Primes PowerMonitor PM Series User manual

PowerMonitor PM
PM 48, PM100, PM HP75
LaserDiagnosticsSoftware LDS
PowerMonitorSoftware PMS
Original Instructions
Revision 01 EN - 10/2023
35,0(6
PowerMonitor PM100 and PM48

PowerMonitor PM 35,0(6
3
Revision 01 EN - 10/2023
IMPORTANT!
READ CAREFULLY BEFORE USE.
KEEP FOR FUTURE USE.

PowerMonitor PM
35,0(
6
4Revision 01 EN - 10/2023
Table of contents
1 Basic safety notes 7
2 Icons and conventions 8
3 About this operating manual 10
4 Device description 11
4.1 Type overview .........................................................................................................................11
4.2 Functional description .............................................................................................................12
4.3 Measuring principle .................................................................................................................12
4.4 Optical displays and acoustic signal ........................................................................................13
4.4.1 Display......................................................................................................................13
4.4.2 LEDs.........................................................................................................................13
4.4.3 Acoustic warning signal ............................................................................................13
4.5 Explanation of the product safety labels and warning labels ....................................................14
4.6 Scope of delivery and optional accessories .............................................................................15
5 Transport and storage 16
5.1 Warning messages..................................................................................................................16
5.2 Shipping the device with permanently installed lithium metal batteries .....................................17
6 Software installation 18
6.1 Install LaserDiagnosticsSoftware LDS......................................................................................18
6.2 Install PowerMonitorSoftware PMS .........................................................................................19
7 Mounting 20
7.1 Conditions at the installation site .............................................................................................20
7.2 Installation in the laser system .................................................................................................20
7.2.1 Prepare mounting .....................................................................................................20
7.2.2 Possible mounting positions......................................................................................20
7.2.3 Align the device ........................................................................................................20
7.2.4 Mount the device ......................................................................................................22
7.3 Removal from the laser system................................................................................................24
8 Connectors 25
8.1 Overview of connectors...........................................................................................................25
8.2 Power supply ..........................................................................................................................26
8.2.1 Power supply via PRIMES power supply
when used as a stand-alone device ..........................................................................27
8.2.2 Power supply via PRIMES power supply
and communication with the PC via USB..................................................................28
8.2.3 Power supply via PRIMES power supply
and communication with the PC via PRIMES converter.............................................29
8.3 PRIMES bus RS485................................................................................................................31
8.4 USB ........................................................................................................................................31
8.4.1 Specification .............................................................................................................31
8.4.2 Installing the USB driver manually .............................................................................32
8.5 Analog Out..............................................................................................................................33
8.6 Safety interlock (Interlock)........................................................................................................34
8.7 Cooling circuit (Water In/Water Out).........................................................................................35
8.7.1 Connect/remove cooling water hoses .......................................................................35
8.7.2 Damage to the device...............................................................................................36
8.7.3 Avoid measurement inaccuracies..............................................................................37
8.7.4 Damage to the flow meter.........................................................................................38
8.7.5 Parameters of cooling water connection ...................................................................39
8.7.6 Pressure loss ............................................................................................................40

PowerMonitor PM 35,0(6
5
Revision 01 EN - 10/2023
8.8 Compressed air.......................................................................................................................41
9 Measuring 42
9.1 Warning messages..................................................................................................................42
9.2 Preparing measurement readiness ..........................................................................................43
9.3 Measuring with the PM as a stand-alone device......................................................................43
9.4 Measuring with the LaserDiagnosticsSoftware LDS.................................................................44
9.4.1 Connect/disconnect the device with the LDS............................................................44
9.4.2 General information about working with the LDS.......................................................45
9.4.3 Open power measurement mode .............................................................................46
9.4.4 Perform power measurement....................................................................................46
9.4.5 Measurement results display.....................................................................................48
9.5 Measuring with the PowerMonitorSoftware PMS.....................................................................49
9.5.1 Switch on device and start PMS ...............................................................................49
9.5.2 Connect device with the PMS ...................................................................................50
9.5.3 Testing the interface ..................................................................................................51
9.5.4 Testing the communication of multiple devices..........................................................52
9.5.5 Determine device offset.............................................................................................53
9.5.6 Perform power measurement....................................................................................54
9.5.7 Measuring value display ............................................................................................55
10 Troubleshooting 57
10.1 Messages in the LDS during measurement .............................................................................57
10.2 Connection errors when using the LDS ...................................................................................58
10.3 Acoustic warning signal...........................................................................................................58
10.4 Safety interlock was triggered .................................................................................................59
10.5 Other errors.............................................................................................................................59
11 Maintenance and service 60
11.1 Maintenance intervals..............................................................................................................60
11.2 Cleaning the device surface ....................................................................................................60
12 Measures for the product disposal 61
13 Declaration of conformity 62
14 Technical data 64
15 Dimensions 66
15.1 PowerMonitorPM48 ..............................................................................................................66
15.2 PowerMonitorPM100 ............................................................................................................68
15.3 PowerMonitorPMHP75 .........................................................................................................70
16 Appendix 72
A GNU GPL license notice..........................................................................................................72
B System Control (option)...........................................................................................................72
C Operation of the PM with a PRIMES PanelDisplay ...................................................................73
D Fiber adapter...........................................................................................................................75
E Parallel operation of the PM 48/100 with a FocusMonitor FM+................................................76

PowerMonitor PM
35,0(
6
6Revision 01 EN - 10/2023
PRIMES - the company
PRIMES is a manufacturer of measuring devices which are used to analyze laser beams. These devices are
employed for the diagnostics of high-power lasers ranging from CO2-, fiber- and solid-state lasers to diode
lasers. A wavelength range from infrared through to near UV is covered, offering a wide variety of measuring
devices to determine the following beam parameters:
• Laser power
• Beam dimensions and position of an unfocused beam
• Beam dimensions and position of a focused beam
• Beam quality factor M²
Development, production and calibration of the measuring devices is performed at PRIMES. This guarantees
optimum quality, excellent service, and a short reaction time, providing the basis for us to meet all of our
customers’ requirements quickly and reliably.
PRIMES GmbH
Max-Planck-Str. 2
64319 Pfungstadt
Germany
Tel [phone]
[email protected]
www.primes.de

PowerMonitor PM 35,0(6
7
Revision 01 EN - 10/2023
1 Basic safety notes
Intended use
The device has been designed exclusively for measurements in the beam of high-power lasers.
Use for any other purpose is considered as not intended and is strictly prohibited. Furthermore, intended use
requires that all information, instructions, safety notes and warning messages in this operating manual are
observed. The specifications given in chapter14 „Technical data“ on page64 apply. Any given limit values
must be complied with.
If not used as intended, the device or the system in which the device is installed can be damaged or de-
stroyed. In addition, there is an increased risk to health and life. Only use the device in such a way that there
is no risk of injury.
This operating manual is an integral part of the device and must be kept in the immediate vicinity of the place
of use, accessible to personnel at all times.
Every person who is responsible for the installation, start-up or operation of the device must have read and
understood the operating manual and, in particular, the safety instructions.
If you still have questions after reading this operating manual, please contact PRIMES or your supplier for
your own safety.
Observing applicable safety regulations
Observe the safety-relevant laws, guidelines, standards and regulations in the current editions published by
the state, standardization organizations, professional associations, etc. In particular, observe the regulations
on laser safety and comply with their requirements.
Necessary safety measures
The device measures direct laser radiation, but does not emit any radiation itself. However, during the mea-
surement the laser beam is directed at the device. This produces scattered or directed reflection of the laser
beam (laser class 4). The reflected beam is usually not visible.
Protect yourself from direct and reflected laser radiation while working with the device by taking the following
measures:
• Never leave the device unattended when taking measurements.
• Wear safety goggles adapted to the power, power density, laser wavelength and operating mode of the
laser beam source in use.
• Wear suitable protective clothing or protective gloves if necessary.
• If possible, also protect yourself from direct laser radiation and scattered radiation by using separating
protective devices that block or attenuate the radiation.
• If the device is moved from its aligned position, increased scattered or directed reflection of the laser
beam occurs during measuring operation. Mount the device in such a way that it cannot be moved unin-
tentionally, i.e. by bumping or pulling the cables
• Connect the laser control’s safety interlock to the device. Check that the safety interlock will switch off
the laser properly in case of error.
• Install safety switches or emergency safety mechanisms that allow the laser to be switched off immedi-
ately.
• Use suitable beam guidance and beam absorber elements which do not emit any hazardous substances
when irradiated.

PowerMonitor PM
35,0(
6
8Revision 01 EN - 10/2023
Employing qualified personnel
The device may only be operated by qualified personnel. The qualified personnel must have been instructed
in the installation and operation of the device and must have a basic understanding of working with high-
power lasers, beam guiding systems and focusing units.
Conversions and modifications
The device may not be modified in terms of design or safety without the explicit consent of the manufacturer.
The same applies to unauthorized opening, dismantling and repair. The removal of covers is only permitted
within the scope of the intended use.
Liability disclaimer
Manufacturer and distributor exclude any liability for damages and injuries which are direct or indirect con-
sequences of using the device not as intended or modifying the device or the associated software without
authorization.
2 Icons and conventions
Warning messages
The following icons and signal words indicate possible residual risks in the form of warnings:
DANGER
Means that death or serious physical injuries will occur if necessary safety precautions are not
taken.
WARNING
Means that death or serious physical injuries may occur if necessary safety precautions are not
taken.
CAUTION
Means that minor physical injury may occur if necessary safety precautions are not taken.
NOTICE
Means that property damage may occur if necessary safety precautions are not taken.

PowerMonitor PM 35,0(6
9
Revision 01 EN - 10/2023
Product safety labels
The following icons are used on the device itself to indicate imperatives and possible dangers:
Read and understand the operating manual before using the device!
Do not reach inside!
Labeling according to WEEE directive:
The device must not be disposed of with household waste, but in a separate WEEE collection
in an environmentally friendly way.
Further icons and conventions in this operating manual
Here you will find useful information and helpful tips.
Indicates a single instruction.
If several of these instructions appear one below the other, the order in which they are executed is
irrelevant or they represent alternative courses of action.
1.
2.
...
A numbered list identifies a sequence of instructions that must be executed in the specified order.
Indicates the result of an action to explain processes that take place in the background.
Indicates an observation prompt to draw attention to visible feedback from the device or the soft-
ware.
Observation prompts make it easier to check whether an instruction was executed successfully.
Often they also guide to the next instruction.
Points to a control element that is to be pressed/clicked.
Points to an element described in the text (for example an input field).

PowerMonitor PM
35,0(
6
10 Revision 01 EN - 10/2023
3 About this operating manual
This manual describes the installation and operation of the PowerMonitor PM48, PM100, PMHP75 and
how to perform measurements:
• as a stand-alone-device
• with the LaserDiagnosticsSoftware LDS version 3.0 or higher
• with the PowerMonitorSoftware PMS (predecessor of the LDS, now integrated into the LDS 3.0)
In this operating manual, the abbreviations PM, LDS and PMS are used.
For measurement operation with a PC, the LDS or the PMS must be installed on the PC. The LDS and PMS
are included in the delivery. PRIMES will also be happy to provide you with a current download link.
For this purpose, contact your sales partner or send an e-mail to: [email protected]
The compatibility of your PM with the LDS is indicated by the LDS symbol on the identification plate.
If the identification plate does not bear the LDS symbol, the device is not compatible with the new LDS Ver-
sion. Please use PMS instead.
www.primes.de
PRIMES
Type
S/N
PowerMonitor
PM 48
Built 0000
0000
Fig. 3.1: Identification plate with LDS symbol (using the PM48 as example)
The software description includes a brief introduction on using the device for measurements. For a detailed
description of the software installation, file management and evaluation of the measurement data, please
refer to the separate instructions for the LDS.
This operating manual describes the software version valid at the time of printing. Since the LDS is
subject to continuous development, the supplied data medium may have a newer version number.

PowerMonitor PM 35,0(6
11
Revision 01 EN - 10/2023
4 Device description
4.1 Type overview
The various devices differ in regard to the size of the entrance aperture, the absorber size and thus in the
overall dimensions, the specified power range and the cooling water flow rate required.
Type Entrance ap-
erture in mm
Dimensions
in mm
Power range
in kW 1)
Flow rate
(min/max)
PM48 48 394×242×125 0.3–8 4 –20l/min
PM100 100 580x330x215 1–25 8 –30l/min
PMHP75 90 600x330x215 3–75 25 –150l/min
1) depending on wavelength
Tab. 4.1: Type overview

PowerMonitor PM
35,0(
6
12 Revision 01 EN - 10/2023
4.2 Functional description
The PM is a measuring device for determining the power of laser beams in the multi-kilowatt range with
wavelengths in the CO2, NIR and VIS range.
The main application is to monitor the laser power available in the processing area of CO2, solid-state lasers
or high-power diode lasers.
The device is suitable for measuring collimated laser beams as well as divergent and convergent laser
beams.
Alignment guide
Shutter
LEDs
Display
Fig. 4.1: Functional description (using the PM 100 as example)
4.3 Measuring principle
The PM offers a fast, power measurement using the calorimetric measuring principle with active cooling.
The laser beam hits a deflection mirror in the device. This deflects the beam through an aperture and ex-
pands it so that it irradiates as much absorber surface as possible.
The total irradiated laser power is absorbed by a water-cooled absorber in the device. The absorbed power
is determined by measuring the cooling water flow rate and the temperature difference between water supply
and water return.
Based on the temperature rise and thermal properties of the absorber, the microprocessor-based electronics
are able to calculate the laser power with a high degree of accuracy.
Laser beam
Cooling water
(return flow)
Absorber with
inside coating
Cooling water
(supply flow)
Deflection
mirror
Fig. 4.2: Measuring principle (schematic)

PowerMonitor PM 35,0(6
13
Revision 01 EN - 10/2023
4.4 Optical displays and acoustic signal
4.4.1 Display
The display shows the following measured values:
Display Meaning
LPower Laser power in W
Flow Flow rate of the cooling water in l/min
Te Cooling water temperature at the water supply (Water In) in °C
Td Temperature difference between water supply (Water In) and water return
(Water Out) in Kelvin
Tab. 4.2: Meaning of the abbreviations in the display
4.4.2 LEDs
The LEDs indicate different states of the PM.
LED Color Meaning
Power Green Power supply is switched on.
Error Red The safety interlock was triggered by at least one of the following conditions:
• the cooling water flow is too low (depending on device type)
• the cooling water temperature at the water supply (Water In) is too high (Te>70°C)
• the temperature difference between water supply (Water In) and water return (Water Out)
is too large (Td>50K)
• the shutter is not (completely) open
Tab. 4.3: Meaning of the LEDs
4.4.3 Acoustic warning signal
If the permitted temperature of the absorber is exceeded, a warning signal will sound. The permitted tem-
peratures vary depending on the device type:
PM48 PM100 PMHP75
60 °C 75 °C 50 °C
Tab. 4.4: Permitted temperature of the absorber by device types
Switch off the laser immediately.
The further troubleshooting procedure is described in chapter10.3 „Acoustic warning signal“ on page58.

PowerMonitor PM
35,0(
6
14 Revision 01 EN - 10/2023
4.5 Explanation of the product safety labels and warning labels
Potential hazard areas are marked on the device with the product safety label “Do not reach inside” and
2warning labels:
Product safety label “Do not reach inside” and warning label “Do not touch the mirror surface”
Do not reach into the entrance aperture. Touching the deflection mirror underneath the shutter can lead to
localized absorption of the laser radiation at the points of contact, leading to burn marks and increased scat-
tered radiation.
Observe the distance between the focus and the entrance aperture (see chapter7.2.3 „Align the device“ on
page20). Make sure the focus position does not lie on the deflection mirror and that the permitted power
density on the deflection mirror is not exceeded.
Warning label “Do not use compressed air”
The flow meter is damaged by the use of compressed air in the cooling circuit. Do not use compressed air
for emptying the cooling circuit.
Top view
Front view
Umlenkspiegel nicht berühren.
Do not touch the mirror surface.
Abstand zwischen Fokus und
Eintrittsöffnung einhalten.
Ensure the distance between
focus and clear aperture.
www.primes.de
Umlenkspiegel nicht berühren.
Do not touch the mirror surface.
Abstand zwischen Fokus und
Eintrittsöffnung einhalten.
Ensure the distance between
focus and clear aperture.
www.primes.de
ACHTUNG / NOTICE
Verwenden Sie zum Entleeren des Kühlkreises
keine Druckluft.
Do not use compressed air for emptying the
cooling circuit.
ACHTUNG / NOTICE
Verwenden Sie zum Entleeren des Kühlkreises
keine Druckluft.
Do not use compressed air for emptying the
cooling circuit.
Fig. 4.3: Product safety label “Do not reach inside” and warning labels (using the PM100 as example)

PowerMonitor PM 35,0(6
15
Revision 01 EN - 10/2023
4.6 Scope of delivery and optional accessories
The scope of delivery includes:
• PowerMonitor PM
• PRIMES USB flash drive
• Operating manual
• PRIMES power supply (24V) with adapter
• USB cable (B to A connector), 5m
• PRIMES RS485/RS232 converter:
- 2 D-Sub cable, 1.8m
- Extension cable, 10m
- USB-serial converter, 0.1m
• Analog out cable, 5m
• Safety interlock cable, 5m
• 2 sealing plugs for cooling circuit (installed)
The following accessories are optional:
• Transport and storage case
• PRIMES PanelDisplay with up to 20m distance to PM
(see appendix C on page73)
• Fiber adapter for PM48 and PM100
(see appendix D on page75)
• Spacers PM48 and PM100 for FocusMonitorFM+
(see appendix E.1 on page76)

PowerMonitor PM
35,0(
6
16 Revision 01 EN - 10/2023
5 Transport and storage
5.1 Warning messages
WARNING
Injuries caused by lifting the PM100 or the PMHP75
Lifting and positioning heavy devices can, for example, stress intervertebral disks and cause chronic
changes to the lumbar or cervical spine.

Use a lifting device to lift and position the device.

Without available lifting equipment, the lifting and positioning of the unit must be carried out by
several persons.
NOTICE
Damage/Destruction of the device
Hard hits or falls may damage the device.
Touching the deflection mirror underneath the shutter can lead to localized absorption of the laser
radiation at the points of contact, leading to burn marks and increased scattered radiation.

Do not reach into the entrance aperture.

Handle the device carefully when transporting it.
NOTICE
Damage/Destruction of the device caused by leaking or freezing cooling water
Leaking cooling water can damage the device. Transporting and storing the device at tempera-
tures near or below freezing and without emptying the cooling circuit completely can damage the
device.

Empty the lines of the cooling circuit completely.

Even when the lines of the cooling circuit have been emptied, a small amount of residual water will
remain in the device at all times. This may leak out and end up inside the device. Close the con-
nectors of the cooling circuit with the included sealing plugs.
NOTICE
Damage/Destruction of the flow meter
The flow meter is damaged by the use of compressed air in the cooling circuit.

Do not use compressed air for emptying the cooling circuit.

PowerMonitor PM 35,0(6
17
Revision 01 EN - 10/2023
5.2 Shipping the device with permanently installed lithium metal batteries
The device is equipped with 2 permanently installed lithium metal cells (hereinafter referred to as battery). A
removal of the battery by the end user is not intended for this product.
In case of shipment the device is a hazardous good. Because of the permanently installed battery, it is classi-
fied as “batteries contained in equipment”.
Please observe the requirements for shipping according to the valid regulations.
Particularly in case of a damaged battery, special regulations must be observed:
Damaged batteries can cause fire! These batteries must be sorted out, checked and, if necessary, repacked
by qualified personnel!
If you need more information on how to safely remove the battery, please contact us at:
[email protected]
Battery details for shipping:
Cell/battery type: Lithium metal
Cell or battery: Cell
LC or Wh rating: 0.7g
Cell/battery weight: 16g
UN-Classification: UN 3091: Lithium metal batteries contained in equipment

PowerMonitor PM
35,0(
6
18 Revision 01 EN - 10/2023
6 Software installation
The following software can be used to operate the PM with a PC:
• LaserDiagnosticsSoftware LDS
• PowerMonitorSoftware PMS
6.1 Install LaserDiagnosticsSoftware LDS
The LDS is included in delivery. PRIMES will also be happy to provide you with a link to download
the current version. Please contact your sales partner or contact us by
e-mail: [email protected]
1. Please ensure:
• System requirements are met.
• You have administrator rights.
2. Close all programs on your PC.
3. Insert the PRIMES USB flash drive into your
PC and open the directory.
In the standard configuration, Windows
automatically opens the removable storage
device.
System requirements:
• Intel Pentium Corei3 or better
• Windows 10 (64-bit version)
• At least 4GB RAM; 8GB RAM recommended
• Display resolution: Full HD (1920x 1080) at 100% scaling
• A USB interface type A or RS232 interface for the connection
of the measuring device
4. Double-click the LDS_Setup exe file to start
the installation.
5. Follow the instructions on the screen.
If no other Iocation is specified, then the
main program LDS.exe will be copied into
the directory
C:\Programs\Primes\LaserDiagnostics-
Software.

PowerMonitor PM 35,0(6
19
Revision 01 EN - 10/2023
6.2 Install PowerMonitorSoftware PMS
The PMS in version 2.57 is included in delivery.
1. Please ensure:
• System requirements are met.
• You have administrator rights.
2. Close all programs on your PC.
3. Insert the PRIMES USB flash drive into your
PC and open the directory.
In the standard configuration, Windows
automatically opens the removable storage
device.
System requirements:
• Intel Pentium or better
• Windows 10 (32-bit version)
• At least 2GB RAM; 4GB RAM recommended
• Display resolution: XGA (1024x 768) at 100% scaling
• A USB interface type A or RS232 interface for the connection
of the measuring device
4. Double-click the PMS_Setup exe file to
start the installation.
5. Follow the instructions on the screen.
If no other Iocation is specified, then the
main program PMS.exe will be copied into
the directory
C:\Programs\Primes\PowerMonitorSoft-
ware.

PowerMonitor PM
35,0(
6
20 Revision 01 EN - 10/2023
7 Mounting
7.1 Conditions at the installation site
• The device must not be operated in a condensing atmosphere.
• The ambient air must be free of gases and aerosols that interfere with the laser radiation (e.g. organic
solvents, cigarette smoke, sulfur hexafluoride).
• Protect the device from spray water and dust.
• Operate the device in closed rooms only.
7.2 Installation in the laser system
7.2.1 Prepare mounting
1. Switch off the laser beam.
2. Ensure that moving parts, e.g. robot arms, etc. are at a standstill and that they cannot be set in motion
unintentionally.
3. Check the space available before installing the device, especially the required space for the cables and -
hoses.
7.2.2 Possible mounting positions
The PM can be mounted in any position.
7.2.3 Align the device
NOTICE
Damage/Destruction of the device
The deflection mirror can be damaged if the power density is too high.

Make sure that the focus is not on the deflection mirror.

Make sure that the permitted power density on the deflecting mirror is not exceeded.
The device must be aligned to the laser beam. The laser beam must hit the entrance aperture centrally and
perpendicular. The specifications given in chapter14 „Technical data“ on page64 must be observed.
The reticle (alignment guide) printed on the shutter can be used to center the device under the laser. Align
the device using the pilot beam with the shutter closed.
Use of the device with divergent laser radiation
Normally, the device is positioned underneath the focal plane of the beam path for power measurement.
Use of the device with convergent laser radiation
If this is not possible, the device can be positioned above the focal plane.
In this case, observe that the laser radiation is convergent and that the permitted power density on the de-
flection mirror is not exceeded.