MKS Ophir Helios Plus User manual

Helios, Helios Plus
Ophir Optronics Solutions Ltd.
High Power Industrial Laser Measurement
User Manual
210x297 mm
Helios, Helios Plus
Helios, Helios Plus

First version
Rev 1.00
22 Sep 2016
Helios User Manual 2
Table of Contents
.....................................................................................................................................................................1
Table of Contents.........................................................................................................................................2
About this Manual.........................................................................................................................................3
How the Document is Organized..............................................................................................................3
Chapter 1 –Helios Operating Principle.........................................................................................................4
Overview.......................................................................................................................................................4
Physical Principle ........................................................................................................................................4
Example of Use: Laser Welder in a Robotic Cell ...................................................................................4
Chapter 2 –Specifications............................................................................................................................5
Chapter 3 –Setup ........................................................................................................................................7
Profinet Setup ..............................................................................................................................................7
EtherNet/IP Setup........................................................................................................................................9
RS232 Setup..............................................................................................................................................10
PC Application............................................................................................................................................10
Chapter 4 –Check before Use ...................................................................................................................11
Preliminary test..........................................................................................................................................11
Timing Considerations..............................................................................................................................11
Temperature Failsafe................................................................................................................................11
Chapter 5 –Mechanical dimensions...........................................................................................................12
Chapter 6 –Connectors..............................................................................................................................13
Power Connectors.....................................................................................................................................13
RJ45 Connectors.......................................................................................................................................14
RS232 Pinout.............................................................................................................................................14
Chapter 7 –Registers & Commands ..........................................................................................................15
LED indicators table..................................................................................................................................15
Modules and Registers.............................................................................................................................15
Status: 16-bit Register...........................................................................................................................16
Constants:...............................................................................................................................................16
Measurement Results & Information:.................................................................................................17
Commands:.............................................................................................................................................17
Example of sequence of commands and status:...........................................................................................17
Querying and Changing laser options:.........................................................................................................18
Analysis of Example Data, BIG Endian: .....................................................................................................19
Analysis of Example Data, LITTLE Endian:...............................................................................................21
Chapter 8 –RS232.....................................................................................................................................23
General Information: .................................................................................................................................23
Standard Error Messages:.......................................................................................................................23
Details of RS232 Commands:.................................................................................................................23

First version
Rev 1.00
22 Sep 2016
Helios User Manual 3
Chapter 9 –PC Application ........................................................................................................................26
Chapter 10 –Getting Started With EtherNet/IP...........................................................................................33
Chapter 11 –Getting Started With Profinet.................................................................................................36
Appendix 1 –Flow Chart & Timing Diagrams .............................................................................................38
Measurement Flow Chart.........................................................................................................................38
Power Measurement Timing Diagram....................................................................................................39
Shutter Timing Diagram............................................................................................................................39
About this Manual
This manual provides information for the Ophir Helios series:
•“Helios-Profinet” power meter (P/N 7Z02768)
•“Helios-EtherNet-IP” power meter (P/N 7Z02789)
•“Helios Plus –Profinet” power meter (P/N 7Z07100) supporting multiple lasers
•“Helios Plus –EtherNet-IP” power meter (P/N 7Z07101) supporting multiple lasers
Note: Throughout the manual, wherever the name “Helios” appears, it refers to all types of Helios unless
specified otherwise.
The manual describes how to operate and control the Ophir Helios power meters with the following interfaces:
▪Profinet (for P/N 7Z02768, P/N 7Z07100)
▪EtherNet/IP (for P/N 7Z02789, P/N 7Z07101)
▪RS232 (for all models)
How the Document is Organized
This manual describes installation and operation in the following order:
•How the Helios power meter works, Specifications
•Helios setup
•Profinet, EtherNet/IP general communication
•RS232 communication
•PC control application
•EtherNet/IP specific examples

First version
Rev 1.00
22 Sep 2016
Helios User Manual 4
Chapter 1 – Helios Operating Principle
Overview
The Helios sensor measures high power industrial lasers by measuring the energy of a short time exposure of the CW
laser. The laser should be set to pulse from 0.1 to several seconds. The Helios measures the energy and exposure time
of this sample of the power, and from this calculates the CW power.
The Helios can measure power up to 12 kW and energy to 10 kJ. The short exposure time enables power
measurement by a small sensor without water cooling (see the table in Chapter 2 for recommended exposure times by
power level).
The Helios can be operated via RS232 using a PC Application supplied with the sensor, or via RS232 user commands.
In addition, two industrial Ethernet protocols are supported:
•Helios-Profinet (P/N 7Z02768/7Z01700) supplied with RJ45 Profinet connector (P/N 7E01298)
•Helios-EtherNet/IP (P/N 7Z02789/7Z07101) supplied with RJ45 EtherNet/IP connector (P/N 7E01299).
Both are also supplied with the Ophir Power Cable for Helios (P/N 7Z10458A)
Other protocols may be available in the future, contact Ophir for more information.
Physical Principle
The core of Helios is a high power copper thermopile disk that can measure short exposures of very high power lasers.
The response time is 2-3 seconds so only energy of single-shots can be measured at such short exposure times.
An internal, uncalibrated photodiode detects the backscattered light to measure the exposure time.
Average power is then calculated by,
𝑃 = 𝐸
∆𝑡 ,
where Pis power, Eis energy, and Δt is the time interval.
All this allows short measurements of multi-kW lasers in a small, uncooled body.
Example of Use: Laser Welder in a Robotic Cell
A typical application of the Helios is to check the power of a laser welder in between welds. This process can be
automated and optimized to take the least time away from production possible.
Here’s a typical sequence of events:
1. Welding production “Item A” is almost done
2. Open Helios cover and check sensor is “Ready”
3. Finish welding production “Item A”
4. Turn off laser
5. Move laser to Helios
6. Turn on laser for preset amount of time (0.1-10 s)
7. Move laser back to production
8. Start welding production “Item B”
9. Read measurement (~3 seconds after laser measurement)

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Helios User Manual 5
Chapter 2 – Specifications
== Subject to change. Check our website for latest version spec: www.ophiropt.com/laser-measurement
Short Exposure High Power Sensors with Industrial Communications Protocol
Helios Plus -P/N 7Z07100 / 7Z07101 (rev2 23-12-20)
50W to 12000W
Features
•No water cooling, up to 12000W
•Profinet / EtherNet/IP and RS232 interfaces
•Remote actuated protective cover
•Dual wavelength range
The Helios Plus measures high power industrial lasers of up to 12kW by measuring the energy of a short time exposure to this power. The laser is set to a pulse of
from 0.3 to several seconds. The Helios Plus measures the energy and exposure time of this sample of the power, and from this calculates the power. By keeping
the pulse energy under 5kJ, there is no need for water cooling and the sensor can be kept to a compact size. It works in two wavelength ranges: The YAG
fundamental and its second harmonic. The sensor is housed in a dust-resistant industrial body to keep the Helios Plus in clean working order even under harsh
factory conditions. Its protective cover can be opened and closed remotely to protect the sensor when not in use. Its protective window is antireflection coated to
reduce back reflection of the high power beam. The Helios Plus has two versions of communications: Profinet and RS232 or EtherNet/IP and RS232. The Helios
Plus comes with a simple PC application for easier integration into the customer's system. It is equipped with two power and two RJ45 ports for easy integration
into existing line or ring topologies as well as an RS232 connection.
Model
Use
Helios Plus - Profinet / Helios Plus - EtherNet/IP
High power industrial laser measurement
Absorber Type
LP2, absorption ~94%
Power Range
50W –12kW
Energy Range
100J –5kJ
Exposure Time (see table below)
0.3 - 4s (a)
Wavelength
450-550nm, 900-1100nm
Aperture
Ø50mm
Max Beam Diameter
35mm
Maximum Energy Density
4kJ/cm²
Calibration Uncertainty
±1.9%
Accuracy (b)
±3% (900-1100nm)
±3.5% (450-550nm)
Linearity with Energy
±1.5% (c)
Reproducibility
±1%
Response Time
3s
Waiting Time for Next Measurement
12s
Maximum Exposure Before Cooling Down is
Necessary
Maximum operating temperature of 60degC will be reached after exposure to 30kJ (e.g. 6 shots at 5000W, 1s).
Cooling down time before another 5kJ shot, 3min.
Power Supply
24 VDC ±5%, max 5 A (for daisy-chaining)
Power Consumption
24 VDC ±5%, max 2 A
Communication
Profinet, RS232 / EtherNet/IP, RS232
Dimensions
(L x W x H) 200 x 100 x 84 mm (closed); 200 x 123 x 144 (open)
Position of Mounting Holes
6.6 mm holes spaced at 90x190 mm
Weight
2.5kg
Operating Temperature
10-60ºC
Humidity
10-80%
Recommended exposure times and 1/e²
Gaussian beam diameters
Laser Power W
Recommended
Exposure s
Min 1/e² beam
dia. mm
Laser Power W
Recommended
Exposure s
Min 1/e² beam
dia. mm
50
100
2
2
9
9
2000
5000
1
1
12
18
500
2
9
10000
0.3
22
1000
1
9
12000
0.3
25
Connections
2x RJ45 Industrial Ethernet connectors, 2x Han PushPull Power Metal 24V power connection(d),
1x DB9 RS232 connection, 7x indicator LEDs
Cover
Motor driven cover opens sideways
Accessories Supplied with Helios Plus
1. Power Supply Cable (P/N 7Z10458A), 2. Profinet/EtherNet/IP Plug RJ45 IP67 5m Cable (P/N 7E01298/7E01299)
Additional Accessories
1. D9F to D9M Shielded 10m RS232 Cable (P/N 7E01209)
Compliance
CE, UKCA, China RoHS
Version
Part number
7Z07100 / 7Z07101
Notes: (a) Repetitive pulses can also be measured as long as the total exposure time is within this range.
(b) The power is calculated by measuring the energy and exposure time. The laser pulse is assumed to be rectangular for this calculation.
(c) For pulse widths in the range 0.3 –4s.
(d) External power supply should be connected to the right-hand power jack. The left power connector can be used to connect power to another device
(in a ring or line topology). If left unconnected, a plug is provided to keep the connector clean.

First version
Rev 1.00
22 Sep 2016
Helios User Manual 6
== Subject to change. Check our website for latest version spec: www.ophiropt.com/laser-measurement
Short Exposure High Power Sensors with Industrial Communications Protocol
Helios –P/N 7Z02768 / 7Z02789 (rev16 8-12-19)
50W to 12000W
Features
•No water cooling, up to 12000W
•Profinet / EtherNet/IP and RS232 interfaces
•Remote actuated protective cover
The Helios measures high power industrial lasers of up to 12kW by measuring the energy of a short time exposure to this power. The laser is set to a pulse of from
0.3 to several seconds. The Helios measures the energy and exposure time of this sample of the power, and from this calculates the power. By keeping the pulse
energy under 5kJ, there is no need for water cooling and the sensor can be kept to a compact size. The sensor is housed in a dust-resistant industrial body to keep
the Helios in clean working order even under harsh factory conditions. Its protective cover can be opened and closed remotely to protect the sensor when not in
use. Its protective window is antireflection coated to reduce back reflection of the high power beam. The Helios has two versions of communications: Profinet and
RS232 or EtherNet/IP and RS232. The Helios comes with a simple PC application for easier integration into the customer's system. It is equipped with two power
and two RJ45 ports for easy integration into existing line or ring topologies as well as an RS232 connection.
Model
Use
Helios-Profinet / Helios-EtherNet/IP
High power industrial laser measurement
Absorber Type
LP2, absorption ~94%
Power Range
50W –12kW
Energy Range
100J –5kJ
Exposure Time (see table below)
0.3 - 4s (a)
Wavelength
860 –1100nm (b)
Aperture
Ø50mm
Max Beam Diameter
35mm
Maximum Energy Density
4kJ/cm²
Accuracy
±3% (c)
Linearity with Energy
±1.5% (d)
Reproducibility
±1%
Response Time
3s
Waiting Time for Next Measurement
12s
Maximum Exposure Before Cooling Down is
Necessary
Maximum operating temperature of 60degC will be reached after exposure to 30kJ (e.g. 6 shots at 5000W, 1s).
Cooling down time before another 5kJ shot, 3min.
Power Supply
24 VDC ±5%, max 5 A (for daisy-chaining)
Power Consumption
24 VDC ±5%, max 2 A
Communication
Profinet, RS232 / EtherNet/IP, RS232
Dimensions
(L x W x H) 200 x 100 x 84 mm (closed); 200 x 123 x 144 (open)
Position of Mounting Holes
6.6 mm holes spaced at 90x190 mm
Weight
2.5kg
Operating Temperature
10-60ºC
Humidity
10-80%
Recommended exposure times and 1/e²
Gaussian beam diameters
Laser Power W
Recommended
Exposure s
Min 1/e² beam
dia. mm
Laser Power W
Recommended
Exposure s
Min 1/e² beam
dia. mm
50
100
2
2
9
9
2000
5000
1
1
12
18
500
2
9
10000
0.3
22
1000
1
9
12000
0.3
25
Connections
2x RJ45 Industrial Ethernet connectors, 2x Han PushPull Power Metal 24V power connection(e),
1x DB9 RS232 connection, 7x indicator LEDs
Cover
Motor driven cover opens sideways
Accessories Supplied with Helios
1. Power Supply Cable (P/N 7Z10458A), 2. Profinet/EtherNet/IP Plug RJ45 IP67 5m Cable (P/N 7E01298/7E01299)
Additional Accessories
1. D9F to D9M Shielded 10m RS232 Cable (P/N 7E01209), 2. Helios Window Replacement Kit (P/N 7Z08332)
Compliance
CE, China RoHS
Part number
7Z02768 / 7Z02789
Notes: (a) Repetitive pulses can also be measured as long as the total exposure time is within this range.
(b) Lasers down to 780nm can be measured with an additional 2% error.
(c) The power is calculated by measuring the energy and exposure time. The laser pulse is assumed to be rectangular for this calculation.
(d) For pulse widths in the range 0.3 –4s.
(e) External power supply should be connected to the right-hand power jack. The left power connector can be used to connect power to another device
(in a ring or line topology). If left unconnected, a plug is provided to keep the connector clean.

First version
Rev 1.00
22 Sep 2016
Helios User Manual 7
Chapter 3 – Setup
There are four ways to interface with the Helios laser power meter:
1. Profinet
2. EtherNet/IP
3. RS232 commands (e.g., with HyperTerminal)
4. PC application
The setup of Helios depends on the mode of operation.
Profinet Setup
•Place the Helios where it will be convenient to measure the laser (can bolt down to the chassis with M6
screws).
•Connect 24 V DC to standard Profinet / EtherNet/IP jack. (Use Ophir Power Cable for Helios P/N 7Z10458A,
see Chapter 6 “Connectors” for more details)
•Connect Profinet RJ45 cable to jack. (Use Ophir Profinet Cable for Helios P/N 7E01298, see Chapter 6
“Connectors” for more details)
•Integrate the device into the network. (Need: GSDML file from Helios product page in the website;
customer’s network administrator.)
•Set up Profinet network in software (e.g., TIA, STEP7):
•Set up device addresses as marked inside the red circle:

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Helios User Manual 8
Zoomed-In:
•Integrate the power measurement into the customer software (controlled by the PLC) as fits their application
and needs.
•See Chapter 7 for more details on Profinet setup and read/write registers (called “submodules”).
•Begin test measurements.
•Integrate into production line routine.

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Helios User Manual 9
EtherNet/IP Setup
•Place the Helios where it will be convenient to measure the laser.
•Connect 24 V DC to standard Profinet / EtherNet/IP jack. (Use Ophir Power Cable for Helios P/N
7Z10458A, see Chapter 6 “Connectors” for more details)
•Connect EtherNet /IP RJ45 cable to jack. (Use Ophir EtherNet/IP Cable for Helios P/N 7E01299, see Chapter
6 “Connectors” for more details)
•The Helios is delivered with a factory default IP address of 10.0.0.2, Subnet Mask 255.255.255.0, and Default
Gateway 10.0.0.1. Update the IP address of the Helios using one of the following methods.
•If the present IP address is known, and it is possible to connect to it via a PC or PLC, connect to the Helios
using a web browser tool such as Chrome or Internet Explorer. Enter the present IP address in the browser
address window, and the following window should open. Select “Settings”.
•At the next prompt enter the user name “admin” and password “admin”
•The configuration window will open showing the present IP settings. Change them as required and then click
the “submit” button to make the change permanent.
•If the IP address is known but a connection is not possible, if using a PC it may be possible to change the IP
settings of the PC to match the present settings of the Helios in order to connect as above. Go to: Control
Panel -> Network and Sharing Center -> Change adapter settings. Select “Local Area Connection”, properties.
Select “Internet Protocol Version 4 (TCP/IPv4)”, Properties.
•Change the PC IP address to match the same gateway as the Helios but do NOT use the same exact IP
address, for example if the Helios is set to default settings, choose IP address 10.0.0.3, Subnet Mask
255.255.255.0, Default Gateway 10.0.0.1. Then continue as above using a web browser.
•If neither of the above options is possible, a tool called “Ethernet Device Configuration” is available. Please
contact Ophir for more details.
•Install the tool and start it up. Choose “Search Devices” to display all devices found on the network.

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Helios User Manual 10
•Choose the Helios device - it will be identified as “NETIC” or similar as shown above.
•Click the “Configure” button, then “SetIP Address…”. Enter the new values of IP Address and Subnet Mask
(usually 255.255.255.0) and click “OK”. After a few seconds, repeat “Search Devices” to check the IP settings
are updated successfully. Note that this tool changes the IP settings temporarily; to change permanently
connect to the device via a web browser and continue as described above.
•Import the EDS file (available via the Ophir website) using the “EDS Hardware Installation Tool” from
Rockwell Automation, or similar. This tool is part of the Rockwell “RSLinx Classic” tool.
•It is NOT possible to set up the IP address via the RS232 link
RS232 Setup
•Place the Helios where it will be convenient to measure the laser (can bolt down to chassis with M6 screws).
•Connect 24 V DC to standard Profinet jack (Use Ophir Power Cable for Helios P/N 7Z10458A, see Chapter 6
“Connectors” for more details)
•Connect a standard RS232 to the D9 jack.
•Install the “Helios PC Application” by copying it from the Helios product page in the website and following
the installation wizard steps.
•Integrate the power measurement into customer software (by scripting commands) as fits their application and
needs. See Chapter 8 for more detail and a list of commands.
•Integrate into the production line routine, using RS232 program.
PC Application
•The PC application is needed to upgrade the Helios firmware.
•It can also be used to measure with the Helios without any programming. This can be useful for pre-
integration testing.
•To begin test measurements, follow these steps:
oSet scale to be above the max expected energy
oPress “Open” cover
oTurn on laser and wait for measurement results to appear
•Can also use RS232 commands directly by enabling the terminal.
•Options include: logging, instantaneous power reading, housing temperature, and the terminal
•The PC application can be downloaded from the Ophir website