jk700tr series nd: yag industrial laser user...

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JK700TR SERIES

Nd: YAG Industrial Laser

User Manual

GSI LumonicsCosford Lane, Swift Valley

Rugby, Warwickshire, CV21 1QNEngland

Telephone: 44 (0) 1788 570321Fax: 44 (0) 1788 579824www.gsilumonics.com

GSI LumonicsJK700TR: User Manual

Title Page Issue 1.0

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GSI LumonicsJK700TR: User ManualIssue 1.0 Document Approval

Part No: 1EAA70E02 of 236

Document Approval

Issue Revision Author Approved for Issue Date

1.0 0 Terry Cutmore E. Jones 12th Feb 2003

SOFTWARE DISCLAIMER

Any software forming part of this equipment should be used only for the purpose for which itwas supplied by GSI Lumonics. No changes, modifications or copies (except for producing anecessary back-up copy) shall be undertaken by the User.

GSI Lumonics accepts no responsibility for equipment malfunction resulting from any of theabove actions.

SAFETY WARNING

It is of the utmost importance that the Safety Section of this manual is read and fully understoodbefore any attempt is made to operate the equipment or undertake any actions which mightnecessitate removal of any parts from the equipment.

�� . All rights reserved.

The information contained herein is confidential and is the property of GSI Lumonics. Thismanual is supplied without liability for errors or omissions. No part may be reproduced,disclosed or used except as authorised by contract or other written permission. The copyrightand the foregoing restriction on reproduction and use extend to all media in which theinformation may be embodied.


Document Approval Issue 1.0

of 236 Part No: ��

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GSI LumonicsJK700TR: User ManualIssue 1.0 Table of Revisions


Table of Revisions

Revision Page Incorporated by Date


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GSI LumonicsJK700TR: User ManualIssue 1.0 Table of Contents


Table of Contents

1. General Information........................................................................................... 131.1 Class of Laser ................................................................................................. 131.2 Intended Users ................................................................................................ 131.3 Documentation ................................................................................................ 13

1.3.1 Pre-installation Manual............................................................................. 131.3.2 User Manual............................................................................................. 131.3.3 Service and Maintenance Manual ............................................................ 131.3.4 Safety Paragraphs ................................................................................... 14

1.4 Table of Definitions.......................................................................................... 151.5 Customer Support ........................................................................................... 18

1.5.1 Regional Customer Centres ..................................................................... 181.6 CE Mark Information........................................................................................ 181.7 The JK700TR Series Laser ............................................................................. 19

1.7.1 Main Assemblies ...................................................................................... 191.7.2 Fibre Optic Cable Assembly ..................................................................... 211.7.3 Remote Control Interface ......................................................................... 211.7.4 Ancillaries................................................................................................. 21

1.8 Technical Specification.................................................................................... 221.9 Safety Interlocks.............................................................................................. 25

1.9.1 Customer Remote Interlocks .................................................................... 251.9.2 Shutter Interlocks (Beampath Interlocks).................................................. 25

1.10 Laser Power Delivery ...................................................................................... 251.11 Operating Parameters ..................................................................................... 271.12 Remote Control ............................................................................................... 27

1.12.1 Introduction .............................................................................................. 271.12.2 Changing Parameters .............................................................................. 28

1.13 Control Functions ............................................................................................ 291.14 Operating Guidelines....................................................................................... 301.15 Fibre Optic Handling........................................................................................ 30

1.15.1 Description ............................................................................................... 301.15.2 Unpacking Fibre Optic Cable.................................................................... 311.15.3 Fibre Installation....................................................................................... 321.15.4 Recommendation ..................................................................................... 321.15.5 Minimum Bend Radii ................................................................................ 331.15.6 Fibre Optic Termination............................................................................ 331.15.7 Fibre Routing ........................................................................................... 331.15.8 Fibre Removal.......................................................................................... 34

2. Safety.................................................................................................................. 352.1 Laser Classification ......................................................................................... 352.2 Laser Radiation Hazards ................................................................................. 372.3 Control Measures ............................................................................................ 382.4 Electrical Safety............................................................................................... 392.5 Environmental Hazards ................................................................................... 40

2.5.1 Fire........................................................................................................... 402.5.2 Fume........................................................................................................ 412.5.3 Compressed Gases ................................................................................. 422.5.4 Solvents ................................................................................................... 42

2.6 Conditions of Use ............................................................................................ 432.6.1 Approved Materials .................................................................................. 43


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2.6.2 Approved Process.................................................................................... 432.6.3 Approved Conditions ................................................................................ 432.6.4 Due Authorisation..................................................................................... 44

2.7 Safety Control System..................................................................................... 452.7.1 Safety Category ....................................................................................... 452.7.2 Safety Compliance ................................................................................... 452.7.3 Safety Labelling........................................................................................ 45

2.8 Safety Features ............................................................................................... 512.8.1 Remote Interlock Connector..................................................................... 512.8.2 Workstation Interlock................................................................................ 52

2.9 Training ........................................................................................................... 532.10 Personal Protective Equipment ....................................................................... 532.11 Manual Handling ............................................................................................. 53

3. Laser Operation – Operator Control Panel ...................................................... 553.1 Introduction ..................................................................................................... 553.2 Start-up and Shut-down Procedures................................................................ 55

3.2.1 Start-Up-Procedure .................................................................................. 553.2.2 Shut Down Procedure .............................................................................. 563.2.3 Emergency Shut Down Procedure ........................................................... 56

3.3 Alarm Handling................................................................................................ 573.4 Monitoring and Control .................................................................................... 573.5 Control Panel Overview................................................................................... 583.6 Control Groups................................................................................................ 593.7 Functional Description ..................................................................................... 60

3.7.1 Enable keyswitch ..................................................................................... 603.7.2 STATUS Controls..................................................................................... 613.7.3 SYSTEM Controls .................................................................................... 623.7.4 LASER Controls ....................................................................................... 623.7.5 SHUTTER Controls.................................................................................. 623.7.6 Message Display...................................................................................... 633.7.7 DISPLAY Controls.................................................................................... 643.7.8 SELECT Keys .......................................................................................... 65

3.8 Display Keys.................................................................................................... 673.8.1 Functional Description.............................................................................. 67

3.9 Main Rules for Use of Control Panel Keys....................................................... 723.10 Monitoring Parameters and Functions ............................................................. 73

3.10.1 Monitoring Single Parameters .................................................................. 743.10.2 Monitoring Two Parameters Simultaneously............................................. 743.10.3 Shape Monitoring ..................................................................................... 75

3.11 Changing Parameters...................................................................................... 773.11.1 Introduction .............................................................................................. 773.11.2 General Rules .......................................................................................... 783.11.3 Specific Rules .......................................................................................... 793.11.4 Changing Shape and Related Parameters ............................................... 83

4. Laser Operation - GUI........................................................................................ 874.1 Introduction ..................................................................................................... 874.2 Overview ......................................................................................................... 874.3 Laser Start-up.................................................................................................. 874.4 Laser Shut-down ............................................................................................. 884.5 Emergency Shutdown ..................................................................................... 884.6 Alarm Handling................................................................................................ 88

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4.7 Monitoring and Control .................................................................................... 894.8 Generic Laser Interface Program..................................................................... 90

4.8.1 Product Registration Screen..................................................................... 904.8.2 Screen Display ......................................................................................... 914.8.3 Overview Screen...................................................................................... 954.8.4 Level 1 Operator Access .......................................................................... 974.8.5 Level 2 Supervisor Access ..................................................................... 1154.8.6 Level 3 Configuration Access ................................................................. 129

5. Alarm and Warning Handling.......................................................................... 1515.1 Alarm Display ................................................................................................ 1515.2 Alarms........................................................................................................... 152

5.2.1 Alarm Response..................................................................................... 1525.2.2 Alarm Codes .......................................................................................... 152

5.3 Warnings ....................................................................................................... 1695.3.1 Warning Response................................................................................. 1695.3.2 Warning Codes ...................................................................................... 170

6. Optimisation..................................................................................................... 1736.1 Introduction ................................................................................................... 1736.2 Rear Mirror Tuning ........................................................................................ 1736.3 Focus Head Set-up ....................................................................................... 1756.4 Completion .................................................................................................... 176

7. User Maintenance ............................................................................................ 1777.1 Introduction ................................................................................................... 1777.2 User Maintenance Tasks............................................................................... 1797.3 Power ON/OFF Sequence............................................................................. 1817.4 General Inspection ........................................................................................ 1837.5 Coolant Replenishment ................................................................................. 184

7.5.1 Materials ................................................................................................ 1847.5.2 Draining Procedure ................................................................................ 1847.5.3 Filling Procedure .................................................................................... 186

7.6 Filter Replacement ........................................................................................ 1887.7 De-ioniser Replacement ................................................................................ 1907.8 Flashlamp Replacement................................................................................ 193

7.8.1 Materials ................................................................................................ 1937.8.2 Replacement Procedure......................................................................... 1947.8.3 Installation Procedure............................................................................. 196

7.9 PIPA Fibre Optic Cable Replacement............................................................ 1997.9.1 Materials ................................................................................................ 1997.9.2 Replacement Procedure......................................................................... 2007.9.3 Installation Procedure............................................................................. 2027.9.4 Alignment Procedure.............................................................................. 204

7.10 Cover Slide Replacement .............................................................................. 2067.10.1 Materials ................................................................................................ 2067.10.2 Replacement Procedure......................................................................... 2067.10.3 Cleaning and Installation Procedure....................................................... 208

7.11 Fuse Replacement ........................................................................................ 2107.11.1 Materials ................................................................................................ 210

7.12 Bulb Replacement ......................................................................................... 2127.12.1 Materials ................................................................................................ 212

7.13 Bendlock Assembly ....................................................................................... 213


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7.13.1 Assembly Instructions ............................................................................ 213

8. Laser Processing............................................................................................. 2158.1 Overview ....................................................................................................... 2158.2 Jigs and Fixtures ........................................................................................... 2168.3 Shielding Gas................................................................................................ 2178.4 Fume and Spatter Control ............................................................................. 2188.5 Material Welding............................................................................................ 2188.6 Cutting Fixtures ............................................................................................. 2198.7 Cutting Assist Gas......................................................................................... 2198.8 Inert Assist Gases ......................................................................................... 2198.9 Process Preparation ...................................................................................... 220

8.9.1 Choice of Focused Spot Size ................................................................. 2208.9.2 Part/Focus Position ................................................................................ 2208.9.3 Weld Shape, Cut Width and Joint Strength ............................................ 2208.9.4 Cover Slide Damage .............................................................................. 2208.9.5 Processing Access................................................................................. 2218.9.6 Finding Focus ........................................................................................ 2218.9.7 Welding .................................................................................................. 2228.9.8 Cutting ................................................................................................... 225

8.10 Optimisation .................................................................................................. 2268.10.1 Use of Ramp Up and Ramp Down ......................................................... 226

8.11 Record Keeping............................................................................................. 226

9. Spares .............................................................................................................. 227

GSI LumonicsJK700TR: User ManualIssue 1.0 Introduction to GSI Lumonics


Introduction to GSI Lumonics

GSI Lumonics is a worldwide technology company specialising in the development,production and support of Lasers and Laser-based systems. The Companyorganisation includes manufacturing operations located in North America and Europealong with a network of support centres.

GSI Lumonics offers a complete range of Lasers that cover applications in sectorsincluding electronics, aerospace, automotive, advanced manufacturing, packaging andadvanced research.

GSI Lumonics collaborates with customers to develop Laser systems that increaseproductivity, solve manufacturing problems and meet the requirements of leading-edgeresearch.


Introduction to GSI Lumonics Issue 1.0


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GSI LumonicsJK700TR: User ManualIssue 1.0 General Information


1. General Information

1.1 Class of LaserThe JK700TR Series Laser is a Class 4 (IV) Laser system. Refer to Section 2 – Safetyfor information on Laser radiation hazards and safety precautions in a Class 4 (IV)environment.

1.2 Intended UsersAll operators using this Laser equipment must be officially trained and authorised.They must also be fully conversant with the following:

• Laser hazards, safety procedures and correct use of related safety equipment.

• Hazards related to the use of Lasers for materials processing, prescribed safetyprocedures and related equipment.

• The contents of this manual, and therefore the related safety provisions prescribedfor the safe installation of the equipment.

Authorised Personnel are classified as Engineers who have attended official GSILumonics Training Courses and have been certified as competent.

1.3 DocumentationThe JK700TR Series Laser is supplied with a Pre-installation Manual and a UserManual.

1.3.1 Pre-installation Manual

The Pre-installation Manual provides information on Pre-installation requirements,Installation Procedures and De-Commissioning Procedures.

The Pre-installation section specifies site preparation and the interfaces that need tobe in place prior to Laser delivery. The Installation section provides information andthe procedures necessary for installation and commissioning.

1.3.2 User Manual

The User Manual provides information on the Operating Procedures, UserMaintenance and Fault Diagnosis.

1.3.3 Service and Maintenance Manual

A third manual, the Service and Maintenance Manual will be provided for the use ofAuthorised Personnel only.


Section 1 – General Information Issue 1.0


1.3.4 Safety Paragraphs

Throughout the documentation ‘WARNING’, ‘Caution’ and ‘Note’ paragraphs appear.It is the responsibility and duty of all personnel who operate and maintain thisequipment to fully understand the WARNING, Caution and Note procedures in orderto reduce or eliminate hazards.

WARNING

WARNING TEXT MUST BE OBSERVED TO PREVENTPERSONAL INJURY TO YOURSELF AND OTHERS.

Caution

Caution text must be observed to prevent possible damage ordestruction to equipment or loss of operational effectiveness.

Note text must be observed for essential and effective operating procedures andconditions.

GSI LumonicsJK700TR: User ManualIssue 1.0 Section 1 – General Information


1.4 Table of DefinitionsName Definition

Aperture An opening in the protective housing of a Laser enclosure or Laser unitthrough which Laser radiation is emitted.

Assist Gas Gas that is fed to the beam focus at the workpiece to assist the cuttingprocess. See Shielding Gas.

BCD Binary Coded Decimal.

Beam Divergence

Laser beam diameter increases with increasing distance from the Laserowing to beam divergence (i.e. spread). It is expressed as the angle(mrad) the beam diameter increases per unit distance (mm).

Beam divergence can be used to predict the minimum beam diameterachieved by focusing the beam with a lens.

Beam Dump A device used to absorb beam energy when not required.

BET Beam Expanding Telescope.

Beam Focus The location beyond a focusing lens at which the beam diameter reaches aminimum value or focal point.

Beam Tube

A length of metal or PTFE (Teflon) tube located between componentassemblies in the beam path. Prevents human access to the Laser beamand the ingress of dust.The Beam Tube is also known as the Gaiter.

Beam PathLaser light directed to the workstation via a Shutter, Fibre and Focus Head.Lasers fitted with more than one Shutter can timeshare between differentworkstations by selecting a different beam path. See Timesharing.

Beam Stop A device that stops a Laser beam path.

Beam Quality Beam quality is defined using beam radius and half angle divergence andrelates to 86.5% of enclosed power (ISO 11146).

Depth of Focus

When a lens focuses a Laser beam to a small diameter, the Depth ofFocus is that distance along the lens axis over which the beam may still beconsidered focused. Depth of Focus is defined as the axial distance overwhich the beam diameter is no more than 10% larger than the minimumdiameter at the beam focal point.

EyewearPersonal Protective eyewear that prevents Laser radiation reaching theeye directly. Laser safety eyewear reduces the incident light to a safelevel, provided it is used correctly.

Fume Airborne grit, particles, smoke, dust, vapours and gases generated byLaser processing of materials.

GUIGraphical User Interface. The interface between the Operator and theLaser System. The GUI can be either a Personal Computer (PC) or anIndustrial Touch Screen Computer.

IntensityBeam intensity is strictly the power per unit area (Wcm2) of beam cross-section. Intensity is also energy density - the energy per unit area of beamcross-section.

Invisible Light outside the visible wavelength range 400 to 700nm.

Laser Controlled Area A work area controlled and supervised to protect personnel from Laserhazards.

Laser Safety Officer Person knowledgeable in the evaluation and control of Laser hazards andhas responsibility for overseeing control of Laser hazards.

LASER Acronym: Light Amplification by the Stimulated Emission of Radiation.




Name Definition

Laser Resonator

An optical assembly that provides feedback for light emerging from theLaser rod (thus enabling oscillation) and allows extraction of light toprovide the output beam.

The resonator may include additional components to tailor thecharacteristics of the Laser beam - for example, beam divergence,polarisation or monochromaticity.

Light Spectrum

Invisible light of longer wavelength than red light (700nm).

Invisible light of shorter wavelength than violet light (400nm).

Visible light in the wavelength range of 400 to 700nm.

Local Control Laser is operated and monitored via the control console (PC or GUI).

LSD Least Significant Digit.

Remote ControlInterface

Facility that allows an external controlling device such as a PLC to controland monitor the Laser.

MSD Most Significant Digit.

Nd: YAG

Nd Neodymium:

Doping to provide 1064nm wavelength of the beam.

YAG Yttrium Aluminium Garnet.

The host crystal contained in the Laser Head.

Parameter UpdateStrobe The signal that is used to send information into the Laser.

Parameter ChangeAcknowledge The signal that is used to acknowledge receipt of information by the Laser.

Remote Control Laser is operated and monitored via the Remote Control Interface.

Simmer

Simmer current (or simmer arc) is a current which is arranged to flow in theFlashlamp after the lamp has been triggered (i.e. the impedance of thegas inside the lamp has been broken down).

Simmering a lamp allows a quicker, more efficient response to currentpulses and avoids the need to trigger the lamp before every Laser pulse.

Sinking A term used to describe interface signals where current flows into theSignal Driver in the True state. No current flows in the False state.

Sourcing A term used to describe interface signals where current flows out of theSignal Driver in the True state. No current flows in the False state.

Spot Size

There are two possible interpretations of this phrase and care must beexercised. Spot size can represent:

The actual diameter of the beam focus at the surface of theworkpiece, based on knowledge of the Laser beam characteristicsand the parameters of the optical focusing system.

The diameter of a spot weld or drilled hole or the width of a seamweld or cut.

Generally, spot size is interpreted according to the first definition.

The Formula for calculating spot size is as follows:

Focussed Spot Diameter =

Fibre diameter x Focal length of Focus Lens

Focal length of Recollimating Lens

This assumes aberration free lenses.



Name Definition

Shielding Gas Gas that is fed to the beam focus at the workpiece during welding toexclude atmospheric oxygen. This prevents oxidisation of the weld.

Ready Status of equipment during periods of inactivity.

Timesharing The ability to switch Laser power between different workstations byselecting a different beam path. See Beam Path.

The following convention is used throughout this manual

0 = signal False.

1 = signal True.




1.5 Customer SupportThe JK700TR Series Laser is supported by a network of Customer Centres staffedwith trained Service Engineers. For customer service requirements, please contactyour local Customer Centre or GSI Lumonics, Rugby, England.

When contacting a Customer Centre, please have the following information at hand:

• The Laser type (JK700TR Series Laser).

• The Laser serial number.

• Any relevant information (e.g. fault codes and descriptions) that would assist infault diagnosis.

1.5.1 Regional Customer Centres

GSI Lumonics can be contacted in the following countries:

Farmington, Michigan, USATel: 1 (248) 4498989Fax: 1 (248) 7352460

Munich, GermanyTel: 49 (89) 31707-0Fax: 49 (89) 31707-250

Rugby, EnglandTel: 44 (0) 1788 570321Fax: 44 (0) 1788 579824

Hong KongTel: (852) 2549 - 8660Fax: (852) 2549 - 5896

GSI Customer Information

Product news and information resources can also be accessed via the GSI Lumonicswebsite at www.gsilumonics.com

1.6 CE Mark InformationThe JK700TR Series Laser complies with all CE requirements and relevant EuropeanUnion directives.



1.7 The JK700TR Series LaserThe JK700TR Series of Lasers are Pulsed Output, Nd: YAG Lasers used for generalwelding, cutting and heat treatment applications.

The JK700TR Series of Lasers can be supplied as a Single Fibre System, a TimeShare System, an Energy Share System or as Time Share/Energy Share System.

1.7.1 Main Assemblies

The main assemblies of the JK700TR Series Laser are as follows:

1.7.1.1 Laser Head.The main components of the Laser Head are the Pumping Chamber, the Front andRear Mirrors, the Prism Module, the Energy Monitor, the Beam Expanding Telescope(BET) and the PIPA Fibre Interface.

Each Pumping Chamber houses two cylindrical crystalline Laser Rods (Nd: YAG) andone or two gas filled Flashlamps (depending on the JK700TR Series model). Whencombined with the Front and Rear Mirror Module and the Prism Module, this assemblyis called the Optical Resonator.

The Optical Resonator converts electrical power into a beam of Laser light, which isfocused into a Fibre Optic cable.

The JK700TR Series Laser can be supplied with Time Share and/or Energy ShareDistributors. The number of Fibre Optic cables that can be used with each type ofDistributor is shown in the following Table.

System Type Number of Fibres

Slow Time Share Eight

Energy Share Four

Slow Time Share/ Energy Share Eight, no more than four ofwhich may be used forEnergy Share




1.7.1.2 Power Supply UnitThe Power Supply Enclosure contains the Laser Power Supply, the Cooling Systemand the Microprocessor.

The Power Supply provides the services required for operation of the Laser. Highpower electronic circuits control electrical energy to the Flashlamps.

The Cooling System disposes of waste heat from the Laser Head and the PowerSupply enclosure. The Cooling System consists of two units, the Air Cooler Module,which cools the Power Supply enclosure, and the Water Cooler Module, which coolscomponents in the Laser Head.

The Microprocessor controls and monitors the Power Electronics, Cooling System andLaser Head functions.

1.7.1.3 Local Controller1.7.1.3.1 Operator’s Control Panel

The Standard JK700TR Series Laser is supplied with an Operator’s Control Panel.This comprises a sealed membrane panel with twenty-three integral keyswitches,grouped according to function, an eighty-character alphanumeric liquid crystal displaywith light emitting diode (LED) indicator lamps, a five position key control and anEMERGENCY OFF push button.

The key control has two OFF positions and three ON positions corresponding to thethree colour coded keys supplied.

The control panel is supplied in a moulded enclosure for mounting on a desk or bench.By reversing the rear cover, the panel can be mounted on a vertical surface such as amachine enclosure. Alternatively, the panel may be removed from the mouldedenclosure and built into a machine control station.

The control panel is connected to either the Power Supply or Laser Head by a flexibleconduit, which is fitted with detachable connectors at both ends and is available invarious lengths up to 30m (100ft).

1.7.1.3.2 Graphical User Interface

The JK700TR Series Laser is provided with the option of a Graphical User Interface(GUI) as the Local Controller. The GUI can be either a Personal Computer or anIndustrial Touch Screen Computer. The GUI is used to monitor and control the Laser,program parameters, alert the User to any maintenance requirements and for faultdiagnosis.

There are three options for the Graphical User Interface (GUI):

A free-standing podium mounted Industrial Touch Screen Computer.

A 19-inch rack mounted Industrial Touch Screen Computer.

A Customer supplied Personal Computer with software, connector andInterface Box supplied by GSI Lumonics.

GUI software is supplied on CD-ROM as part of the Hardware Installation.



1.7.2 Fibre Optic Cable Assembly

Beam delivery is achieved by focusing Laser light into a Fibre Optic cable. The FibreOptic cable on the JK760TR is 600µm diameter and on the JK745TR, 730TR and715TR it is 400µm diameter. The light is homogenised as it passes through the cableto the Focus Head.

As light exits from the fibre-optic cable, it expands into the Focus Head. Thisincorporates a Re-Collimating and Focusing lens assembly.

The Re-Collimating lens re-collimates the expanding beam from the fibre and theFocusing lens focuses the beam to a small spot on the workpiece surface. Differentspot sizes are achieved by changing the combination of Recollimating and Focus lensfocal lengths.

A Fibre-Optic Continuity Monitoring System (FCMS) monitors the integrity of the fibrecable. If any fracture or disconnection occurs in the cable, the FCMS will place thesystem into shutdown and generate an alarm on the Local or Remote Controller.

1.7.3 Remote Control Interface

The Remote Control Interface allows total operational integration of the Laser into aproduction line or cell. Options include Timeshare, Energy Share, Shutter Control,Power Control, Parameter Selection and Alarm Reporting.

1.7.4 Ancillaries

A range of ancillary fittings is available for the JK700TR Series Laser including aCrossjet Nozzle, Cutting Nozzle, CCTV viewing and Auto-Focus Cutting Head.




1.8 Technical SpecificationThe following table provides general technical data on the JK700TR Series Lasersincluding the output specification and the services necessary for Laser operation.

Environment

Storage Environment Temperature not to fall below 2°C (35°F) unless thecooler has been drained.

Operating Environment Max temperature: 40°C (104°F)

Min temperature: 5°C (40°F)

Humidity Specification Max humidity: 96% RH at 15°C (68°F)

Max humidity: 32% RH at 35°C (95°F)

These figures indicate the maximum humidity at theupper and typical temperature limits.

Electrical Supply Requirements

Supply Three-phase, three-wire plus earth (ground).

Line Voltages (rms) 208V, 220V, 240V, 380V, 400V, 415V, 440V, 460V,480V

Voltage Tolerances ±6%

JK760TR JK745 JK730 JK715

Supply Rating 17 kVA 15 kVA 11 kVA 8 kVA

Maximum Power Consumption 15.3 kW 13.7 kW 9.5 kW 6 kW

Note: This equipment is built to operate at 50Hz or 60Hz within the relevant supplyvoltage range. This frequency is not interchangeable because a different CoolerPump motor is used in each case. Consult GSI Lumonics if it is necessary tooperate this equipment on a different supply frequency.



Cooling Water Supply

A clean water supply is required to the following specification:

JK760TR JK745TR JK730TR JK715TR

Minimum Supply 26 litres/min(6.9 USgal/min)

22 litres/min(5.5 USgal/min)



Water pH 6.5 to 8.5

Minimum Inlet Temperature 10ºC (50ºF)

Maximum Inlet Temperature 15ºC (59ºF)

Minimum Differential Pressure 2 bar (30psi)

Maximum Absolute Pressure 6 bar (85psi)

Cooling water flow rate is automatically regulated internally according to water inlettemperature and duty of the equipment. This maintains the internal cooling water at thecorrect temperature.

Equipment Weight andDimensions JK760TR JK745TR JK730TR JK715TR

Weight Laser HeadPower SupplyControl Panel

GUI Podium mountedGUI Rack mounted

40kg (88lbs.)600kg(1320lbs)2kg (4.5lbs)85kg (188lbs)51.5kg (114lbs)




DimensionsLaser Head width 280mm (11in)Length 953mm (37.5in)Height 222mm (8.75in)Power Supply width 1400mm (55in)Depth 600mm (23.6in)Height 1600mm (63in)Control Panel width 177mm (7in)

length 304mm (12in)height 60mm (2.36in)

Graphical User InterfacePodium mountedwidth 597mm (23.5in)depth 480mm (18.9in)height 960mm (37.8in) plus 185mm (7.3in) for the castorsRack Mounted width 482mm (19 in)depth 105mm (4.13in)height 265mm (10.43in)




Output Specification JK760TR JK745TR JK730TR JK715TR

Average Laser Power 600W 450W 300W 150W

Peak Power 10kW 10kW 5kW 5kW

Beam Quality (in mm.mrads) 28 25 20 15

Pulse Energy 100J 100J 50J 50J

Pulse Width range (ms) 0.5-50ms 0.5-50ms 0.5-50ms 0.5-50ms

Max Repetition Rate 500Hz 500Hz 500Hz 500Hz

Fibre Optic Cable JK760TR JK745TR JK730TR JK715TR

Fibre Diameter 600µm 400µm

Standard Fibre Lengths 5m, 10m, 15m, 30m, 50m

Customer Supplied PC

Operating System: Windows NT

Minimum Hardware Specification: Pentium Processor 450MHz

20Gb Hard Drive

32Mb RAM

Floppy Drive

CD Drive

1 x RS422 Interface Port (optional)

1 x RS232 Interface Port

Modem (requires additional serial port)



1.9 Safety Interlocks

1.9.1 Customer Remote Interlocks

A Remote Interlock Connector (RIC) provides connection for customer remoteinterlocks to the JK700TR Series Laser.

The interlocks, connected in series, are normally closed. Opening the interlocks cutsthe power supply to the Flashlamp circuits. Manual intervention is then required to re-establish the power supply. Refer to Section 2.8.1 for detailed information.

Remote interlock connection is via TB801 terminals 1 to 4 on the Interface TerminationPanel, located in the Termination Chamber.

1.9.2 Shutter Interlocks (Beampath Interlocks)

The JK700TR Series Laser has two independent circuits that control the Shutter:

Process Shutter control: Operated from a remote device or Local Controller andis used for processing purposes only. This Shutter issoftware controlled and must not be relied upon toprovide Operator safety.

Safety Shutter control: Employs a 24V solenoid mechanism for Shutteroperation. Spring-assisted closing provide Operatorsafety.

The Shutters are physically located in the optical path.

Shutter interlock connection is via TB801 terminals 9 to 10 on the InterfaceTermination Panel, located in the Termination Chamber.

1.10 Laser Power DeliveryLaser output power is delivered, via a fibre optic cable, to the Focus Head at theWorkstation for processing.

The Process Shutter can be controlled locally or via the Remote Control Interface toallow laser light to the workpiece. The Safety Shutter will close if the Control Circuitrydetects any faults. When the Laser is producing an output but the Process Shutter isclosed, the Laser output is ‘dumped’ into a water-cooled Beam Dump. The ProcessShutter can only be activated when the associated safety circuits are healthy.

Refer to Figure 1 for details on Shutter timing.




External Shutter Control

CustomerCommand

ControlDemand

Acknowledge

//

//

//

��

��

Figure 1 - Shutter Timing

Name Description Typical Max

TCR Control Response Time 25ms 120ms

TSOTime from Customer Command toShutter Open Acknowledge 50ms 170ms

TSCTime from Customer Command toShutter Closed Acknowledge 50ms 170ms



1.11 Operating ParametersLaser processing is determined by the parameters of the Active Shape. Up to tenshapes with different parameters can be stored. Each shape is identified by a number.The following operating parameters can be changed via the Local or RemoteController.

• Pulse Repetition Rate.

• Pulse Height.

• Pulse Width

The JK700TR Series Laser is capable of storing up to ten programmable Shapes. Theactive Shape can be selected via either the Local or Remote Controller. This allowsthe correct parameter values for specific processes to be established and programmedinto the Laser.

It is possible to specify a set of operating limits for each set of parameters. Operatinglimits are the maximum and minimum power limit and delay times set before the trip isactive. The limits are used to help ensure consistent quality of the parts processed bythe Laser by preventing production of components at Laser power outside thepredetermined limits.

1.12 Remote Control

1.12.1 Introduction

One of the major features of the JK700TR Series laser system is the facility to controlthe operation of the laser remotely using a CNC, PLC or other remote device. This isan optional feature requiring the CNC Interface Card (Part Number E85C3180D) to befitted in the microprocessor control unit.

To use all of the facilities available on the remote control interface the remote devicewill ideally require 32 digital outputs and 8 digital inputs but connections can beomitted if not required. Refer to Drawing Nos. E84C632EA E84C633EA,E84C634EA, E84C635EA, E84C636EA and E84C656AB in the JK700TR DrawingPack.

To prevent operational problems due to earth loops, the remote interface is opto-isolated from the laser system. The interconnections can be configured in groups, tobe ’sinking’ or ’sourcing’ to suit the remote device.

The inputs and outputs incorporated on the remote control card are monitored directlyby the microprocessor and the logic of operation is determined by the control software.The user cannot therefore gain access to signals other than those available at theremote interface connectors. However, this does allow the inputs and outputs to bedecoded in a number of ways.

1.12.1.1 Control ModesTwo modes of operation are offered giving control as follows:

Mode 0 Control

This mode of control is most compatible with previous LUMONICS industrial lasersystems and provides the following control of parameters:

Height 0-99% in 1% increments




Width 0.6-19.8mS in 0.2mS increments

0.5-9.9mS in 0.1mS increments

Rate 1-99Hz in 1Hz increments

2-198Hz in 2Hz increments

Mode 1 Control

This mode of control extends the resolution of parameter changes to match theresolution of the front panel. It also provides for control of additional features asfollows.

Height 0-100% in 0.1% increments

Width 0.5-20mS in 0.1mS increments

Rate 0.2-500Hz in 0.1Hz increments

Output Shape 1-10 all stored shapes

Multipulse Count 1-9999 in 1 pulse increments

1.12.2 Changing Parameters

Two modes of parameter control are provided on JK700TR Series lasers. Mode 0 iscompatible with past LUMONICS industrial laser systems

Note however that JK700TR systems may take up to 20mS to detect new data. Inaddition, new data is assessed to see if it is valid and this may take a further 20mS orlonger. If the handshaking facility is not used the remote device should allow 100mSfor the valid data to be issued by the laser.

Mode 1 control is more flexible and it is recommended for new applications. Figure 2illustrates the times taken to change the parameters.

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Figure 2 - Parameter Timing Diagram



Name Description Min Max

TSD Strobe Delay Time 1ms --

TSPTime from Strobe toAcknowledgement

-- 100ms (Typ 40ns)

TSM Minimum Strobe Width 20ms --

Ti Interval between parameter set -- 20ms

1.13 Control FunctionsIn addition to parameter control both modes use digital inputs and outputs to providefurther control and status information as follows:

• Shutter Open (I/P)

Allows the remote device to open and close the process shutter as required.

• Shutter Multi Shot (I/P)

Allows the remote device to open the process shutter to output the number ofpulses defined by the Multipulse Count.

• Ramp Up (I/P)

Allows the remote device to ramp the laser output up and down as required. Thelaser output has a variable ramp time of 0 to 9.99 seconds.

• Gate (I/P)

Allows the remote device to disable the laser output.

• External Trigger (2 I/P’s)

Allows the remote device to select between internal rate and external trigger and totrigger the laser when external is selected.

• Strobe (I/P); Acknowledge (2 O/P’s)

These signals provide a ’handshaking’ facility between the JK700TR laser and theremote device that eliminates the need for delay routines in the remote device whenlaser parameters are changed.

• Power Limit (O/P)

This confirms to the remote device that parameters sent to the laser wereacceptable.

• Energy Trip (O/P)

This indicates to the remote device that the laser energy is running at a levelbetween the Hi and Lo limits.

• Laser In Remote (O/P)

This indicates to the remote device that the laser is under REMOTE control (i.e.REMOTE key active).

• Laser Ready (O/P)

This provides an indication to the remote device that the laser is in the ready state(i.e. READY indicator lit).

• Sync (O/P)




This is an output synchronous with the pulse Height demand which enables eventsin the remote device to be synchronised with the laser.

• Shutter Closed (O/P)

This indicates to the remote device whether the shutter is open or closed.

1.14 Operating GuidelinesTo conserve energy consumption and extend Flashlamp life, it is good practice toswitch the Laser to Ready during periods of inactivity (no processing).

The frequency at which the Laser will be switched to Ready depends on theprocessing being carried out and may vary from high (between components) to low(production line maintenance periods).

The Nd: YAG Lasers used in the JK700TR Series require a short time for the Laseroutput to become usable after a large change in input power to the Flashlamps (e.g.the transition from READY to ON).

It is not advisable to switch the Laser to Ready if process time is less than severalseconds. If the Laser is operating under this condition, the Laser must remain ON andthe process must be controlled using the Shutter.

The time taken for the Laser output to increase from the Ready level to the targetoutput and visa versa can be programmed as a Ramp Up and Ramp Down time. Thistime can be set from 0 to 9.99 seconds.

1.15 Fibre Optic HandlingThese guidelines must be read before unpacking and handling the Fibre Optics.

Caution

Serious damage can be caused if the Fibre Optic cable is handledincorrectly.

1.15.1 Description

All JK Series Lasers are equipped with fibre optic beam delivery. The standard fibrecable lengths are 5m, 10m, 15m, 30m and 50m.

Optimum fibre routing from the Laser to the point where processing is to be carried outis essential if long fibre lifetime is to be achieved. This is particularly important whenthe fibre is used in conjunction with a Robot.

The fibre optic is a complex component that incorporates optical, electrical andmechanical parts. Although fibres are designed for use in factory environments, caremust be taken during installation and use to ensure optimum performance andacceptable lifetime.

Fibres optic cables are more fragile than electrical cables, although superficially theylook similar. If fibres are treated and handled as electrical cables, they will failprematurely. Fibre replacement can be both time-consuming and expensive.



1.15.2 Unpacking Fibre Optic Cable

Particular care should be taken with regard to possible termination damage whenunpacking and uncoiling the fibre as there is a tendency for the coil to spring apart,possibly resulting in the terminations colliding with other objects.

• The cable is very flexible and easily bent when uncoiling. At no time shall theminimum bend radius be exceeded.

• Take care not to twist the cable when uncoiling. Always unravel the cable with afeeding action and compensate for any twist that might occur.

• Do not drop the cable or allow it to impact with surfaces or other objects.

• Never pull on a termination to unravel a fibre.




1.15.3 Fibre Installation

• Ensure that the bend radius limitations (refer to Section 1.15.5) are observed.

• Avoid sharp or abrasive surfaces.

• When fitting the fibre cable, ensure that the orientation key in the fibre terminationand the keyway in the fibre receiver are aligned.

• When fibre cable is run horizontally it is to be supported, or secured, at intervals nogreater than 4m.

• Lengths of fibre cable subject to movement, particularly in robot applications, mustbe carefully routed and supported to maintain curvature above minimum bendradius throughout all motion. Adjustable spring tensioners or the incorporation of ahelix in the cable route must accommodate motion without imparting excessive twistor to the conduit.

• Grouping the cable with stiffer service cables/pipes is permissible but the cablemust not be used as a supporting member for a group of more flexible cables/pipes.

• Fibre termination must not be subjected to forces caused by dropping, impacting orcollision by heavy objects.

• Where the fibre input receiver is inside the Laser enclosure, ensure that there isenough conduit slack between the fibre receiver and the strain relief gland on theLaser lid. Make sure that there is no induced stress on the fibre termination or theinput receiver.

1.15.4 Recommendation

When processing materials with highly reflective surfaces, such as gold, silver,aluminium and copper etc, GSI Lumonics recommend that the focus head should beoffset from the workpiece by approximately 10 degrees from the perpendicular.



1.15.5 Minimum Bend Radii

Condition Min Bend Radius

Handling/Momentary 120mm

Manually coiling/uncoiling.

Threading cable through supports or laying in cable supports.

Attaching to permanent stationary fixings.

Static/long Term 180mm

Processes where Focus Head remains stationary.

Final installed location of cable between Laser and work enclosure.

Repetitive Flexing/Dynamic 180mm

Pre- or post-process positioning.

In-process movement of cable.

Multi-axis robot motion of Focus Head.

Single-axis gantry type motion of Focus Head.

Inertial acceleration/decelerations of suspended cable.

Winding/unwinding of residual, suspended coils.

1.15.6 Fibre Optic Termination

Fibre termination is the section of fibre from the beginning of the termination boot tothe exposed end of the fibre. This includes all mechanical, electrical and optical parts.No single part of the fibre termination is replaceable/repairable outside themanufacturing base.

• Ensure the fibre termination is always kept in a clean environment. If this is notpossible, use the clean termination cover provided.

• During installation of the fibre, ensure that the protective covers are removed onlywhen necessary.

• Keep the fibre termination placed downwards when uncovered and not installed.

• Do not attempt to dismantle the fibre termination.

• Always handle the termination by the boot not the optical termination.

• Care must be taken to prevent damage or contamination of any exposed electricalcontacts.

• The fibre termination must not be subjected to forces caused by dropping,impacting or collision by heavy objects.

1.15.7 Fibre Routing

In static applications (i.e. fibre and Focus Head do not move), the fibre must not bebent greater than the minimum bend radius at any point along the route (refer toSection 1.15.5).

In dynamic applications (i.e. fibre and Focus Head move), the following points of goodpractice should be adhered to:




• The fibre cable should be held off the floor and routed along a path so that the fibrecable does not bend more than the minimum bend radius at any point along thefibre cable length throughout the production sequence.

• The fibre cable should be supported at points along its length to prevent grossmovements under the action of its own weight during the production sequence.

• At the fibre cable support points, the fibre cable should be held using mechanicalparts which prevent the minimum bend radius being exceeded and which do notresult in a radial compressive force on the fibre cable.

• The fibre cable should never be pulled tight at any point along its length during theproduction sequence.

• The external surface of the fibre cable should be prevented from rubbing/abrasionat support points or on any other parts in the workstation (e.g. jigs, fixtures,production parts, workstation walls, floors, robot parts).

• Acceleration and deceleration of the fibre cable and Focus Head should be kept toa minimum consistent with achieving process cycle time.

• At fibre cable installation and periodically during operation (e.g. once per shift), adry run of the production sequence should be made. The fibre cable motion shouldbe checked to ensure that the fibre routing still complies with the points of goodpractice above.

1.15.8 Fibre Removal

When removing the fibre termination from the fibre receiver (input or output), hold thetermination and ease the fibre free. Never jerk the fibre free.

GSI LumonicsJK700TR: User ManualIssue 1.0 Section 2 - Safety

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2. Safety

2.1 Laser ClassificationLaser classification indicates the potential hazard presented to the User. There aretwo standards used to define Laser Products: Throughout the World, with theexception of North America, regulation IEC 60825-1 (EN 60825-1 in Europe) isused. This regulation defines Laser Products as Class 1 to Class 4.

The classifications and risks for IEC60825-1 are defined in the following table.

Class Risk Description

Class 1

No risk toeyes.No risk toskin

Class 1 Laser Products are defined as safe in normal operations under reasonablyforeseeable conditions, including direct viewing of the laser beam with optics that couldconcentrate the laser output into the eye. In addition to some intrinsically low powerlasers products, Class 1 Laser Products also includes embedded products that totallyenclose a higher Class of laser e.g. CD players, laser printers and most industrial laserprocessing machines.

Class 1M

Low risk toeyes.No risk toskin.

Class 1M Laser Products are defined as safe in normal operations under reasonablyforeseeable conditions, including direct viewing of the laser beam, providing the user doesnot employ optics that could concentrate the laser output into the eye. Unsafe conditionsinclude use of a telescope or binoculars with a 1M laser emitting a well-collimated laserbeam or use of an eye loupe or magnifier with a high divergence 1M source.

Class 2

Low risk toeyes.No risk toskin

Class 2 Laser Products are those emitting visible light for which the natural aversionresponse to bright light (including the blink reflex) prevents retinal injury. This includesdirect viewing of the laser beam with optics that could concentrate the laser output into theeye. These lasers do present a dazzle hazard and appear uncomfortably bright whenviewed directly but should not cause harm if viewed for less than 0.25 seconds.

Class 2M

Low risk toeyes.No risk toskin

Class 2M Laser Products are those emitting visible light for which the natural aversionresponse to bright light (including the blink reflex) prevents retinal injury. However, aswith Class 1M Laser Products, only provided the user does not employ optics that couldconcentrate the laser output into the eye.

Class 3R

Low risk toeyes.Low risk toskin

Class 3R Laser Products are those in which the output is up to a factor of five over themaximum allowed for Class 1 or Class 2. Because of inherent safety factors in the limitsfor these classes, the risk of injury for direct viewing of a Class 3R laser beam remainslow, but greater precautions should be taken when using these lasers to prevent directeye exposure, especially for invisible Class 3R lasers.

Class 3B

Mediumrisk toeyes.Low risk toskin

Class 3B Laser Products are those to which direct exposure of the eye is hazardous, evenconsidering aversion responses. Scattered laser light is usually safe, for example diffusereflections from a matt surface. However, viewing of specular reflections can behazardous, e.g. from a mirror surface. The higher power Class 3B lasers are also a skinhazard, but the natural aversion response to localised heating generally prevents a skinburn.

Class 4

High risk toeyes.High risk toskin

Class 4 Laser Products are those to which direct exposure of the eye and skin ishazardous and scattered laser light may be hazardous to the eyes. Such lasers are alsoa fire hazard and their use requires extreme caution.

The JK700TR Series Laser is a Class 4 Laser System. All operators using this Laserequipment must be officially trained and authorised.

In North America, the Center for Devices and Radiological Health, a division of theFDA, regulates the classification of Laser Products and uses Federal Regulation 21CFR Chapter J 1040.10.

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of 236 Part No: 1EAA80E02

This regulation defines Laser Products as Class I to Class IV.

The classifications and risks for 21 CFR Chapter J 1040.10 are defined in thefollowing table.

Class Risk Description

Class I

No risk toeyes.No risk toskin

Class I Laser Products are considered to be incapable of producingdamaging radiation levels and are determined to be eye safe. TheseLasers are exempt from most control measures. Class I Laser Productsalso include embedded products that totally enclose a higher Class ofLaser e.g. CD players, laser printers and most industrial laser processingmachines.

Class IIa

Low riskto eyes.No risk toskin

Class IIa Laser Products are those emitting visible light for which thenatural aversion response to bright light (including the blink reflex)prevents retinal injury. These lasers are not intended for viewing but arenot hazardous if viewed for less than 1000 seconds. An example is aSupermarket Bar Code Scanner.

Class II

Low riskto eyes.No risk toskin

Output Power less than 1mW.

Class II Laser Products are those emitting visible light for which thenatural aversion response to bright light (including the blink reflex)prevents retinal injury. This includes direct viewing of the laser beam withoptics that could concentrate the laser output into the eye. These lasersdo present a dazzle hazard and appear uncomfortably bright when vieweddirectly but should not cause harm if viewed for less than 0.25 seconds.

Class IIIa

Low riskto eyes.Low riskto skin

Output Power up to 5mW.

The risk of injury for direct viewing of a Class IIIa laser beam remains lowunless viewed with optics that could concentrate the laser output into theeye.

Class IIIb

Mediumrisk toeyes.Low riskto skin

Output Power 5mW to 500mW.

Direct exposure of the eye to the laser beam is hazardous. Scatteredlaser light is usually safe, for example diffuse reflections from a mattsurface. However, viewing of specular reflections can be hazardous, e.g.from a mirror surface. The higher power Class IIIb lasers are also a skinhazard. The Class IIIb laser is not normally a fire hazard.

Class IV

High riskto eyes.High riskto skin

Output Power exceeds 500mW.

Class IV Laser Products are those to which direct exposure of the eye andskin is hazardous and scattered laser light may be hazardous to the eyes.Such lasers are also a fire hazard and their use requires extreme caution.

The JK700TR Series Laser is a Class IV Laser System. All operators using thisLaser equipment must be officially trained and authorised.

GSI LumonicsJK700TR: User ManualIssue 1.0 Section 2 – Safety


2.2 Laser Radiation HazardsThe JK700TR Series Laser is a Nd: YAG Laser. This Laser produces radiation witha 1064nm wavelength, powerful enough to melt and vaporise most materials. Evendiffuse reflections can inflict serious injury if allowed to strike the body.

Effects on Body Tissue

Laser radiation is concentrated energy. If it strikes the body, most of the energy willbe transferred to body tissue. Tissues will show burn damage that will spreaddepending on the irradiated area and duration of exposure.

High power exposure may cause the absorbing body tissue to explode andvaporise. Displacement of absorbing tissue may result in shear damage to adjacenttissue.

Effects on the Eye

Nd: YAG light presents a hazard to the eye because the light can damage retinaltissue. Exposure to moderate levels of Laser light can cause burns, which may bepermanent. Nd: YAG light is invisible and personnel will be unaware of the risk ofexposure.

Indirect Exposure

Control measures reduce the risk of direct beam exposure. However, there is alsoa risk of indirect exposure to radiation re-directed by components located in thebeam path.

Reflective components present the greatest risk, since virtually 100% of the beampower can be redirected. The level of risk depends on the direction of the reflectedbeam relative to the personnel. A Class 4(IV) Laser beam can be reflected fromnon-reflective surfaces.

Exposure can be minimised by tilting of components in the beam path and/orappropriate positioning of personnel with respect to the reflected radiation.

The risk of indirect exposure can be minimised by the following precautions:

• Ensure no unintended/unnecessary components are in the Laser beam path.

• Ensure all optical components in the beam path are maintained in good condition(clean and undamaged).

• Ensure all necessary components in the beam path re-direct the lowest possibleamount of light.

• Ensure all components in the beam path are securely mounted to avoidunexpected changes in component position/tilt.

• Ensure that components and personnel are positioned to reduce exposure ofpersonnel to re-directed radiation.

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2.3 Control MeasuresThe risk of personal injury can be minimised by the following measures:

• Never direct the Laser beam at other people.

• Never direct the Laser beam upwards. If possible, direct the Laser beam downtowards the floor.

• Avoid mounting the Laser or any part of the beam path at eye level. If possiblealways arrange horizontal beam paths well above or below eye level.

• Always use a Beam Stop behind the target/work piece.

Precautions must be taken to prevent unauthorised personnel from entering theequipment work area when the Laser is operating.

Warning notices must be displayed to inform personnel of hazards.

Access must be restricted to only those personnel who need to be present.

Control measures reduce the risk of injury to personnel but are not adequate ontheir own.

The safest mode of operation is to use a Class 1(I) enclosure in conjunction with theLaser. This establishes a physical barrier to prevent access and indirect exposureto the Laser beam/radiation. This method of operation is preferred by SafetyAuthorities and is recommended by GSI Lumonics for use with the JK700TR SeriesLaser.

If a Class 1(I) enclosure is not employed and the Laser operates under Class 4(IV)conditions then additional precautions are required. Approved Laser safety gogglesmust be used at all times by all personnel in sight of the Laser. Laser safetygoggles must be suitable for use with high power Lasers of 1064nm wavelength. Itmust be remembered that radiation from the JK700TR Series Laser is invisible.

Administrative procedures must be introduced to enforce the above requirement onuse of protection. In Europe, Laser safety goggles must comply with EN 207and EN 208.



2.4 Electrical SafetyThe JK700TR Series Laser power supply output can reach potentially lethal highvoltage levels. Servicing of the power supply must be carried out by certifiedpersonnel only. Observe all precautions complying with accepted working codes ofpractice in the servicing of electrical equipment at all times.

Additionally, the following precautions must be observed:

• Where it is necessary to raise the Laser head lid with the power supply switchedon (for setting-up or servicing procedures, e.g. fibre-optic alignment, rear mirroradjustment, etc.), extreme care must be taken when working on the equipment.

• Do not open cabinet doors while the supply isolator is closed.

• A two minute period must be allowed after isolation of the power supply beforeopening the cabinet doors, removing covers or raising the Laser head lid. Thisdelay permits the high voltage capacitors in the equipment to fully discharge.

Additional information and advice on the safe electrical practices associated with theJK700TR Series Laser is given below:

• All personnel working with the JK700TR Series Laser must be fully aware of thedangers of misuse of high voltage equipment and be familiar with its safe workingpractices.

• Before using this equipment, operators must be familiar with the operatinginstructions provided in the User Manual. If any uncertainty arises, seek advicefrom the Appointed Engineer or directly from GSI Lumonics.

Service Engineers must comply with all Local Safety Precautions and follow theadvice given below:

• Do not permit inexperienced personnel access to the Laser electrical circuits.

• Always ensure that cables and terminal connections are positioned to preventarcing between components.

• Do not assume polarities of cabling or components, refer to available circuitdiagrams or contact GSI Lumonics.

• Do not attempt to carry out work on electrical circuits when alone. Always have acolleague nearby.

• Use only GSI Lumonics approved spare parts.

• Always adhere to Local Plant Regulations relating to work on electricalequipment.

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2.5 Environmental HazardsMaterials used in Laser processing applications can become hazardous if safeworking practices are not followed. Hazards can result from the following:

• Fire.

• Fume.

• Compressed Gases.

• Solvents.

2.5.1 Fire

Particular care is necessary when processing combustible materials.

The use of oxygen as an assist gas on combustible materials can exacerbate a firehazard. Combustible materials include plastics, waxes, and some metals.Compressed gases and solvents used for equipment maintenance also increase therisk of Laser-initiated fires.

Do not attempt to process reactive metals such as titanium and magnesium usingoxygen as an assist gas. Such materials must be processed using inert gases only(e.g. nitrogen, argon, etc). Always consult the material manufacturer safetyinformation before commencing processing.

To test for the potential reaction of a metal in the presence of oxygen, use thefollowing procedure:

Use a sample piece of the metal on which to test.

Ensure that the gas line is fitted with a flashback arrestor.

Ensure a colleague is present to turn off the Laser in the event of fire.

Ensure a second colleague is present with a suitable fire extinguisher.

Operate the Laser to safe test the metal.



2.5.2 Fume

Fume and fine particulate can be generated during processing. Fume can includemetallic particles, dust, chemical and gaseous vapours. Such materials mustalways be regarded as a potential health and safety hazard. Ensure measures aretaken to prevent inhalation.

Always consult the following regulations/recommended practices:

• Health and Safety Regulations.

• Local and Plant Regulations.

• Material Manufacturers‘ Safety Recommendations.

The following guidelines will reduce or eliminate fume hazards:

• Containment of processing by-products in a safety enclosure.

• Evacuation of the processing by-products and assist gases.

An exhaust appliance must be provided because, when assist gasesare used in Laser processing, the local oxygen concentration maysignificantly increase from the normal value by 20% by volume. Theexhaust appliance must be positioned as near as possible to the pointof origin to prevent processing fumes contaminating the air of theworkroom.

Care is needed in the choice of evacuation equipment to avoid re-circulation of fine particulate around the building. Simple filteringsystems are unlikely to remove harmful vapours and gases.

Ensure that the venting of fume outside the building complies withLocal Statutory Requirements. Particular care is needed in the siting ofthe exit vent, to ensure adequate atmospheric dilution has occurredprior to personnel exposure. The vent must be located away frompersonnel access, preferably at roof level.

• Use of Personal Protection Clothing (PPC).

Personal Protective clothing must be supplied and worn. However, this isa last resort precaution and PPC should not be used as the primary safetyprecaution.

Guidance on welding fume and its removal can be obtained by contacting:

The Welding Institute,Abington Hall, Abington,Cambridge CB1 6AL, England.

General guidance can also be obtained from GSI Lumonics.

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2.5.3 Compressed Gases

Statutory requirements relating to the storage, use and transport of compressedgases must be followed, in particular the handling of gas cylinders.

Do not use grease on components that are exposed to oxygen. This increases riskof explosion.

All high-pressure gas lines must be constructed to a high standard using highintegrity components. Flashback arrestors must be used in oxygen lines.

Strictly adhere to Manufacturers’ Safety Recommendations and Procedures.

2.5.4 Solvents

Solvents are used for the maintenance of equipment. Solvents are hazardous tohealth if adequate precautions for use and storage are not taken.

GSI Lumonics recommend that only PROPAN-2-OL (IPA) is used for cleaningoptics. IPA is also identified as ISOPROPANOL or ISOPROPYL ALCOHOL.

WARNING

PROPAN-2-OL (IPA) IS FLAMMABLE AND TOXIC TO EYES,SKIN AND RESPIRATORY TRACT.

SKIN/EYE PROTECTION MUST BE USED.

AVOID REPEATED PROLONGED CONTACT.

USE ONLY IN WELL VENTILATED AREAS.

KEEP AWAY FROM OPEN FLAME OR OTHER SOURCES OFIGNITION.



2.6 Conditions of UseThe JK700TR Series Laser must only be used under the following circumstances:

• On approved materials.

• Using an approved process.

• Under approved conditions.

• With due and proper authorisation.

WARNING

USE OF CONTROLS, ADJUSTMENTS OF PERFORMANCEOR PROCEDURES OTHER THAN THOSE SPECIFIED MAYRESULT IN EXPOSURE TO HAZARDOUS RADIATION.

2.6.1 Approved Materials

Approved materials can be processed without hazard to personnel or damage to theLaser product. These materials have been assessed for their toxicity and firepotential. Approved materials have an approved process method andrecommended arrangements for fume containment and removal.

2.6.2 Approved Process

An approved process does not present a hazard to the health of personnel orpossible damage to the Laser equipment. The approved process hasrecommended arrangements for processing by-products and fume containment andremoval.

2.6.3 Approved Conditions

Approved conditions satisfy the requirements of applicable safety standards andstatutory requirements relating to electrical, Laser radiation and health hazards.Approved conditions meet the requirements of the Plant Safety Officer and theLocal Safety Inspectorate.

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2.6.4 Due Authorisation

Due authorisation is the proposed arrangements, reviewed and approved by thefollowing members of the User’s organisation:

• A competent authorised person having a professional qualification in anappropriate technical discipline (’Technical Referee’).

• The Supervisor of the Technical Referee.

• The Plant Safety Officer or an authorised GSI Lumonics engineer.

WARNING

EXPOSURE OF THE HUMAN BODY TO LASER RADIATIONIS EXTREMELY DANGEROUS.

Practices that may result in accidental bodily exposure, e.g. holding work pieces byhand, must be avoided.

Do not attempt to process parts with personnel inside the safety enclosure.

Safety equipment must be complete, intact and free from damage.

Parts must only be processed in strict conformity with GSI Lumonics InstructionManuals, Local Safety Regulations and using established good working practicesfor Laser processing.



2.7 Safety Control System

2.7.1 Safety Category

A Laser Safety Officer must be appointed to specify the level of safety precautionsand control to be implemented during normal operating and maintenance work.

At all times a Laser must be operating in a controlled area, appropriate to the levelof hazard it represents.

If a Class 1 enclosure is breached for servicing or maintenance work, and the Laser isin a Class 4 environment, appropriate controls must be specified.

2.7.2 Safety Compliance

The following standards apply to Laser safety:

Worldwide: IEC 60825-1: 2001

Europe: EN 60825-1: 2001

North America: FDA Regulation 21 CFR Chapter J 1040.10.

2.7.3 Safety Labelling

Safety labels are fitted to the equipment in compliance with IEC regulations.

Before operating on any part of the Laser system, the hazard level must be checkedby examining the Safety and Compliance labels - refer to Figure 3 and Figure 4.

This information is supplied for safety purposes only and serves principally to assistin the selection of suitable protective eyewear and guarding, including integralviewing panels. These values reflect an appropriate safety margin.

Labels must not be defaced or removed. Damaged or missing labels must bereplaced immediately by contacting GSI Lumonics quoting the label identificationreference given on each label.

Customers must ensure any component fitted has the correct labelling (refer to GSILumonics).

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Intentionally Blank


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Item 1

Item 2

Item 1

Item 3

Item 1

Item 1

Item 1

Item 1 fits insideon base of Module

Key:

Item Part No. Description1 E68E0431B IEC Invisible Radiation Label2 4300W0131 S/A High Voltage Label3 E84C7681B CDRH High Voltage Label

Figure 3 – Safety and Compliance Labels – Laser Head

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Intentionally Blank



Item 5

Item4

Item 6

Key:

Item Part No. Description4 EE113361C JK715TR & JK730TR IEC Radiation Label

EE113351C JK745TR & JK760TR IEC Radiation Label5 EE109861B GSI Lumonics Label6 EE113371B JK700TR Series Label

Figure 4 – Safety and Compliance Labels – Laser Head

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2.8 Safety FeaturesTwo safety features of the JK700TR Series Laser which protect personnel fromexposure to Laser radiation are:

• Remote Interlock Connector.

• Workstation Interlock.

2.8.1 Remote Interlock Connector

The Remote Interlock Connector enables an external Remote Safety Interlock to befitted to the interlock circuit of the Laser. The Remote Interlock Connector is arequirement of the two principal Laser radiation standards:

Worldwide IEC 60825-1 (Europe EN 60825-1).

North America FDA Regulation 21 CFR Chapter J 1040.10.

When the terminals of the RIC are open circuit, exposure to Laser radiation isprevented. This is caused by either the RIC plug being removed or the terminals of aSafety Interlock Switch connected to the plug being open circuit.

In these circumstances, the interlock chain is broken, causing the Flashlamp powercircuits to be de-energised and the Shutter closed.

Restoring electrical continuity at the RIC will not restart the Laser. To restart, a normalLaser Start-Up Sequence has to be followed.

This facility is equivalent to a remote emergency stop control. It must not be used forplanned shutdown of the Laser.


Section 2 – Safety Issue 1.0


2.8.2 Workstation Interlock

Where safety interlock switches are operated frequently, a RIC is not suitable. Inthese circumstances, workstation interlocks are used.

If the terminals of the workstation interlock are open-circuit (not electrically joined) thenthe Laser Shutter closes, preventing the Laser beam from emitting from the Laser.

To enable Laser output, the terminals of the workstation interlock must be electricallyjoined, either by fitting a short-circuit link within the Shutter interlock plug or byconnecting a safety interlock switch to the Shutter interlock plug.

WARNING

NO ONE MUST ENTER AN AREA WHERE EXPOSURE TO HARMFULLEVELS OF RADIATION IS POSSIBLE.

DO NOT CLOSE THE SHUTTER BY MEANS OF THE SHUTTER CLOSECOMMAND OR FROM A REMOTE CONTROLLER AS A MEANS OFPREVENTING EXPOSURE TO LASER RADIATION.

IF A SHUTTER INTERLOCK PLUG IS FITTED WITH A SHORT-CIRCUITING LINK, THE PLUG MUST BE WITHDRAWN FROM THESOCKET BEFORE ENTERING AN AREA WHERE LASER RADIATION ISLIKELY TO EXCEED THE CLASS 1 (I) LIMIT.

IF THE LASER BEAM TERMINATES IN A CLASS 1 (I) WORKENCLOSURE, THE ACCESS DOORS MUST BE PROTECTED BY SAFETYINTERLOCK SHUTTER SWITCHES CONNECTED TO THE SHUTTERINTERLOCK SOCKET.



2.9 TrainingOperation of a Class 4 (IV) Laser system can represent a hazard not only to the Userbut also to personnel considerable distances from the system.

Persons in control of a Class 4 (IV) Laser system are required to have successfullycompleted training in the following areas:

• System operating procedures.

• The proper use of hazard control procedures, warning signs etc.

• The need for personal protection.

• Accident reporting procedures.

• The effects of the Laser upon the eye and skin.

2.10 Personal Protective Equipment

Eye Protection

Eye protection designed to provide adequate protection against specific Laserradiation, must be used in all hazard areas where Class 3B or Class 4 Lasers are inuse.

The eye protection (goggles) is designed to protect the wearer against low levelscattered light. Eye protection cannot withstand direct beam exposure. Eyeprotection must be in good condition, fit properly and be inspected regularly. Alwaysdispose of damaged eye protection.

Protective eyewear must conform to the following standards:

Europe: EN 207 and EN208

2.11 Manual Handling

Manual Handling Requirements

Manual handling procedures must be observed and carried out in compliance withlocal factory regulations.

An assessment must be carried in order to carry out the following:

• Moving/positioning the cabinet without the use of lifting aids.

• Removal of component parts.


Section 2 – Safety Issue 1.0


Intentionally Blank

GSI LumonicsJK700TR: User ManualIssue 1.0 Section 3 – Laser Operation – Operator Control Panel


3. Laser Operation – Operator Control Panel

3.1 IntroductionThe Standard JK700TR Series Laser is supplied with an Operators Control Panel asthe User Interface. This Section describes the operation of the Laser using theOperator’s Control Panel.

The JK700TR Laser can be supplied with a Graphical User Interface. Operation of theLaser with this option is described in Section 4.

3.2 Start-up and Shut-down Procedures

3.2.1 Start-Up-Procedure

1. Turn on the external water supply.

2. Switch on the external Power Supplies.

3. Switch ON the MAINS Disconnect switch on the Power Supply Cabinet.

4. Insert the yellow Supervisor key into the ENABLE switch and turn the key toposition 3.

5. Ensure that the EMERGENCY OFF button is in the outer (ON) position.

6. Press the blue reset button on the Power Supply Cabinet.

Verify that:

The SUPPLY indicator remains lit.

The WARNING and ALARM INDICATORS go out.

7. Press the POWER button and wait for the READY indicator to light.

8. Select the required laser parameters.

Decide to use an existing shape or compose a new one.

Set the Height and Width as required.

Ensure that the Demand Range and Height Type are as required.

Set the Multishot Count to the required value.

9. ENSURE ALL PROCESS SAFETY PRECAUTIONS ARE IN PLACE.

10. When laser operation is required:

Set the Display with ENERGY MONITOR on the top line.

11. Press LOCAL to initiate operations.

12. Set the height demand to achieve the desired pulse energy.

13. Set the Repetition Rate to achieve the desired mean output.

14. When Laser Output is required:

Confirm that it is safe to open the Shutter.


Section 3 – Laser Operation – Operator Control Panel Issue 1.0


Press the MULTISHOT key to obtain the required train of pulses or press theOPEN key for a continuous output.

15. Press the CLOSE key on completion of the Process.

3.2.2 Shut Down Procedure

1. Ensure the Shutter is closed.

2. Press the LASER OFF key to terminate Laser operation. If the Laser is to beused again within a few minutes, it can be left in this position. Otherwise, turn offall Process Functions (gas supply, fume extraction etc.).

3. Press the SYSTEM OFF key.

4. When the Cooler Indicator goes out, Turn the ENABLE key to position 1 andremove the key.

5. Switch OFF the Mains Disconnect switch on the Power Supply Cabinet.

6. Switch off the external Power Supplies.

7. Turn off the external water supply (flow and return).

3.2.3 Emergency Shut Down Procedure

1. Push the nearest red EMERGENCY OFF pushbutton.

2. Switch OFF the Mains Disconnect Switch on the Power Supply cabinet.

3. Switch OFF the external Power Supplies.

4. Switch OFF the external water Supplies.

5. Obey all Local Emergency Procedures.

The EMERGENCY OFF is a large red two-position pushbutton. In the normal outer(ON) state, laser operation is possible. When the pushbutton is pushed, it latches in itsinner (OFF) position. Since the EMERGENCY OFF is in the main interlock chain,pressing the EMERGENCY OFF button immediately stops laser operation. To releasethe button from its inner position, rotate the button 45° clockwise, then allow the buttonto self-rotate to its normal position.

This button is intended only for emergency use. In normal circumstances, the normalshutdown procedure will be used.



3.3 Alarm HandlingAn alarm will be generated if an ‘alarm condition’ occurs. This will be indicated to theUser in the following manner:

An audible alarm sounds.

An Alarm indicator will flash.

A message will appear in the Alarm Banner.

To accept the alarm message, press the ALARM key. This stops the audible alarm andswitches the alarm indicator to continuous.

Repeated operation of the ALARM key will alternate the display between the alarmmessage and the monitor display.

The Alarm message and the alarm indicator will extinguish only when the alarmcondition has been rectified.

Refer to Section 5.2 for details of the alarm messages and fault diagnosis.

3.4 Monitoring and ControlLocal monitoring and control of the Laser is via a the Operators Control Panel.

There are four levels of User access. These are defined as follows:

Level 0 Operator Blue Key Monitoring only.

Level 1 Operator Blue Key Level 0 plus Laser SwitchREADY/ON.

Level 2 Supervisor Yellow Key Level 1 plus control.

Level 3 Maintenance – Red Key Level 2 plus configuration andfault diagnosis.




3.5 Control Panel OverviewThe Control Panel is the User interface with the microprocessor that has control overmost aspects of the laser. The operator can select his requirements via the panel.Correspondingly, the microprocessor can indicate to the operator, via indicator lightsand displayed messages, the status of the laser including parameter settings,explanations, warnings and fault conditions.

The Control Panel comprises a sealed membrane panel; usually mounted in amoulded plastic enclosure

Figure 5 – Operators Control Panel

The Control Panel incorporates:

• Twenty-three pushbutton keys.

• Five discrete indicator lights.

• A keyswitch.

• A red EMERGENCY OFF pushbutton.

• A two line eighty character alphanumeric display.

• An ambient light sensor..

All but five of the keys have integral indicators to signify when the keys are switchedon (active). There are two exceptions to this, the COOLER and POWER keys.

Close to the SHAPE key is a small light sensor that causes the brightness of the panelindicators to vary according to the ambient light level.



3.6 Control GroupsThe keys and indicators are grouped according to function in six groups under thefollowing headings:

STATUSSYSTEMLASERSHUTTERDISPLAYSELECT.

The composition of each group is as follows:

STATUSSUPPLY indicatorEMISSION indicatorREADY indicatorWARNING indicatorWARNING keyALARM indicatorALARM key

SYSTEM (all keys)COOLERPOWEROFF (system off)

LASER (all keys)LOCALREMOTEOFF (laser off)

SHUTTER (all keys)MULTI SHOTOPENCLOSE

DISPLAY (all keys)SHAPEHEIGHTWIDTHRATEOPTICSLAMP POWERTEST

SELECT (all keys)SET↑ the INCREMENT key↓ the DECREMENT key→ the CURSOR key.

Three of the control groups - SYSTEM, LASER and SHUTTER - are used primarily tooperate the laser; the three other groups have wider-ranging functions.




3.7 Functional Description

3.7.1 Enable keyswitch

The ENABLE keyswitch has five positions - three ON and two OFF.

Each laser is provided with a set of three keys stamped P, Z and X and colour-codedRed, Yellow and Blue respectively. Each key has a different status and this determineswhich key positions can be accessed.

The Blue key (the Operator’s key) has access to positions 1 and 2.

The Yellow key (the Supervisor's key) has access to positions 1, 2 and 3.

The Red key (the Service key) has access to all five positions.

The key positions vary in function as follows.

Position 1

This is the normal OFF position. In this position all keys can be inserted andremoved but the laser is cannot be operated.

Position 2

This position allows laser operation only. No parameters can be changed.

Position 3

In addition to laser operation, laser output parameters can be changed.

Position 4

At this position, alarm and warning values can be changed, in addition tochange of output parameters and laser operation. This is therefore the higheststatus position, accessed only with the Red key.

Position 5

This is a special OFF position that is only accessible with the Red key. Thesystem can be disabled in this position for all keys except Red - for example,when the laser needs to be left in an inoperable state because a serviceoperation is incomplete.



3.7.2 STATUS Controls

This group comprises five indicators and two related keys as follows.

The SUPPLY indicator (Green) shows that the electricity supply is connected and thepower supply disconnect switch is ON.

The EMISSION indicator (Amber) lights when the POWER key is pressed. TheEMISSION indicator is a safety device required by Laser Safety Regulations. Itindicates that the laser is capable of producing output and safetyprecautions/measures should be in force. Output includes 633nm if a Pointing Diodelaser is fitted.

On JK700TR lasers, emission is possible only after the READY indicator lights; thisoccurs about 15 seconds after the EMISSION indicator lights up.

The READY indicator (Green) signifies that the laser powering-up sequence has beencompleted and the laser is ready to produce output when required.

The WARNING indicator (Amber) signals that a warning condition exists.

The WARNING key enables warning messages to be accepted (i.e. removed from thedisplay, thus allowing normal messages to displayed) and an updated message to bedisplayed, relating to an ongoing warning condition.

The ALARM indicator (Amber) shows that an Alarm condition exists.

Alarm conditions are associated with system faults that could endanger the laser.Accordingly when an alarm condition develops, the system will be prevented fromoperating and, in the case of a failure, it will be shut down to a safe state.

When an alarm condition first develops an audible alarm sounds and the ALARMindicator flashes. Pressing the ALARM key accepts the Alarm which stops the audiblealarm, switches the ALARM indicator from flashing mode to continuously-on andcauses the appropriate alarm message to be displayed.

Repeated operation of the ALARM key causes the display to alternate between thenormal message and the alarm message. The ALARM indicator will stay lit as long asthe fault persists. The laser cannot be operated until the cause of the alarm conditionhas been corrected. Then, the alarm message can be reset and the ALARM indicatorwill extinguish.




3.7.3 SYSTEM Controls

A group of three keys used during laser start-up and shut-down procedures

The COOLER key switches on the Water Cooler Pump thus initiating coolant flow. Themain use of this facility is to test for water leaks after maintenance/service. TheCOOLER indicator also lights when the Power key is pressed.

The POWER key initiates the powering-up sequence of the laser which switches onthe water cooler pump, illuminates the COOLER indicator, closes the powercontactors, triggers the Flashlamps to establishes simmer current, and illuminates theREADY indicator.

The SYSTEM OFF key initiates the powering-down sequence which switches off thewater cooler pump and the Flashlamps power circuits.

3.7.4 LASER Controls

The LASER group of controls stop/start laser operation (i.e. energise the Flashlamps)and determines whether the laser is under remote or local control.

The LOCAL key initiates laser operation according to parameters set via the ControlPanel or the GUI.

The REMOTE key puts the laser under remote control

The LASER OFF key terminates laser operation. Laser operation can be immediatelyresumed by pressing the LOCAL or REMOTE key. Only one of these keys can beactive at any time. If a new key is pressed, this becomes the active key and theindicator extinguishes on the previous key.

3.7.5 SHUTTER Controls

The group of three shutter keys controls the operation of the process shutter.

The OPEN key opens the process shutter, provided a hand shutter control is notconnected, the shutter is not under remote control and the shutter interlock is notopen-circuit.

The microprocessor ensures that shutter operation is synchronised with the laserpulses so that the shutter is not in motion during a pulse. This relates to all threeshutter keys. If necessary (e.g. at high pulse rates) the space between pulses will beextended to 25ms to allow time for shutter operation.

The CLOSE key closes the process shutter, provided the shutter is not under RemoteControl, even if a hand shutter control is connected.

The MULTI SHOT key opens the process shutter to allow the issue of a burst (i.e.train) of pulses. The number of laser pulses output in a burst is set by the multi-pulsecount Thus if multi-pulse count is set to 1, a single laser pulse will issue each timeMULTI SHOT is pressed. Correspondingly, if multi-pulse count is set to 200, then 200pulses could issue when MULTI SHOT is pressed.

This key is only operational provided the hand shutter control is not connected, theshutter is not under remote control and the Shutter Interlock is not open-circuit.

To obtain a complete burst of laser pulses the MULTI SHOT key must be continuouslypressed for the duration of the count. When the burst is completed the MULTI SHOT



indicator goes off and the indicator within the CLOSE key comes on. If the MULTISHOT key is released during the burst, the shutter will close within 1s and a warningmessage (Multi Shot Error) will be displayed. This key must be released for at least 1sbefore pressing it again to demand another burst of pulses.

Following any shutter-close operation (such as the release of MULTI SHOT key) themulti-pulse count is automatically reset to 1. Multi-pulse count is also reset to 1 whenthe laser is switched from REMOTE to LOCAL or OFF. The multi-pulse count is alsoreset to 1 after a 5 minute timeout which begins when the count is set.

3.7.6 Message Display

The alphanumeric display has two lines each of forty characters. It displays the:

monitored values of laser parameters

changed values of laser output parameters

operational parameters (e.g. shot count alarm limit)

warning messages

alarm messages

explanation displays.

Each function key within the DISPLAY group has a number of associated one-linemessages.

When a key is pressed, the associated message appears on the bottom line of thedisplay and the previous message moves to the top line (i.e. scrolls). New messagesalways appear first on the bottom line.

When the same key is pressed repeatedly then the remaining messages associatedwith that key appear in turn on the bottom line; the messages do not scroll. Furtherrepeated key operation will cause the message sequence to be repeated.

In this respect, the HEIGHT, WIDTH and RATE keys act as if they were one key.When any key of these three keys is pressed following on directly from another ofthem, then the messages do not scroll. The new message overwrites the previousmessage on the bottom line.

The contrast of the display messages can be optimised by adjustment of the displayangle relative to the operator. To change contrast, select TEST/P4 - Display Angle andoptimise in SET mode using the INCREMENT and DECREMENT keys.




3.7.7 DISPLAY Controls

The DISPLAY group comprises eight keys, all with integral indicators, which areprimarily used for setting system parameters and operational modes. Many of the keysare multifunction and each key has a display message associated with each function.Messages are displayed by pressing the relevant key - more than once formultifunction keys.

This section serves as a brief introduction to the keys and their primary functions. Formore information, particularly on the additional functions, refer to Section 3.8.

SHAPE key

Shape denotes the lamp current-time profile of each laser pulse. Up to ten shapes canbe composed and stored in the JK700TR laser memory. Shapes can be simplerectangular profiles or complex profiles comprising up to twenty sectors.

The SHAPE key is used to select any of the stored Shapes for parameter changes,monitoring or for laser output.

HEIGHT key

Height refers to the Flashlamp current during the laser pulse. The units of Height arepercentage (%). Each sector in a Shape has a user-definable Height that can bemonitored and changed using this key.

WIDTH key

Width refers to the duration in milliseconds (ms) of a pulse, for a single-sector Shape.

For a more complex Shape, each sector within the pulse has a user-definable Widthwhich can be monitored and changed using this key. The WIDTH key is a single-function key.

RATE key

Rate is an abbreviation for ’pulse repetition rate’, which signifies the number of laserpulses emitted each second. Also termed ’Rep. rate’.

The units of rate are Hertz (Hz) e.g. 20Hz signifies 20 pulses per second.

The laser has an internal clock which generates regularly spaced trigger pulsesaccording to the rate set via the RATE key. When the laser is under local control thetrigger pulses initiate current pulses in the Flashlamps at the selected RATE via thepower transistor control circuit.

It is possible to pulse the Flashlamps using an external trigger source which thendetermines the pulse rate. However in this case, the pulse rate cannot exceed thevalue previously set using the RATE key.

The RATE key is a dual-function key that can be used to monitor or change the Ratefor LOCAL operation. It can also be used to determine whether the lamps are triggeredby the internal clock or an external trigger source.



OPTICS key

The OPTICS It is used to switch on/off the optional Pointing Diode laser, when fitted.The Pointing Diode laser has a Red beam which can be used to trace the path of theinvisible Nd:YAG laser beam.

ENERGY key

Energy refers to the output energy of each laser pulse; the units are Joules (J). TheENERGY key is a dual-function key which monitors output energy and sets energytrip-levels.

Pulse energy is not a directly user-definable parameter. Energy can only be variedindirectly via pulse Height and/or Width. However the user can set high (Hi) and low(Lo) level limit values for pulse energy.

LAMP POWER key

This is a single-function key used to monitor the mean electrical power fed to eachFlashlamp in kW units.

Lamp Power is not a directly user-definable parameter.

TEST key

This is a multi-function key which is used to monitor/define operational systemparameters including warning values and alarm limits.

The TEST key is also used to define functions under remote control; and to define thevalue of the multi-pulse count.

3.7.8 SELECT Keys

The SELECT group comprises four keys associated with the Set-mode. These keysare only used in conjunction with DISPLAY keys and enable operational modes andparameter values to be changed.

SET key

Press the SET key to enter the Set-mode. Display functions can only be changedwhen in the Set-mode. The SET indicator lights when the Set-mode is active.

To leave Set-mode, press a new DISPLAY key.

CURSOR key

The cursor is a short horizontal line which appears on the display below the right handdigit of a parameter value on the bottom line of the display, when Set-mode is firstentered.

The cursor always moves one digit right on each press. When it can go no fartherright, it jumps under the extreme left-hand digit. The digit above the cursor is the onlydigit which is changed (initially). Thus, for small changes in parameter value, leave thecursor under the right hand digit. For larger changes, it is quicker to move the cursorfarther to the left before changing the value. On leaving Set-mode, the cursor and anyunnecessary zeros on the left end of the parameter value disappear.

INCREMENT key

The INCREMENT key is operative only when the Set-mode is active.




When the Set-mode is active and the INCREMENT key is pressed, the digit above thecursor increases. A momentary press causes an increase of one unit.

Continuous pressure on the INCREMENT key causes an increase in the relevant digituntil the key is released.

When an operating mode is displayed on the bottom line in Set mode, the repeatedpressing of the INCREMENT key causes the message to alternate between thealternative operating modes.

DECREMENT key

The DECREMENT key is operative only when the Set-mode is active.

Key pressure causes the digit above the cursor to decrease. Momentary pressurecauses a decrease of one unit in the relevant digit. Continuous pressure causes acontinuous decrease.

When an operating mode is displayed, repeated pressing of the DECREMENT keycauses the optional modes to alternate in the display. In this respect, theDECREMENT key acts in the same way as the INCREMENT key. Thus, either key canbe used to change an operating mode.



3.8 Display KeysMany of the DISPLAY keys have more than one function. The functions associatedwith a particular key are accessed in turn by repeated pressing of the key until therelevant message appears on the display.

A list of functions for each DISPLAY key appears in Table 5.4A. P1 is used todesignate the first key-press; P2, the second press on a particular key, and so on.Thus, TEST/P4 signifies that if the TEST key is pressed four times, the Display Anglemessage will appear on the display.

If continuous pressure is applied to any key, the messages will continuously changeuntil the key is released.

Some of the keys are used to monitor parameters (e.g. Energy Monitor). Others areused to implement changes (e.g. Display Angle). Many keys can be used to monitorpreset parameter values and to effect changes. In Table 5.4A, M denotes ability tomonitor the particular parameter/mode while C denotes ability to change theparameter/mode. MC denotes that both functions are possible.

Note: The Remote Control message (TEST/P7) is only displayed when LASER OFF isactive.

3.8.1 Functional Description

SHAPE/P1: Output Shape

Stored shapes are allocated a number in the range 1 to 10. ’Output Shape 3’ meansthat pulse shape 3 is coupled to the flashlamps and will be output when the lamps areenergised.

SHAPE/P2: Change Shape

If a change is required to any parameter (e.g. number of sectors, Width or Height ofany sector) for example shape 3, then ’Change Shape’ must first be selected followedby ’Change Shape 3’, then go to Change Sector (SHAPE/P3).

SHAPE/P3: Change Sector

After Change Shape, press the SHAPE key again to display ’Change Sector’. Then theparticular sector can be accessed for parameter changes, deletion or insertion ofadditional sectors.

SHAPE/P4: Demand Range

The Demand Range values apply to all ten stored shapes.

HEIGHT/P1: Sector Height

Allows the Sector Height to be monitored or changed.

HEIGHT/P2: Height Type

Allows the Height Type - absolute or proportional - to be monitored or changed.

WIDTH/P1: Sector Width

Allows Sector Widths to be monitored or changed.

RATE/P1: Rep Rate




Enables pulse repetition rate to be monitored or changed. A different rate can be setfor each of the ten Shapes.

RATE/P2: Trigger Mode

Allows a choice of laser triggering source - internal clock or external source.

Note: The lamp triggering source referred to here is not the trigger source whichbreaks down the lamp impedance to initiate simmering. The trigger source here is thatwhich initiates high current pulses through the flashlamps, which result in laser outputpulses.

If external Trigger mode is selected this is not necessarily the same as remote control

When the laser is under LOCAL control, Trigger mode is selected via RATE/P2 - eitherinternal ’Clock’ (repetition rate generator) or an external trigger source.

When the laser is in REMOTE, Trigger mode can be under either local control (theControl Panel) or remote control.

When local Trigger control is selected, the options are the same as for LOCAL control.

When remote Trigger mode is selected, the remote controller has the option to choosean external trigger source or to specify the Trigger mode as set on the Control Panel.

When Rate is put under remote control the remote controller has the choice of theinternal clock or an external clock.

OPTICS/P1: Alignment Pointing Diode

Allows the optional internal Pointing Diode laser (Alignment laser) to be switched ONor OFF, and the on/off state to be monitored.



ENERGY/P1: Energy Monitor

Allows the output pulse energy to be monitored for each pulse shape. Thus if theshapes are being output in a random order under remote control a stable energyreading can be seen for each shape.

ENERGY/P2: Energy Trip

Enables high (Hi) and low (Lo) energy trip levels to be monitored and changed. Eachpulse shape has its own energy trip settings and the one being monitored is defined bythe shape number in ENERGY/P1.

An output signal from the optional remote interface indicates whether output energy iswithin the range defined by the Hi/Lo limits. When pulse energy is inside the range thesignal is True; outside the range the signal is False.

This facility is used for remote control to indicate output energy status to the remotecontroller. However, this output is operational under local and remote control andwhen the LASER OFF is active.

ENERGY/P3: Output Power

Allows the average output power to be monitored. The energy for the shape selectedin ENERGY/P1 will also be displayed.

ENERGY/P4: O/P Power Trip

Enables the average output power trip to be monitored. If the output power exceedsthis value the laser will switch to the LASER OFF state and give an alarm.

LAMP POWER/P1: Lamp Power

Allows the mean electrical power fed to each Flashlamp to be displayed.

TEST/P1: Shot Count

Each time the lamps are pulsed, to generate a laser pulse, it counts as one ’shot’. Itcan refer to the output (laser shot) or to the Flashlamps.

Each shot reduces lamp life. Lamp life is therefore measured in shots. Shot Countdenotes the number of times the lamps have been pulsed, irrespective of the Width orHeight parameters for each shot.

This key setting allows a check on the number of Flashlamp shots at a given time.Shot Count will normally be set to zero each time new Flashlamps are fitted.

Note: Shot Count is updated at half second intervals. Shots of very low Sector Heightare not recorded.




TEST/P2: Shot Alarm

This message allows a warning value (the Shot Alarm) to be entered. When the Shotcount exceeds the Shot Alarm value, a warning message is displayed to remind theoperator that a change of lamps is due.

The Shot Alarm value is displayed in the centre of the message (Pls is an abbreviationfor pulses).

Since it is not a grave matter to continue operating higher than the Shot Alarm value,the laser need not be switched off, but the Warning Condition remains until the lampsare changed and Shot Count is set to zero. When the Shot Alarm value is monitored,the Shot Count is also displayed for comparison.

TEST/P3: Flow Count

Flow Count refers to the flow rate of coolant through the laser head - a criticalparameter. Flow rate is measured by an electronic flowmeter in arbitrary units.

This key setting allows the present values of Flow Count and Flow Alarm to bemonitored. Flow Count is displayed in the middle of the bottom line of the display; FlowAlarm is displayed at right end of the bottom line.

Because continued operation with inadequate flow may well damage pumpingchamber components, an Alarm condition will arise when the Flow Count falls below90% of the Flow Alarm value and the microprocessor will shut the laser down.

Notes:

The Flow Alarm value can only be reset using a Service key and should only be resetby an authorised engineer for a valid reason.

The user does not have complete freedom when re-setting the Flow-Alarm value. Theonly option is to switch on the cooler and then re-set the Flow-Alarm value at the valueof the prevailing Flow Count value.

The Flow Alarm value cannot be re-set at a value below 150. If the Flow Alarm value isset with the cooler not running then, the microprocessor will automatically set the FlowAlarm at the minimum value of 150.

TEST/P4 : Display Angle

Enables the display angle to be changed, in order to optimise the contrast of thedisplay.

TEST/P5: Coolant Temperature

Enables the circulating coolant temperature to be monitored. No alarms are associatedwith this monitor. However, if the coolant temperature exceeds about 50°C (122°F)then a separate temperature sensor will switch off the laser until the coolanttemperature has fallen to an acceptable value - typically about 30°C (86°F).



TEST/P6: DC Link Volts

Allows the d.c. link voltages on the two lamp supplies to be monitored (see Figure4.3F). The protection circuit raises an alarm condition when the d.c. link voltage fallsoutside the range 250V (under-volt limit) to 470V (over-volt limit). The protection circuitalso checks that the d.c. link voltage has reached prescribed values at specificintervals during the powering-up sequence (see Section 6.4).

TEST/P7: Remote Control

This key setting displays a message which contains a number with up to eight digits.This number defines which functions and parameters have been put under the remotecontrol of an external controller. Thus the remote control number can be monitored orchanged. Each of the eight digits corresponds to a particular function or parameter, asindicated below. In this explanation, the digits are numbered, left-to-right, 1 to 8.

Each digit should be set to either 0 or 1. Any other number is treated as 0.

Digit Parameter/Function

1 Height

2 Width

3 Rate

4 Shutter

5 Trigger Mode

6 Not allocated

7 Not allocated

Digit Nos. 1-4

Value 0: Parameter/mode under Local Control.

Value 1: Parameter/mode under Remote Control.

Digit No.5

Value 0: Trigger source selected by Local Controller.

Value 1: Trigger source selected by Remote Controller

Digit No.8

Value 0: Mode 0 Remote Control selected

Value 1: Mode 1 Remote Control selected

Note: The remote control number cannot be displayed or changed when the laser isoperating.




TEST/P8: Multipulse Count

This key setting indicates the multipulse count - the number of pulses (Pls) that areissued when the MULTI SHOT key is pressed. The multipulse count can be set in therange, 1 to 9999 pulses.

TEST/P9: Cooler Runtime

Displays the number of hours for which the system cooler has been running. Whenthe value exceeds 2000 hours a warning message is displayed to indicate that thecoolant de-ioniser and filter should be changed.

TEST/P10: Display Language

Allows the display language presently in use to be viewed and changed if required.

3.9 Main Rules for Use of Control Panel KeysAll ENABLE keys can access all parameters for monitoring purposes.

When a new key is pressed:

the P1 message for that key appears on the bottom line of the display

the previous message scrolls (moves to the top line), with a few exceptions asdetailed below.

When the same key is repeatedly pressed:

the P2 message overwrites the P1 message on the bottom line.

Following the next press:

the P3 message overwrites the P2 message.

This continues to the end of the message list, then the P1 message appearsagain.

Thus messages resulting from repeated presses of the same key do not scroll.

To access, for example, Flow Count when Display Angle is currently displayed, keeppressing the SHAPE key until Flow Count is displayed.

The HEIGHT, RATE and WIDTH keys behave like a single key with regard to scrolling.When two of these keys are pressed in succession, the message associated with thefirst key does not scroll when the second key is pressed.

Some messages change when scrolled, as follows:

Initial Message After Scrolling

Trigger mode Rep. Rate (unless external displayed)

Energy Trip Energy Monitor

Demand Range Output Shape

Shot Alarm Shot Count



3.10 Monitoring Parameters and FunctionsMonitoring a parameter simply involves putting the appropriate message on thedisplay. The present value of that parameter will appear in the message.

The following Table gives a list of parameters and functions that can be monitored andchanged. Note that in addition to parameters, functional states (e.g. alignment PointingDiode ON/OFF, remote control) can also be monitored.

Shape Height

P1 Output Shape MC Sector Height MC

P2 Change Shape C Height Type MC

P3 Change Sector MC

P4 Demand Range MC

Width Rate

P1 Sector Width MC Repetition Rate MC

P2 Trigger Mode MC

Optics Energy

P1 Alignment PointingDiode

MC Energy Monitor MC

P2 Energy Trip MC

P3 Output Power M

P4 Output Power Trip MC

Test Lamp Power

P1 Shot Count MC Lamp Power M

P2 Shot Alarm MC

P3 Flow Count MC

P4 Display Angle C

P5 Coolant Temperature M

P6 Cooler Runtime MC

P7 DC Link Volts M

P8 Remote Control MC

P9 Multipulse Count MC

P10 Display language MC

Key – M = MonitorC = Change




3.10.1 Monitoring Single Parameters

To monitor a particular parameter or functional state:

1. Refer to Section 3.2.1 and start-the Laser.

2. Select the appropriate DISPLAY key

3. Press the DISPLAY key the correct number of times to display the relevantmessage

3.10.2 Monitoring Two Parameters Simultaneously

There are two common situations where there is a need to monitor two parameterssimultaneously:

Monitoring the Height or Width of individual sectors in a complex shape.

Setting laser parameters with the laser operating. The Operator needs to beable to monitor pulse energy and mean output power whilst maintaining theability to monitor/change primary parameters - Height, Width or Rate

This procedure can be undertaken as follows.

To display the first parameter, press the appropriate DISPLAY key the correctnumber of times.

Select the DISPLAY for the second parameter and press it the correct numberof times, to display the second parameter on the bottom line. The firstparameter will move to the top line.

Since parameters can be changed only when they are displayed on the bottom line,this may influence which parameter is selected second.

When displaying pulse energy (Energy Monitor), this will always be selected first sincethis parameter can only be monitored; it cannot be demanded.



3.10.3 Shape Monitoring

3.10.3.1 Active ShapeTo monitor the Active Shape (numbered 1 to 10), select SHAPE/P1 i.e. press theSHAPE key once.

3.10.3.2 Shape CompositionTo determine the number of sectors in a particular shape:

Select the desired shape number

Select SHAPE/P2 (change shape).

Note that SET mode automatically becomes active.

Using the INCREMENT/DECREMENT keys, change the shape number to thedesired value.

If the shape has a single sector then, the message at the right side of the bottom linewill read ’Main Sector’.

If the shape has more than one sector then the message will read ’Sector 1’,irrespective of the number of sectors in the shape.

To determine the precise number of sectors in the chosen shape

Select SHAPE/P3 (change sector).

The sector message (e.g. Sector 1) will now move to the centre of thebottom line and the Shape message will move to the right hand end.

The sector message always indicates the first (i.e. left-hand) sector inthe shape.

Press the INCREMENT key repeatedly to make the display indicate the othersectors in the shape in turn.

In a four-sector Shape, three successive operations of the INCREMENT key will revealthe following messages in turn:

Sector 1

Sector 2

Sector 3

Main Sector.




3.10.3.3 Sector Height and WidthTo monitor Sector Heights, it is necessary to display/monitor two parameterssimultaneously - Sector Height, and Change Sector. Sector Height should be on thetop line of the display in order to go through the sectors in turn, displaying their Heightvalue.

Monitor Sector Height

Press the HEIGHT key once (HEIGHT/P1).


Change the shape number to the desired SHAPE using theINCREMENT/DECREMENT keys.

Select SHAPE/P3 (change sector) to access individual sectors.

Use the INCREMENT/DECREMENT keys to run through the sectors in turn.

As each sector number appears on the bottom line, the corresponding Height valuewill appear on the top line of the display within 0.5 seconds.

Monitor Sector Widths

Press the Width key once (Width/P1).


Change the shape number to the desired SHAPE using theINCREMENT/DECREMENT keys.

Select SHAPE/P3 (change sector) to access individual sectors.

Use the INCREMENT/DECREMENT keys to run through the sectors in turn.

As each sector number appears on the bottom line, the corresponding Width value willappear on the top line of the display within 0.5 seconds.



3.11 Changing Parameters

3.11.1 Introduction

This Section deals with changing laser output parameters and system operatingparameters, changing operating modes (e.g. Trigger mode) and switching ancillaryequipment (alignment Pointing Diode).

The following Table shows which Access Level key can change parameters/functions.

Shape Height

P1 Output Shape SU Sector Height SU

P2 Change Shape SU Height Type SU

P3 Change Sector SU

P4 Demand Range SU

Width Rate

P1 Sector Width SU Repetition Rate SU

P2 Trigger Mode SU

Optics Energy

P1 Alignment PointingDiode

ALL Energy Monitor ALL

P2 Energy Trip SU

Output Power Trip SV

Test

P1 Shot Count SU

P2 Shot Alarm SV

P3 Flow Count SV

P4 Display Angle ALL

P6 Cooler Runtime SV

P8 Remote Control SV

P9 Multipulse Count SU

P10 Display language ALL

Key – ALL = Any KeySU = Supervisor and Service Key onlySV = Service Key Only




3.11.2 General Rules

In general, to change parameters/functions, the following rules apply:

The Control Panel must be enabled i.e. the start-up procedure must have beencarried out.

Select the appropriate DISPLAY key; press it the right number of times todisplay the relevant message.

Enter SET mode, (i.e. press the SET key).

In the case of a numerical parameter:

Increase the value using the INCREMENT key and the CURSOR key asnecessary

Decrease the value, using the DECREMENT key and the CURSOR key asnecessary.

In the case of an operational mode

operation of either the INCREMENT key or the DECREMENT key will switchfrom the present mode to the alternative mode.

Exit SET mode by pressing a new key.

Notes:

There are exceptions to these rules when relating to the SET mode.

Two key selections (change shape and change sector) automatically engage SETmode.

In the case of change shape and change sector, exit SET mode by pressing a newDISPLAY key.

In the case of demand range and energy trip, where there are two parameters to beset, depression of the SET key after setting the first parameter, causes the secondparameter to be moved into the centre of the display bottom line for change. Furtherpresses on the SET key cause the two parameters to be displayed in turn in thechange position.



3.11.3 Specific Rules

Output Shape (SHAPE/P1)

Follow the General Rules. Any one of ten shapes can be selected to be Active Shape.

Change Shape (SHAPE/P2)

SET mode automatically becomes active.

Any one of ten shapes can be selected for composition/changes.

Follow the General Rules to change the shape number.

The next logical step, after Change Shape, is usually Change Sector; in this case, SETmode remains active.

Otherwise, press another DISPLAY key to exit SET mode.

Change Sector (SHAPE/P3)

Follow the General Rules to access a particular sector.

Use the INCREMENT key to increase sector number, ultimately reaching the mainsector; use the DECREMENT key to proceed from the main sector towards Sector 1

Exit SET mode by pressing a new DISPLAY key.

Demand Range (SHAPE/P4)

There are two values to be set - Imax and Imin. Set these values as follows:

Select SHAPE/P4 (demand range).

Press the SET key.

The bottom line message will now look similar to:

’Imin Set Up 000% 0.00J’

In this particular case, Imin was 0% and the laser was switched off (ie. zeropulse energy) (message may contain different numbers).

Use the INCREMENT, DECREMENT and CURSOR keys to set a new value forImin.

Press the SET key again.

The bottom line message will now look similar to this:

’Imax Set Up 100% 0.00J’

Reset the Imax value using the INCREMENT, DECREMENT and CURSORkeys.

Note that Imax cannot be set less than Imin.

Exit SET mode.

Sector Height (HEIGHT/P1)

Follow the General Rules for a single-sector shape.




To affect the laser output, the output shape number must be the same as the changeshape number.

Height Type (HEIGHT/P2)

Follow the General Rules to select either of the alternatives - absolute or proportional.

Sector Width (WIDTH/P1)

Follow the General Rules for a single-sector shape.


Repetition Rate (RATE/P1)

Follow the General Rules.


Trigger Mode (RATE/P2)

Follow the General Rules to select either of the alternatives - internal or external.

Alignment Pointing Diode (OPTICS/P1)

Follow the General Rules for operational modes to select either of the alternatives forthe Pointing Diode - ON or OFF.

Energy Monitor (ENERGY/P1)

The display will always be in SET mode and a cursor will be shown under the shapenumber.

’Energy Monitor Shape 04 12.9J’

Use the INCREMENT and DECREMENT keys to set the monitored shape number.



Energy Trip (Energy/P2)

There are two parameters to set for each pulse shape - the Hi (High) and Lo (Low)energy trips as follows.

Select ENERGY/P1

Select the shape whose trip values are to be set.

Select ENERGY/P2 (Energy Trip)

Press the SET key

The cursor will appear under the right hand digit in the Lo-value i.e.

’Energy Trip Lo 00.0J Hi 55.0J’

Use the INCREMENT, DECREMENT and CURSOR keys to set a new Lo-value (e.g. 10J).

Press the SET key again.

The bottom line will now appear as follows.

’Energy Trip Hi 55.0J Lo 10.0J

Use the INCREMENT,DECREMENT and CURSOR keys to set a new Hi-value.

Exit Set mode.

O/P Power Trip (Energy/P4)

Follow the general rules.

Shot Count (TEST/P1)


Press the SET key to enter SET mode.

Press the SET key again to zero the Shot Count.

Shot Alarm (TEST/P2)


The Shot Alarm value is the number in the centre of the display.

Note that the Shot Count is also displayed for comparison at the right hand end of thebottom line.




Flow Count (TEST/P3)

The present Flow Count is the number in the centre of the display message. The FlowAlarm value is the number at the right hand end of the display message.

To reset the Flow Alarm, proceed as follows:

Select TEST/P3 (Flow Count).

Press the SET key.

Press the CURSOR key.

This automatically re-sets the Flow Alarm to the value of the Flow Count, provided thatthe Flow Count is at least 150. Otherwise the microprocessor will set the Flow Count tothe minimum acceptable value, 150.

Note: It is important that the water cooler pump is running (COOLER key active) whenFlow Alarm is set to ensure the Flow Alarm value is to a realistic value. The FlowAlarm value should only be reset when necessary - e.g. after replacement of coolercomponents.

Display Angle (TEST/P4)


SET mode automatically becomes active.

Use the INCREMENT and DECREMENT keys to optimise the contrast of the display.

Cooler Runtime (TEST/P6)


Press the SET key.

The runtime value can be reset to zero by pressing the CURSOR key and should bereset when the coolant deioniser and filter have been replaced.

Exit SET mode.

Remote Control (TEST/P7)


When SET mode is selected all eight digits will appear. The cursor will appear underthe right-hand digit.

Note that:

The left hand digit is digit No.1

Digit Nos. 6 and 7 are not allocated

Digits should only be set to 0 or 1

If a digit is set to any other value (2 to 9) then that digit will be interpreted as 0.



Multipulse Count (TEST/P8)


Display Language TEST/P10


Press the SET key.

The required display language can be selected by using the INCREMENT orDECREMENT keys.

Exit SET mode.

3.11.4 Changing Shape and Related Parameters

This Section gives detailed guidance on how to change the number of sectors in apulse shape, the Height and Width of each sector and the pulse Rate.

3.11.4.1 Changing Pulse ParametersIt is important to realise that any changes relate to the pulse shape specified in thechange shape message (SHAPE/P2) and where relevant, to the sector specified in thechange sector message (SHAPE/P3). The Active Shape is that specified in the outputshape message (SHAPE/P1). If these shape numbers are not identical then anychanges made will have no immediate effect on the laser output.

Thus, if the laser is set for output shape 7 and change shape 4, changes can be madeto shape 4 will not affect the Laser Output.

Selection of SHAPE/P2 will reveal a message similar to:

’Change Shape 6 Sector 2’ (1)

and SHAPE/P3 will show:

’Change Sector 2 Shape 6’ (2)

Message (1) allows the user to select the pulse shape to be changed and message (2)selects the sector within that shape that is to be changed. Selection is made using theINCREMENT and DECREMENT keys.

3.11.4.2 Setting Pulse Repetition RatePulse repetition rate is set by pressing the RATE key and displaying a message suchas:

’Rep. Rate 25.0Hz’

By pressing the SET key the rate can be changed using the INCREMENT andDECREMENT buttons until the desired value is achieved.

The rate set will refer to the pulse shape selected for change (the change shapenumber) and will only affect the output of the laser if the change shape number is thesame as the output shape number.




3.11.4.3 Setting the Height of a SectorThe Height of a sector is set by pressing the HEIGHT key and displaying a messagesuch as:

’Sector Height 57.6%’

By pressing the SET key, Height can be changed using the INCREMENT andDECREMENT keys until the desired value is achieved.

When setting Height, the energy monitor output will be displayed at the right hand endof the display. The indicated energy will only be valid if the change shape number isthe same as the output shape number.

The Height set will refer to the pulse shape and sector selected for change and willonly affect the laser output if the change shape number is the same as the outputshape number.

3.11.4.4 Setting the Width of a SectorThe Width of a sector is set by pressing the WIDTH key and displaying a messagesuch as:

’Sector Width 3.0ms’

By pressing the SET key the Width can be changed using the INCREMENT andDECREMENT keys until the desired Width value is achieved.

The Width set will refer to the pulse shape and sector selected for change and will onlyaffect the laser output if the change shape number is the same as the output shapenumber.

3.11.4.5 Inserting a SectorTo increase the number of sectors in the pulse shape the user can insert them asrequired. This is achieved by repeated pressing of the SHAPE key until the displayshows a message such as:


If the user then presses the SET key, the display will change to show:

’Change Sector 2 DEL/INS’ (2)

By then pressing the INCREMENT key, a sector will be inserted and the display willreturn to (1). In this example the new sector is inserted in front of sector 2 and nowbecomes sector 2; the old sector 2 becomes sector 3. Subsequent sectors aresimilarly re-numbered. The inserted sector has initial Height and Width values of 0.0%and 1.0ms respectively. These can be changed in the normal way (see Setting theHeight of a Sector and Setting the Width of a Sector).

The system will not allow the user to insert more than nineteen sectors to give amaximum of twenty sectors. If an attempt is made to do so, a warning message will bedisplayed.

Note that because sectors can only be inserted in front of other sectors, the mainsector will always remain as the last one in the pulse shape.



3.11.4.6 Deleting a SectorTo decrease the number of sectors in the pulse shape the user can delete them asrequired. This is achieved by repeated pressing of the SHAPE key until the displayshows a message such as:


If the user then presses the SET key the display will change to show:

’Change Sector 4 DEL/INS’ (2)

By then pressing the DECREMENT key, a sector will be deleted and the display willreturn to (1). The sector deleted is the one shown in the change message (Sector 4 inthis example). All sectors following the deleted sector are renumbered such that sectorM becomes sector M-1.

The system will not allow the user to delete the main sector. Thus the minimumnumber of sectors allowed in a pulse shape is 1. If an attempt is made to delete themain sector a warning message will be displayed.




Intentionally Blank

GSI LumonicsJK700TR Series: User ManualIssue 1.0 Section 4 – Laser Operation - GUI


4. Laser Operation - GUI

4.1 IntroductionThis Section describes the operation of the JK700TR Series Laser supplied with theGraphical User Interface Option (GUI). The GUI software is generic, the JK701 Laserhas been used to illustrate the screen displays. Certain displays may differ slightlyfrom those shown in this Manual depending on the Laser Type.

4.2 OverviewLaser operation consists of the following procedures:

• Start up.

• Shutdown.

• Emergency Shutdown.

• Monitoring and Control.

4.3 Laser Start-up1. Ensure external water supply is ON.

1. Ensure external power supplies are available and switched on.

2. Set MAINS DISCONNECT Switch on Power Supply Cabinet to ON.

3. Verify white POWER ON lamp is lit.

4. Turn the keyswitch fully clockwise.

5. Wait for GUI software to power up.

6. Press the blue reset button on Laser PSU (below Mains Disconnect switch).

7. Select RESET on GUI screen to cancel “Alarm 205 – Customer Interlock 1”.

8. Select the green button on the GUI screen. The cooler will start and the

button will flash. When the PSU is powered up the button will turn black andthe status will indicate READY.

WARNING

THE LASER IS SWITCHED ON IN THE NEXT STEP.

ENSURE ALL SAFETY PRECAUTIONS HAVE BEEN TAKEN.

9. Select the black button. The Laser will start and the button will flash. When

the laser is on the button will turn green and the status will indicate ON.

GSI LumonicsJK700TR Series: User Manual

Section 4 – Laser Operation - GUI Issue 1.0


4.4 Laser Shut-downThis is the normal method of switching the Laser System off. Under normal conditions,the Laser System must NOT be switched off by turning the MAINS DISCONNECTORSWITCH to OFF or by using the EMERGENCY STOP button.

1. At the GUI:

Select the button. When the PSU is powered down the button will turn

black and the status will indicate READY.

Select the red button.

The Laser is now OFF. The Coolant Pump will continue to run for 10 secondsto allow cooling after Laser operation.

Select the button. A screen prompt will be displayed. Select the tickto quit.

Shutdown the PC using the Windows © shutdown sequence.

10. Set MAINS DISCONNECT switch to OFF.

11. Switch OFF the main power supply.

12. Turn OFF the external water supply.

4.5 Emergency ShutdownThe Emergency Stop procedure must only be used if external conditions deem itnecessary. It must not be used as a shutdown method in normal conditions.

1. Press the closest red EMERGENCY STOP button.

2. At the PSU, set the MAINS DISCONNECT switch to OFF.

3. Switch OFF the external Power Supply Isolator.

4. Switch OFF the external water supply.

5. Obey all Local Emergency Procedures.

4.6 Alarm HandlingAn alarm will be generated if a fault occurs. This will be indicated to the User in thefollowing manner:

The border of the relevant icon on the GUI screen will flash red.

A message will appear in the Alarm Banner.



Refer to Section 5.2 for details of the alarm messages and fault diagnosis. When thefault has been cleared, select the RESET button on the GUI screen to clear the AlarmMessage.

If more than one alarm message exists, the Alarm Banner will display the next highestpriority alarm message.

4.7 Monitoring and ControlLocal monitoring and control of the Laser is via a Graphical User Interface which canbe either a Personal Computer (PC) or an Industrial Touch Screen Computer (TSC). Ifa PC is used, placing the cursor on the appropriate icon and clicking the mouse buttonaccesses the menus. If a TSC is used, touching the appropriate icon on the screenaccesses the menus.

Parameter settings can be entered by pressing the keys on the PC keyboard, clickingon the PC display or touching the TSC screen.

Throughout this manual, the term ‘select’ is used to denote pressing, clicking ortouching the icons and keys of the PC or TSC.

There are four levels of User access. These are defined as follows:

Level 0 Operator – Monitoring only.

Level 1 Operator – Level 0 plus Laser Switch READY/ON.

Level 2 Supervisor – Level 1 plus control.

Level 3 Maintenance – Level 2 plus configuration and fault diagnosis.

All levels are password protected.




4.8 Generic Laser Interface Program

4.8.1 Product Registration Screen

The Product Registration screen will be displayed on boot up if the Product has notbeen registered. The User must enter a sixteen character Product Activation Code(supplied by GSI Lumonics) to access the Generic Laser Interface program. If no codeis entered, the display defaults to the Simulation program.

If the Generic Laser Interface program is to be loaded onto another computer, pleasecontact GSI Lumonics for a new Product Activation code.

Icon Description

Select to enter Activation Code on keypad that appearson the screen.

Select to proceed with program when code has beenaccepted.



4.8.2 Screen Display

The screen is divided into five areas. Areas 1, 2, and 4 are displayed on all screenviews. Areas 3 and 5 change according to the User access level and display selected.

Area 1

Icon Description

Data Display

These three icons display the status or value of a selectedparameter.

Parameters to be displayed are selected in Level 3 ConfigurationSettings, refer to Section 4.8.6.2.

Double selecting a Data Display icon will place the status/value ofthat parameter into Area 5 at an enlarged size.

Double selecting one of the other Data Display icons will replacethe enlarged display without exiting the screen.

Select the EXIT button in the top right hand corner of Area 5 toexit the enlarged display screen.




Area 2

Icon Description

Laser Status

This icon displays the status of the Laser.

It can be either COOLER, READY, ON or OFF.

READY/ON

Select this button to toggle the Laser between ON andREADY when the Laser is in READY/ON mode.

OFF

Select this button to switch Laser OFF

Area 3

Icon Description

Keyswitch

This icon allows access to the application program. It alsoindicates the access level of the User.

Grey Level 0

Blue Level 1

Yellow Level 2

Red Level 3

Select this icon to display the LOGON screen, refer toSection 4.8.3.1.

Help

Select this icon to display the HELP screen, refer toSection 4.8.4.10.

Exit

Select this icon to exit the program. When in Level 0, 1and 2 access, a Windows® Shutdown will occur. When inLevel 3 access, the GUI will remain in Windows®.

Additional icons will be displayed in this area appropriate to the access level of theUser. These are described in the relevant section of this Manual.



Area 4

Icon Description

Alarm Banner

This displays Alarm messages.

Message Banner

This displays text messages to inform the User ofthe current activity.

RESET

Select this button to reset the Alarm messagebanner. Alarms messages can be reset only whenthe fault has been cleared, refer to Section 5.2.

Area 5

Icon Description

Overview

This area displays the details of the selected view.The default view is the Overview screen, refer toSection 4.8.3.




Information Windows

Throughout the program, some actions may cause a warning or information windowsimilar to the one above to appear.

Select the appropriate button to respond to the text displayed.



4.8.3 Overview Screen

The Overview screen displays a set of icons that represent the component systems of theLaser. The actual display will vary slightly according to which of the JK700TR Series Lasersis being used.

If an alarm occurs, the periphery of the appropriate icon will flash in red.

The screen display will default to the last active User Level (see caution below). Selecting anicon will display further screens that allow the Operator to monitor and control the Laser.These are explained in Level 1 Operator Access in Section 4.8.4.

CAUTION

The default User Access Level on the initial run of the generic laserinterface program will be Level 0. However, on subsequent runs it willdefault to the Access Level of the last User.

It is imperative that Level 2 and Level 3 Users change the access to asafe level before they log off.




4.8.3.1 Logon ScreenSelect the Keyswitch icon. This will display the Logon screen.

The Logon screen allows the User password to be entered using either the PCkeyboard or selecting the display keyboard on the screen.

Enter User password.

Select ↵If the password is accepted, the display reverts to the Overview screen with theKeyswitch icon in the appropriate access level colour.

If the password is not accepted, the display will remain in the Logon screen and awaitentry of the correct password.

To exit the Logon screen without entering a password:

Select the Esc key.

The display will return to the Overview screen at the original User access level.



4.8.4 Level 1 Operator Access

Select the Keyswitch icon. Logon as a Level 1 User (refer to Section 4.8.3.1). TheKeyswitch on the Overview screen will be blue.

4.8.4.1 Shape Parameter ScreenSelect the Shape Parameter button in the Overview screen to display the Active ShapeParameter screen.

The Active Shape Parameter screen displays the Active Shape Parameter values. Italso provides a dynamic display of monitored points.

Select the Shape Parameter button whilst in the Shape Parameter screen to revert tothe Overview screen.




4.8.4.2 Laser Head/Shutter ScreenSelect the Laser Head/Shutter icon in the Overview screen to display the Laser Headscreen.

The Laser Head screen displays a schematic of the Laser Path and the Opticalcomponents. It also displays the Shot elapsed count number, the Shot Alarm set pointand indicates whether the Pumping Chamber cover is open or closed. The display willvary slightly according to which of the JK700TR Series Lasers is being used.

Icon Description

Select the INFORMATION button to display the Laser Head Data Logshowing the number of Shutter operations, the elapsed hours of the lamps,the Shot Count and any errors that have been logged, refer to Section4.8.4.2.1.



4.8.4.2.1 Laser Head/Shutter Data Log Screen

Icon Description

Select the COG button to revert to the Laser Head screen.




4.8.4.3 Machine Interface ScreenSelect the Machine Interface icon in the Overview screen to display the MachineInterface screen.

The Machine Interface screen displays the status of the Customer Interlocks and theselections made for the Machine Interface.

Icon Description

Select the INFORMATION button to display the Machine Interfacedata log showing the Run Time hours and any errors that havebeen logged, refer to Section 4.8.4.3.1.



4.8.4.3.1 Machine Interface Data Log Screen

Icon Description

Select the COG button to revert to the Machine Interface screen.




4.8.4.4 Switching Module ScreensSelect the Switching Module #1 icon to display the Switching Module #1 screen.

Select the Switching Module #2 icon to display the Switching Module #2 screen.

The details on these screens are identical for each module.

The Switching Module screens display a schematic of the Switching Module electricalcircuit. Value and Status indicators are displayed for input voltage and a Valueindicator is displayed for the output power.

Icon Description

Select the INFORMATION button to display the Switching ModuleData Log showing the Run Time hours and any errors that havebeen logged, refer to Section 4.8.4.4.1.



4.8.4.4.1 Switching Module Data Log Screens

Icon Description

Select the COG button to revert to the Switching Module screen.




4.8.4.5 Transformer and Output Module ScreensSelect the Transformer and Output Module #1 icon to display the Transformer andOutput #1 screen.

Select the Transformer and Output #2 icon to display the Transformer and Output #2screen.

The details on these screens are identical for each module.

The Transformer and Output Module screen displays a dynamic schematic diagram ofthe Transformer Modules. The position of the Power Contactor and the BypassContactor is indicated. The Temperature status and the Output Voltage value andstatus is also shown.

Icon Description

Select the INFORMATION button to display the TransformerModule Data Log showing the Run Time hours and any errors thathave been logged, refer to Section 4.8.4.5.1.



4.8.4.5.1 Transformer and Output Module Data Log Screens

Icon Description

Select the COG button to revert to the Transformer and OutputModule screen.




4.8.4.6 Microprocessor Module ScreenSelect the Microprocessor Module icon in the Overview screen to display theMicroprocessor Module screen.

The Microprocessor Module screen displays the status of critical system components.

Icon Description

Select the INFORMATION button to display the MicroprocessorModule Data Log showing the Run Time hours and any errors thathave been logged, refer to Section 4.8.4.6.1.



4.8.4.6.1 Microprocessor Module Data Log Screen

Icon Description

Select the COG button to revert to the Microprocessor Modulescreen.




4.8.4.7 Power Distribution

The Power Distribution screen displays a dynamic schematic of the power distributioncircuit. The position of the Trip contactors and the status of the AutotransformerTemperature Trip are shown.

Icon Description

Select the INFORMATION button to display the Power DistributionModule Data Log showing the Run Time hours and any errors thathave been logged, refer to Section 4.8.4.7.1.



4.8.4.7.1 Power Distribution Data Log Screen

Icon Description

Select the COG button to revert to the Power Distribution screen.




4.8.4.8 Air Cooler ScreenSelect the Air Cooler icon in the Overview screen to display the Air Cooler Modulescreen.

The Air Cooler screen displays an animated schematic of the Laser Air Coolingsystem.

Icon Description

Select the INFORMATION button to display the Air Cooler Moduledata log showing the Run Time hours and any errors that havebeen logged, refer to Section 4.8.4.8.1.



4.8.4.8.1 Air Cooler Data Log Screen

Icon Description

Select the COG button to revert to the Air Cooler Module screen.




4.8.4.9 Water Cooler ScreenSelect the Water Cooler icon in the Overview screen to display the Water Coolerscreen.

The Water Cooler Module screen shows an animated schematic of the Water Coolingsystem. It indicates the status of the water level. The Flow Alarm Set Point and thestatus and value of the Temperature and Flow are also shown.

Icon Description

Select the INFORMATION button to display the Water CoolerModule data log showing the Run Time hours and any errors thathave been logged, refer to Section 4.8.4.9.1.



4.8.4.9.1 Water Cooler Module Data Log Screen

Icon Description

Select the COG button to revert to the Air Cooler Module screen.




4.8.4.10 Help Screen

The Help screen contains a tabbed display that provides information on Safety.

Icon Description

Select the EXIT button to revert to the previous screen.



4.8.5 Level 2 Supervisor Access

Log on (refer to Section 4.8.3.1) at Level 2 to display the Level 2 Overview screen.

The Level 2 Overview screen contains all the icons and functions of Level 1 with theaddition of the Process icon. The keyswitch will be yellow.

Icon Description

Select the PROCESS button to display the Process screen, refer toSection 4.8.5.1.




4.8.5.1 Process Screen

This screen allows the User to edit the Shape Parameters, open and close the Shutter,set the Pointing Diode ON or OFF (if fitted) and select Local or Remote control.

Parameters settings and control operations are only available when the Laser systemis in LOCAL mode.

Icon Description

Process view, this icon is available when Process Vision in theSettings/General screen is ticked. This is for future use.

Select the GRAPH button to view the Laser Power graph, refer toSection 4.8.5.1.4.

This button is only be available if SPC has been selected, refer toSection 4.8.6.2.1.



4.8.5.1.1 Parameter Selection

Parameter selections are only available when the Laser system is in LOCAL mode.

Select the OPERATOR Tab. The following parameters can be set.

Item Range Description

Parameters

Shape 1 - 10 Any Shape can be edited whilst the Laser is operating includingthe Active Shape.

Up to ten Shapes can be stored.

Select the Shape to be edited by selecting either the name orthe value box.

If the Shape to be edited is not the active shape, change theShape number by either using the + or – keys toincrement/decrement the number value or select the relevantnumber keys and then select ENT. The PC keyboard can alsobe used.

The MAKE SHAPE ACTIVE button will highlight to enable theselected Shape to be made the Active Shape if required.

The parameters of the selected Shape can be edited byselecting the parameter and using the keyboard to alter thevalue.

Rate Hz The times per second the Pulse is fired.





Ramp Up 0 - 9.99seconds

The time taken for the Laser to attain the set Laser power outputwhen switched from READY to ON. Selectable in 0.1 secondincrements

Ramp Down 0 - 9.99seconds

The time taken for the Laser power output to reach zero whenswitched from ON to READY. Selectable in 0.1 secondincrements.

Shape

Sector 1-20 Each Pulse Shape can contain up to 20 sectors. New sectorscan be generated or existing sectors edited using the width andHeight buttons. The selected sector will be shown in red in thedynamic Shape display. Unselected sectors are shown in green.

Width Seedescription.

The width of the sector in mS. The first sector has a range of 0.5to 20mS. Subsequent sectors have a range of 0.5 to 20mS. Thetotal width of all sectors (pulse width) can be a maximum of50mS.

Height 0 to 100% The height of the sector as a percentage of the operating rangedefined by Imin. and Imax.

Insert a sector.

Select all sectors.

Delete selected sector.

Make selected Shape the Active Shape.

Saves new or edited Shape Parameters to disc.



Select the SETTINGS Tab. The Process Settings screen will be displayed.

The following parameters can be monitored or edited.


ParametersMulti-Pulse The number of pulses to be fired. Used in conjunction with the Multi-Pulse

button in the Shutter control area of the screen.

Power Trip Watts The value at which the power will be tripped out

Hi Energy Trip

Lo Energy Trip

Joules The set points for the High and Low Energy Trips. If High point isexceeded an alarm is displayed. If the Low point is exceeded an OUT OFRANGE indication is displayed on the Remote Workstation.

I Max

I Min

0-100% Defines the operating range within the Lasers maximum Power range.If I min = 0% and I max = 50% then 100% power will be 50% of themaximum possible power.

ShotsCountAlarm

Configured in Level 3 Access, refer to Section 4.8.6.4.1.Elapsed number of Shots fired.Shot Count Alarm Set PointThe Shot count is also displayed as a percentage of the Alarm set point.

Flow

CountAlarm

PulsesPulses

Count is configured in Level 3 Access, refer to Section 4.8.6.4.1.Alarm can be changed in this screen.Water flow.Water flow alarm set point.The Flow count is also displayed as a percentage of the Alarm set point.





CoolerHoursAlarm

HoursConfigured in Level 3 Access, refer to Section 4.8.6.4.1.Elapsed hoursCooler elapsed hours alarm set point.Elapsed Hour count is displayed as a percentage of the Alarm set point.



4.8.5.1.2 Laser Mode

The Laser System can be in either LOCAL or REMOTE.

When the system is in REMOTE mode, it is controlled by the Main Process Controllervia the Machine Interface. No parameter settings or control operations can be carriedout by the GUI whilst the system is in REMOTE mode.

When the system is in LOCAL mode, it is controlled by the GUI. All parameter settingsand control operations are enabled.

Mode Description

Selects LOCAL mode. LOCAL appears in red next to the MODElabel. The Loc button is greyed out.

Selects REMOTE mode. REMOTE appears next to the MODElabel. The Rem button is greyed out.




4.8.5.1.3 Shutter Operation

The Shutter can be operated from this screen.

Parameter Description

Enabled

Select this button to ENABLE the Shutter.When selected, the MULTIPULSE and OPEN buttons will behighlighted.The button will revert to ENABLE if the Shutter is not opened or Multi-Pulse operation is not selected within 3 seconds.

Multi Pulse

Select this button within 3 seconds of being highlighted, to open theShutter for Multi-Pulse operation.

The required number of pulses is entered using the display keyboardand is shown in the Multi-Pulse value box on the SETTINGS Tabscreen.

The MULTI-PULSE button must remain selected until the shuttercloses. If it is released, the shutter will close and the required number ofpulses may not be achieved.

A countdown of pulses is shown in the Multi-Pulse value box on theSETTINGS Tab screen.

The Multi-Pulse counter defaults to 1 when operations are complete.

Open Select this button within 3 seconds of being highlighted, to OPEN theShutter.

Close Select this button to CLOSE the Shutter.



Pointing Diode

If a Pointing Diode is fitted, it can be switched ON or OFF by selecting the appropriatebutton.




4.8.5.1.4 Power Graph

The Power Graph is only available if SPC has been selected, refer to Section4.8.6.2.1.

Icon Description

Select to return to Process screen.

Select to display Laser Energy screen, refer to Section 4.8.5.1.5.

The screen may not contain a graph if the Shutter has not been operated, as no datawill have been logged. It will also be blank if SPC has not been selected, refer toSection 4.8.6.2.1.



4.8.5.1.5 Energy Graph

The Energy Graph is only available if SPC has been selected, refer to Section4.8.6.2.1.

Icon Description

Select to return to Process screen.

Select to display Laser Power screen, refer to Section 4.8.5.1.4.

The screen may not contain a graph if the Shutter has not been operated, as no datawill have been logged. It will also be blank if SPC has not been selected, refer toSection 4.8.6.2.1.




4.8.5.1.6 Pulse Selection

This screen enables the User to edit, copy, delete and rename Pulse Shapes.

The Loaded Shapes panel shows all the Shapes loaded on the system. The ActiveShape is indicated by an asterix.

The Available Shapes panel shows Shapes that are available but not loaded on thesystem.

Shapes can be copied to and from either panel using the appropriate COPY arrow.

This facility allows Pulse Shapes to be edited and named to match specific ProductProcesses.

Draft Pulse Shapes can be edited and stored under a suitable name until the editinghas been completed and the Shape is ready for use.

When EDIT is selected the screen will revert to the Operator Tab screen in theProcess screen, refer to Section 4.8.5.1.1.



4.8.5.1.7 Filename Request Screen

When copying or renaming a Shape, a Filename Request screen will be displayed.

The Filename Request screen allows a filename to be entered using either the PCkeyboard or selecting the display keyboard on the screen.

Enter Filename.

Select ↵If the filename is accepted, the display reverts to the Pulse Selection screen.

If the filename is not accepted or the name already exists, the display will revert to ainformation screen and requests a decision.

To exit the Pulse Selection screen without entering a filename:

Select the Esc key.

The display will return to the Pulse Selection screen.




4.8.5.1.8 Process View Screen

The Laser Processing data can be viewed on this screen.



4.8.6 Level 3 Configuration Access

Log on (refer to Section 4.8.3.1) at Level 3 to display the Level 3 Overview screen.This contains Diagnostic and Configuration screens for fault diagnosis and system set-up.

The Level 3 screen contains all the icons and functions of Level 2 with the addition ofthe Configuration icon. The Keyswitch will be red.

Icon Description

Select the Configuration button to display one of the Diagnostic andConfiguration screens. The actual screen displayed will be the lastactive screen.




4.8.6.1 Screen Selection

The Configuration screen displays a set of icons that enable the User to select therequired facility.

Icon Description

Settings

Select this button to display the Settings screen, refer to Section 4.8.6.2.

Data Logs

Select this button to display the Data Logs screen, refer to Section4.8.6.3.

Maintenance

Select this button to display the Maintenance screen, refer to Section4.8.6.4.

Monitor

Select this button to display the Monitor screen, refer to Section 4.8.6.5.

Diagnostics

Select this button to display the Diagnostics screen, refer to Section4.8.6.6.



4.8.6.2 Settings Screen

This screen contains a set of tabbed displays that allow the User to configure thesystem settings.

4.8.6.2.1 General Tab


View Process View. For future use.

SPC Statistical Process Control. Select to enable collection of Laserpower data. This enables the Power and Energy graphs to bedisplayed, refer to Section 4.8.5.1.4 and 4.8.5.1.5.

Data Display Selects the items to be displayed in the Data Display icons,refer to Section 4.8.2.




4.8.6.2.2 Password Tab

This screen allows the passwords to be edited.

Select the EDIT button to display the Password Edit screen.



4.8.6.2.3 Password Editing Screen

The Password Edit screen allows the password for each Access Level to be editedusing either the PC keyboard or selecting the display keyboard on the screen.

Enter new password for the Access Level.

Select ↵The display reverts to the Password Setting screen and shows the new password.

To exit the Password Edit screen without entering a password:

Select the Esc key.

The display will return to the Password Setting screen and show the original password.




4.8.6.2.4 Language Tab

This screen enables the display language to be selected.

Select the appropriate button to display the required language.



4.8.6.2.5 Comms Tab

This screen allows the Communications parameters to be set. The text entries will beFactory set and will only be changed if a different PC or modem is to be used. Textentry will be made using the PC keyboard.

The TRACK icon in the Modem area of the screen will allow screen activity to betracked.


Modem Select to allow modem access.

Select the port required.

Enter the Initiation string, Dial string and Connect time.

Network Select to allow Network access.

Enter the Internet Provider address.

OPC Select to allow Object linking and embedding for Process Control.

Enter Laser number. This feature is for future use.




4.8.6.2.6 Laser Type Tab


Simulation Settings Select the required Laser Type to be shown in SimulationMode.

This allows the use of Generic Laser Interface Programsto simulate different types of Laser.

This cannot be utilised whilst the Laser being used forProduct Processing.



4.8.6.2.7 MCIF Tab

The MCIF Tab screen allows the Machine Interface parameters to be set.


Control SettingsShutter ControlTrigger ControlTrigger SourceControl ModeHeightWidthRate

Enables or Disables External Shutter ControlEnables or Disables External Trigger ControlSelects between PL805 and SK8203Selects either Control Mode 0 or Control Mode 1.)) Tick to enable control)

Serial I/F For future use.

Start-up Mode Determines whether the Laser starts in Local or Remotemode.




4.8.6.3 Data Logs Screen

This screen contains a set of tabbed displays that show the data collated by theControl System. The Data Logs screen also contains File Management icons.



4.8.6.3.1 File Management

Each Data Log can store up to ten files. The active file is Log 0 and the earliest is Log9. When the limit is exceeded, the File Manager will delete Log 9, re-number thecurrent logs and generate a new Log 0.

These files are automatically restricted to 1.4Mb to allow archiving on to floppy disc. Anew Log will be generated when the active Log reaches this limit.

File management icons are displayed according to the screen selected.

To display a log other than the Log 0:

Select FILE MANAGER

Select SELECT LOG.

Select the required Log

Select EXIT.

Icon Description

File Manager.

Displays the File Manager Screen.

Delete Log

Deletes the selected Log.

Archive Log

Saves Log to floppy disc

.

Select Log

Selects the Log to be displayed on the Tab screen.

Exit

Exit and return to Tab screen.

Date/Event

Toggles the selected Log between date and event number order.

Print.

Prints selected Data Log.




4.8.6.3.2 Error Tab

The Error Tab screen displays the active or the selected Error Log.

4.8.6.3.3 Event Tab

The Event Tab screen displays the active or the selected Event Log.



4.8.6.3.4 Warning Tab

The Warning Tab screen displays the active or the selected Warning Log.

4.8.6.3.5 Soak Tab

The Soak Tab screen displays the active or the selected Soak Log.




4.8.6.3.6 Maintenance Tab

The Maintenance Tab screen displays the active or the selected Maintenance Log.

4.8.6.3.7 CommsTab

The Comms Tab screen displays the active or the selected Comms Log.



4.8.6.3.8 SPC Tab

The Statistical Process Control Tab screen displays the active or the selected SPCLog. This is only active when SPC is selected, refer to Section 4.8.6.2.1.




4.8.6.4 Maintenance Screen

The Maintenance screen contains a set of tabbed displays that allow the User tomonitor, configure and tune the Laser System.



4.8.6.4.1 Counters Tab

This screen enables the system counters to be reset.


Water Alarm The number of hours that will generate an alarm. This figure is set using theDisplay keyboard.

Water Run Time The elapsed hours of the Cooling Water. This figure is reset to zero using theDisplay keyboard. A Maintenance Confirm window will appear on reset.

Shutter Ops The total number of Shutter operations. This figure is reset to zero using theDisplay keyboard. A Maintenance Confirm window will appear on reset. If theLaser System has the Timeshare facility, all Shutter counts will be displayed.

Shot Alarm The number of hours that will generate an alarm. This figure is set using theDisplay keyboard.

Shot Count The elapsed number of pulses fired. This figure is reset to zero using the Displaykeyboard. A Maintenance Confirm window will appear on reset.

System On Time The elapsed hours of System operation. This figure is reset to zero using theDisplay keyboard.

Laser On Time The elapsed hours of Laser operation. This figure is reset to zero using theDisplay keyboard.

Maintenance prompttick box

When ticked, generates an automatic prompt when maintenance is due.




4.8.6.4.2 Tuning Tab

This screen enables the User to tune the Laser System for optimum power, refer toSection 6.


Power A dynamic, real time indication of the power. The red indicatorindicates the maximum power achieved.

Start Tune Select to start or stop the Tuning cycle.

Readings Dynamic, real time indicators of maximum and mean power.

Laser Settings Height, width and rate can be selected to set the tuningparameters. Refer to Section 6.2 for Tuning.



4.8.6.4.3 Soak Tab

This screen starts and stops the Soak Test. It also generates the Soak Log.


Start/Stop Soak Select this button to start or stop the Soak Test.

A message appears in the Message Banner when the Soak Testcommences.

Sample Rate The number of minutes between samples. Incremented by the< and > buttons.

% Dynamic indication of the percentage of time until next soaksample.




4.8.6.5 Monitor Screen4.8.6.5.1 PC Tab

This screen displays the details of the User Interface, Hardware Platform, OperatingSystem and Software.



4.8.6.5.2 Comms Tab

This screen allows all Communications Channels to be monitored.

Icon Description

Enables/Disables filtering of Communications Alarm events.

Enables/Disables filtering of Communications Process events.

Enables/Disables filtering of Communications Control events.

Log Comms

Select to log Comms details.

Enables/Disables recording of Comms events to a file which maythen be viewed in the LOGS area.

Delete all displayed events in Rx DATA and Tx DATA fields.

4.8.6.6 Diagnostics ScreenThis screen allows the system to be operated.




4.8.6.6.1 System Tab

IconDescription

Cooler OFF/ON Select to set Cooler ON or OFF.

Laser to Ready Select to set Laser to READY.

Laser to ON Select to set Laser ON.

Shutter Open Select to set Shutter to OPEN.

Shutter Close Select to set Shutter to CLOSE.

Pointing Diode On Select to set Pointing Diode to ON.

Pointing Diode Off Select to set Pointing Diode to OFF.

System to Off Select to set System OFF..

GSI LumonicsJK700TR Series: User ManualIssue 1.0 Section 5 – Alarm and Warning Handling


5. Alarm and Warning Handling

5.1 Alarm DisplaySystem faults will cause either an Alarm or a Warning to be displayed on the screen.

Alarms will normally stop the Laser operating (some Shutter and Machine Interfacealarms do not stop the Laser).

On the GUI, alarms cause the periphery of the relevant icon to flash in red and anAlarm Message to be displayed in the Alarm Banner. Alarm indications will remainpresent until the fault has been cleared and the RESET button selected. If more thanone alarm exists, the next highest priority alarm will be displayed. All alarms must becleared before RESET can be selected.

On the Operator’s Control Panel, alarms cause:

An audible alarm to sound.

An Alarm indicator to flash.

A message to appear in the Alarm Banner.

To accept the alarm message, press the ALARM key. This stops the audible alarm andswitches the alarm indicator to continuous.

Repeated operation of the ALARM key will alternate the display between the alarmmessage and the monitor display.

The Alarm message and the alarm indicator will extinguish only when the alarmcondition has been rectified.


Section 5 – Alarm and Warning Handling Issue 1.0


5.2 AlarmsAlarms are identified by codes displayed in the Alarm Banner on the GUI or in theDisplay Panel on the Operators Control Panel.

5.2.1 Alarm Response

The following responses should be taken when an Alarm is generated.

Step Action Response

Reset Alarm.

If Alarm resets go to Step 3.

1 GUI Periphery of appropriate iconon GUI screen displayed inflashing red.

Alarm code and messagedisplayed in Alarm Banner.

Control Panel Audible Alarm.

Alarm Indicator lights.

Message on Display Panel.

If Alarm does not reset, refer to Section5.2.2 and rectify cause of Alarm

2 Alarm List generated Clear Alarm list.

3 Alarm List cleared Resume Operations.

5.2.2 Alarm Codes

Code Alarm Reason Remedy

Severe contact bounce whencontactor energised afterpressing POWER key.

Cancel Alarm Message andtry again.

Low mains supply voltage. Check mains supplyvoltage is within +/- 6% ofnominal value.

Check system has beenconfigured for correctnominal supply voltage.

100 Power Supply Contactor 1

The auxiliary contact ofPower Supply Contactor 1(RL401-1), monitored by theControl System, did not closewhen the coil was energisedor did not open when the coilwas de-energised.

Power Supply Fault. Call Service Engineer.

Severe contact bounce whencontactor energised afterpressing POWER key.


Low mains supply voltage. Check mains supplyvoltage is within +/- 6% ofnominal value.



The auxiliary contact ofPower Supply Contactor 2(RL401-2), monitored by theControl System, did not closewhen the coil was energisedor did not open when the coilwas de-energised.





Broken Flashlamp. Check and replace.

No high voltage simmersupply, Fuse F1101 blown.

Check and replace.

High coolant conductivity. Drain and refill coolantsystem. Change Filter andDe-ioniser.

Trigger Circuit Fault, SimmerSupply Fault, Wiring Fault.

Call Service Engineer.

102 Lamp 1 Not Simmering

After selecting POWER ON,no simmer current wasdetected for 30 seconds afterthe DC link achieved itsnormal voltage i.e. lamp didnot trigger.

Water in Pumping ChamberMounting screw holesfollowing Flashlamp change(only early systems withoutsealing plug in screw holes).

Remove Pumping Chamberlid and dry out counterboresof Pumping ChamberMounting screw holes.

Broken Flashlamp. Check and replace.

No high voltage simmersupply, Fuse F1102 blown.

Check and replace.

High coolant conductivity. Drain and refill coolantsystem. Change Filter andDe-ioniser.

Trigger Circuit Fault, SimmerSupply Fault, Wiring Fault.


103 Lamp 2 Not Simmering

After selecting POWER ON,no simmer current wasdetected for 30 seconds afterthe DC link achieved itsnormal voltage i.e. lamp didnot trigger.

Water in Pumping ChamberMounting screw holesfollowing Flashlamp change(only early systems withoutsealing plug in screw holes).

Remove Pumping Chamberlid and dry outcounterbores of PumpingChamber Mounting screwholes.

Failure of a reservoir capacitoron Switching Module 1.

These failures are oftenself-healing.

Cancel the Alarm Messageand select POWER ON toattempt to clear the fault.

If message recurs, callService Engineer.

104 Low Volts Detected on DCLink 1

The Control System hasdetected lower thanexpected voltage on DC Link1 during the power onsequence initiated byselecting POWER ON.


Failure of a reservoir capacitoron Switching Module 2.

These failures are oftenself-healing.

Cancel the Alarm Messageand select POWER ON toattempt to clear the fault.

If message recurs, callService Engineer

105 Low Volts Detected on DCLink 2

The Control System hasdetected lower thanexpected voltage on DC Link2 during the power onsequence initiated byselecting POWER ON.

Power Supply Fault Call Service Engineer





Severe contact bounce whencontactor energised afterselecting POWER ON andlamps have triggered.


Low Mains Supply voltage. Check Mains Supplyvoltage is within +/-6% ofnominal value.

Check system has beenconfigured for correctnominal mains voltage.

106 Bypass 1 Contactor

The auxiliary contact ofBypass Contactor 1 (RL402-1), monitored by the ControlSystem, did not close whenthe coil was energised or didnot open when the coil wasde-energised.


Severe contact bounce whencontactor energised afterselecting POWER ON andlamps have triggered.


Low Mains Supply voltage. Check Mains Supplyvoltage is within +/-6% ofnominal value.


107 Bypass 2 Contactor

The auxiliary contact ofBypass Contactor 2 (RL402-2), monitored by the ControlSystem, did not close whenthe coil was energised or didnot open when the coil wasde-energised.


Connecting a Hand ShutterControl to SK A304 when PL900 is already connected toexternal equipment.

If Hand Shutter Control is tobe used, disconnectexternal equipment fromPL 900.

Connecting externalequipment to PL 900 when aHand Shutter Control isconnected to SK A304.

Disconnect Hand ShutterControl.

108 Ambiguous ShutterControl

The Control System hasdetected that both possiblesources of Remote ShutterControl, PL 900 in the PowerSupply Termination Chamberand SK A304 on the LaserHead, are connected at thesame time. This AlarmCondition switches the Laserto OFF: the Power Circuitsand Cooler remain ON.

System fault. Call Service Engineer.

Fuse F1111 Blown. Check and replace fuse.



200 24V Interlock Fuse Blown

No +24V DC Interlock Supplydetected by Control System.


Extreme interference hascorrupted the microprocessoror memory.

Switch the Disconnectswitch OFF and ON again.

201 Watchdog Shutdown

The Watchdog circuit hasdetected a malfunction in themicroprocessor system.

Control System Fault. Call Service Engineer.




ENABLE KEYSWITCH insystem disabled (OFF)position.

Turn to one of thesystem

enabled (ON) positions.(This alarm will becancelled automaticallywhen the cause is reset.)

202 Enable Key

The Control System hasdetected the Interlock Circuitis incomplete at theOperators Control Panel dueto the ENABLEKEYSWITCH.

Control Panel fault. Call Service Engineer.

EMERGENCY OFFpushbutton operated.

Release pushbutton.

(This alarm will becancelled automaticallywhen the cause is reset.)

203 Emergency Stop

The Control System hasdetected the Interlock Circuitis incomplete at theOperators Control Panel dueto the EMERGENCY OFFpushbutton. Control Panel fault. Call Service Engineer.

204 Laser Protection Circuit

The Control System hasdetected the Interlock Circuithas been interrupted by theLaser Protection Circuit.

One of seven distinct abnormalconditions has been detected.

Alarm Message numbers 400to 407).

This message and theseven specific LaserProtection Failuremessages can only bereset by switching OFF themains electricity supply.

205 Customer Interlock 1

The Interlock Circuit hasbeen interrupted at theCustomer Interlock.

External circuit between TB801-1 and TB 801-2 is opencircuit.

Check external equipmentfor abnormal condition, e.g.covers, doors or guardsopen, work handling notready etc.

Damaged Shutter Mirror,damaged Beam DumpWindow or Shutter fault.

Inspect Process Shutterand Dump Assembly. Ifdamaged, call ServiceEngineer.

206 Process Shutter ThermalFuse

The Interlock Circuit hasbeen interrupted by theProcess Shutter ThermalFuse opening.

Failure of thermal fuse. The Thermal Fuse cannotbe reset.

Check and replace.

Shutter jammed fully orpartially open or closed.


207 Shutter Failure

The Process ShutterMonitoring Circuit, whichchecks for correct operationof the Process Shutter, hasinterrupted the InterlockCircuit.

Shutter functioning but slowerthan normal.






Process Shutter jammed openAND Process ShutterMonitoring Circuit failed.

Inspect Process Shutterassembly. If faulty, callService Engineer.

Failure of Thermal Fuse. The Thermal Fuse cannotbe reset.

Check and replace.

208 Safety Shutter ThermalFuse

The Interlock Circuit hasbeen interrupted by theSafety Shutter Thermal Fuseopening.

Safety Shutter cabledisconnected (plug PL A501)on BET lid.

Check and reconnect.

209 Head Interlock 2

This message is associatedwith a spare position in theInterlock circuit.

Wiring fault. Call Service Engineer.

210 Pumping Chamber Cover



211 Resonator Cover

One or both of the microswitches beneath the clearplastic cover have interruptedthe Interlock circuit over thePumping Chamber.

Cover removed. Replace cover.

212 Resonator Cover (Int. 2)



213 Head Interlock 3



214 Inner Head Cover

This message is associatedwith a spare position in theInterlock circuit


215 Head End Plate

One or both of the microswitches behind the LaserHead rear end Cover Platehave interrupted the Interlockcircuit.

Cover Plate removed. Replace Cover Plate.




216 Transformer 1 OverTemperature

One or both of thetemperature trip switches inTransformer T401-1 onTransformer Module 1 haveinterrupted the Interlockcircuit.

Transformer overheated. Call Service Engineer.

The trip switches will resetwhen the temperaturereturns to normal.

Random trip. Reset trip.DO NOT repeatedly resettrip, or alter trip setting from21.5 amps.

217 Overload 1

The Interlock Circuit hasbeen interrupted by theoverload trip OL401-1 onTransformer Module 1.

Fault in power circuits forFlashlamps.


218 Transformer 2 OverTemperature

One or both of theTemperature Trip Switches inTransformer T401-2 onTransformer Module 2 haveinterrupted the Interlockcircuit.


The Trip Switches will resetwhen the temperaturereturns to normal.

Random trip. Reset trip.

DO NOT repeatedly resettrip, or alter Trip settingfrom 21.5 amps.

219 Overload 2

The Interlock Circuit hasbeen interrupted by theoverload trip OL401-2 onTransformer Module 2.

Fault in power circuits forFlashlamps.


Auto-Transformer OverTemperature

On standard 50Hz supplysystems, this message isassociated with a spareposition in the Interlockcircuit.


220

On standard 60Hz supplysystems, one or both of theTemperature Trip Switches inTransformer T102 on thePower Distribution Modulehave interrupted the InterlockCircuit.



221 Cabinet Over Temperature

The Interlock Circuit hasbeen interrupted by thePower Supply Enclosure(Cabinet) Over TemperatureSwitch TS101.

External water supply turnedoff.

Turn on external watersupply.






Failure of air circulating fan. Call Service Engineer.

222 Dump Resistor 1 OverTemperature

This message is associatedwith a spare position in theInterlock circuit and is notused in the JK70TR SeriesLasers.


223 Dump Resistor 2 OverTemperature

This message is associatedwith a spare position in theInterlock circuit, and is notused in the JK70TR SeriesLasers


224 Spare 1

This message is associatedwith a spare position in thecircuit, and is not used in theJK70TR Series Lasers.


225 Spare 2

This message is associatedwith a spare position in theinterlock circuit, and is notused in the JK70TR SeriesLasers


226 Spare 3

This message is associatedwith a spare position in theinterlock circuit, and is notused in the JK70TR SeriesLasers


Fuse F1107 blown. Check and replace.

Low mains supply voltage. Check mains supply iswithin +/-6% of nominalvalue.


Faulty Contactor. Call Service Engineer.

227 Cooler Contactor

The auxiliary contact of theWater Cooler Contactor,RL101, was not closed whenthe contactor coil wasenergised.

Wiring Fault. Call Service Engineer.

228 Customer Interlock 2

The Interlock Circuit hasbeen interrupted at theCustomer InterlockConnection between TB 801-3 and TB 801-4.

External circuit between TB801-3 and TB 801-4 is opencircuit.

Check external equipmentfor abnormal condition, e.g.covers, doors or guardsopen, work handling notready etc.




External water supply turnedoff, flow inadequate ortemperature too high.

Check external watersupply.

When fault is rectified,select READY button to runWater Cooler pump tocirculate the water so it canbe cooled by the externalwater supply.

Select the Water Coolerscreen to display thecoolant temperature.

It may take up to 5 minutesto cool the water sufficientlyto reset the TemperatureSwitch.

The Temperature tripswitch will reset when thetemperature returns tonormal.

Laser Fault. Call Service Engineer.

Temperature Switch fault. Call Service Engineer.

229 High Coolant Temperature

The Coolant TemperatureTrip Switch, TS301, hasinterrupted the InterlockCircuit.

Wiring Fault. Call Service Engineer.

230 Door Interlocks

This message is associatedwith a spare position in theInterlock circuit and is notused in the JK70TR SeriesLasers.


231 Micro Enable RelayRelay RL6303 has failed tooperate and complete theInterlock Circuit.

Control System fault. Call Service Engineer.

ENABLE KEYSWITCH in OFFposition.

Turn to one of the systemON positions (2, 3 or 4).

EMERGENCY OFFpushbutton operated (in).

Release pushbutton.

250 Front Panel Interlock

The Control System hasdetected the Interlock Circuitis incomplete at theOperators Control Panel.

Wiring fault in Interlock circuitto Control Panel.

Check for looseconnections.


(This alarm will becancelled automaticallywhen the cause is reset.)





Air in the cooling system.Opening the pumping chamberto inspect or change theFlashlamps or disconnectingthe water-cooled block whenchanging the resonatorconfiguration, causes air toenter the system. This cantake more than 5 seconds toflush out.

Cancel Alarm Message andpress READY button.

Any air in the system canbe seen through thecoolant hoses to the LaserHead. Wait 15 seconds oruntil all air bubbles havedisappeared beforeselecting POWER ON.

Damaged cooling hoses. Check and rectify.

Obstruction in mesh filter ofPumping Chamber.

Check filter and removeany obstruction withtweezers

Filter cartridge on WaterCooler Module partiallyblocked.

Replace Filter. It isrecommended to changethe De-ioniser Resin andreplace the Coolant at thesame time.

300 Less than 90% FlowDetected

The Control System hasdetected that laser coolingwater flow is less than 90%of the nominal (Flow Alarm)value.

Pump fault. Call Service Engineer.

400 Excessive Mean Power

The Control System hasdetected that actual meantotal Lamp Power exceeded14kW. This Alarm Conditionswitches the laser to OFF:the power circuits and Coolerremain ON.

Selection of a combination ofpulse Height, Width and Ratethat resulted in exceeding themean power trip.

Modify the laserparameters (Height: Width:Rate).

Select LOCAL or REMOTEto resume operation.

High mains supply voltage. Check mains supplyvoltage is within +/-6% ofnominal value.


Extreme transient on mainssupply.

Switch mains supply OFFand ON to reset message.If message recurs, checkmains supply.

401 Overvolts on DC Link 1

The Control System hasdetected that the voltage onDC Link 1 exceeded 470volts.

This message can only bereset by switching the mainssupply OFF and back ON.

Power supply fault. Call Service Engineer.




Failure of reservoir capacitoron Switching Module 1.

Switch the Disconnectswitch OFF and back ONagain.

Select POWER ON toattempt to clear fault.

If the message recurs, callService Engineer.

Fuse F106, F107 or F108blown.

Check and replace.

402 Under-volts on DC Link 1

The Control System hasdetected that the voltage onDC Link 1 was less than 250volts.



High mains supply voltage. Check mains supplyvoltage is within +/-6% ofnominal value.


Extreme transient on mainssupply.

Switch mains supply OFFand ON to reset message.If message recurs, checkMains Supply.

403 Over-volts on DC Link 2

The Control System hasdetected that the voltage onDC Link 2 exceeded 470volts.



Failure of reservoir capacitoron Switching Module 2.

Set the Mains Disconnectswitch OFF and back ONagain.

Select POWER ON toattempt to clear fault.

If the message recurs, callService Engineer.


Check and replace.

404 Under-volts on DC Link 2

The Control System hasdetected that the voltage onDC Link 2 was less than 250volts.



Failure of Flashlamp 1. Check and replaceFlashlamp.

Selection of a combination ofpulse Height, Width and Ratethat exceeded the power limit(component variations cancause the Power 1 limit to bereached before the Power 2limit).

Modify laser parameters:Height, Width and Rate.

405 Excessive Power 1

The Control System hasdetected an abnormal powerlevel in the power circuits forFlashlamp 1.


Power Supply fault. Call Service Engineer.





Failure of Flashlamp 2. Check and replaceFlashlamp.

Selection of a combination ofpulse Height, Width and Ratethat exceeded the power limit(component variations cancause the Power 2 limit to bereached before the Power 1limit).

Modify the parameters:Height, Width, and Rate.

406 Excessive Power 2

The Control System hasdetected an abnormal powerlevel in the power circuits forFlashlamp 2.


Power Supply fault. Call Service Engineer.

Failure of either Flashlamp. Check and replaceFlashlamps.

One or both Flashlamps fittedwrong way round.

Check Flashlamps.

One or both Flashlamps of thewrong type.

Check Part Numbers onLamp Box. Correct Numberis P55B6770B.

407 Excessive PowerDifference

The Control System hasdetected a power differencegreater than 750W betweenFlashlamps 1 and 2.



500 No Control Stationdetected

Refer to Code 250 Refer to Code 250

600 Watchdog not updatedwithin 10mS

The Control System hasdetected a timing fault in thecontrol software.

Control System Fault. Call Service Engineer.

Fuse F1110 Blown. Check and replace.



Fault may be in external wiringor equipment connected to:

Remote Interface PL 800.

Shutter Control SK 801 andSK A304.

Machine Interface PL 804and PL 805.

Remote Gate TB 801-5 and 6.

Shutter Interlock TB 801-9 and10: SK A301.

External Emission Indicator TB801-13 to 18.

Disconnect external wiring.

Progressively reconnectexternal equipment untilfault is located.

901 Check General 24V SupplyFuses

No +24 volt DC supplydetected by Control System.This supply is used formonitoring, emissionindicator, remote interfaceetc.





Random trip. Reset trip.

DO NOT repeatedly resettrip, or alter trip setting from3 amps.

Pump Motor running on 2phases instead of 3.

Reset trip.

DO NOT repeatedly resettrip, or alter trip setting from3 amps.


Check and replace.

On 60Hz supply systems only,Fuse F112, F113 or F114blown.

Check and replace.

902 Check Cooler OverloadRelay

The Control System hasdetected the Water CoolerPump Motor Overload OL101has tripped.

Pump Motor Fault. Call Service Engineer.

Check Ready 1 Circuit

The simmer current inFlashlamp 1 was interruptedwhile the Power circuits wereon.

Simmer arc blown out, mostlikely at narrow width (0.8mS)and high amplitude (70%Height) pulses.

Flashlamp at or near end of life.

Broken Flashlamp.

System fault.

Increase Pulse Widthand/or reduce PulseHeight.

Check and replaceFlashlamps.

Check and replace.


903

The Control System hasdetected simmer current inFlashlamp 1 more than 1.5seconds after the SYSTEMOFF has been selected.Normally the simmer arcgoes out within 1 second.

Incorrect type of Flashlampfitted.

Correct type of Flashlamp butcharacteristics out ofspecification.

High cooling waterconductivity.

Insulation on Flashlamp flexibleleads damaged.

System fault.

Check and replace.

Replace.

Drain and refill coolingsystem. Change Filter andDe-ioniser.

Check and replaceFlashlamp.






Check Ready 2 Circuit

The simmer current inFlashlamp 2 was interruptedwhile the Power circuits wereon.

Simmer arc blown out, mostlikely at narrow width (0.8mS)and high amplitude (70%Height) pulses.

Flashlamp at or near end oflife.

Broken Flashlamp.

System fault.

Increase Pulse Widthand/or reduce PulseHeight.

Check and replaceFlashlamps.

Check and replace.


904

The Control System hasdetected simmer current inFlashlamp 2 more than 1.5seconds after the SYSTEMOFF has been selected.Normally the simmer arcgoes out within 1 second.

Incorrect type of Flashlampfitted.

Correct type of Flashlamp butcharacteristics out ofspecification.

High cooling waterconductivity.

Insulation on Flashlamp flexibleleads damaged.

System fault.

Check and replace.

Replace.

Drain and refill coolingsystem. Change Filter andDe-ioniser.

Check and replaceFlashlamp.


Severe contact bounce whencontactor energised.


Low mains supply voltage. Check mains supplyvoltage is within ±6% ofnominal value.



The auxiliary contact ofPower Supply Contactor 1(RL401-1), monitored by theControl System malfunctions.







The auxiliary contact ofPower Supply Contactor 2(RL401-2), monitored by theControl System malfunctions.









907 Bypass Contactor 1

The auxiliary contact ofBypass Contactor 1 (RL402-1), has malfunctioned.






908 Bypass Contactor 2

The auxiliary contact ofBypass Contactor 2 (RL402-2), has malfunctioned.


Coolant level below minimum. Check and Top-up.

Air lock in Float Switchassembly.

Float Switch stuck or jammed.

Air bubbles are trapped in theassembly due to the highsurface tension of de-ionisedwater, preventing the FloatSwitch from operating whenthe coolant is topped up orrefilled.

Remove the retaining clipssecuring the Float Switchassembly on the WaterCooler.

Unclip the assembly andshake vigorously up anddown.

Replace assembly andretaining clips.

Float Switch faulty. Call Service Engineer.

Do not operate system iffloat switch appears to befaulty.

1000 Low Coolant Level

The Control System hasdetected the Float Switch onthe Water Cooler Module isopen circuit.






High or Low mains supplyvoltage.

Check mains supplyvoltage is within +/-6% ofnominal value.


Momentary loss or drop ofmains supplies (’Brown-Out’).

Cancel Alarm Message andresume operation.

1002 Mains Supply Out ofExpected Limits

The Control System hasdetected the system mainssupply is more than 10%above or below the nominalvoltage.

Momentary Over-voltage ortransient on mains supplies

Cancel Alarm Message andresume operation.

If this occurs regularly,system damage couldresult. Consult yourRegional Customer Centre

Operator/CNC has selectedtoo high a value for pulsewidth, height or rate.

Cancel Alarm message.Reduce one of the Laserparameters. Resume Localor Remote control.

Operator/CNC has selectedtoo low a value for Trip level.

Cancel Alarm message.Increase the Output PowerTrip level if possible.Resume Local or Remotecontrol.

1100 Laser Output Over Limit

The Control System hasdetected that the averageLaser output has exceededthe set Trip value.

Remote control of OutputPulse Shape has caused aShape with high energy to beoutput too often.

Cancel Alarm message.Increase the Output PowerTrip level if possible.Resume Remote control.

Cancel Alarm message.Decrease the repetition ratefor the high energy Pulse.Resume Remote control.

Operator/CNC has selectedtoo high a value for pulse widthor height on Pulse 1.

Cancel Alarm message.Reduce one of the Laserparameters in Pulse 1.Resume Local or Remotecontrol.

1101 Laser Pulse 1 Energy OverLimit

The Control System hasdetected that measuredPulse Energy has exceededthe set Trip value (Hi).

Operator/CNC has selectedtoo low a value for high energyon Pulse 1.

Cancel Alarm message.Reduce the high energy triplevel for pulse shape 1 ifpossible.Resume Local or Remotecontrol.






1110 Laser Pulse 10 EnergyOver Limit




5.3 WarningsWarnings indicate a problem but allow continued operation.

On the GUI, warnings cause the periphery of the relevant icon to flash in yellow and awarning message to be displayed in the Message Banner. Press the RESET button toaccept the warning.

On the Operator’s Control Panel, warnings cause a warning message to be displayedin the Display Panel. Press the WARNING key to accept the message.

Warning indications will remain present until the problem has been cleared. This mayor may not require manual intervention.

5.3.1 Warning Response

The following responses should taken when a Warning is generated.

Step Action Response

Reset Warning.

If Warning resets go to Step 3.

1 GUI Periphery of appropriate iconon GUI screen displayed inflashing yellow.

Warning code and messagedisplayed in Warning Banner.

Control Panel Message in Display Panel

If Warning does not reset, refer toSection 5.3.2 and rectify cause ofWarning.

2 Warning List generated. Clear Warning list.

3 Warning List cleared. Resume Operations.




5.3.2 Warning Codes

Code Warning Reason Remedy

3 Change Coolant Filter andDe-ioniserThe cooler runtime hasexceeded 2000 hours

The Coolant Filter and De-ioniser have reached the endof their useful life.

Select the Water Cooler DataLog screen to confirm Coolerruntime value.

Replace Filter and De-ioniserif necessary.

Reset Cooler runtime to zero.

4 Shot Count Over Alarm Limit

The Flashlamp Shot Countvalue exceeds the pre-set ShotAlarm limit.

The Flashlamps havereached the end of theireconomic life.

Confirm Shot Count and ShotAlarm settings.

Inspect and if required changeFlashlamps.

Reset Shot Count to zero iflamps are changed.

Change Shot Alarm value ifFlashlamps in good condition.

5 System Not Ready

The laser cannot be switchedon in Local or Remote until thePower has been selected, thePower On sequence hascompleted and the Readyindicator is illuminated.

Select Local or Remotebefore the Ready indicator isilluminated.

Cancel warning message andwait until the laser is Ready.

Calculated Pump PowerLimit

The Control System hascalculated that selected laserparameters exceed themaximum available FlashlampMean Power or Pulse Energy.

A combination of pulseheight, width and rate hasbeen selected that willexceed the maximumavailable Mean Power orEnergy.

Reduce one or more of thelaser parameters:

Height: Width or Rate.

7

The calculated limit mayslightly exceed the Power orEnergy permitted by theSystem Protection Circuit.

A combination of Imin andImax has been selected thatmay exceed the maximumavailable Mean Power orEnergy for one or more ofany of the pulse shapes (notonly the one in use).

Imin and Imax are usuallyused to compensate forFlashlamp ageing. Thereforethis indicates the end ofeconomic Flashlamp life.Inspect and if necessarychange Flashlamps.




8 Multi Shot Timeout

When using shutter Multi-Shotoperation in conjunction withExternal Triggering of the laserpulse, more than 30 secondshas elapsed without anExternal Trigger signal. Theshutter will close automatically.

This is a safety feature andprevents the shutter beingarmed to open or left openindefinitely.

Fault in External Triggersource, e.g. work handlingequipment.

Check External Triggersource.

9 Shutter Under ExternalControl

Shutter Open and Multi-Shotkeys on Control Panel aredisabled when a Hand ShutterControl is connected toSKA304 or external equipmentis connected to PL800.

Shutter Close key is alwaysoperative.

Select Shutter Open or Multi-Shot on Control Panel whenRemote Shutter or externalequipment is connected.

Disconnect Hand ShutterControl or externalequipment.

10 Laser Not Running

Shutter Multi-Shot cannot beused unless the laser is ON inLocal or Remote.

Select Shutter Multi-Shot keywhen laser is OFF.

Select Local or Remote asrequired.

Remote Control Option NotFitted

Selecting Remote when thisoption not fitted.

Cancel Warning Message.Only Local operation can beused.

11

The Control System detectsthe presence of the RemoteControl card in the ControlModule. If fitted, Remote Control card

is faulty.Call Service Engineer.

If system is to be used inLocal, it is recommended thatthe Remote Control option isremoved.

12 Main Sector Cannot BeDeleted

The fixed or Main Sector of aPulse Shape cannot bedeleted.

Attempting to delete theMain Sector of a PulseShape.

Delete the last but one sectorand reallocate Sector Heightsand Widths.

13 Pulse Already Has 20Sectors

The maximum number ofsectors, including the MainSector, is 20.

Attempting to insert anadditional sector when apulse Shape already has 20sectors.

Restrict the Pulse Shape to20 sectors by amalgamatingsimilar adjacent sectors.





14 No Permission

Control of laser parameters,pre-set values etc. is passwordprotected.

Attempting to perform afunction outside thepermission granted to thecurrent User.

Logon at the appropriatelevel.

15 Customer Gate Disabled

The Customer Gate circuit atTB801 (5 and 6) is interrupted.This disables the FlashlampPower Circuit wheneverLOCAL or REMOTE isselected. See note below.

Selecting LOCAL orREMOTE when theCustomer Gate circuit isinterrupted.

Check external equipmente.g. work handling, beamdelivery, connected to TB801-5 and 6.

16 Remote Gate DisabledThe Remote Gate input atPL805-4 is false or is opencircuit. This disables theFlashlamp power circuits whenthe laser is in REMOTE.The Control System checksthis input whenever REMOTEis selected.

See note below.

Selecting REMOTE whenthe Remote Gate input isFalse or open circuit.

Check external equipment,e.g. work handling, beamdelivery, CNC etc. connectedto PL 805-4.

The Shutter Interlock circuitis interrupted either atSKA301 on the Laser Heador TB801 (9 and 10) in thePower Supply.

Check external equipment,e.g. work handling, beamdelivery, CNC etc. connectedto PL805-4.Check working procedure

17 Safety Shutter Interlock Set

The Shutter Interlock Circuit isinterrupted whilst the Laser isON and the Process ShutterOPEN.

Safety Shutter Fault. Call Service Engineer.

The Shutter Interlock circuitis interrupted either atSKA301 on the Laser Heador TB801 (9 and 10) in thePower Supply, e.g. by safetyenclosure door or cover.

Close safety enclosure doors,covers etc. that have switcheswired into the ShutterInterlock circuit.

18 Shutter Disabled

The Shutter Interlock Circuit isinterrupted: the Safety Shutteris closed and the ProcessShutter disabled.

Safety Shutter Fault. Call Service Engineer.

NOTE: In these cases the WARNING indicator will go off when RESET is selectedeven if the appropriate Gate input is still False.

GSI LumonicsJK700TR: User ManualIssue 1.0 Section 6 – Optimisation


6. Optimisation

6.1 IntroductionThe Optimisation procedure consists of tuning the Rear Mirror. When the optimumpositions are set, the Laser will operate at maximum efficiency.

This section describes the operation of the GUI to carry out the OptimisationProcedure.

Refer to Section 4 for GUI Operating Instructions.

6.2 Rear Mirror TuningRefer to Section 4.3 and start Laser.

Log On to the GUI. Level 3 access is required for Optimisation.

Ensure Safety Interlocks (TB801 pins 9 and 10) are removed to prevent Laseroperation during set-up.

Select the LASER ON button to switch Laser ON (if the Laser is not in the Laser ONstatus then the Tuning Procedure cannot be started).

Item Action Remarks

1 Select CONFIGURATION button

Select MAINTENANCE button

Select TUNING

Insert the correct Tuningparameters for the Laser Type(refer to the Table below).

Select START TUNING

2 Rotate the X and Y adjusters on theRear/Front Mirror Assembly to give amaximum Mean Power output.

WARNINGBE SURE TO ADJUST ONLY THE

REAR MIRROR AND NOT THEFRONT MIRROR.

The Mean Power value is displayed in the MEANPOWER icon.

Maximum Mean Power is the maximum valueachieved during the Tuning.

If a maximum Mean Power value is achieved butsubsequently cannot be repeated it isrecommended that the tuning cycle is stoppedand restarted.

3 Select STOP TUNE

4 Increase height from 40% until fullpower is reached.

If laser specification still can not be reachedplease contact GSI Lumonics.


Section 6 – Optimisation Issue 1.0


Laser ParametersLaser Type

Height (%) Width (mS) Rate (Hz)

JK760TR 40 5 20

JK745TR 40 5 20

JK730TR 40 5 20

JK715TR 40 5 20

GSI LumonicsJK700TR: User ManualIssue 1.0


6.3 Focus Head Set-upThis procedure sets the focal point of the beam at the workpiece to achieve optimumperformance. This is achieved by taking a number of ‘burns’ at progressive distancesfrom the workpiece to ascertain the minimum spot size (beam waist).

Step Action

Caution

If a Pointing Diode is fitted to the Laser System, it must be noted that theposition of the focal plane of the Pointing Diode beam is different to thatof the YAG beam. Therefore, the Pointing Diode beam must NOT be usedto define the focal point for the Process.

Caution

Fibre ends are easily damaged.

Fibre handling precautions must be observed throughout this procedure,refer to Section Error! Reference source not found..

1 Secure the Focus Head in a Z-axis position that allows small increments invertical movement.

2 Clamp test piece (stainless steel) in position below the Focus Head.

3 Position and secure the Focus Head approximately 5mm above the specifiedFocal Point of the Focus Head.

4 Ensure Laser Status is READY.

5 Set to desired operating parameters.

6 Set the Laser to ON.

7 Set SHUTTER to ENABLE.

Step 8 must be carried out within five seconds of Step 7.

8 Select MULTI PULSE to produce a single spot weld on the test piece.

9 Position the test piece so that a clean section is exposed to the Focus Head.

10 Position the Focus Head 1mm closer to the test piece.

11 Repeat steps 7 to 10 until the Focus Head is 5mm below the specified FocalPoint of the Focus Head.

12 Measure the spot size recorded on the test piece. Refer to Figure 6

13 The Focal Point that gives the smallest spot size is the optimum and should beset on the Focus Head.

Figure 6 – Focus burns


Section 6 – Optimisation Issue 1.0


6.4 CompletionWhen the Optimisation has been completed:

Replace Safety Interlock (TB801 pins 9 and 10).

Select OVERVIEW screen.

Select the KEYSWITCH.

Set the Access Level for normal operation.

GSI LumonicsJK700TR: User ManualIssue 1.0 Section 7 – User Maintenance


7. User Maintenance

7.1 IntroductionUser Maintenance is restricted to the following items:

• General inspection.

• Coolant replenishment.

• Coolant Filter replacement.

• De-ioniser cartridge replacement.

• Flashlamp replacement.

• Fibre Optic Cable replacement and alignment.

• Fuse replacement.

• Bulb replacement.


Section 7 – User Maintenance Issue 1.0


Intentionally Blank



7.2 User Maintenance TasksTask Periodicity Reference Maintenance

Level

General Inspection Weekly Section 7.4

Filter Replacement 12 months or 2000 hours* Section 7.6 1

De-ioniser Replacement 12 months or 2000 hours* Section 7.7 1

Flashlamp Replacement When Height Demand hasbeen increased by 10%orNormal output cannot beachievedorWhen elapsed hours of Lampreaches the configured limit

Section 7.8 1

Fibre Optic Cable Replacement As necessary Section 7.9 2

Cover Slide Replacement As necessary Section 7.10 1

Fuse Replacement On failure Section 7.11 1

Bulb replacement On failure Section 7.12 1

* Whichever is sooner.




Intentionally Blank



7.3 Power ON/OFF SequenceThroughout the User Maintenance Procedures, the terms Power ON Sequence andPower OFF Sequence are used. When using a standard control panel, refer toSection 3.2 for Start-up and Shut-down procedures.

The Power ON Sequence is defined as:

• Ensure external water supply is ON.

• Ensure external power supplies are available and switched on.

• At the Control Panel:

Set MAINS DISCONNECT switch to ON.

Verify white POWER ON lamp is lit.

• Ensure GUI is on. Reset any Alarm messages.

• At Control Panel:

Push and hold green READY button (I) until amber EMISSION lamps stop flashing.The system will commence the start-up sequence and the green READY lamp willflash.

The green READY lamp will stop flashing and remain lit. The Laser is now inREADY mode.

The Power OFF Sequence is defined as:

• At GUI, verify Laser Status icon indicates READY. If not, select the LaserREADY/ON button. Ensure Laser Status icon indicates READY.

• At Control Panel:

Push red POWER OFF button (O).

Laser is now OFF. The Coolant Pump will continue to run for ten seconds to allowcooling after Laser operation.

When Coolant Pump stops running, set MAINS DISCONNECT switch to OFF.




Intentionally blank



7.4 General InspectionStep Action

WARNING

ELECTRIC SHOCK HAZARDS EXIST.

ELECTRIC SHOCK CAN CAUSE SERIOUS OR FATAL INJURY.

1 Carry out the Power OFF Sequence.

Wait for 2 minutes. This ensures that the capacitors have discharged to a safe level.

2 Remove the Laser Head Lid.

3 Carry out an inspection of the Fibre Optic Assembly.

Check for signs of damage, overheating, loose joints or any indication that could beinterpreted as an early warning of a problem.

A damaged Fibre Optic Assembly or component must be replaced immediately.

4 Examine the Laser beam path and ensure all housings and beam sealing tubes (gaiters)are in good condition, installed correctly and are secure.

Check for any gaps or openings between the Laser path and the Beam Deliverycomponents.

WARNING

IF ANY FAILURE OR DAMAGE IS NOTED, THE LASER MUST NOT BE OPERATEDAGAIN UNTIL THE DEFECT HAS BEEN CORRECTED.

IF ANY FAILURE OR DAMAGE APPEARS TO BE A RESULT OF EXPOSURE TO THELASER BEAM, THE CAUSE MUST BE ASCERTAINED AND CORRECTEDIMMEDIATELY.

5 Check all Safety Labels are in position, secure and legible

Refer to Section 2.7.3 for label details and locations.

If any labels are missing or illegible, replacements can be obtained from GSI Lumonicsquoting the part numbers given in Section 2.7.3.




7.5 Coolant ReplenishmentPersonnel authorised to Maintenance Level 1 can carry out this procedure.

7.5.1 Materials

Parts Required Part Number

20 litres of Analar Grade 3 Water(5.5 US gallons) (based on 5m length waterpipes).

1D0M00801

Tools/Equipment Spares/Consumables

Standard Tool Kit O-Ring Kit

Door Key Paper Towels

Container - 60 litre capacity Plastic Bag

Funnel

7.5.2 Draining Procedure

Figure 7 – Coolant Draining

Refer to Figure 7 for item identification.

Step Action



Step Action

WARNING






3 Remove and retain the Vent screw to allow the Coolant to drain into the reservoir. Refitthe Vent Screw.

4 Unlock and open the right-hand Bay door.

5 Identify the Reservoir Hose (item 5). Position a container on the floor adjacent to theReservoir Hose (item 5).

6 Remove the Reservoir Hose (item 5) from the Retaining Clip (item 6). Loosen the cap(item 4). Lower the Reservoir Hose (item 5) into container.

7 Remove and retain the Reservoir Hose cap (item 4) and allow the Coolant to drain intocontainer.

8 Refer to Section 7.6 and 7.7 if the Filter and De-ioniser cartridges are to be replaced.

9 If the Coolant System is to be re-filled, refer to Section 7.5.3 for the Filling Procedure.

10 Replace the Reservoir Hose Cap (item 4).

11 Replace the Reservoir Hose (item 5) in the Retaining Clip (item 6).

12 Close and lock the right-hand Bay door.

13 Replace the Laser Head lid.




7.5.3 Filling Procedure

The Coolant level should be between the red minimum line and the green maximumline on the Coolant Level Indicator (item 2, Figure 8). If it is close to the red line,Coolant should be added.

Figure 8 – Coolant Filling




Step Action

WARNING





2 Unlock and open the right-hand bay door.

3 Refer to Section 7.6 and 7.7 if the Filter and De-ioniser cartridges are to be replaced.

4 Ensure the Reservoir Hose (item 5) is securely held in the Retaining Clip (item 6).

5 Remove the Reservoir Hose cap (item 4). Insert the funnel.

Caution

Always use new Coolant. Do not fill Laser with used Coolant as it may becontaminated.

6 Fill the Reservoir Tank with Analar Grade 3 water until level reaches the green line onthe Level Indicator (item 2).

7 Replace the Reservoir Hose cap (item 4).

8 Depress the red vent (item 1 & 3) on each cartridge to release air from the system and toprime the Pump.

9 Carry out the Power ON Sequence.

10 Allow the cooling system to run for 1 minute.


12 Inspect the pipework and fittings for any signs of leaks.

13 Rectify the cause of any leaks.

14 Check the Coolant level. Add more Coolant if necessary.

15 Wipe up any spillage with paper towels.

16 Close and lock the right-hand bay door.

17 Replace the Laser Head cover.


19 Select the Maintenance/Counters screen and reset the Water Run Time to zero.When using the Control Panel refer to Section 3.8.




7.6 Filter ReplacementPersonnel authorised to Maintenance Level 1 can carry out this procedure.


Carbon Filter 550000101



Filter Wrench Paper Towels

Door Key Plastic Bag

Figure 9 – Filter Replacement




Step Action

WARNING







4 Unlock and open the right-hand Bay door.

5 Refer to Section 7.5.2 and drain the Coolant.

6 Pull the Retaining Strap (item 10) outwards and turn it through 90 degrees.

7 Using a Filter Wrench, unscrew and remove the Filter Body (item 11).

8 Empty the Coolant from the Filter Body (item 11).

9 Remove and dispose of the Carbon Filter.

The Carbon Filter is non-hazardous and can be disposed of through normal IndustrialWaste routes.

10 Inspect the O-Ring for signs of damage. Replace if necessary.

11 Remove packaging from the new Filter.

12 Part fill the Filter Body (item 11) with Coolant.

13 Install the new Filter in Filter Body (item 11). Ensure the Filter is located correctly overthe spring on the base of the Filter Body.

14 Ensure the O-Ring is installed and serviceable.

15 Install the Filter Body (item 11). Tighten using a Filter Wrench.

16 Refer to Section 7.7 if the De-ioniser Cartridge is to be replaced.

17 Refer to Section 7.5.3 and refill the Coolant.

WARNING

ENSURE COOLER OPERATES FOR AT LEAST ONE MINUTE AND CHECK FORLEAKS BEFORE RUNNING THE LASER IN LASER ON STATUS.




7.7 De-ioniser ReplacementPersonnel authorised to Maintenance Level 1 can carry out this procedure.


De-ioniser Resin Refill M7357060X



Door Key Paper Towels

Filter Wrench Plastic Bag

Figure 10 - De-ioniser Replacement




Step Action

WARNING







4 Unlock and open the right-hand bay door.

5 Refer to Section 7.5.2 and drain the Coolant.

6 Unscrew and remove the De-ioniser Body (item 9).

7 Remove the De-ioniser cartridge from De-ioniser Body (item 9).

8 Remove and retain the rubber gasket. Inspect for signs of damage. Replace ifnecessary.

9 Inspect the O-Ring for signs of damage. Replace if necessary.

10 Unscrew, remove and retain the cartridge lid.

11 Empty used resin into a plastic bag and dispose.

Resin is non-hazardous and can be disposed of through normal Industrial Wasteroutes.

12 Wash out the cartridge until all resin is removed.

Dry the cartridge using a paper towel.

13 Open the new resin container. Tip new resin into the cartridge.

14 Install the cartridge lid. Ensure it is finger tight only.

15 Install the cartridge in the De-ioniser Body (item 9).

Ensure the spring on the base of the cartridge is correctly located over the spigot onbase of the De-ioniser Body.

16 Install the washer.

17 Ensure the O-Ring is installed and serviceable.

18 Install the De-ioniser Body (item 9).

19 Refer to Section 7.6 if the Filter Cartridge is to be replaced.

20 Refer to Section 7.5.3 and refill the Coolant.

WARNING





Intentionally blank



7.8 Flashlamp ReplacementPersonnel authorised to Maintenance Level 1 can carry out this procedure.

7.8.1 Materials


Flashlamps x 2 or complete set P55B6770B

GSI Lumonics recommends that Flashlamps are changed as a complete set or in pairs. Thiswill increase system running time.



Flashlamp handle Paper towels

Eye protection Plastic gloves.

Lint free cloth




7.8.2 Replacement Procedure

Figure 11 – Flashlamp




Step Action

WARNING



1 Carry out Power OFF Sequence.



3 Remove and retain the Vent screw (item 1) to allow the Coolant to drain into thereservoir. Refit the Vent Screw.

4 Remove and retain the 8 bolts (item 2) securing the Pumping Chamber lid (item 3).

Caution

WEAR PLASTIC GLOVES

Optical components are fragile and are easily damaged. Extreme care must betaken when handling optical components. Always handle optical components ina clean environment.

5 Lift the Pumping Chamber Lid clear of the Pumping Chamber. Tilt the PumpingChamber Lid towards rear of the Laser cabinet to prevent wetting of the Laser Rail andequipment.

6 Remove the Pumping Chamber lid. Place in a clean area.

Caution

The Flashlamps are made of glass and may splinter or shatter. Eye protectionmust be worn whilst removing the Flashlamps. Carefully remove broken glasswith tweezers or long nose pliers.

7 Exerting an even pressure, lift the Flashlamp (item 4) until it is clear of the PumpingChamber (item 5).

8 Exerting an even pressure, lift the Flashlamp (item 4) until it is clear of the PumpingChamber (item 5).

9 If the Flashlamp (item 4) has broken, carefully remove glass with tweezers or longnose pliers. Dispose of glass in suitable container.

10 Using lint free cloth, carefully dry excess water from inside the Pumping Chamber.




7.8.3 Installation Procedure

Figure 12 - Flashlamp




Step Action

WARNING



Caution

WEAR PLASTIC GLOVES.

Optical components are fragile and are easily damaged. Extreme care must betaken when handling optical components. Always handle optical components in aclean environment.

1 Ensure the Pumping Chamber (item 5) is dry.

2 Remove the new Flashlamp from packaging.

3 Carefully push the new Flashlamp (item 4) into the Flashlamp connectors.

4 Using an even pressure, push the Flashlamp (item 4) down until secure.

5 Using an even pressure, push the Flashlamp (item 4) down until secure.

6 Inspect the O-rings on the Pumping Chamber sides and verify they are intact andsecure. Replace if necessary.

Caution

Care must be taken when replacing the Pumping Chamber lid to avoid damage tothe Flashlamps, Laser Rod or ceramic Reflectors.

7 Tilt the Pumping Chamber lid towards the rear of the Laser Head to prevent wetting theLaser Rail.

Position the Pumping Chamber lid over the Pumping Chamber (item 5).

8 Lower the lid onto the Pumping Chamber (item 5).

9 Secure the Pumping Chamber lid to the Pumping Chamber (item 5) with 8 bolts (item 2).


11 Ensure the GUI is powered up and running.

12 Log on to the GUI at Access Level 3.

13 Select CONFIGURATION.

14 Select DIAGNOSIS.

15 Select ‘COOLER TO ON’.

The Coolant Pump will start.

WARNING


16 Check the Pumping Chamber for signs of leaks. If leaks are detected shut down theLaser immediately.




Step Action

17 If necessary, rectify cause of the leak. Wipe up any spillage using paper towels.

18 If the Laser was shut down in step 16, repeat step 10 to restart the Laser.

19 Ensure the GUI is powered up and running.

20 Log on to the GUI at Access Level 3.

21 Select CONFIGURATION.

22 Select MAINTENANCE.

23 Select Counters tab,Reset shot count to zero.

Select ENTER.

Respond to Screen Prompt.

The Counter will reset to zero.When using the Control Panel refer to Section 3.8.

24 Refer to Section 6 and carry out the Optimisation Procedure if required.

25 Replace the Laser Head cover..



7.9 PIPA Fibre Optic Cable ReplacementPersonnel authorised to Maintenance Level 2 can carry out this procedure.

7.9.1 Materials


PIPA Fibre Cable Refer to Section 9


Standard Tool Kit Fibre Termination Protective Cover

Digital Volt Meter Tape





Figure 13 – PIPA Fibre Cable Removal




Item Action

WARNING



1 Ensure Power is switched OFF.


CAUTION

Refer to Section 1.15– Fibre Optic Handling.

2 Pull back the Blue Protective Cover (item 1) to expose the PIPA Fibre Termination(item 2).

3 Unscrew, but do not remove, the clamping screw (item 6) to loosen the RetainingClamp.

4 Carefully and in a straight line, withdraw the PIPA Fibre Termination (item 2) from thePIPA Fibre Receiver (item 7).

5 Fit a protective cover (not illustrated) over the PIPA Fibre Termination (item 2).

6 Carefully remove the PIPA Fibre cable from the Laser Head.

7 Place a piece of tape over the exposed end of the PIPA Fibre Receiver (item 7) toprevent ingress of dirt or moisture.




7.9.3 Installation Procedure

Figure 14 - PIPA Fibre Cable Installation




Item Action

WARNING




CAUTION

Refer to Section 1.15– Fibre Optic Handling.

2 Remove the protective cover (not illustrated) from the PIPA Fibre Termination (item 2).

3 Inspect the PIPA Fibre cable for damage. Replace if necessary.

4 Ensure the O-Ring (item 4) is fitted and serviceable. Replace if necessary.

5 Pull back the blue protective Cover (item 1) from the PIPA Fibre Termination (item 2).

6 Ensure that the rear edge of the PIPA Fibre Termination (item 2) IS chamfered.

7 Ensure the Locating Pin (item 3) on the PIPA Fibre Termination (item 2) is aligned withthe Locating Hole (item 5) on the PIPA Fibre Receiver (item 7).

8 Insert the PIPA Fibre Termination (item 2) into the PIPA Fibre Receiver (item 7).

The Fibre Termination will enter the Fibre Receiver easily and then stop. Slightpressure is then required to ensure that the FCMS connectors have fully connected.The Fibre Termination is fully inserted when no aluminium on the Fibre Termination isvisible at the entrance to the Fibre Receiver.

9 Tighten the Retaining Clamp screw (item 6) to secure the PIPA Fibre Termination (item2) in the PIPA Fibre Receiver (item 7).

10 Position the blue protective Boot (item1) over the PIPA Fibre Termination (item 2).

11 Refer to Section 7.9.4 and carry out the PIPA Alignment Procedure




7.9.4 Alignment Procedure

Personnel authorised to Maintenance Level 2 can carry out this procedure.

Figure 15 – Fibre Optic Cable Alignment




Item Action

WARNING




CAUTION

Refer to Section 1.15 – Fibre Optic Handling.

2 Ensure Fibre Optic cable is fitted correctly and is serviceable.

3 Ensure that the Output end of the Fibre Optic Cable is positioned so that the laserbeam is directed into a Beam Dump. GSI Lumonics recommend using a water-cooledbeam dump (Part Number – PG037430X).

4 Connect DVM to the BNC connector on the Fibre Receiver. Set DVM to DC Voltsrange.

WARNING

THE LASER IS SWITCHED ON IN THE NEXT STEP.

WEAR GOGGLES.

ENSURE ALL SAFETY PROCEDURES ARE OBEYED.

5 Set the Demand to 0% and switch the Laser ON.

6 Set the Shutter Status to NORMAL and OPEN the Shutter.

7 The DVM should indicate approximately 350mV.

8 Loosen, but do not remove, the Locking screw on the Z Adjuster (item 9).

9 Adjust the X, Y and Z setting screws (items 9 & 10) until the DVM indicates the lowestvoltage reading.

Note There is no requirement to adjust the Z axis at low power settings as thebeam size is too small.

10 Increase the Demand by 10% increments up to approximately 50%. This will give fullpower at source, ie 600W for JK760TR. Repeat step 9 at each Demand setting.

11 When Alignment is successfully completed, set the Shutter to CLOSED, switch theLaser to OFF and carry out the Power Down sequence.

12 Tighten the Locking screw on the Z Adjuster (item 9).

13 Remove the DVM.




7.10 Cover Slide ReplacementPersonnel authorised to Maintenance Level 1 can carry out this procedure.

7.10.1 Materials

Part Required Part Number

Cover Slide 123412301



Rubber Bulb Puffer PROPAN-2-OL

Bulb Removal Tool Lint Free Tissues

Door key

Small Vacuum Cleaner


Figure 16 – Cover Slide




Step Action

WARNING




2 Remove any excess dust from the area around the Cover Slide (item 3) using a smallvacuum cleaner.

3 Remove the Retaining Spring (item 4) and Cover Slide (item 3).

Take care not to strike or damage the Focusing Head (item 1).

4 Remove the O-Ring (item 2).

5 Remove the Cover Slide (item 3) from the Retaining Spring (item 4).




7.10.3 Cleaning and Installation Procedure

Figure 17 – Cover Slide



Refer to Figure 17 for item identification

Step Action

WARNING



1 Clean the Retaining Spring (item 4) and place in a clean environment.

2 Using the Rubber Bulb Puffer, remove dust particles from the faces of the Cover Slide(item 3).

If the Cover Slide (item 3) is damaged or cannot be cleaned sufficiently, replace theCover Slide.

Caution

WEAR PLASTIC GLOVES.

Optical components are fragile and are easily damaged. Extreme care must betaken when handling optical components. Always handle optical components ina clean environment.

3 Place the Cover Slide (item 3) in a clean environment.

4 Carefully fold a lens tissue into a pad that is just slightly narrower than the Cover Slide(item 3).

5 Dampen tissue using PROPAN-2-OL (or approved cleaner).

Wipe tissue across the full area of the Cover Slide (item 3) in a single stroke.

(Do not use multiple passes as it leaves streaks on the slide).

6 Hold the Cover Slide (item 3) by the edge and wipe once more in a single straightmovement. Dispose of the pad.

If necessary, make up a new pad and repeat the process until the Cover Slide (item 3)looks clean when viewed as a mirror.

7 Check the cleanliness of the Cover Slide (item 3) again.

8 Ensure the Retaining Spring (item 4) is clean.

9 Ensure the O-Ring (item 2) is serviceable.

10 Install the Cover Slide (item 3) in the Retaining Spring (item 4).

Ensure the O-Ring (item 2) is in position on the Focusing Head (item 1).

Offer both the Cover Slide (item 3) and Retaining Spring (item 4) together to theFocusing Head (item 1).

Secure the Cover Slide (item 3) in position with the Retaining Spring (item 4).




7.11 Fuse ReplacementPersonnel authorised to Maintenance Level 1 can carry out this procedure.

7.11.1 Materials


Refer to Section 9 for Fuse part numbersand ratings

Tools/Equipment Consumables

Standard Tool Kit

Door key

Figure 18 – Fuse Replacement




Step Action

WARNING





2 Unlock and open the right hand Power Supply cabinet door.

3 Locate and remove the unserviceable fuse.

Power Fuses F101 to F111 or F114:Pull down the appropriate Link Handle to expose the fuse cartridge.Remove fuse.

Auxiliary Fuses F1101 to F1111:Remove Protective Cover.Using a flat-head screwdriver, press lightly on the fuse and turnanti-clockwise through ninety degrees to release the fuse from the fuse holder

4 Verify the fuse is unserviceable and install a serviceable fuse.

Power Fuses F101 to F111 or F114:Insert fuse cartridge into fuse holder.Push up the appropriate Link Handle until it clicks into position.

Auxiliary Fuses F1101 to F1111:Insert the fuse into the fuse holder.Using a flat-head screwdriver, press lightly on the fuse and turn clockwise through ninety degrees to secure the fuse in the fuse holderRe-install the Protective Cover.

5 Close and lock the right hand Power Supply cabinet door.




7.12 Bulb ReplacementPersonnel authorised to Maintenance Level 1 can carry out this procedure.

7.12.1 Materials


Bulb 24V 6W 640000821

Tools/Equipment Consumables

Bulb Extraction Tool

Step Action

WARNING





2 Unscrew, remove and retain the coloured outer Cover of the appropriate Lamp.

3 Remove and retain the inner Cover.

4 Using the Lamp Extraction Tool, rotate the unserviceable Bulb 900 anti-clockwise andremove.

5 Using the Lamp Extraction Tool, insert the serviceable Bulb and rotate 900 clockwise.Ensure the bulb is secured.

6 Withdraw the Lamp Extraction Tool.

7 Install the Inner Cover.

8 Install the Outer coloured Cover.



7.13 Bendlock AssemblyThe Bendlock Assembly is available for the Output Fibre Termination on PIPA Fibresused in robot applications.

7.13.1 Assembly Instructions

1. Fit the two Bendlock adaptors using the 4 M3 screws 2. Remove Locator Screw

3. Fit the 18 rings over the Fibre Termination onto the cable

4. Replace the Locator screw

5. Build up the Bendlock assembly using the split-rings, sleeve and snap ring

6. Completed bendlock assembly




Intentionally blank

GSI LumonicsJK700TR: Service and Maintenance ManualIssue 1.0 Section 8 –Spares


8. Laser Processing

8.1 OverviewSetting up a Laser process is an involved process. This section is for guidanceonly and is not intended for use without reference to Technical Instruction.

Fibre-optic beam delivery is achieved by focusing Laser light into a fibre-optic cable.The fibre optic cable is 600µm diameter on the JK760TR and 400µm diameter onthe JK745TR, JK730TR and JK715TR. The light is homogenised as it passesthrough the cable to the Focus Head.

As light exits from the fibre-optic cable, it expands into a Focus Head. Thisincorporates a re-collimating and focusing lens assembly.

A primary lens re-collimates the expanding beam from the fibre and a focusing lensfocuses the beam down to a small spot on the workpiece surface. Different spotsizes are achieved by changing the combination of recollimating and focus lensfocal lengths.

The JK700TR Laser can be fitted with a Focus Head that uses a variety ofRecollimating and Focusing Lens combinations. This provides a range of focusedLaser beam spot sizes.

Different Focus Lenses used in conjunction with a 200mm Recollimating Lens willachieve the following nominal spot sizes:

Focus Lens JK760TR SpotSize (mm)

JK745TR SpotSize (mm)



80 0.24 0.16 0.16 0.16

100 0.30 0.20 0.20 0.20

120 0.36 0.24 0.24 0.24

160 0.48 0.32 0.32 0.32

200 0.60 0.40 0.40 0.40

300 0.90 0.60 0.60 0.60

At a given demand (Mean Power), smaller spot size achieves greater intensity andhigher processing speeds. However, small spot sizes require the use of a lens witha short focal length. This means that the lens has to be positioned close to theworkpiece thus increasing risk of damage to the optics caused by fume and spattergenerated during processing. The degree of risk is dependent on the materials andtype of process being undertaken.

The use of an Air Knife positioned in front of the output housing can protect theoptics during welding operations. This consists of a jet of high velocity compressedair directed perpendicular to the beam path

GSI LumonicsJK700TR: Service and Maintenance Manual

Section 8 –Spares Issue 1.0


8.2 Jigs and FixturesControl of the material position relative to the Laser beam is achieved using Jigsand Fixtures. Good position control is essential if good quality, consistent results areto be achieved.

If flat sheet materials are to be processed, the simplest form of control is byclamping the material in a fixed plane relative to the Laser beam. Error! Referencesource not found. shows two simple arrangements, A - clamping from below and B- clamping from above.

Figure 19 – Position Control Methods

Clamping from above allows high pressures to be exerted on the workpiece andenables rapid changing of components.

Clamping from below offers the advantage of always presenting the surface of theworkpiece consistently in position with respect to the Laser beam. This method isrecommended when processing sheet materials which vary in thickness.

Experience has shown that the clamping method used should ensure that the partsto be welded are held with the joint ±0.2mm relative to the Laser beam focusposition.

2

1

2

1

3

3

4

4

5

5

A

B

GSI LumonicsJK700TR: Service and Maintenance ManualIssue 1.0 Section 8 – Spares


8.3 Shielding GasDuring welding operations, it is normally necessary to provide an inert gas shieldaround the weld to prevent oxidation.

Under normal conditions, adequate gas shielding can be provided via a pipe to theweld area around the beam/material interaction point. Gas flow should typically be10 - 20 litres/minute Argon.

Where materials such as Titanium and its alloys require processing with zerocontamination, it is necessary to employ a more sophisticated gas delivery system.

Using a Gas Shoe will achieve the conditions required to process materials withoutcontamination. This device provides an inert atmosphere not only in the region ofthe molten weld puddle but also to the solidified weld as it cools. Slightly more gasflow is required when using the gas shoe, typically 30 - 50 litres/minute Argon.

Processing materials such as Stainless Steel, Aluminium and Titanium may requireinert gas shielding to the Weld Underbead during full penetration welding. A veryeffective method is to introduce a channel flooded with inert gas underneath theweld. A gas inlet at one end of the channel and an outlet at the other is one methodof maintaining a constant stream of gas along the underbead. The gas outlet shouldbe slightly constricted to help retain the gas at the underbead but not to causeexcessive pressure. Excessive pressure causes concavity of the Underbead orblows holes in the weld. Flow rates should typically be 2 - 5 litres / minute.

The absence of gas shielding when welding thin sheet mild steel (< 0.3 mm) maynot adversely affect the properties of the weld and will, in general, allow welds to beproduced at higher speeds and with greater penetration.

For most welding applications, Argon is efficient and cheap. The use of Helium as ashielding gas is not normally necessary. However, the use of Helium when weldingAluminium alloys is a significant benefit as it offers improved process stability. Thisresults in a smoother top bead and allows greater penetration to be achieved.

The table below gives details of Gas Shielding requirements and the recommendedShielding Gas.

Material Gas Shielding Requirements Recommended Gas

Mild steel 0 -3.0 mm Gas shielding not always necessary Argon

Steel > 3.0 mm Gas shielding recommended Argon

Stainless steel andnickel alloys

Gas shielding recommended Argon

Aluminium alloys Gas shielding essential Argon/Helium

Titanium alloys Gas shielding essential Argon

Copper alloys Gas shielding may prevent effectivecoupling of the beam into workpiece




8.4 Fume and Spatter ControlDuring welding operations it is normally necessary to prevent spatter and fume fromimpacting and accumulating on the Cover Slide that protects the Focusing Lens.

Fume and spatter control is easily achieved by use of a Crossjet. This is a highvelocity compressed air jet, directed perpendicular to the beam path, in front of theFocus Head between the Cover Slide and the workpiece.

If a Crossjet is used, care must be taken to locate it in a position where the airflowdoes not disrupt the gas shielding.

8.5 Material WeldingLaser welding is a highly controllable fusion welding process. This process can beused to weld all metallic materials that are weldable using conventional weldingprocesses.

Materials welded using high power Lasers are as follows:

Material Information

Zinc-coatedautomotive steel

Generally weldable with coating thickness up to 15µm/side if a joint gapis introduced to allow vaporising zinc to escape.

Carbon and Carbon-Manganese steels

Readily weldable up to 3mm without gas shield and in greater thicknesswith gas shield. May encounter cracking in steels with high Carboncontent.

Stainless steel andNickel-based alloys

Readily weldable with good gas shield. Cleaning and degreasing priorto welding often necessary.

Titanium andTitanium alloys

Readily weldable but requires excellent gas shielding

Aluminium andAluminium alloys

Pure and lean alloys are readily weldable with good gas shielding. 5000and 6000 series alloys may require filler wire in addition to overcomecracking.

Copper and Copperalloys

Generally weldable although combination of high reflectivity andthermal conductivity can cause problems. Bismuth- and alloyscontaining Lead can crack.

Some highly reflective materials can be difficult to weld because the majority of theLaser beam is reflected from the material surface preventing heating and melting.This is the case with Gold, Silver, their alloys and with some Copper alloys.

With all materials, it is important that surfaces to be welded are free of oxidation, oil,grease, cutting fluid etc. Contamination of this kind is likely to result in porosity andother defects in the weld. Appropriate cleaning procedures must be applied toremove contamination from surfaces to be welded.



8.6 Cutting FixturesControl of the material position relative to the Laser beam is achieved using Jigsand Fixtures. Good position control is essential if good quality, consistent results areto be achieved.

If flat sheet materials are to be processed, the simplest form of control is byclamping the material in a fixed plane relative to the Laser beam. Refer to Error!Reference source not found. which shows two simple arrangements, clampingfrom above or below.

Experience has shown that the clamping method used should ensure that the partsto be welded are held with the joint ±0.5mm relative to the Laser beam focusposition.

8.7 Cutting Assist GasThe co-axial assist gas used in Laser cutting facilitates removal of molten materialfrom the cut.

Both Air and Oxygen are used in Laser cutting and contribute additional heat duringthe cutting of steels. This is due to an exothermic reaction that occurs between theOxygen in the assist gas and the Iron in the steel. This additional heat increasesboth cutting depth and cutting speed.

Oxygen bearing assist gas pressure is required to be optimised to achieve bestresults.

Excessive pressure can produce uncontrolled burning of the cut edge. This mayresult in a cut of varying width.

Insufficient pressure may lead to failure to cut through the material and possiblenozzle blockage or optic damage.

A good starting pressure for cutting with Air or Oxygen assist gas is 3-5 bar(measured close to the nozzle).

Gases with high Oxygen purity can offer an increase in performance of between 10and 20%; however the benefits of increased performance must be balanced againstthe corresponding increase in the cost of the gas.

8.8 Inert Assist GasesInert gases such as Argon or Nitrogen can be used as assist gases during cutting.Unlike Oxygen-bearing gases, they do not contribute additional heat to the process.Their use is primarily to assist in the removal of molten material and preventoxidation of the cut faces. This is important for applications where the cut faces areto be welded subsequently without the need for further edge preparation andcleaning.

At very high pressures, e.g. ~15bar, cuts free from dross can be produced whichrequire no further cleaning. Careful optimisation of gas pressure and cutting speedis required to achieve this condition. It is essential to ensure that the cutting nozzleand gas system are adequate to handle such high pressures safely.




8.9 Process Preparation

8.9.1 Choice of Focused Spot Size

High welding and cutting speed is normally desirable from a productivity viewpointbut, in some applications, the use of short focal length lenses to achieve highspeeds can present problems.

The following factors need to be considered when choosing focused spot size:

8.9.2 Part/Focus Position

The process tolerance to variations in Laser focus point is a function of the depth offocus, i.e. the distance above and below the actual focus position over which thefocused spot diameter is approximately constant. The depth of focus is proportionalto lens focal length. If the position of the part is within the depth of focus, theprocess will be consistent and reproducible.

If parts cannot be positioned accurately relative to the focus position of the beambecause, for example, part to part dimensional variations are significant or lowaccuracy work handling is used, then it may be necessary to use a longer focallength focusing lens. This will increase process tolerance but will limit maximumprocessing speed.

8.9.3 Weld Shape, Cut Width and Joint Strength

Processing using small focused spot size at high speed results in production ofnarrow welds or cuts of small cross-sectional area.

When welding, this increases the need to ensure accurate alignment of the joint tobe welded and the focused Laser beam. If this is difficult, for example because ofpart to part variations or low accuracy work handling, a larger spot size may benecessary resulting in production of a wider weld. This allows a greater tolerance toalignment of the focused beam with the joint.

When cutting this produces a narrow cut (or kerf) which increases the need toensure accurate focused Laser beam alignment with the desired cut path. A widercut, produced using a larger focused spot size, may be more tolerant to partalignment.

Additionally, producing a narrow cut can present problems as scrap material, forexample circular slug resulting from cutting a circular aperture, may not drop cleanlyaway because of limited clearance. A wider cut, produced using a larger focusedspot size, would increase clearance and improve the chances of scrap partsdropping away cleanly.

With overlap and overlap T-welds, the production of a narrow weld results in limitedweld width at the joint interface. For structural overlap welds, it is normallynecessary for weld width at the interface to be greater than the material thickness.To produce a weld of suitable width, a larger focused spot size may be required atthe expense of welding speed.

8.9.4 Cover Slide Damage

The use of a short focal length lens is not advisable when welding or cuttingmaterials that generate high levels of fume and spatter. Fume and spatter canimpinge on the Cover Slide below the Focusing Lens and cause a reduction in



Laser beam transmission through it. Eventually this will result in overheating andfracture of the Cover Slide and possible irreparable damage to the Focusing Lens.

Materials that may generate high levels of fume and spatter are Zinc coated steelsand some high Magnesium content Aluminium alloys.

8.9.5 Processing Access

Processing access is affected by the choice of focusing lens focal length. The Laserbeam diameter after it has passed through the Recollimating Lens in the FocusHead is constant; however a short focal length Focusing Lens results in greaterfocused beam cone angle than a long focal length Focusing Lens

The greater cone angle can limit beam access that could be a problem when, forexample, welding in the bottom of a groove or between closely packed tubes. Insuch cases, it may be necessary to use a longer focal length focusing lens thatresults in a smaller cone angle.

8.9.6 Finding Focus

Nearly all welding and cutting is carried out with the Laser beam focused on thematerial surface. Before setting up a new process, it is important to know theaccuracy of the focus beam position.

The focus beam position is a fixed distance from the end of the Focus Head, i.e. thecover slide position.

Refer to Section 6.3 for details.




8.9.7 Welding

8.9.7.1 Gas ShieldingWhen preparing a welding process, it is important to establish a gas shield/gas flowrate that achieves effective shielding and is reliable for production use. Care insetting up gas shielding at this point can prevent time consuming and costlyproblems before production welding starts.

Because of the wide range of materials/components and different End Userrequirements, there are few rules that apply to setting up effective gas shielding.

However, the following points should be considered when setting up gas shielding:

• Turn on shielding gas on prior to initiating a weld in order to purge the gasdelivery system and displace air from the weld region.

• A pipe fitted to deliver shielding gas to the weld must be positioned ahead of thewelding point and arranged to direct shielding gas at the point of beam / materialinteraction. Pipe to be angled at ~45º to the surface of the part being welded

• The distance from the end of the pipe to the beam material interaction point mustbe far enough to prevent the pipe being damaged by heat from the process butclose enough to ensure good coverage of the weld. Normally, a distance of 10-20mm is suitable.

• Gas flow rate should be adjusted to the minimum value necessary to achieve therequired shielding effect. Normally the requirement is to prevent visible oxidationof the surface, i.e. to produce a bright, shiny weld topbead. This is achievablewith flow rates of 10-20 litres/minute when using a pipe or 30-50 litres/minutewhen using a Gas Shoe.

• Ineffective shielding does not necessarily indicate insufficient gas flow rate.Excessive gas flow rate can cause turbulence in the weld area and result inentrapment of air that leads to oxidation.

• When a weld is terminated, it may be necessary to stop the workpiece or FocusHead motion and continue the supply of shielding gas for a few seconds toprevent oxidation of the hot solidified metal at the weld termination point.

• Care must be taken to prevent interaction between the Air Knife, used to protectthe Cover Slide from fume and spatter, and the flow of shielding gas.

• Many variables influence the effectiveness of gas shielding. Take note of allaspects of successful set-ups so that they can be reproduced if necessary.



8.9.7.2 CrossjetsIt is important to set up a Crossjet that prevents fume and spatter impinging on theCover Slide.

It is normally sufficient to use a Crossjet positioned to blow a high velocity jet of airacross the gap between the Cover Slide and the workpiece.

When setting up a crossjet, the following points should be considered:

• Some materials produce more fume and spatter than others. Materials thatproduce a lot of fume and spatter for example, Zinc-coated steels and someAluminium alloys, warrant additional attention on setting up a Crossjet.

• The optimum Crossjet position between the workpiece and The Cover Sliderequires investigation for each welding task. If the Crossjet is placed too close tothe workpiece, the jet of air can interact with the flow of shielding gas and reduceshielding effectiveness. If it is placed too close to the Cover Slide, the crossjetmay be ineffective in preventing fume and spatter hitting the Cover Slide.

• The optimum rate of airflow for Crossjet use requires investigation for eachwelding task. If the rate is too low, the Crossjet will be ineffective. If the rate is toohigh, an excessive volume of air will be used and the process will become verynoisy.

• The Crossjet should be positioned so deflected fume and spatter is not blownonto other equipment in the workstation.

• The Crossjet air supply must be switched on prior to initiation of welding to allowsteady state flow conditions to be achieved. Crossjet air supply must be leftrunning for a period after weld termination. This prevents fume in the atmospherefrom being deposited on to the Cover Slide.

• The air supplied to the Air Knife is to be clean and free from moisture and oil.




8.9.7.3 Part Fit-upLaser welding is a high precision fusion welding process that is often carried outwithout material addition in the form of wire, powder and shim.

This means that the parts to be Laser welded have to fit closely together to achievesuccessful welds.

Generally, parts should fit together so that any gap remaining between them is lessthan10% of the thickness of the thinnest material being welded. If greater gaps existthan it is likely that the weld produced in an overlap configuration will exhibitundercut (a concave underbead and/or topbead, see Error! Reference source notfound.). It is possible that with inadequate fit-up the Laser beam will melt the topand bottom plates in a lap joint but fail to join them together. It is possible that, in abutt weld, no weld will be produced as the focused Laser beam will pass through thejoint gap without melting the material.

Figure 20 – Undercut Overlap Weld

It is important when setting up a new process to ensure that the parts to be weldedhave a dimensional accuracy suitable to ensure good fit-up and that the fixing ofparts into the jigs is accurate.



8.9.8 Cutting

8.9.8.1 Nozzle Set-upThe quality of cut, ultimate cutting speed and consistency of cutting performance indifferent cutting directions are all dependent on the positioning of the cutting nozzlerelative to the Laser beam focus and the workpiece surface.

When setting up for Laser cutting, the following points should be considered:

• Optimum results will be achieved with the beam accurately positioned to passcentrally down the nozzle and to exit the nozzle aperture concentrically. Nozzleposition should be adjusted to achieve this.

• The optimum position of the Laser beam focus below the nozzle is dependent onmaterial type and thickness, assist gas type and pressure and cut qualityrequirements. For most cutting tasks, the Laser beam focus position should be~1mm below the end of the nozzle. The workpiece should be positionedcoincident with the Laser beam focus position. (The distance between the end ofthe nozzle and the workpiece is termed Stand-off).

• Cutting performance is highly dependent on cutting nozzle condition. Nozzlesdamaged by workpiece contact, contamination or overheating due to beamclipping should be replaced.

8.9.8.2 Assist GasCut quality and cutting speed are dependent on gas type and pressure

When setting up a cutting process, the following points should be considered:

• If using Oxygen gas assist, great care must be taken to optimise gas pressure toachieve high cut speed and quality. Optimum pressure is dependent on materialtype and thickness, nozzle outlet diameter, and Stand-off. For most cutting tasksin steel and stainless steel, gas pressure is ~4 bar.

• If using inert gas assist, it may be necessary to cut with the Laser beam focusposition below the material surface to produce a cut with minimum taper. In thiscase, the nozzle position will require adjustment to maintain a ~1mm Stand-off.

• If using inert gas assist, great care must be taken to optimise gas pressure toachieve good cut quality free from oxidation. Optimum pressure is dependent onmaterial type and thickness, nozzle outlet diameter and Stand-off. For mostcutting tasks, the gas pressure is ~8 bar, although the use of significantly higherpressures may be needed if cuts free from dross are required.

• Switch on assist gas prior to commencement of cutting to allow purging of thegas delivery system and establish steady state flow conditions.




8.10 Optimisation

8.10.1 Use of Ramp Up and Ramp Down

Optimisation of Ramp Up and Ramp Down is important in welding applicationswhere weld initiation and termination points form an integral part of the weldedcomponent and must be free of defects and/or of good surface appearance

Ramp Up time is defined in the Parameter Set Table (refer to Section 4.8.4.1) andsets the time for the Laser to reach the set Laser power output when switched ONfrom READY. When welding, the Ramp Up feature can be used to increase weldpenetration in a controlled manner at the start of the welding to fade in the weldsmoothly.

Ramp Down time sets the time for the Laser to reach zero when switched from ONto READY. When welding, the Ramp Down feature can be used to decrease weldpenetration gradually in a controlled manner at the end of welding to fade out theweld smoothly. The Ramp Down facility is used when welds are made in circularcomponents to ensure smooth fade out in the area of weld overlap.

Optimum settings depend on material type and thickness, welding power and speedand other processing parameters as well as the precise quality and appearancerequirements of the finished component.

Optimum settings are best defined by conducting structured processing trials atdifferent Ramp Up and Ramp Down times on representative components.

8.11 Record KeepingEstablishing a Laser process for use in a production welding or cutting applicationrequires many parameters to be set and adjusted. The goal is to develop anoptimised and tolerant process that will prove reliable in use and allow the speedand quality benefits offered by Laser processing to be realised.

In order for such a process to be established and to ensure it can be repeated, it isimportant that accurate process records are kept and maintained.



9. SparesThe complete Spares List is annotated on the following pages.

The Spares List is divided into major assemblies and the Figures have been annotatedwith these assemblies. Sub-assemblies and components are annotated in the Serviceand Maintenance Manual.

Please contact GSI Lumonics for further details or for ordering Spares.

GSI LumonicsJK700TR: User ManualIssue 1.0 Section 9 – Spares


Laser Head

Location Item Description Part No. MaintenanceLevel

Laser head Prism JK700TR Prism Assy COMPLETE PA036720X

PumpingChamber JK700TR P/C COMPLETE(rev 5) PA038610X

JK700TR P/C COMPLETE(rev 6) PA038520X

Rod Assy SINGLE Not Available

Flow Tube SINGLE Not Available

Ceramic SINGLE Not Available

Flashlamp SINGLE P55B6770B

Flashlamp terminal SINGLE M61R9540X

Manifold Assy JK700TR MA040480X

PC Baseplate Assy JK700TR MA040470X

Trigger Transformer E60E7071B

F/M & R/M Front & Rear Mirror Assy COMPLETE PA036630X

Turning Mirrors 100% T/M & Backing Plate SINGLE P62B6280A

Adjustable Mirror Mount Assy SINGLE PC036610X

Energy Monitor Energy Monitor Assy COMPLETE PH036800X

Photo diode Assy EH111970X

En. Mon. Splitter & Mount Assy PA040300K

JK700TR En. Mon. Filter Calibration PA040310K

Process Shutter Process Shutter Assy COMPLETE PG038480X

Thermal Fuse Assy M68B4210A

Process Shutter Terminal PCB Assy M68B6670B

Proximity Switch Assy E68C7590B

Shutter arm+solenoid+mirror Assy P68B6630A

Beam Dump Window 12210210A

Laser head Process Shutter Dump body elbow water fittings MG040540X

Heat sink cone M6893791B

Conditioning Lens Conditioning Lens Assy COMPLETE PC038500C

Conditioning Lens ONLY 1231064YA

Pointing Diode Pointing Diode Assy COMPLETE Not available

Pointing diode replacement Not available

Pointing diode periscope Not available

Pointing diode gaiters Not available

BET BET Assy (MECH. ITEMS ONLY) M70J4070D

BET lens set P43D8820X

BET YAG window 12210140A

Safety Shutter Safety Shutter Terminal PCB Assy E68C4520B

Thermal fuse Assy M68D2330A

Shutter arm+solenoid M68D2290C

Proximity Switch 19P100101




Gaitering JK700TR Gaiters Twin Lamp + DiodeCOMPLETE MA040350K

JK700TR Gaiters Twin LampCOMPLETE

MA040360K

JK700TR Gaiters Single Lamp + DiodeCOMPLETE MA040330K

JK700TR Gaiters Single LampCOMPLETE MA040340K

P/C gaiters (PTFE) x2 MA040530X

Process Shutter Input gaiter (PTFE) MA038231B

Gaitering Process Shutter Output gaiters x3 MA040520X

Conditioning lens Output gaiters x1 MA040500X

BET Output gaiter MA040510X

Laser Head End Laser Head Electronics PCB E60C0590C

Laser Head Trigger PCB E60E4320C

Fibre Receivers PIPA Adapter Plate MC033631B

PIPA adapter plate (E/S & T/S) PC037800X

PIPA Fibre Receiver (SINGLE) ML034360X

PIPA Fibre Focus lens Housing MC035790X

JK700TR Fibre Input Lens cellCOMPLETE PC038840X

JK700TR Fibre Input Lens ONLY 1231213YA

Temperature Switch 19A128001


Section 9 – Spares Issue 1.0


User Interface

Location Item Description Part No. Maintenance.Level

User Interface Control Panel(STD)

Control Panel EMC (ENGLISH)COMPLETE E84X9400X

Control Panel EMC (GERMAN)COMPLETE

E84X9401X

Control Panel EMC (DUTCH)COMPLETE

E84X9402X

Control Panel EMC (FRENCH)COMPLETE E84X9403X

Control Panel EMC (ITALIAN)COMPLETE E84X9404X

Control Panel EMC (SWEDISH)COMPLETE E84X9405X

Control Panel EMC (SPANISH)COMPLETE E84X9406X

Control Panel Conduit EMC 1m E84X9450X

Control Panel Conduit EMC 2.5m E84X9460X





Control Panel PCB Sub Assy E84A7180C

LCD display module Assy E84X2540X

Emergency Stop 195G00001

Control Panel Keys E84C5500A

GUI (OPTION) GUI Assy COMPLETE (Podium) EK112810X

GUI Assy COMPLETE (19" Rack) EM112580X

GUI Assy COMPLETE (PC Box) EM112590X

Densitron Panel (No software!!!) 230006041

GUI wiring adapter EM112610X

GUI conduit 10m EM112320X


User Interface GUI (OPTION) GUI conduit 30m EM112360X




Power Supply Unit


Power SupplyUnit

MicroprocessorUnit Micro Module Assy COMPLETE EJ105730X

Micro Mod Transformer Assy JK700TR E84C0440C

Micro Mod PSU Assy EJ109110X

Motherboard Assy E84A9980D

Interface PCB Assy E84C0460D

CNC Interface PCB Assy E85E7820C

CNC Interface Configuration IC +Jumpers E85C6560B

Microprocessor Card Assy E84E3040C

Control EPROM JK760TR EK113870X




Control EPROM JK760TR-B EK113910X




DistributionModule Distribution Module Assy COMPLETE EK107900X

Fuse & Connector Card Assy E84A3330D

Single Phase Transformer E84G3531D

E/Stop unit (Rear) 1GSC10101

24Vdc Relay Plug-In (Rear) 1G0C00601

Thermal Overload Relay 1G6600201

48V Contactor 1G5300501

Temp Switch (70 C) 19A100101

Power SupplyUnit

DistributionModule Auto Transformer E84A2951D

390R Resistor 1388J4390

Trans/OutputModule Trans/Output Module COMPLETE E84X3720X

3 Phase Transformer E84A2731D

Simmer Supply Card Assy E84A2360B

Dump Resistor Card Assy E84X3771C

Heatsink Assy - O/P Module E84X4630X

Diode Avch 1.2KV 80A SA 14AK70010

Diode Avch 1KV 9.5A SA 14AJ40010

Contactor 3N/O 40A 48V 1G5300011

Contactor Auxillary Block 1N/O 1GM000701

Snubber Assy E84Z5350X

Resistor 4K7 100W 138DJ5471

Thermal Overload Relay 1G6600101





Capacitor Elect. 1000uF 450V 1054N1011

PC Caps Card Assy E84A2290B

Resistor 12R 100W 138DJ3121

3PH Diode Bridge 1.2KV 60A 146K70001

Shunt 30A 620001201

Resistor 100R 100W 138DJ4101

Switching Module Switching Module JK700TR (IGBT)COMPLETE

EK109500X

Capacitor Elect AL 3300uF 450 Not available

Capacitor 40uF 450V Not available

Transfoshunt Not available

Error Amp/IGBT Drive PCB Assy Not available

Power SupplyUnit Water Cooler Water Cooler JK700TR Series

COMPLETE MF019660X

Float Switch Assy JK700TR M64D8790C

Water Valve 540000100

Filter & DI Assy M6462050C

Flow Switch Transducer 530000501

Heat Exchanger 520000201

Pump Assy E64Z5380K

Temperature Switch 50 C 19A100201

Resin Container 550000111

Deioniser Resin Refill M7357060X

Carbon Filter 550000101

Air cooler Air Cooler JK700TR SeriesCOMPLETE M64D3540D

Water Valve 540000100

Air Blower Unit 300W 460000501

Heat Exchanger M64B1951C



Beam Delivery


Beam Delivery PIPA Fibre 5m x 1000µm PA035110X

10m x 1000µm PA039750X

15m x 1000µm PA035120X

30m x 1000µm PA035130X

50m x 1000µm PA035140X

5m x 600µm PA035160X

10m x 600µm PA039740X

15m x 600µm PA034280X

30m x 600µm PA034290X

50m x 600µm PA034300X

5m x 400µm PA035150X

10m x 400µm PA039730X

15m x 400µm PA034250X

30m x 400µm PA034260X

50m x 400µm PA034270X

PIPA Focus Head, Straight, 57mm Dia./120mm Recoll PL039810X

Straight, 57mm Dia./160mm Recoll PL035470X

Straight, 57mm Dia./200mm Recoll PL034410X

Right Angle 57mm Dia./120mm Recoll+ CCTV PL039830X

Right Angle 57mm Dia. 160mm Recoll+ CCTV PL036490X

Right Angle 57mm Dia. 200mm Recoll+ CCTV PL037100X

Right Angle 57mm Dia. 120mm Recoll PL039820X



Cutting Head Right Angle Auto Focus 655435-002

Beam Delivery Cutting Head Straight Auto Focus 655434-001




Hardware


Hardware Ancillaries focus lens 80mm x 50 dia 1231060YA

focus lens 100mm x 50 dia 1231059YA

focus lens 120mm x 50 dia 123108401




Time Share Module - SINGLE P44H4460C

E/S + T/S Mirror 100%R 1222045GA

A/R cover slide 1234123YA

Uncoated cover slide 123412301

Gas nozzle assy 80mm P44H6510C

Gas nozzle assy 120mm P44L0580C

copper tip M62H6521B

PTFE tip M65H2001B

Crossjet nozzle 100mm P59W9380X

Crossjet nozzle 120mm P59W9370X

PIPA Fibre Bendlock Assy ML036240X



Consumables

Item Description Part No.

Spare Fuse Set TBA

O-Ring Set TBA

Spare Bulb Set TBA

Safety Labels TBA




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