industry have the following requirements:
•Safe laser diode operation
•Broad range of control of output current
•Safe rise/fall times
•Auxiliary power supplies to simplify overall laser system design
•Power factor correction to conform with CE requirements
•Low conducted electromagnetic emissions
Referring to Figure 1, the “LDD-3000 Laser Diode Driver Block Diagram” , the following is a brief
description of operation.
AC Input Power Circuitry
AC input power is processed through a line filter to reduce the conducted EMI to an acceptable level.
The LDD-3000 line filter has minimum capacitance to ground to minimize leakage currents. Earth
Ground stud is provided near the AC input terminals and should be connected to the system ground.
Power Factor Correction Boost Inverter
The rectified input power is next applied to power factor boost inverter. This boost inverter boosts
the input power to 400VDC. In the process of boosting the input AC voltage, the input AC current is
adjusted so that is in phase with the input AC voltage. Without this power factor correction circuit,
the AC input current would be delivered to the power supply in high amplitude, narrow spikes, which
have a high harmonic content. With power factor correction, the non-50/60 Hz harmonics are
reduced to near zero. Since only the fundamental frequency is now used to deliver power, the
efficiency of the power supply is improved considerably.
One problem with standard input power factor correction circuits is that a high frequency switching
circuit is placed across the line on the input side of the traditional input capacitor filter. This results in
substantial switching noise conducted to the line. Lumina Power employs a proprietary soft-switching
boost inverter which produces minimum switching noise, reduces switching losses, and results in a
smaller heat sink associated with the power factor circuit.
Zero Voltage Switching (ZVS) Inverter
The ZVS inverter and the output transformer are used to step the 400VDC bus to the appropriate
output value. The ZVS inverter is the most modern high frequency/low loss/low noise topology
utilized in power electronics today. Instead of running the inverter in a traditional PWM mode, the
inverter is run in a phase shift mode. With the appropriate output inductor and the appropriate
capacitance across each switching device, in this case MOSFETS, there are virtually no switching
losses in the inverter. The only losses in the devices are I2R losses associated with the Drain/Source
resistance of the MOSFETS. Therefore, the ZVS inverter also contributes to reduced losses, reduced
EMI noise and a reduction in overall system heatsink requirements.
Output Circuit
The output filter is a two stage RC filter designed to keep ripple and output noise very low.

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Control Circuit
The control circuit handles all the responsibilities associated with safe operation of the laser diode.
Controlled rise and fall times, as well as tight current regulation, overvoltage and over power
protection are controlled and monitored in the control circuit.
Auxiliary Power
All internal power supply requirements as well as the external +/-15V and +5V power supplies are
derived from the power factor control boost inductor. All auxiliary power supplies are regulated by
standard linear regulators.

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Figure 1
LDD-3000 Block Diagram

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LDD-3000 Specifications
Model
Poutmax
Output Current
Input Voltage
Size (L x W x H)
LDD-3000-XX-YY 3000W Up to 200A 200-240VAC
17” x 16.6” x 3.4”
43.2cm x 42.2cm x 8.6cm
Where XX = Ioutmax
YY = Vcompliancemax
XX * YY cannot exceed 3000W
Auxiliary Outputs: +5V @0.2A, +15V @0.2A, -15V @0.2A
Table 1: Specification Overview
Input
Voltage: 200-240VAC, 21.5A-17.8A, 50-60Hz
Power Factor: >.98
Interface
Connector: 15 Pin “D” Sub Female
Current Program: 0-10V for 0-Max Current
Current Monitor: 0-10V for 0-Max Current
Voltage Monitor: 0-10V for 0-Max Voltage
RS-232 Interface available per special request.
Performance
Max Rep Rate: 500Hz
Rise/Fall Time: ~1msec standard, 600usec – upon request (10% to 90% Full Current)
Current Regulation: 0.5% of Maximum output current
Current Ripple: <0.5% of maximum output current
Current Overshoot: <1% of maximum output current
Power Limit: Limited to maximum power with power fold-back circuit
Environment
Operating Temp: 0 to 40 oC
Storage: -20 to 85 oC
Humidity: 0 to 90% non-condensing
Cooling: Forced air
Regulatory:
Industrial Safety: IEC60950-1:2001 (1st Ed.), EN60950-1:2001, UL60950-1, CSA 22.2 No. 60950-03
EMC Emissions: EN55022:1998 /A1:2000/A2:2003 Class A ITE emissions requirements (EU, AS/NZS)
ICES-003 Issue 4 Class A Digital Apparatus emission requirements (Canada)
VCCI Class A ITE emission requirements (Japan)
FCC 47 CFR Part 15 Class A emission requirements (USA)
EMC Immunity: EN 61000-6-2:2005 Immunity for heavy industrial environment-Generic.
RoHS compliant.
Leakage Current: <1800uA

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LDD-3000-XX-YY Interface
(Where XX = Iout max, and YY = Voutmax)
Connector Type: 15 pin D-sub Female
(Refer to Figure 2, LDD-3000 Interface Schematic)
RS-232 Interface available upon request.
Pin #
Pin Name
Functional Voltage
Level
Description
1 Enable
(input)
High = RUN = +5V to
+15V
Low = OFF = 0V
The Enable function turns the output section of the
power supply ON and OFF. When the power supply is
enabled, current is delivered to load as programmed via
Iprogram(+), Pin 7. Rise times resulting from Enable
are approximately 25msec.
2
Current Limit
(Input)
(OPTIONAL)
0-10V = 1-100% output
Current
Default = 105%.
This is the secondary protection. Output current will be
limited by this signal. Leaving it open defaults at 105%
current.
3
Interlock
(input)
Open = OFF
Connect to GND = RUN
The Interlock function can be connected to external
interlock switches such as door or overtemp switches.
4, 9,
15
GND
5
Vout Monitor:
(output) 0 – 10V = 0 – Voutmax
The output voltage of the supply can be monitored by
Vout Monitor.
6
Iout Monitor
(output)
0 – 10V = 0 – Ioutmax
The output current of the supply can be monitored by
Iout Monitor.
7
Iprogram(+):
(input)
0 – 10V = 0 – Ioutmax
The power supply output current is set by applying a 0-
10V analog signal to Iprogram(+).
8 Pulse Control
(input)
TTL High = On
TTL Low = OFF
Default = On
The output may be pulsed OFF by applying a TTL 0 to Pulse
Control, pin 8. When a TTL 1 is applied to pin 8, the amplitude
of the output current pulse is determined by the current level
programmed via Pin 7, Iprogram(+). Rise fall times of 1msec
are typical. The default condition is ON, which permits
CW operation with no connection to Pin 8.
10,11
+5V @ 0.2A
(output)
Auxiliary +5V power supply for user. Up to 0.2A output
current capability.
12
-15V @0.2A
(output)
Auxiliary -15V power supply for user. Up to –0.2A output
current available.
13,14
+15V @0.2A
(output)
Auxiliary +15V power supply for user. Up to 0.2A output
current available.
Table 2: LDD-3000 Interface Pinout

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Optional RS-232 Protocol
LDD-3000-XX-YY-RS
Refer to Figure 4, LDD-3000 Outline Drawing for location of RS-232 Connector
The RS232 interface for Lumina supplies has the following characteristics:
Baud rate: 9600
Command format: ASCII characters terminated by carriage return
Reply formats: ASCII characters terminated by carriage return
Connection: 9 Pin “D” Female (Tx: Pin 2, Rx: Pin 3, GND: Pin 5)
The interface supports programming the output current and power limit of the supply and reading back the
output current and voltage. The output can be turned on and off with a command as well.
Command Reply Function
P[email protected]<cr> <cr> Program output current to max rated output current
xx.xx between 0 and 10.00 = 0 – Ioutmax
(Note: Pxx.xx<cr> will also work)
I<cr> xx.xx<cr> Read output current xx.xx between 0 and 10.00 = 0
Ioutmax
V<cr> xx.xx<cr> Read output voltage xx. xx between 0 and 10.00 = 0
to Voutmax
ON<cr> <cr> Enable supply output
OFF<cr> <cr> Disable supply output
Jhkhkh<cr> ?<cr> Response to unrecognized command
Numbers sent to the supply should be in fixed point decimal format. The numbers sent back will have four
digits and a decimal point, but the resolution is limited to 12 bits and the accuracy is limited by the
specifications of the supply.
Connections to Analog Interface when using RS-232
Interlock function, Pin 3, must be employed whether using LDD analog interface or RS-232. None of the
other controls in the Analog interface need be utilized when using the RS-232 optional interface.

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Figure 2
LDD-3000-XX-YY Interface Schematic

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Installation and Operation of
LDD-3000 Diode Drivers
Figure 3
LDD-3000 Input/Output Connections
1. Installing the power supply: Refer to Figure 4, the LDD-3000 Outline Drawing. There are two 8-32
threaded PEM holes on both sides of the power supply which can be used to mount rack slides. Also,
there are four 10-32 threaded PEM holes on the bottom of the supply for mounting purposes. The
mounting screws should not penetrate the power supply more than 3/8”
2. Connecting to Diode Laser: Figure 3 shows the location of the LDD-3000 output terminals. Connect
diode laser load to the output terminals. Although CW diode laser applications are generally free of
voltage spikes associated with high speed Quasi-CW applications, it is still good practice to keep
connections between the diode laser and power supply as short as possible to minimize inductance and
avoid I2R losses in the wire.
IMPORTANT INSTALLATION NOTES
•The LDD-3000 diode driver is air cooled by internal fans. Do not restrict air
flow near the input or output air vents of the power supply. If the unit
overheats due to restricted air flow, it will shut down and remain off until the
unit has cooled to a safe operating temperature.
SAFETY WARNING
Because LDD-3000 is designed for OEM applications, the user must connect
AC input power to the power supply AC Input terminal strip. Any input AC
voltage must be considered extremely dangerous, and as such, care must be
taken to connect AC input power to the unit.

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3. Interface Connection: Connect user interface to Analog Interface 15 pin D-sub connector shown in
Figure 3. (Although this interface is typically designed by the user, Lumina Power can provide any
assistance necessary to modify interface program and monitor levels) See Table 2 and related schematic
for a description of the LDD-3000 Interface Pinout.
4. AC Input Power Connection: Connect AC power connections to power
supply input power terminals as follows (refer to Table 3 and Figure 3.):
MODEL
INPUT POWER
LDD-3000-XX-YY
200-240 VAC, 50/60 Hz,
Table 3: LDD-3000 Input Power
•AC Connections (#12AWG) are connected to the terminal strip connections shown in
Figure 3.
•Ground wire (#12AWG) is connected to the ground stud shown in Figure 3.
5. Apply AC Input Power: Turn ON AC power. After a few seconds the power supply fans should begin
to run.
6. Programming Output Current: Program LDD-3000 power supply for desired output current. A 0-
10V signal applied to interface pin 7 (see Table 2) will program the LDD-3000 diode driver for 0 to
maximum rated output current.
IMPORTANT APPLICATION NOTE
When the power supply is enabled using the ENABLE signal, internal soft
start functions limit the rise time of the output current to approximately
25msec. Once the power supply is enabled, the rise/fall time of the
Iprogram(+) signal is approximately 2msec. Slower rise/fall times are
available upon request. A rise/fall time of 2msec does not typically result in
dangerous voltage spikes on the diode laser.
IMPORTANT NOTE
Make sure when connecting interface that the current program
setting, Iprogram(+), is set no higher then the value required for
operation. When AC power is applied and system ENABLE is
applied, output current will rise to this program value
IMPORTANT APPLICATON NOTE REGARDING AC INPUT POWER
AC Input wires should be at least #12 AWG, rated for at least 300V and
105DegC.
IMPORTANT SYSTEM NOTE ON AC INPUT POWER
LDD-3000 units are fused on both lines.

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7. Enable Output: Enable LDD-3000 power supply by applying +15V to Enable Pin 1 (see Table 2).
Current will now be delivered to laser diode as programmed.
8. Current Monitor: Power supply output current can be monitored via pin 6 (see Table 2). A 0-10V
signal will represent the output current from 0 to maximum rated output current.
9. Voltage Monitor: Power supply output voltage can be monitored via pin 5 (See Table 2). A 0-10V
signal will represent the output voltage from 0-maximum rated output voltage.
10. Pulsing: The LDD-3000 laser diode driver is designed for CW applications. However due the fast
response achievable with very high frequency switchmode power supplies, it is possible to pulse this
unit at sub-Quasi-CW speeds. The typical rise and fall times of the LDD-3000 is ~ 1msec, but can be
configured for rise times as fast as 0.6msec. Therefore, pulsing at frequencies up to 500Hz is possible.
Pulsing can be accomplished with the Pulse Control function, Pin 8 (see Table 2). When Pin 8 is
grounded, an internal circuit defeats the Iprogram signal. When Pin 8 is High, Iprogram is delivered
to the control system as programmed. When no connection is made to Pin 8, the Pulse Control function
is internally set HIGH, permitting CW operation. The Pulse Control function is much faster than the
ENABLE function, which has a soft-start function.
Typical Response of Iout to ENABLE signal
Typical LDD-3000 Rise Fall Time using Pulse Function
Consult the factory for faster rise/fall times.
CH 1
Iout
20A/div
CH 2
ENABLE
CH 1
Iout
20A/div
CH 2
Pulse Signal

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Figure 4
LDD-3000 Outline Drawing

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Rev
ECO
Description
Date
Doc
Control
1
7062
Release
3/13/12
MJ
26 Ward Hill Avenue, Bradford, MA 01835
Ph: 978-241-8260 Fx: 978-241-8262
www.luminapower.com
[e-mail]
Servicing LDD-3000 Diode Drivers
LDD-3000 units has no serviceable parts. Do not attempt to repair or service
this unit in the field. For further information, contact Lumina Power at 978-
241-8260.