Photonics ON-TRAK OT-7000 RF User manual

OT-7000 RF
Auto Aligning Straight
Line Laser System
User’s Manual

Introduction
Congratulations on the purchase of your OT-7000 Auto Aligning Laser
System with 902-928 MHz RF Spread Spectrum communication
technology. Optimized for computerized precision laser alignment, the
OT-7000representsthestate-of-the-artinlaserpositioningtechnology.
By aiming the visible laser beam at the reference target, and then
positioning transparent measurement targets along the beam path, your
projects are assured the utmost in alignment accuracy – better than
0.001” over distances of 300 feet. Using RF spread spectrum
communication, a closed loop feedback path is established with the
reference target to automatically maintain laser alignment. If the laser
deviates from the center of the reference target, the laser automatically
corrects itself until the laser is realigned. A user interface positioned on
the front panel of the OT-7000 RF Controller Module makes system
operationconvenient andeasy to monitor.
We suggest you read this owner’s manual carefully to become familiar
with the features and how they work. The manual explains in simple
stepshow to install, use, and care for your AlignmentLaserSystem.

Standard System Components.
The following components are standard with each OT-7000 system. Your standard
systemconsistsof:
•Alignmentlaser(ModelOT-7000LL)
•CentralProcessingUnits(ModelOT-7000 CPU)
•Transparenttargets(ModelOT-7000TTS4)
•Referencetarget(ModelOT-7000TS4)
•ControllerModule (OT-7000RF)
•Interface cables
•Power supplies
•OperationsManual

System Set Up
The OT-7000 system is designed to mount in conventional optical tooling fixtures.
The alignment laser, reference target, and transparent targets each feature a precision
NAS 2.2498 inch diameter stainless steel, chrome plated boss that mounts into a
standardopticaltoolingsphere.
Setting up the Alignment laser (OT-7000 AL)
Mount the front of the laser into a tooling sphere assembly similar to those in the
“Recommended Accessories” section at the end of this manual. The laser should
be mounted in the sphere such that the sphere is in between the two parallel scribe
lines on the laser front. There is a notch at the rear of the laser. This should be in
the up position. The rear of the laser is best mounted in a device (Model 71-5170
Alignment Telescope Bracket) that allows tip/tilt movement for the rough
alignment necessary to put the laser spot within +/- 0.050” on the Reference
Target. Once mounted, the alignment laser is positioned to produce a visible
beam that emits from the center of the sphere. It is critical that the center of the
sphere be at a known reference point.
Internal and External Radiation Paths
The internal radiation paths are as follows:
Laser light is generated by one visible laser diode and emitted by at the laser
aperture.
Radiation Field Specification:
Wavelength 635nm
Power (Peak) 1.8mW
Frequency 500Hz
Pulse Width 1mS
Diameter 8.2mm
Mode TEM00
Radiation Non Ionizing
CDRH Class 2M

Recommended Eyewear
Due to the Class 2M classification of this product safety eyewear is only required
for performing service on the OT-4040. See the service documentation for data
on the recommended eye wear.
Since the OT-4040 does not emit higher than Class 2M levels of laser light, no
eyewear is required for normal operation.

"LASER LIGHT - DO NOT STARE INTO THE BEAM OR VIEW
DIRECTLY WITH OPTICAL INSTRUMENTS"
.
Since the OT-7000 LL alignment laser is powered by the OT-7000
Controller Module. Connect the laser to the Controller Module front
panel via the supplied military style bayonet connector. Connect the
12V/5A power supply to the Controller Module back panel.
Setting up the Reference target (OT-7000 TS4)
Connect the target to the dedicated CPU using the supplied DB15 cable. It is
important that each target and CPU are paired with like serial numbers. If the target is
accidentally plugged into the wrong CPU, the CPU will give “Prob Err” as an
indication a mismatch has occurred. It will also flash the serial number of the target
that it expects. . Like the alignment laser, the reference target is mounted into a
tooling sphere. The target center is coincident with the center of the sphere. The
reference target is installed at the opposite end of the alignment structure. This way,
when the laser is switched on, a straight line in space is established between the
spherecenters.
Setting up the Transparent Targets (OT-7000 TTS4)
Connect the target to the dedicated CPU using the supplied DB15 cable. It is
important that each target and CPU are paired with like serial numbers. If the target is
accidentally plugged into the wrong CPU, the CPU will give “Prob Err” as an
indication a mismatch has occurred. It will also flash the serial number of the target
that it expects. Transparent targets are mounted into tooling spheres, which are in

turn mounted onto the structures that need to be brought into alignment. Each
transparent target is positioned such that the laser beam passes through the target. The
transparent target then reads the X and Y position of the structure, and sends the data
backtothe OT-7000 ControllerModulevia RF spread spectrum transmission.
Connecting, Squaring Up and Leveling the Targets
To complete the setup process, level and square the targets to the laser beam. The
reference target and transparent targets include a 30 minute bubble vial that should be
aligned within the circular scribe of the vial. Next, the target should be squared to the
incoming laser beam. This is easily accomplished with the OT-7000 system. Each
target reflects about 4% of the visible beam back towards the laser. When the
reflected beam is within the 2.5-inch diameter of the laser face, the targets are
sufficiently squared to the beam. The targets only need to be square and level to
within4degreesforproperoperation.
OT-7000 Power Up Sequence
To begin using the OT-7000 Auto Aligning Straight Line Laser system, we
recommend that the CPU’s are turned on first. Then, turn on the OT-7000 Controller
Module. The controller will start the system in the “Manual Align” mode. The laser
willbe on.
The first step, after power up, will be to adjust the external physical mounting
system that holds the laser such that the beam falls within +/- 0.050” for X and Y on
thereferencetarget. Afterdoingthisyouarereadytobeginsystemoperation.

System Operation
Auto Aligning
With the alignment laser, reference target, and transparent targets all
set up on the factory floor and in the “Manual Align” mode, you can
now press “Auto align” and begin using the system.
IMPORTANT – IF THE BEAM PATH TO THE REFERENCE
TARGET IS INTERUPTED DURING AUTOALIGN
INITIALIZATION, THE SYSTEM WILL REVERT TO THE
MANUAL ALIGN MODE.

The system does this because, during the initialization process, the
laser is “learning” the distance to the target by moving the beam in the
X and Y direction on the reference target. An interrupted beam will
cause the system to compute the distance incorrectly. Therefore, the
system monitors for beam path interruptions. The initialization
process typically takes approximately 30 seconds.
The OT-7000 Controller Module gives you the ability to modify and
control many different system parameters that effect the operation of
the closed loop process used for auto aligning the laser on the
reference target. The following text describes some of the user
controllable parameters available.
System Operation – OT-7000 Controller Module
The OT-7000 Controller Module provides four primary functions. It
allows setup of system parameters, display of target position data,
power to the OT-7000 AL Laser, and RF spread spectrum closed loop
control of the OT-7000 TS4 Reference Target. There is also an RS-
232 interface for computer control (see engineering manual for
details).
To setup the Auto-align system parameters or view the target data,
press the “Menu” button on the front panel.

Setup of System Parameters
The OT-7000 has an LCD display which allows the user to define the
system operation parameters. To enter the menu of options, press the
right arrow key. This allows access to the following setup options:

Max Dev.
Zero Pos.
Time
Max Pos.
The four arrows to the right of the display allow the user to navigate
the menu structure. The “up/down” buttons move between the
individual setup options. The “left/right” buttons increase and
decrease the value of the selected option.
“Max Dev.” Is the maximum distance the laser is allowed to travel
from center before auto aligning takes place. The minimum allowed
value is 0.002”. The maximum is 0.050”. This value is automatically
at least 0.001” greater than the “Zero Pos.”
“Zero Pos.” is the distance from center (X=0.000, Y=0.000) that the
auto aligning process corrects to. This has a minimum value of

0.001” and a maximum of 0.010”. It can’t be greater than the “Max
Dev.” value
“Time” is the time that the laser can be outside “Max Dev.” before
the system initiates auto aligning. The minimum value is 1 second.
The maximum value is 10 seconds.
“Max Pos.” is the maximum the laser can travel before it is “out of
range”. The minimum value is 0.100”. The maximum value is
0.400”.
To exit, press the “Menu” button. Press the Auto Align button to
begin using the system.
Display of target position data
After pressing the menu key, use the down arrow to select “View all
targets”. The right arrow key will display the target data for all targets
in the alignment string. The reference target is always target #1.

The display will give data for six targets at a time. If additional
targets are in the chain, use the down arrow key to scroll down.
To exit, press the “Menu” key.
RS-232 / USB communication
The OT-7000 RF Controller module has two communication options.
RS-232 communication is facilitated via a 9 pin standard (pin 2 to 2,
pin 3 to 3, ect..) RS-232 connector on the front panel. A USB
connector is also provided on the front panel. When the system is first
used with a new computer, Windows must install the necessary

drivers to recognize the new hardware (OT-7000 RF Controller). The
necessary drivers are provided on a CD with the system.
The installation process for the drivers are as follows:
1. Turn on the OT-7000 RF Controller
2. Plug in the USB cable to both the OT-7000 RF and the
computer.
3. Windows will indicate that it has found new hardware and the
found new hardware wizard will appear.
4. You will be asked to connect to Windows Update to find the
appropriate drivers. Select No.
5. Insert the OT-7000 USB Driver CD at the prompt and choose to
“install from a list or specific location.”
6. Check the box that says “Include this location in search” and
browse to find the directory containing the CD with the OT-
7000 USB Driver disk. Click on “Next” and the software will
find the appropriate drivers.
7. On some computers this process must be completed twice for
all the drivers to be installed.
You are ready to communicate with the OT-7000 RF controller via
computer.
System Operation - OT-7000 CPU
UserInterface
After turning on power to the CPU, the POWER LED will illuminate.
The display will turn all segments on for about two seconds and

briefly display four dashes. Then, the display will show the
CPU/target ID number and the preamble setting. As an example:
I 3
p 4
This means that the target ID is “3” and the preamble is “4”. A
typical laser alignment system consists of one laser, a controller, and
several targets. All the targets in a specific setup communicate via
one common preamble number. In this case, all the targets are
communicating on preamble number 4. Different systems have
different preamble numbers. This allows multiple systems to operate
adjacent to each other without any unwanted crosstalk between
systems. The preamble and ID settings are in software and can be
modified in the calibration process. Each target within a given laser
alignment system has a unique CPU/target ID number for
communication and data processing purposes. This allows the OT-
7000 RF Controller to identify each CPU/target in the laser chain.
After the preamble and CPU/target ID number are shown, the CPU
will display the model number of the CPU and the serial number of
the target it is expecting. For example:
7000
3289

The CPU model is 7000. The serial number of the target the CPU
expects is #3289. Each CPU is calibrated with a specific target.
Target linearity and centering calibration data is loaded into the CPU
for the requested target. The CPU will only work with the target it is
paired with.
When the CPU is ready to operate, the display will show four dashes
(- - - -), indicating standby mode. When a laser strike is detected, the
red LASER LED will illuminate on the CPU and the target.
WARNING: DO NOT CONNECT OR DISCONNECT THE
REMOTE SENSOR WHILE THE POWER IS TURNED ON.
The CPU will display and update the beam position to a resolution of
0.001”. If no laser is detected the OT-7000 CPU will return to
standby mode and will display four dashes (- - - -). Background
illumination is sensed automatically and compensated for. If the total
illumination (background plus laser pulse) exceeds the maximum
level, the display will show EEEE.
Average Mode
The OT-7000 CPU has a user selectable averaging feature. Readings
can be averaged over a period of time. The E/N button controls the
averaging time (note that the button is recessed and requires a small
tool for operation). When the E/N button is pressed, the average time

in seconds is incremented and displayed. The range of values is from
0.25 seconds to 5.00 seconds. After displaying the value, the unit
defaults back to normal operation.
Zero Offset
The zero offset feature can be activated by pressing the recessed
button. This will have the effect of defining the current position as
X=0.000 and Y=0.000. All subsequent measurements will be relative
to the new zero. The indicator light above the button will be activated
when this feature is in use.
Display Brightness
The OT-7000 CPU has three selectable levels of display brightness
and one off condition. The display intensity can be increased or
decreased (conserving battery power).
Gain Control
The OT-7000 CPU has automatic gain control. The system will
automatically select the optimum internal gain for laser sources with
peak output power between 0.3mW and 2mW. There are four gain
levels numbered 1 through 4. When the OT-7000 is powered up, the

gain defaults to a maximum. Any time the OT-7000 detects a signal
that is too high, the gain is reduced. If the gain is accidentally set too
high due to a strobe light or other bright, momentary source, the OT-
7000 may stop detecting the laser. If this occurs, the OT-7000 CPU
will auto range to reset the optimum gain range.
Battery Operation
The OT-7000 CPU has rechargeable internal NiMH batteries. When
the battery charge state is low, the BAT LED will light up. The unit
should be recharged at this point with the supplied 15V/1.5A wall
charger. The CPU can continue to operate while it is charging. The
OT-7000 CPU will automatically turn itself off when the battery
reaches a critical level.
Approximate battery life in operating mode is listed as follows:
Mode Battery Life (Approx.)
Display Off 20 hrs.
Minimum Brightness 16 hrs.
Maximum Brightness 12 hrs.
A wall transformer charger is supplied with the OT-7000 CPU.
Charge time is approximately 8 hours.
OT-7000 Power Down Sequence

The OT-7000 system automatically centers the laser upon system
shutdown. This process takes approximately 45 seconds to complete.
Upon completion, power is then shutoff to the laser and controller and
the laser is ready for its next use.
PLEASE DO NOT UNPLUG POWER TO THE CONTROLLER
MODULE WHILE THE SYSTEM IS IN THE SHUTDOWN
SEQUENCE
If power is removed from the controller during this process, the OT-
7000 Controller will center the laser the next time the system is
activated.

Recommended Accessories
Model187-SStrideLevel
Designed for leveling cylindrical surfacesbetween2-3inchesin diameter.
CompatiblewiththeOT-7000LLUltralignlaser.Indicatesoff-levelconditionsas
smallasonearc-second.
Model521SphericalMount
Capableofmountingany2¼-inchdiametercylindrical laser or target assembly in
themodel560-2Adjustable cup mount. Compatible with ON-TRAK NAS standard
compatible targets and lasers.
Model560-2Adjustablecupmount
SteelcupmountonironbasetoholdModel521SphericalMount.