UltraPulse 5000

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ULTRAPULSE® SERIES
(Models 3000, 4000, 5000, 3000L & 5000L)
&
EXCELASE™ SERIES
(Models 1000, 2000 & 3000)
SERVICE MANUAL
This service manual is to be used in conjunction with the operator manual for the
product. The operator manual contains important information regarding instrument
description, location of controls, specifications, and normal operating procedures.
DANGER
VISIBLE AND INVISIBLE LASER RADIATION.
AVOID EYE OR SKIN EXPOSURE TO
DIRECT OR SCATTERED RADIATION.
CARBON DIOXIDE LASER
* 150 WATTS MAX CW
HELIUM NEON LASERS
11 MILLIWATTS MAX CW
* PRA CTICAL LIMIT CLASS IV LASER PRODUCT
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2400 Condensa Street

Santa Clara, CA 95051
(408) 764-3000
0616-629-01
FEBRUARY 97
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This manual is copyrighted with all rights reserved. Under the copyright laws, this manual can not be copied
in whole or part without the express written permission of Coherent, Inc. Permitted copies must carry the
same proprietary and copyright notices as were affixed to the original.
Please note that while every effort has been made to ensure that the data given is accurate, the information,
figures, illustrations, tables, specifications, and schematics are subject to change without notice.
Coherent, the Coherent Logo, and UltraPulse are registered trademarks of Coherent Inc.
Please direct all inquiries about this manual to:
Coherent, Inc.
Technical Support B-35
2400 Condensa Street
Santa Clara, CA 95051
(408) 764-3638
© Coherent Inc. 06/91, 11/94, 06/95, 02/97

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DISCLAIMER
Coherent service manuals are written specifically for use by Coherent service engineers who have received
formal training in the servicing of Coherent equipment, and by customers who have taken and passed a
Coherent certification service training course for the equipment being serviced. Information on certification
service training courses offered to customers can be obtained by contacting the Technical Training Coordina-
tor at 800-367-7899.
Coherent does not accept responsibility for personal injury or property damage resulting from the servicing
of Coherent equipment by its customers or by third parties, except where such injury or property damage is a
direct result of Coherent's negligence. Customers, by accepting the service manual, agree to indemnify
Coherent against any claims alleging personal injury or property damage resulting from the servicing of
Coherent equipment by the customer or by third parties, except where such injury or property damage is a
direct result of Coherent's negligence. These limitations include situations where Coherent personnel are
advising customers on the repair of Coherent equipment over the telephone.
The servicing of Coherent equipment by persons who have not passed a current Coherent certification
service training course for that equipment will void Coherent's product warranty.
UltraPulse Service Manual Disclaimer 0616-629-01 02/97

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REVISION INFORMATION
This is the FEB 97 release of the UltraPulse Service Manual. Contact Coherent Medical Group Technical
Support to determine if this is the most current release of this service manual.
Each page of this manual has a MM/YY date at the bottom. This indicates the release date for the individual
page. Note that when the manual is updated, not all of the pages are necessarily updated, so some pages
may have a MM/YY earlier than the release date for the manual (the release date for the manual is the MM/
YY that appears on the cover and in the first sentence of this revision information page). The following list
provides a complete list of the release date information, by section, for this release of the Service Manual.
Cover page, copyright page, disclaimer page, this page, table of contents page or pages are all dated with the
release date of the manual (02/97).
SECTION 1 All pages, 08/94
SECTION 5 Pages 5-10, 11, 02/97

All other pages, 08/94
SECTION 7 FSB’s released for this service manual are listed in the Ultrapulse FSB Index.
Each time an FSB for this manual is released or updated the Index is also
updated and distributed with the FSB. The current Index is placed behind
the single sheet that makes up Section 7, and the FSB’s are placed in order
behind the Index. Contact Coherent Medical Group Technical Support for
the date of the most current FSB Index.
SECTION 8 Pages 8-1, 06/95

Pages 8-2, Thru 8-28, 08/94
Pages 8-29, Thru 8-37, 06/95
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Table Of Contents
DISCLAIMER .................................................................................................................................................. 3
REVISION INFORMATION ........................................................................................................................ 4
TABLE OF CONTENTS ................................................................................................................................. 5
1.0 GENERAL INFORMATION ............................................................................................................... 1
1.1 USE OF THIS MANUAL ..................................................................................................................... 1
1.2 CONVENTIONS USED IN THIS MANUAL .................................................................................. 1
1.3 SYSTEM DIFFERENCES ..................................................................................................................... 1
1.4 DELIVERY SYSTEMS .......................................................................................................................... 2
2.0 INSTALLATION .................................................................................................................................... 1
2.1 INSTALLATION INSTRUCTIONS .................................................................................................. 1
3.1 INTRODUCTION ................................................................................................................................. 1
3.1.1 Overview of the Procedures ................................................................................................................. 1
3.1.2 SAFETY PRECAUTIONS .................................................................................................................... 2
3.2 OPTICAL CHECK OUT ....................................................................................................................... 3
3.3 OPTICAL ALIGNMENT ...................................................................................................................... 7
3.4 THERMOPILE CENTERING, DETECTOR AMPLIFIER GAIN, & LOOP GAIN ADJUST-
MENTS ...................................................................................................................................................... 11
3.5 POWER CALIBRATION ................................................................................................................... 13
3.6 TEMPERATURE SENSE CALIBRATION ...................................................................................... 14
3.7 SAFETY AND OPERATIONAL CHECK OUT .............................................................................. 14
4.0 THEORY OF OPERATION .................................................................................................................. 1
4.1 INTRODUCTION ................................................................................................................................ 1
4.1.1 Operational Overview .......................................................................................................................... 1
4.1.2 Functional Overview ............................................................................................................................ 2
4.2 POWER DISTRIBUTION .................................................................................................................... 5
4.2.1 AC input and conditioning ................................................................................................................. 5
4.2.2 Circuit breaker on, key switch off ..................................................................................................... 5
4.2.3 KEY SWITCH ON ................................................................................................................................ 6
4.2.4 Turn off/shutdown ................................................................................................................................ 7
4.2.5 48 VDC Supply ..................................................................................................................................... 7
4.3 COOLING .............................................................................................................................................. 8
4.4 CONTROL ELECTRONICS ............................................................................................................... 9
4.4.1 Microprocessor and associated circuits .......................................................................................... 10
4.4.2 EPROM, RAM, and NVRAM ........................................................................................................... 11
4.4.3 D/A conversion circuits ...................................................................................................................... 11
4.4.4 A/D conversion circuits ..................................................................................................................... 11
4.4.5 Digital I/O circuits .............................................................................................................................. 12
4.4.6 Timer circuits ....................................................................................................................................... 18
4.4.6.1 Heartbeat timer .................................................................................................................................. 18
4.4.6.2 RF drive enable circuit ...................................................................................................................... 18
4.4.7 Power measuring and power seek circuits ................................................................................... 20
4.4.8 Control Panel ....................................................................................................................................... 22
4.4.9 Auxiliary Control Panel ..................................................................................................................... 22
4.4.10 Mast Display ........................................................................................................................................ 23
4.4.11 Safety Circuit & Audible Indicator ................................................................................................. 23
4.5 RF EXCITER & TUBE ........................................................................................................................ 24
4.6 OPTICS ................................................................................................................................................. 25
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4.7 SOFTWARE .......................................................................................................................................... 26

5.0 TROUBLESHOOTING & REPAIR .................................................................................................... 1
5.1 OVERVIEW ............................................................................................................................................. 1
5.1.1 Service Philosophy ................................................................................................................................ 1
5.1.2 Safety Precautions ................................................................................................................................. 2
5.2 INTERIOR ACCESS ............................................................................................................................. 3
5.3 FAULT ISOLATION .............................................................................................................................. 7
5.3.1 Turn on/shutdown problems ............................................................................................................... 8
5.3.2 "No Fault Code Reported" fault isolation ........................................................................................ 8
5.3.3 Fault Codes ............................................................................................................................................ 8
5.4 CHANGE NOTES ............................................................................................................................... 13
5.5 TEST POINTS ...................................................................................................................................... 14
5.6 PERIODIC MAINTENANCE REQUIREMENTS ........................................................................ 15
5.7 CLEANING OPTICS .......................................................................................................................... 16
6.0 PARTS LIST ............................................................................................................................................ 1
SPECIAL TOOLS ............................................................................................................................................. 1
MAJOR SUB ASSEMBLIES .......................................................................................................................... 1
ELECTRICAL COMPONENTS .................................................................................................................... 2
SOFTWARE ...................................................................................................................................................... 2
PRINTED CIRCUIT BOARDS ..................................................................................................................... 3
INTEGRATED CIRCUITS ............................................................................................................................. 4
FRAME, MAST ................................................................................................................................................ 5
COOLING SYSTEM ....................................................................................................................................... 5
OPTICS .............................................................................................................................................................. 5
8.0 SCHEMATICS & DRAWINGS ............................................................................................................... 1
8.1 LIST OF SCHEMATICS: ......................................................................................................................... 1
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1.0 GENERAL INFORMATION
1.1 USE OF THIS MANUAL
This manual contains service instructions for the Coherent UltraPulse® 3000, 4000, 5000, 3000L and 5000L CO2
laser systems and the Excelase™ 1000, 2000 and 3000 CO2 laser systems. The information in this manual is
intended for use by Coherent service engineers, or by customer technicians who have successfully completed
a Coherent service course on these products. Coherent can not be responsible for service or repairs attempted
by unauthorized persons, and the use or copying of this manual by same is prohibited.
These service instructions are to be used in conjunction with the applicable Coherent operator manuals. The
operator manuals contain important information regarding instrument description, location of controls,
specifications, and normal operating procedures.
As required, Coherent Medical Group Service Department releases Field Service Bulletins to update this
manual. The manual is not complete unless it includes all released service bulletins.
1.2 CONVENTIONS USED IN THIS MANUAL
The schematics in this manual do not always include individual designations for the logic elements or
operational amplifiers within a single component. Individual logic elements/amplifiers will be referred to by
component number and output pin(s), in the format Ux-p, where "x" is the component number, and "p" is the
pin number of the output pin of the element within the component. For example, U11-4 is the logic element
within U11 with an output at pin 4.
Logic signals which are "notted" are indicated by slashes, e.g., /RD/, is the logic name of the "read" signal
which is active in the low logic state.
1.3 SYSTEM DIFFERENCES
The UltraPulse product line includes the following models:
The "L" models, manufactured to provide optimum performance through a laparoscope. The laser
tube uses a carbon isotope to provide 11.1µm output instead of the standard CO2 10.6 µm. The 11.1
µm wavelength is less absorbed/reflected by the gas used to to inflate the chest cavity (insufflation).
This minimizes the thermal blooming that typically restricts the use of conventional wavelength CO2
systems through a laparoscope (especially at higher average powers).
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The 3000L provides a maximum pulse energy of 100 mj and maximum average power of 60
Watts.
The 5000L provides a maximum pulse energy of 200 mj and a maximum average power of 80
Watts (208 VAC version) or 45 Watts (117 VAC version).
The UltraPulse 3000, 4000 and 5000; best suited for non-laparoscopic procedures (lower tract
gynecological, ENT, Nuero, cosmetic). The 4000 system is no longer in production. The 3000 provides
maximum pulse energy of 125 mj and maximum average power of 80 Watts (208 VAC system) or 60
Watts (117 VAC version). The 5000 system provides a maximum pulse energy of 250 mj and
maximum average power of 100 Watts (208 VAC version) or 60 Watts (117 VAC version).
At the release of this manual the UltraPulse 3000 and 5000 were being revised to provide much larger
maximum pulse energies ( e.g., up to 500 mj for the 5000). The increased pulse energy is planned to
be retrofitted in a number of existing systems. One or more Field Service Bulletins will be issued to
introduce servicing information on these revisions.
The Excelase 1000, 2000 and 3000; essentially UltraPulse systems with the "UltraPulse" feature
disabled, these systems are no longer in production.
Some of the earliest Ultrapulse units shipped with two commercial DC power supplies instead of the Coher-
ent built 48 VDC power supply. These units have a different version of software. A schematic of the power
supply connections for these early units is included in Section 8.
Existing systems can be upgraded in most cases. Information on system upgrades can be obtained from the
Coherent Sales Representative or Coherent Medical Group Technical Support.
1.4 DELIVERY SYSTEMS
Standard delivery systems include .2mm and 1.0 mm hand pieces.
Optional delivery systems currently available include laparoscope adaptors (Nezhat Coupler and Variable
Spot coupler) Micromanipulators (Clearspot™ 350 and 160), colposcope adaptors and waveguide delivery
systems (Infraguide™ and Arthroguide™).
GENERAL INFORMATION ULTRAPULSE SERVICE MANUAL

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2.0 INSTALLATION
2.1 INSTALLATION INSTRUCTIONS
Perform the following steps to install an UltraPulse (or Excelase 2000) system:
1. Check for proper site preparation. This should include proper AC service and adequate room for the
console.
The UltraPulse 5000L, 5000 and 3000 models can be configured to operate with either of the following
two mains inputs. New systems are shipped configured to operate with one or the other. Power
conversion kits are available to re-configure a system for either (see FSB 18).
220 VAC ±10% 20 A, 50/60 Hz, single phase. The unit will work well with 208 VAC supply
voltage.
117 VAC ± 10% 20 A, 50/60 Hz single phase.
The UltraPulse 3000L requires 220 VAC ±10% 20 A, 50/60 Hz, single phase. The unit will work with
208 VAC supply voltage.
The UltraPulse 4000 (no longer in production) requires 220 VAC ±10% 20 A, 50/60 Hz, single phase.
The unit will work with 208 VAC supply voltage.
The Excelase 1000 and 2000 (no longer in production) require 117 VAC ±10%, 20 A, 50/60 Hz, single
phase.
The Excelase 3000 (no longer in production) required 220 VAC ±10%, 20 A, 50/60 Hz, single phase.
The console dimensions are 17.5"W x 77.25" H x 27" D. The arm has a 6 foot radius from the column.
The console should be a minimum of 20" from walls, furniture, or other equipment. The power cord
length is 22 feet. The footswitch cable length is 10 feet.
2. Check the shipping crates (2) for any damage.
3. Remove the console and accessories from the crates.
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The larger crate contains the console. Unlock the securing hardware (6 pieces) to remove the door
from the crate. The door serves as a ramp. The system is rolled down the ramp to remove it from the
crate. Additional boxes are included in the crate for accessories, footswitch, etc. The smaller crate
contains the articulating arm.
4. Roll the console to the installation site.
5. Remove the mast and side covers, then inspect the interior of the console for loose connectors and
shipping damage.
6. Connect the footswitch.
7. Fill the cooling reservoir with water.
8. Measure the voltage of site mains and configure (tap) the system isolation transformer to match site
mains voltage.
The isolation transformer has three taps for 200-240 VAC service. For 200-240 VAC mains, tap to
match the measured mains voltage. Determine which of the two transformers the system has by
referring to the two transformer drawings in Section 8. The 0616-759-01 transformer has 12 terminal
connections. The 0615-042-01 transformer has 10 terminal connections.
The 0616-759-01 transformer can also be tapped to operate off of 117 VAC (the other transformer does
not allow tapping for 117 VAC mains).
9. Plug the system into the AC power source.
10. Turn on the circuit breaker and keyswitch, then observe the unit for any indication of leaking coolant
or component failures.
The system will go through its self test sequence, then move to STANDBY.
11. Perform the optical check out and safety checks in Section 3 (topics 3.2 and 3.6).
12. Verify the power calibration.
Check the output at the arm, using a calibrated power meter, across the power range (at least 4 power
settings). Measured power must be within ± 20% of indicated power throughout the range of output
powers, but is typically much closer (±5% or better). If measured power deviates from indicated
power by more than 15%, at any power setting, re-calibrate (see section 3).
13. Replace all covers.
14. Verify system operation with all accessories on hand.
15. Demonstrate system operation to the user.
16. Fill out and mail the Installation Quality Audit Report which came with the unit.
INSTALLATION ULTRAPULSE SERVICE MANUAL

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3.0 CALIBRATIONS, ADJUSTMENTS &

ALIGNMENTS
3.1 INTRODUCTION
3.1.1 Overview Of The Procedures
This section provides the procedures for field calibrations, adjustments and alignments for the UltraPulse.
The procedures assume the reader has successfully completed a Coherent service training course on the
UltraPulse and is certified to work on the unit to be serviced. In general, the procedures should be done in the
order presented, from beginning to end. If only a portion of the procedures are to be done, the service engi-
neer must consider the possible effect of doing just that portion of the procedures, i.e., there may be adjust-
ments – alignments done earlier or later in the procedures that impact or are impacted by the portion done.
Since the introduction of the UltraPulse a number of models and versions have been produced. These proce-
dures were written to apply to all models of the UltraPulse as produced at or before the release date of this
section.
The procedures are:
3.2, Optical checkout confirms that the HeNe(s) and CO2 beams are coaxial (coincident at tower
output and at several feet from the output) and centered out of the tower (positional and angular run
out within specifications), and that the CO2 beam is roughly circular, without lobes or satellites. If any
portion of the checkout fails, the optical alignment procedure is required.
3.3, Optical alignment corrects any misalignment of the HeNe or CO2 beams and optimizes the shape
of the CO2 burn.
3.4, Thermopile centering, detector amplifier gain, and loop gain adjustments are covered together.
The detector amplifier gain adjustment is done only for UltraPulse systems with the millijoule control
panel and safety shutter circuit. It sets the power detector output level to agree with the value written
into the software. The thermopile centering adjustment centers the CO2 beam reflected off the shutter
convex mirror into the thermopile. The loop gain adjustment sets up the response of the gain stages
in the power measuring and power seek circuits. It uses both the loop gain and power detect
EPROMs.
3.5, Power calibration matches the power measuring circuits inside the system to the service
engineer's power meter, and establishes the values to be used in the power seek routine.
3.6, Temperature sense PCB calibration sets the output of the temperature sensor PCB to a specified
value.
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3.7, Safety & Operational Checks confirm the safe and correct operation of the system.
Special purpose tools required: HeNe alignment disk; first surface mirror; positional run out tool; angular run
out tool; power detect, loop gain and light off service software EPROMs. See Section 6 for part numbers for
these tools.
3.1.2 Safety Precautions
Lethal voltages and laser emission are the primary dangers to the servicing engineer. In addition to the
general safety precautions which always apply when working on electronics and lasers, the servicing engi-
neer must be aware of the following specific precautions:
Only Coherent certified UltraPulse Service Engineers should attempt any service on this system.
Even with the key switch in the "OFF" position there are potentially lethal voltages present inside
the console.
Storage capacitors inside the system are capable of holding a lethal charge, even after power has
been removed from the unit. Before contacting any capacitor, disconnect the system from primary
power and use a shorting probe to discharge the capacitor to ground.
The 10.6µm (or 11.1 µm for "L" systems) laser light is invisible to the human eye. Because the
energy can not be seen, there is no visible indication of the primary or reflected beam. Eye protection
that attenuates the treatment wavelength to a safe level must be worn by all persons in the area of the
laser system whenever the laser is being serviced.
The 10.6 µm (or 11.1 µm for "L" systems) laser light and its reflections are potential burn hazards
and can ignite flammable materials. Use extreme caution when operating the system with covers
opened or removed. The covers contain the beam and reflections safely within the console. Only
those persons required should be present during servicing, and eye protection that safely attenuates
these wavelengths must be worn by all present.
The 10.6µm (or 11.1 µm for "L" systems) laser light and its reflections are potential hazards to the
eye. Use extreme caution when operating the system with the covers opened or removed. The covers
contain the beam and reflections safely within the console. Only those persons required should be
present during servicing, and eye protection that safely attenuates the system treatment wavelength
must be worn by all those present.
Use caution when operating the unit with any of the mast covers removed, the articulating arm
removed or disassembled, or when test firing the system. Before firing, confirm that the beam will
be safely terminated, and that all persons present are wearing protective polycarbonate goggles with
side shields that safely attenuate the laser treatment wavelength (10.6 µm for UltraPulse systems, 11.1
µm for UltraPulse "L" systems).
During firing, be alert for any indication of reflection or misdirection of the treatment beam.
Consult the instructions for interior access (Section 5, subtopic 5.2) before attempting to remove
any of the covers. When loosening the screws to lower the panel power assembly (behind left side
cover), be prepared to support and swivel the heavy panel power assembly into its lowered position.
CALIBRATIONS & ADJUSTMENTS ULTRAPULSE SERVICE MANUAL

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Excessive duty cycle will damage the RF amplifier. Never ground the RFDREN line (TP1 on the
Controller PCB). Unlike the XL40/50/60 series, the UltraPulse systems must never operate at a duty
cycle above approximately 40%.
3.2 OPTICAL CHECK OUT
This optical check out determines if optical alignment (as described in 3.3) is required. If the system passes all
steps in this topic, the optical alignment is not required.
1. Set up.
Turn the system on, select 5 Watts power @ a .2 second exposure, then go to ready.
2. Check the CO2 to HeNe coincidence at the arm output.
Fire the laser onto a piece of burn paper at the arm output, observing the position of the HeNe ( if the
system has both red and yellow HeNe, check the position of both) in relation to the burn. The
HeNe(s) must be centered on the burn. If not, the optical alignment must be done.
3. Check the CO2 to HeNe coincidence 2 feet from the arm.
Move the burn paper out to a distance of ≈ 2 feet from the arm output, then fire again. The HeNe(s)
should be centered on the burn. If not, the optical alignment must be done.
4. Check the burn.
The burn should be circular, although it will almost always exhibit a somewhat oval shape (oblong).
A typical burn profile will exhibit an approximate 1.5:1 ratio maximum to minimum diameter. If the
burn is not roughly circular in shape, or if any "lobes" or satellites are present, the optical alignment
must be performed.
5. Measure the positional run out.
Install the positional run

out tool. Note that there
POSITIONAL RUN OUT -
are two slightly different The diameter of the
positional run out tools - circle described by the
one for older systems middle of the HeNe as
with the smaller diameter the arm is rotated through
360.
HeNe and another for
newer systems (systems
without the HeNe TARGET CENTER
POSITIONAL ERROR-
diverging and HeNe Once positional run out is
collimating optics) that minimized, positional error
Range of HeNe movement
have the larger diameter is measured as the
through 360 of arm movement.
HeNe. The only maximum distance the
HeNe moves from the
difference is in the reticle. target center, when the
arm is moved through 360.

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Holding the arm knuckles in a fixed posture, walk the unit around its normal limit of reach (360˚),
observing the HeNe spot on the positional run out target.
Positional run out is observed as movement of the HeNe spot as the arm is moved through 360˚. It is
the diameter of the circle described by the HeNe center as the arm is rotated 360˚ around the mast. It
must be less than 2 mm for the old style articulating arms, or less than 1 mm for the new style
articulating arm. If not, the optical alignment procedure must be performed.
Note that the HeNe does not necessarily rotate about the center of the target.
6. Check the positional error of the HeNe.
Positional error is the maximum distance the center of the HeNe travels from the target center as the
arm is rotated through 360˚ of travel. It must be less than 2 mm for the old style arms, or less than 1
mm for the new style arm. If not, the optical alignment procedure must be performed.
Note that positional error can exceed positional run out if the target center is outside the circle
described by the HeNe as it is rotated through 360˚.
7. Check the angular run out of the HeNe.
Perform the following substeps to determine the angular run out. The resulting number (angular run
out in milliradians) should be less than 3 for the old style arm or less than 2 for the new style arm.
a. Install the angular run out tool (with a piece of graph paper) then make a single burn on
the paper (5 watts, .02 second).
b. Measure and note the burn diameter (Y), using the reticle of a magnifying telescope
(typical diameter is .5 mm).
c. Set the laser to FAST repeat (leave the power and exposure time settings as above).
d. While firing the laser and spinning the angular run out tool tube, move the arm through its
360˚ of travel and move both of the arm sections through 30˚ to each side at the knuckle.
e. Measure the burn diameter (X), then calculate the angular run out using the following
formula:
Angular run out = (Xburn diameter from step e - Yburn diameter from step b ) 1.88

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3.3 OPTICAL ALIGNMENT
There are three different CO2 optical schemes used for the UltraPulse.
Early systems used the 0162-410-00 tube. The optics included a CO2 corrective optic located just
below the HeNe-CO2 beam combiner. The optic is rotated to minimize the elongated shape of the
delivered CO2 beam. A "sliding aperture" is also included to allow the blocking of lobes or satellites
that were sometimes present with this old style tube. The "00" tube and associated optics were
original equipment on all 4xxx s/n systems and model 5000 systems with s/n's below 51050.
With the introduction of the "L" type SL611 tube, the tube optics were improved, and several
changes in the optical path were made along with it. These changes were also incorporated into the
SL600 tube design. These changes are found on all SL611 tubes ("L" technology tubes) and on SL600
tubes that have part numbers ending in "-01".
A new CO2 near mirror assembly is used. This optic serves the dual function of near mirror
(position it to adjust the CO2 beam position in the near field) and corrective optic (rotate the
mirror to optimize the beam shape).
A collimating meniscus is added where the CO2 corrective optic was located in the old style "-
00" tube systems. Since the beam shape adjustment is incorporated into the near mirror
assembly, the corrective optic as used in the "00" style tubes is no longer required, and a
collimating meniscus is added to improve the beam collimation.
When an old style "00" tube is replaced with a new style tube, the old corrective optic is replaced by
the collimating meniscus and a new near mirror assembly (incorporating the beam shaped
adjustment) is added. This replacement near mirror assembly is not the same as the near mirror
assembly used in system produced with the new style tube –␣it serves the same function but has to be
physically different to fit in the old style systems.
The UltraPulse is sold in a single HeNe (red) and Dual HeNe (separate red and yellow) configuration. In
systems with the dual HeNe, the yellow HeNe far mirror effects the red HeNe position, so the yellow HeNe
must be adjusted first.
In some steps, the yellow HeNe is specified, while the word red appears in parenthesis after it:
yellow (red) HeNe
This indicates that the yellow should be adjusted for dual systems, or the red for single HeNe systems.
Systems built previous to s/n XX300 included a diverging lens and collimating lens in the HeNe path. Both
were removed in later systems (a protective dust cover , p/n 0621-739-01, is installed where the diverging
lens was mounted) to improve delivery through micromanipulators.
1. With the laser off, remove the mast cover, articulating arm, optics bench PCB, the cover plate (to which
the optics bench PCB mounts) and the HeNe folding mirror assembly.
See Section 5 for instructions on removing covers. Leave the optics bench PCB electrically connected,
as the laser will have to be fired during this procedure. Provide support for the PCB and insure that
the back side of the PCB is not in contact with any conducting surfaces.

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(Beam shape adjustment)

Good
The CO2 beam shape should be circular, with an approximate
constant diameter (not elongated/oblong), and with no "satellites" or
protruding lobes. Beam shape (diameter) is adjusted by rotation of a
CO2 corrective optic in systems with the old style tube, or by rotating
the CO2 near mirror in systems with the new style tube. Some of the
old style tubes produced lobes and/or satellites. A sliding aperture is
included in the optics path on systems with the old style tube. The
sliding aperture can be positioned to block lobes and satellites.
Elongated
2. Place a 45˚ mirror over the tower output to direct laser output
towards a wall.
The wall should be 6 to 8 feet from the mirror, approximately the length of the articulating arm.
3. Tape a burn card on the wall in the beam path.
4. Turn on the laser and confirm that the CO2 beam is directed to the card on the wall ( e.g., "walk" the
burn out to the wall, using a second burn card).
5. Adjust the CO2 corrective optic (old style tubes) or near mirror (new style tubes) to obtain the most
circular burn (use low power/short exposure, just enough to get a good burn on the card).
The CO2 beam shape should be as close to circular as possible. However, optimal beam shape will
vary from tube to tube, and few will provide a truly circular burn (a 1.5:1 ratio is typical). Adjust for
the best beam shape obtainable.
There are three different styles of beam shape adjustments, depending upon the type of system being
adjusted. Systems with the old "-00" style tube are adjusted by a separate "corrective optic". Systems
retrofitted with the new style tube and systems produced with the new style tube have a beam shape
adjustment built into the CO2 near mirror assembly (although the adjustment mechanisms are
different). See the drawings of the CO2 beam path for instructions on the beam shape adjustment for
each of these three types of adjustment.
(Satellite/lobe adjustment for systems with the old style tube)
6. Check for satellites or lobes by making timed exposures (20 watts, .01 seconds) on the burn card.
If no lobes or satellites are observed, no further adjustment is necessary.
Lobes and satellites are not typical of the new style tube, and no adjustment is provided to correct for
them.
Burn with Lobe Burn with satellite

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In an old style tube, lobes or satellites can be

corrected using a "sliding aperture" mounted on the
bottom of the mounting plate for the beam
combiner. The aperture is held in place by a single
hex head screw. When the screw is loosened the
aperture can be repositioned to block a satellite or
lobe. Reposition the aperture, then make a burn.
Repeat this process until all satellites – lobes are
removed, then confirm that power drop through
the aperture is 20% or less. If not, the aperture is
blocking too much of the beam and must be
repositioned.
(HeNe alignment out of the mast)
7. Adjust the HeNe(s) to center HeNe output at the top of

the mast by performing the following substeps (a through
e) first for the yellow HeNe, then the red. If only a red
HeNe is installed, adjust the red.
a. Place the HeNe alignment disk in the tower,

where the arm was removed.
b. Adjust the applicable HeNe near mirror to center

the HeNe in the disk.
c. Remove the alignment disk and install the first

surface mirror (first surface down).
d. Adjust the applicable HeNe far mirror to align

HeNe retroreflections on the surface of beam
combiner.
e. Repeat substeps "a" through "d" until the HeNe is

centered in the alignment disk and the
retroreflections are minimized.
8. Remove the alignment tool (mirror or disk).
(CO2 Beam alignment to the HeNe out of the mast)
9. Place a thermal burn card on the tower and make burns (2 watt power setting), adjusting the CO2 near
mirror to center the burns on the yellow (red) HeNe.
10. Place a target on a wall 6 to 8 feet away from the tower opening (turn the beam with a right angle
mirror).
The yellow (red) HeNe beam should be visible on the target. Ensure that the burn will be on the
target by making burns on a thermal card as it is moved progressively closer to the target (walk the
burn to the target).

0616-629-01 8/94 3-9
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11. Make burns (5 watt power setting) on the target, adjusting the CO2 far mirror to place the burns on the
yellow (red) HeNe at the target.
12. Repeat steps 9 through 11 until the CO2 and yellow (red) HeNe are coincident at the target and at the
output of the tower.
(Dual HeNe systems red HeNe alignment out of the mast)
13. For dual HeNe systems, adjust the red HeNe near and far mirrors until the CO2 and red HeNe beams
are coincident, (i.e., coaxial at the target and the top of the tower).
14. For systems with the safety shutter circuit, perform the thermopile centering and detector amplifier
gain adjustments from Topic 3.4, then continue this procedure (step 15).
The power detector gain adjustment is done with the articulating arm removed, so it is convenient to
do the adjustment here, before the arm is reinstalled. The thermopile centering adjustment should be
done before the power detector gain adjustment, so it must also be done at this point if the detector
amplifier gain adjustment is to be done here.
15. Install the articulating arm.
(HeNe fine adjustment through the arm)
16. Install the positional run out tool on the end of the arm, then check positional run out.
Holding the arm knuckles in a fixed posture, walk the unit around its normal limit of reach (360˚),
observing the yellow (red) HeNe spot on the positional run out target. "Positional run out" is
observed as movement of the HeNe spot as the arm is moved through 360˚. Note that the HeNe does
not necessarily rotate about the center of the target.
17. Make small adjustments to the yellow (red) HeNe far mirror until the run out is minimized. The
positional run out must be less than 2 mm for the old style articulating arm, or less than 1 mm for the new
style articulating arm.
18. Remove the positional run out tool.
(CO2 fine adjustment though the arm)
19. Affix the arm to a stable object (tape it down), so that it points towards a vertical surface (a wall 6 to 8
feet away). Affix a burn card to the wall in the beam path.
20. Make burns (2 watt power setting) into a thermal burn card placed close to the output aperture, adjust-
ing the CO2 near mirror to center the burns on the yellow (red) HeNe.
21. Make burns on the card affixed to the wall, adjusting the CO2 far mirror to center the burns on the
yellow (red) HeNe spot.
22. Repeat steps 20 and 21 until the yellow (red) HeNe and CO2 are coaxial at the aperture, and 6 feet from
the aperture.
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(Dual HeNe system fine adjustment of red HeNe through arm)
23. For dual HeNe systems, adjust the red HeNe near and far mirrors for red HeNe/CO2 coincidence at the
wall and at the output aperture.
(Final optical checks)
24. Perform the optical check out procedure (Topic 3.2), then return to this procedure (step 25).
The system must pass all steps of the optical check out procedure.
25. Verify the alignment through all accessory delivery systems used with the system.
26. Replace the mast covers.
3.4 THERMOPILE CENTERING, DETECTOR AMPLIFIER GAIN, & LOOP GAIN ADJUST-
MENTS
(Thermopile centering)
1. Install light off EPROM in the Controller PCB U21 slot.
Refer to Section 6 to determine the correct p/n of the light off software to use for a particular system.
2. Connect oscilloscope to Controller PCB TP16.
Use +/-15V return for ground ref. Set oscilloscope for 1V/div, 1sec/div.
3. Turn on the system.
After a short delay, the system will begin firing.
4. Maximize the voltage seen on the oscilloscope by adjusting the thermopile housing position relative to
the optics bench.
(Detector amplifier gain)
5. Perform the following substeps (a and b) only on UltraPulse systems with the millijoule control panel
and safety shutter circuit.
a.) Measure the power out of the tower.

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Place power meter head on top of the laser tower then depress the footswitch. After a short
delay the shutter will rotate out of the beam path, and the CO2 beam will reach the power
meter head. Note the power as indicated on the power meter (≈5 watts is typical), then
release the footswitch. The shutter will rotate back into the beam path, then the system will
continue to fire.
b.) Adjust power detector gain.
Attach an oscilloscope to Controller PCB TP16, then adjust R4 on the power detector PCB to
obtain a voltage level at TP16 that is half the value of the power as measured and noted in
step 3, e.g., for a 5 Watt power reading, adjust TP16 for 2.5 Volts.
(Loop gain)
6. Turn off the system and replace the light off EPROM with the power detector test EPROM.
8. Adjust optics bench PCB R41 (R33 for 0617-523-01 optics bench PCBs) for best rise/fall time (no over-
shoot).
9. Turn off the system, then replace the power detector EPROM with the loop
gain EPROM.
11. Adjust controller PCB R31 (R17 on controller PCB 0615-880-01) for best rise/
fall time (no overshoot).
12. Repeat steps 6 through 11 until rise/fall time with both EPROMs shows
minimum overshoot.
3.5 POWER CALIBRATION
The calibration must be done whenever optical alignment, thermopile centering, and loop gain dampening
adjustments/calibrations have been done.
1. With the system off, connect the FDT to the RS-232 diagnostic port (located inside rear door, top).
2. Turn on the unit.
The system will go through its self test sequence, then go to standby. The FDT display will indicate
"PRESS ENTER TO BEGIN CALIBRATION.
3. Press the ENTER key, then follow the prompts on the FDT, as described below.

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A few software versions required the system to be in CW mode,

2 Watts in order to begin the calibration (instead of the default
"UP1" setting that the system comes up in). If the system
displays a "please wait" message after going through self tests
(won't begin the calibration process), cycle the system off to on, 1 2 3 4 5 E
N
then press "CW" to move the system to the CW mode (2 Watts .
T
6 7 8 9 0
is the default CW power setting). The system should then begin E
R
the calibration routine.
NOTE: The first value in the WATTS routine may

exceed 100 watts average power.
The milliwatt mode calibration sequence is done first, followed by the watt mode calibration
sequence. The microprocessor begins with the attenuator wheel in the beam path, loads 5 VDC into
the command DAC (this is the DAC mid range value), sets the two gain stages up for the highest
power range (first stage lowest gain, second stage highest gain), then turns on the laser. It adjusts the
pulse width to zero the error, notes the voltage from the power detector circuit once the error is
zeroed, then turns off the laser. The field data terminal display now prompts "MEASURE THE
MILLIWATT OUTPUT - ENTER READING #1". The service engineer directs the output of the
articulating arm into the head of the external power meter, depresses the footswitch, notes the power
as measured at the power meter, releases the footswitch, enters the measured value (in watts, e.g..,
200 mwatts is entered as .2)) into the field data terminal, then presses the enter key.
The prompts continue, repeated for the other three gain settings, and then the attenuator wheel is
rotated out, and the process repeats for each of the gain stage settings for WATT mode. Note that the
laser has been fired 16 times to complete the calibration; 8 times by the service engineer into the
external power meter, and 8 times by the microprocessor through the internal power measuring
circuitry. After the service engineer enters the last of the eight values, the FDT display indicates
"DATA ENTRY COMPLETE", and prompts for the service engineer to press "0" to continue the
calibration process, or "1" to review/edit the set of eight values already entered. The review/edit
option allows the engineer to correct entry errors, or to look back through the entries. Once all entries
are satisfactory, the service engineer selects "continue" and the new calibration factors (16 values) are
moved form the FDT to the NVRAM within the system.
4. Turn off the system, then disconnect the FDT.
5. Use the external power meter to confirm that the power calibration is within ±15% throughout the
power range (displayed/selected power is within +/-15% of delivered power).
The calibration is typically better than 5% across the range.

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3.6 TEMPERATURE SENSE CALIBRATION
Tools required: thermometer*, potentiometer adjustment tool, DVM.
1. Locate the temperature sense PCB (behind right side cover), and locate the potentiometer on the tem-
perature sense PCB.
2. With the system running, use a thermometer to monitor coolant temperature.
3. At the Controller PCB, monitor the DC voltage at TP14.
4. Adjust R2 on the Temperature Sense PCB so that the voltage at TP14 agrees with the following:
VTP14= Coolant temp in ˚C (.129)
NOTE: (˚C*1.8)+32=˚F
* - If a thermometer is not available, adjust for a voltage of 2.5 to 2.6 volts at TP14 with the system at room
temperature (this assumes a room temperature of 20-21˚␣C).
3.7 SAFETY AND OPERATIONAL CHECK OUT
1. Check attenuator position detector.
In watts mode, manually rotate the attenuator wheel to its energized position - confirm that a fault 13
occurs.
In milliwatts mode, manually force the attenuator to its de-energized position - confirm that a fault 14
occurs.
2. Check shutter position detector.
Select a low power setting, wait for the completion of the power seek routine (the beep), then
manually hold the shutter in place and select ready. Confirm that a fault 15 occurs.
Select a low power setting, then go to ready. Manually hold the shutter open, then select standby.
Confirm that a fault 12 occurs.
3. Check Interlock plug.
Remove the interlock plug and confirm that a fault 3 occurs, then reinsert the plug and confirm that
the fault clears.
4. Verify audible indicator PCB operation.

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Confirm that the audio tone is heard whenever the footswitch is depressed in the ready mode.
5. Remove the footswitch.
Confirm that a fault 1 occurs, then replace the footswitch.
6. Press emergency off switch.
Confirm that the system shuts off.
7. Turn the system back on. Test operate in milliwatts, watts, and UltraPulse (if present) modes.
Confirm that mast and control panel displays are operational and that all operator inputs respond
properly.
8. Confirm the power calibration across the range of power.

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4.0 THEORY OF OPERATION
4.1 INTRODUCTION
4.1.1 Operational Overview
The UltraPulse (and Excelase) sealed tube CO2 laser systems are designed for use in surgical applications.
The user operates the laser via a control panel and attached footswitch. A key switch is used to turn on the
system. At turn on, the system conducts a series of initialization and self test steps, then moves to STANDBY,
or, if faults are detected, an indication of the fault is displayed at the control panel.
Once in STANDBY, the user can select a power mode, a power/energy setting within the selected mode, and
the desired timing settings.
Once the desired operating parameters are selected, the operator presses the READY push-button to select the
laser READY mode. Once in READY, the laser will deliver 10.6 µm (or 11.1 µm in "L" systems energy at the
selected operating parameters in response to depression of the footswitch.
The power modes are:
MILLIWATTS - The power range of the laser is from 50 to 950 milliwatts, selected by the UP/
DOWN arrow push-buttons, in 10 mWatts steps up to 200 mWatts, and then in 50 mWatts steps up to
the 950 mWatts maximum.
WATTS - The power range of the laser is from 2 watts to the maximum (varies with the model),
selected by the UP/DOWN arrow push-buttons, in 1 or 5 watt steps (1 watt for a brief depression, or
5 watts if the button is held down).
ULTRAPULSE (not available in Excelase systems) - the laser produces short duration pulses of very
high energy. See the Operators manual for a complete description of the operating controls for
Ultrapulse mode.
Exposure selections can be timed, timed repeat, or continuous. In TIMED mode, times of .01, .02, .05, .1, and .2
seconds are available. A repeat function can be selected in conjunction with the exposure time, with settings
of SINGLE, SLOW, MEDIUM, OR FAST. In CONTINUOUS the exposure continues as long as the footswitch
is held down.
Laser output is directed, by mirrors, through a counterbalanced articulating arm. Various standard and
optional delivery systems attach to the end of the arm, such as .2 and 1 mm spot size hand pieces, variable
spot size hand pieces, micromanipulators, and colpascope adaptors.
ULTRAPULSE SERVICE MANUAL THEORY OF OPERATION

0616-629-01 8/94 4-1
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The articulating arm is mounted on the mast. When the system is not in use, the articulating arm is stored
behind a door on the mast . A manual safety shutter is located on the mast, allowing the beam path to be
blocked when the laser is not needed. A mast display is provided, duplicating most of the operational indica-
tors on the control panel.
A visible aiming beam is provided by one or both of a HeNe laser and "Yellow HeNe" laser. The COLOR
button on the auxiliary control panel enable either or both, to provide a red, yellow, or orange aiming beam.
The yellow HeNe is an optional feature, and may not be included on a particular system. A manual bright-
ness control for the HeNe is located on the mast. A HeNe blink feature is selectable at the auxiliary control
panel; when selected, the aiming beam will blink off and on at a constant rate. There is also an "AUTO" mode
selectable at the auxiliary control panel, which, when selected, turns the HeNe off for the duration of each
treatment pulse.
An emergency off button is located on top of the console, towards the right, near the mast. Pressing the
emergency off button shuts down the system. An overtemperature warning indicator is located on the
auxiliary control panel, it lights when coolant temperature reaches 115˚ F. If coolant temperature reaches 125˚
F, the footswitch will be disabled, and a fault 3 will be displayed on the main control panel.
Consult the appropriate system or delivery system Operator manual for more detailed information on
operation.
4.1.2 Functional Overview
For the purposes of this discussion, the system is divided into the following functional elements:
Power distribution and turn on circuits - The mains input is conditioned and distributed to AC loads
(fans, coolant pump, lamp handle, uv light, and two DC power supplies) via two contactors. The
contactors are operated by the key switch via two thermal fuses and the emergency off switch. One
DC power supply (The 48 VDC supply) provides operating voltages to the RF exciter. The other
supply (the "C" supply) provides DC operating voltages (+5, ±15, +24 VDC) used throughout the
system. The uv light power supply and lamp handle (illumination) are on whenever the unit is on.
A few early systems shipped with a pair of vender supplied DC power supplies to produce the 48
VDC operating voltage for the RF amplifier (instead of the Coherent produced single box 48 VDC
power supply).
Cooling - Coolant (water) is circulated through a closed loop that includes the tube, RF exciter, 48
VDC supply, thermopile, heat exchanger, two flow switches, temperature sensor, reservoir, and
pump. Heat transferred to the coolant in the tube, exciter, DC supply, and thermopile is removed
from the coolant at the heat exchanger. Two fans force air through the heat exchanger. Coolant flow
and temperature are monitored. A fan controller PCB monitors the interior temperature and controls
the fan speed to maintain the exhaust air temperature within an acceptable range. Insufficient flow
results in a fault 18. When coolant temperature reaches 115˚F, the overtemperature warning indicator
illuminates. When coolant temperature reaches 125˚ F, fault 3 is displayed, and the footswitch is
disabled. The fault 3 will clear when coolant temperature drops below 115˚F. Note that the flow
switch loop is tested shortly after power up, before the water flow is sufficient to close the switch, to
insure that it is not stuck in the closed position (system halts and displays fault 22 if switch is found
to be closed during this test).
THEORY OF OPERATION ULTRAPULSE SERVICE MANUAL

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Control Electronics - The control electronics include the Controller PCB, Optics Bench PCB, Control
Panel, Auxiliary Control Panel, Mast Display, footswitch, and various electromechanical/electro-
optical devices/sensors located throughout the system. The microprocessor on the Controller PCB
executes a set of software instructions permanently stored in EPROM to provide overall control of the
system.
RF exciter - Supplied by Coherent Laser Products Division, with a matched laser tube, the RF exciter
outputs RF excitation (81.36 MHZ) to the CO2 tube in response to inputs from the control electronics.
Its operating voltage is supplied by the 48 VDC Power Supply.
Optics - The optics include the CO2 and two HeNe tubes, and all components which act on the laser
beams.
Software - The software instructions are permanently stored in EPROMs on the Controller PCB.
These instructions define the logical sequence of tasks that the microprocessor must perform to
operate the system. Software revisions are installed by replacing the EPROMs. Not all models use the
same software. Section 6 provides the P/N's for the various software versions which are current at
the release of this manual.
The CO2 laser outputs energy in response to RF excitation applied across the cavity through capacitive
coupling. The RF energy acts as the laser energy pump, exciting the CO2 gas molecules within the cavity,
causing lasing. The average power output from the tube is controlled by the on/off time (duty cycle) of the
RF signal. The RF signal comes from the RF exciter. A timer controlled by the microprocessor provides the
on/off signal to the RF exciter. This on/off signal to the RF exciter is also referred to as the modulation signal.
There are three power modes; MILLIWATTS, WATTS, and ULTRAPULSE. The WATTS and MILLIWATTS
modes (also referred to as the "CW modes") are similar, except that an attenuator is placed in the beam path
in milliwatts mode (and at 2 watts and below in watts mode for newer systems) to drop the power down into
the milliwatts range.
In Ultrapulse mode the laser is pumped with a very short duration RF voltage signal to achieve higher peak
power out of the tube. The power is limited, however, to short pulses (100 to 950 µseconds) at a low duty
cycle ( approx. 20% maximum). The operator selects a pulse width and rep rate. Note that even though peak
power is high, the average power is much less than the peak, due to the relatively low duty cycle (i.e., the
laser is off for longer periods than it is on). Ultrapulse mode typically achieves a more dramatic effect on
tissue, with less thermal damage to surrounding tissue than similar average power in the "CW" modes.
In MILLIWATTS and WATTS modes, each time a new power setting is selected, and each time the system
rests (no firing) at any power setting for five minutes, the software initiates a power seek routine. This routine
finds the correct pulse width signal to provide the power selected at the control panel. It does so in the
following manner:
• The shutter is closed during this routine. When the shutter is closed, a convex mirror mounted on
the shutter is placed in the beam path. The mirror will direct any tube output towards the thermopile.
The thermopile and associated circuitry form an internal power measuring circuit which generates a
DC voltage proportional to the average power of the CO2 beam.

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• The microprocessor loads a digital to analog convertor (the command DAC) with a digital value
which corresponds to the DC voltage expected from the thermopile when actual power (as measured
by the thermopile) is equal to selected power (the setting at the control panel). The DAC output will
be used as a reference voltage to be compared with the output of the thermopile power measuring
circuits. When the two voltages are within ±5% for one second, actual power is equal to selected
power. The microprocessor determines the reference voltage to load into the DAC by reading the
calibration data stored in NVRAM. The calibration data is entered in the NVRAM during the power
calibration routine, performed by the service engineer (see below).
• The microprocessor loads and starts the two timers that generate the RF exciter modulation signal.
This provides the pulse width information that determines the on/off time of the signal that enables
the RF exciter. The higher the duty cycle of the RF exciter/amplifier (i.e., the higher the percentage of
time the modulation signal is "on" (at a logic low)), the higher the average power out of the tube.
• The timer output turns the RF exciter on and off at the duty cycle established by the timer output.
The RF exciter input to the tube results in energy output from the tube and into the thermopile via
the shutter convex mirror.
• The power measuring circuit output voltage (indication of actual average power) is sent to the
power seek circuit on the Controller PCB. There the thermopile voltage is compared with a voltage
generated from the command DAC.
• The microprocessor reads in the "error voltage" (difference between voltage from thermopile circuit
and DAC) via the ADC circuit. The magnitude and sign of the error voltage indicates if the
modulation frequency is providing too much, too little, or the desired power out of the tube.
• If the error voltage read in from the ADC indicates actual power is not within ±5% ( or ±15% for
power settings in the upper 15% of the laser operating range) of desired power, the microprocessor
loads a correction into the modulation timers to move tube power in the correct direction, then reads
the ADC circuit again.
• The adjustments to the timer count and the measurement of the error voltage continue until the
tube output stays within ±5% (or ±15% for upper 15% of laser operating range) of selected power for
one second. The system "beeps" to indicate the power seek is successful and complete. If after 7
seconds the tube output has not met this condition, a fault 4 occurs.
System calibration is accomplished by the service engineer using an externally connected field data terminal
and calibrated power meter. The field data terminal (FDT) is connected to the microprocessor RS232 port.
When the system is powered up with the FDT terminal connected, the microprocessor begins running a
calibration routine stored in an EPROM. The calibration routine fires the laser into its own power measuring
circuit (shutter closed) and then prompts the service engineer to fire the laser into the external power meter
and enter the value of the measured power using the FDT keyboard. This is repeated eight times; once for
each of four gain settings in MILLIWATTS mode, then once for each of four gain settings in WATTS mode.
During the MILLIWATTS firings, the attenuator wheel is rotated into the beam path. Eight error factors and
eight D/A factors are determined from the process. These values are collected in the FDT, and then trans-
ferred to the system NVRAM at the end of the calibration process.

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4.2 POWER DISTRIBUTION
There are a three different power distribution versions among the UltraPulse and Excelase systems covered in
this manual, as follows.
• Dual commercial 48 VDC power supply version - These very early units were produced with a
pair of vendor supplied 48 VDC power supplies instead of the Coherent manufactured 48 VDC
power supply. These units operate from 230 VAC, 30 amp mains input (the transformer cannot be
tapped). Identify these units by the 30 amp circuit breaker.
•␣ Non–ETL approved - Coherent 48 VDC power supply version- These systems were produced
with the Coherent built 48 VDC power supply but without the later changes that were required for
ETL approval. Some of these units can be configured for 115 VAC line inputs as well as 220 VAC.
Identify these units by the presence of the Coherent 48 VDC power supply and the last three digits of
the system serial number being less than 100.
•␣ ETL approved version - These systems incorporate changes required for the ETL approval, but are
essentially similar to the Non-ETL approved version. Identify these units by the last three digits of
the system serial number being greater than 099.
Subtopics 4.2.1 through 4.2.5 describe the systems with the 48 VDC power supply in detail. Subtopic 4.2.6
describes the ETL approved version as it differs from the Non-ETL version. A schematic diagram of the dual
commercial supply system power distribution is provided on 8-26.
4.2.1 AC Input and Conditioning
(Refer to 8-2) The mains input is applied through a three conductor power cord to CB1. The primary power
components can be configured for use with 117, 200, 208, or 230 VAC, although some models will not operate
with the 117 VAC configuration.
4.2.2 Circuit Breaker On, Key Switch Off
When the circuit breaker is closed, but before the key switch is turned on, the mains is applied to the T2/T3
contacts of the main contactor CON1, to power indicator DS1, and to the primary of T2. T2 secondary is the
supply for operating the control windings of the main contactor (CON1) and the soft start contactor (CON2).
With the key switch in the off position, the 24 VAC path from the secondary of T2 is not completed to either
contactor. Both contactors are de-energized, and 220 VAC is not applied to the isolation transformer T1. Note
that even with the key switch off, deadly voltages are present inside the unit. Disconnect the unit from AC
power before contacting any of the AC line components.

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4.2.3 Key Switch On
To start the laser, the key switch is rotated to the start (II) position momentarily, and then released to the on
(I) position. While the key switch is in the start position the B and C contacts are close. In the on position only
the B contact is closed. While the momentary contact "C" is closed, the 24 VAC is applied across the control
winding of the main contactor CON1 (assuming the emergency off switch is not depressed). The main
contactor energizes, and the following events result:
• The T3-L3 and T2-L2 contacts close, applying AC to the primary of isolation transformer T1. At this
point, the CON2 contactor is not energized, so current through the primary is limited by resistors R1
and R2, and the 115 VAC secondary output is opened at CON2 contact L2-T2 (although DS2 is
connected directly across the secondary, and will turn on). The 28 VAC secondary supplies the 48
VDC Power Supply. Note that the 48 VDC Power Supply is used to control the CON2 contactor.
After a short delay, the 48 VDC Power Supply will complete the 24 VAC T2 secondary to CON2,
energizing it. During the delay the soft start resistors R1 and R2 prevent excessive current into the
storage capacitors in the 48 VDC Supply, preventing damage to various components in the charge
path.
• The T1-L1 contact closes, providing a hold on line for the main contactor through the emergency off
button, key switch "B" contact, and thermal fuses THR1 (mounted on transformer T1) and THR2
(mounted between the soft start resistors R1/R2).
HEAT EXCHANGER
RESERVOIR
FAN
CONTROLLER
AC
FLOW
SWITCH RF AMPLIFIER PUMP
MANIFOLD
(.5GPM)
LASER
MOTOR
POWER
DETECTOR MANIFOLD
AC
48VDC
SUPPLY
FLOW
TEMP SWITCH
SENSE (.5GPM)
PCB

4-6 0616-629-01 8/94
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Once the storage capacitors are charged to a nominal level, the 48 VDC Power Supply completes the path
between the HOLD1 and CON1 lines to energize the CON2 contactor. The CON2 contactor energizes,
removing the soft start resistors (T3-L3 closes) and applying the 115 VAC from T1 secondary to loads
throughout the system (T2-L2 closes).
The 115 VAC loads are:
• "C" supply, which generates DC voltages (±15, +24, +5) for use throughout the system.
• Water pump
• Fan controller
• UV Lamp Power Supply
• Lamp handle
4.2.4 Turn Off/Shutdown
Turn off is normally accomplished by turning the key switch to the off position, but can also be accomplished
by pressing the emergency off switch. In either case, the main contactor is de-energized.
4.2.5 48 VDC Supply
The 48 VDC Power Supply provides the RF exciter with operating current. It is a "boost" type supply, and
uses an ML4812 controller chip to maintain a charge of 48 volts on the storage capacitors from the 28 VAC T1
secondary, at a high power factor. The use of this type of supply allows the system to operate with a low line
current and less noise. The supply requires water cooling.
(Refer to 8-2) The T1 28 VAC secondary is sent to a bridge rectifier in the 48 VDC Supply. The fullwave
bridge rectifier output is applied to input boost inductor L1 (a sample of the rectifier output is also sent to the
controller chip U1 as "E IN"). The inductor operates in one of two conditions, determined by the condition of
the Bus Plate MOSFET:
• When the MOSFET is on, the inductor and MOSFET form a complete current path between the
positive and negative terminals of the rectifier, and the inductor stores energy in its magnetic field as
current surges through it. Note that the MOSFET on/off condition is controlled by the ML4812 chip.
• When the MOSFET is OFF, the magnetic field in the inductor collapses to maintain the current, but
the current path has changed; the schottley diodes (free wheeling rectifier) provide a path for the
current to the three parallel storage capacitors, C1, C2, and C3. This dumps current into the storage
capacitors, increasing the voltage stored in them.

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The controller chip monitors the bridge rectifier output (E IN), the capacitor storage voltage (E OUT), and the
current from the inductor (sampled by LEM M1, which outputs a 1/1000 sample of current). From these
inputs it determines the appropriate control of the MOSFET to maintain the 48 VDC charge on the capacitors
while keeping the power factor high. The switching frequency at which the MOSFET is turned on is approxi-
mately 20 KHz.
U3-13 and U3-14 monitor the DC voltage out of the Power Supply (E OUT) to report low voltage conditions
to the Controller PCB. The voltage divider R21, R22, and R23 place a voltage proportional to the DC Power
Supply output voltage on pins 11 and 8 of U3. The voltage will be slightly above (approx 5.3 VDC) 5 VDC
when the power supply output is 48 VDC. If the power supply output drops enough to allow the voltage on
pins 11 and 8 to drop below 5 VDC, the op amp outputs will switch (U3-13 goes low, U3-14 goes high),
signaling an undervoltage condition to the controller.
U3-1 monitors the Power Supply output for over voltage conditions, and commands the controller chip to
shutdown if an overvoltage is detected.
U4, Q1, U5, U2 and associated components monitor the E IN and E OUT voltages, and control the operation
of CON2. Note that when U2 is on, the CON2 contactor is closed ( providing 115 VAC throughput the
system and removing the soft start resistors from the AC line), and when U2 is off, the CON2 contactor is
opened. The E OUT voltage is regulated to 12 VDC by U4 to be used as a supply voltage for the circuit. After
the main contactor closes, the storage capacitors begin to charge, and the E OUT voltage rises. In a second or
two the "E OUT voltage should rise sufficiently for the charge on C12 to turn on the comparator U5. U5 will
then turn on U2, causing the CON2 contactor to close. Q1 is used to turn off U5/U2 if the E IN voltage
exceeds the E OUT voltage.
4.3 COOLING
The cooling system removes heat generated in the 48 VDC Power Supply, tube, RF exciter, and thermopile.
Coolant (water) is circulated by a pump in a closed loop through the tube, 48 VDC Power Supply, RF exciter,
thermopile and heat exchanger. Two flow switches and a coolant temperature sensor monitor the condition
of the cooling system, reporting to the microprocessor. A vendor supplied Fan Controller PCB monitors the
air temperature inside the cabinet, controlling fan RPMs to maintain the temperature in an acceptable range
(minimizing audible noise).
The coolant pump and the two heat exchanger fans run off of 115 VAC switched by contactor CON2. CON2
is energized shortly after the key switch is turned to the "ON" position. The 115 VAC for the fans is actually
sent to the vendor supplied fan controller PCB, and then on to the fans.
Early in the power up initialization and self test sequence the flow switch signals and coolant temperature
signals are checked. If an overtemperature or insufficient flow condition is detected, the appropriate fault
code is displayed, and the microprocessor is halted. After the power up initialization and self test sequence,
the software continues to monitor the flow and temperature at regular intervals.
(Refer to 8-23) The temperature sensor module operates off of ±15 VDC, and outputs an analog voltage
proportional to the sensed coolant temperature. R2 is adjusted to provide an output from U2 that is .129
VOLTS/˚C. (Refer to 8-8) The signal is sent to the controller PCB (J8-9), through the CDRH plug, as TMP-A
(TP14). The microprocessor measures the analog voltage by selecting the TMP-A input to multiplexer U41.
The multiplexer connects the TMP-A signal to the A/D convertor U38.

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Note that if the CDRH plug is removed the TMP-A input on the multiplexer gets pulled up to 15 VDC,
causing an overtemperature fault (F3).
(Refer to 8-7) Both flow switches close on sufficient flow, grounding the J8-5 input to the controller PCB.
Digital I/O tri-state buffer U45 is read by the microprocessor to determine the logic level of the FLWSW-L
signal.
4.4 CONTROL ELECTRONICS
The control electronics provides overall control of the system in response to operator inputs. It includes:
An 8031/8032 microprocessor (and associated circuits) to execute the software instructions.

(subsection 4.4.1)
EPROM, RAM, and NVRAM memory, to store software instructions and data. (subsection 4.4.2)
D/A conversion circuits, which allow the microprocessor to send analog commands to the power
loop circuit. (subsection 4.4.3)
A/D conversion circuits, which allow the microprocessor to measure analog voltages from the power
seek circuit and temperature sensor. (subsection 4.4.4)
Digital I/O circuits, which are used by the microprocessor to send digital commands and read in
digital values. (subsection 4.4.5)
The microprocessor writes to digital I/O output channels to set command line outputs high
or low, controlling the operation of relays, solenoids, integrated circuits, etc..
The microprocessor reads in digital I/O input channels to determine the status (logic high
or low) of slotted optical switches, the flow switch, the footswitch, etc..
Timers, which are used to time various events, provide a check of proper software operation
(heartbeat timer), and to provide precise on/off control signals to enable/disable the RF exciter.
(subsection 4.4.6)
Power measuring and power seek circuits, which are used to measure power out of the treatment
laser and provide a feedback voltage to the microprocessor indicating the difference between
measured and desired (selected) power. (subsection 4.4.7)
Control panel, which accepts operator inputs and transmits them to the microprocessor, and accepts data
from the microprocessor for display. (subsection 4.4.8)
Auxiliary control panel, which provides for additional operator inputs, and displays. (subsection 4.4.9)
Mast display, which duplicates most of the control panel display to allow for easier viewing during proce-
dure. (subsection 4.4.10)

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Newer systems have the following additional circuits:
Safety circuit, which monitors the shutter, footswitch and microprocessor self test lines and provides
an enable to the RF amplifier. The safety circuit will only enable the RF amplifier during self tests-
power seeks if the shutter is closed, and will only enable the RF amplifier during normal operation if
the shutter is open and the footswitch is depressed.
Audible indicator circuit, which produces a tone whenever the footswitch is depressed during
normal operation.
Note that most of the control electronics circuits are located on the controller PCB. The controller PCB has
been produced under four different part numbers, but all are essentially the same design and layout with a
few modifications from the previously produced PCB. The majority of the circuits on the four PCB's are
identical. The 0615-880-01 controller PCB (newest version at the release of this manual) has different compo-
nent numbering. The circuit descriptions that follow call out the component numbers for the earlier controller
PCBs.
4.4.1 Microprocessor and Associated Circuits
(Refer to 8-4) U4, an 8031 (older controller PCBs) or 8032 microcontroller, reads and/or writes to its memory
and I/O devices utilizing an 8 bit data bus and 16 bit address bus. The data bus is multiplexed on the lower 8
bits of the address bus. The 8031 includes internal RAM and a serial interface.
To execute a read or write instruction, U4 first places the 16 bit address to be operated upon on the address
bus, and then asserts ALE (address latch enable). The ALE signal causes address latch U20 to read in and
hold the lower 8 bits of the address, freeing up the P0 lines to handle the data transfer. U39 and U40 decode
address, /WR/, and /RD/ lines to enable the appropriate memory or I/O device.
At power up, the 5 VDC supply begins charging C54, which will quickly reach a level high enough to be seen
as a logic high to NAND gate U13-8. U13-8 comes up with a low output, which goes high after C54 charges
sufficiently. This 0 to 1 transition out of U13-8 resets and starts the microprocessor, which begins executing
the software instructions stored in ROM. Note that the other input to U13-8 is from the heartbeat timer. The
heartbeat timer is a safety circuit which will reset the microprocessor if the timer is not triggered at regular
intervals.
AND gate U23-8 outputs a low to reset various integrated circuits. At start-up, the charging action of C54
causes a reset. Resets can also occur under software control (U39 Y7 output), or when the heartbeat timer
times out.
Y1, C55 and C56 form a 12 MHZ oscillator which provides a time base for the microprocessor. The oscillator
is also used to drive dividers U31 and U30, which generate 6 MHZ, 1 MHZ, 500 KHZ, and 250 KHZ timing
signals used by the programmable timer circuits.
The TXD and RXD lines on the microprocessor are the transmit and receive lines (respectively) of the serial
interface. These lines are used during calibration to communicate with the field data terminal (FDT) carried
by the service engineer. The serial interface is not used during normal operations.
The P1.0 and P1.1 lines are used by the keyboard decoder circuit to notify the micrcontroller that an input
from the control panel or auxiliary control panel has been received.

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The P1.2 and P1.3 lines are used to send display data to the control panel and mast. P1.2 transmits a clock
signal, P1.3 transmits serial data.
The P1.4/5/6 lines allow the microprocessor to send and receive serial data from NVRAM U7.
4.4.2 EPROM, RAM, and NVRAM
The software instructions are permanently stored in EPROM (erasable, programmable, read only memory)
U21. Software upgrades can be accomplished by replacing the EPROM. There are different software versions
for the various models, so the correct Coherent P/N EPROM must be installed. Consult section 6 (parts list)
for a list of P/N's for the software versions current at the release of this manual.
U18 and U19 form 1K byte of RAM. The microcontroller uses this area to keep track of miscellaneous values
while the system is turned on. Data stored in RAM is lost when the system is turned off.
U7 provides nonvolatile storage of 16 "words" of 16 bits each. The microcontroller uses it to store system
power calibration and error factors. The information is retained in the NVRAM, even when power is removed
from the unit.
4.4.3 D/A Conversion Circuits
There are two digital to analog convertors on the controller PCB; U43 and U44. U44 is not used. The micro-
processor writes digital values to U43, which the chip then converts to an analog output voltage (0 to 10 VDC
range).
The analog output voltage from U43 is used by the power seek circuit during the power seek routine. The
voltage represents the selected power at the control panel, and is compared with a voltage signal from the
power measuring circuit which represents the actual power out of the tube. The microprocessor uses the
result of the comparison to determine if the pulse width to the tube needs to be adjusted in order to get actual
power to match selected power. See the subtopic on the power seek circuit for a detailed description of the
power seek circuit and routine.
4.4.4 A/D Conversion Circuits
U38 is a "successive approximation" 12 bit analog to digital convertor. The microprocessor uses it to measure
any one of the five following analog voltages:
Temperature sensor output
Error signal
Power signal
Filtered power signal

0616-629-01 8/94 4-11
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(Refer to 8-8) An A/D conversion begins with the microprocessor closing one of the four electronic switches
in U41. This connects one of the four signals listed above to the input of A/D convertor U38. The micropro-
cessor then commands U38 to convert the analog voltage selected to a 12 bit digital value. After the conver-
sion is completed, the digital value is transferred to the microprocessor over the data bus, in two 8 bit
transfers. The temperature sensor signal is described in topic 4. 3 (cooling system) and the remaining three
signals are described in subsection 4.4.7 (power measuring and power seek circuits).
4.4.5 Digital I/O Circuits
The microprocessor uses the digital I/O to:
Read in high or low logic levels from throughout the system. In this manner the microprocessor can
check the condition of various sensors/components throughout the system. This function is provided
by (Controller PCB) U45, U14, and U24.
Output high or low logic levels to control devices such as solenoids, power supplies, integrated
circuits, etc.. In this manner the microprocessor can control the overall operation of the system. This
process is provided by (Controller PCB) U22, U34, U17, and U53.
(Refer to 8-8) U14 and U24 are quad pack tri-state differential input, tri-state output receiver buffers (note
that four of the buffers are not used). Each buffer output is connected to a separate data bus line. The output
of each buffer is open, freeing the data bus for use by other devices, until the microprocessor addresses U14/
24 via the decode circuit. When so addressed, the signal RDPT30-L goes low, enabling each buffer to output a
high or low, depending upon its input. The microprocessor can then read in the buffer outputs from the data
bus. Each buffer input includes the signal input and an inverted input. These two buffer input lines are
always in opposite states. The input signals processed by U14/U24 are:
RFCNT - This signal is operational on systems with the enabled safety shutter circuit. The signal
indicates the status of the safety shutter enable to the RF amplifier. Controller PCBs that do not
support the safety shutter circuit has the signal inputs wired to indicate the RF amplifier is enabled.
FRWPOK - This signal is generated by the RF amplifier. It is an indication of satisfactory transfer of

RF from the RF amplifier to the tube (VSWR) when high.
ATNST - The output of a slotted optical switch mounted on the attenuator. It is high when the
attenuator is in the beam path (attenuator solenoid de-energized). The microprocessor uses this signal
to determine the attenuator position. (Refer to 8-10) The signal from the slotted optical switch is
connected to the Optics Bench PCB at J5-8. U15-2/3 converts the signal to differential logic, then
sends it on to the Controller PCB.
SHTST - The output of a slotted optical switch mounted on the shutter. It is high when the shutter is
in the beam path (shutter solenoid de-energized). The microprocessor uses this signal to determine
the shutter position. (Refer to 8-10) The signal from the slotted optical switch is connected to the
optics bench PCB at J5-9. U15-10/11 converts the signal to differential logic, then sends it on to the
controller PCB.

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(Refer to 8-8) U45 is an octal buffer with tri-state outputs. Five of its buffers are used. The five signals are read
though to the data bus when the microprocessor (via its decode circuits) sets RDPT2C-L low. This enables the
buffer outputs to the data bus, resulting in a high or low out to the bus lines, depending on the input to the
buffer. The microprocessor can then read the data bus to obtain the values. The following signal inputs are
processed by U45:
FTSW0-L /FTSW1-H - The two inputs from the footswitch. When the footswitch is depressed FTSW1-
L is high, and FTSW0-L is low. A ground is sent to the footswitch through J10-3, and the footswitch
returns the ground on pin 1 (footswitch depressed) or pin 2 (footswitch not depressed).
FLWSW-L - The output of the two flow switches, connected in series. When both switches are closed,
a low is returned, indicating flow is sufficient.
REFPOK-H /FRWPOK-H - Two go/no go indications from the RF exciter/amplifier. The signals are
high to indicate a fault. The faults are insufficient forward power transfer or excessive reflected
power, between the RF amp and laser tube.
(Refer to 8-6) The signals enter the controller PCB as differential logic, and are converted to 5V logic
by receivers U37-3 and U37-5. The receiver outputs go to the D inputs of two separate FF's. The clock
signal to the FF's is the RFDREN signal; the same signal used to enable the RF exciter. The RFDREN
signal goes low to turn on the exciter. At the end of each enable to the RF exciter, the RFDREN signal
goes from low to high, which clocks in whatever is on the D inputs to the FF's. The /Q/ outputs of
the FF's are used as the inputs to tri-state buffer U45 (refer to 8-8). Note that the use of the /Q/
outputs of the FF's invert the signals, as seen at the tri-state buffer input.
U17, U22, and U34 are HEX pack D type flip flops. The microprocessor writes to these chips to send digital
control signals to various places throughout the system. To write to one of these I/O devices, the micropro-
cessor places the appropriate address on the address bus, asserts ALE, then places the 8 bit data word to be
written on the data lines. The address is decoded to drive the WRPT30-L (for U22) WRPT2C-L (for U34) or
WRPT20-L (for U17) line low. This clocks in the data to each of the six FF's in the chip. The FF's then hold
their Q outputs at the level clocked in at the D inputs until a subsequent write operation changes it. The
following signals are generated by U17, 22, and 34:
U22:
HeNe on/off (6Q) - The microprocessor sets this signal high to enable the 24 VDC supply to the
HeNe. (Refer to 8-6) The pin 15 output of U22 goes to differential driver U15-13/14. The differential
output of U15-14/13 is sent to the Optics Bench PCB. (Refer to 8-12) The HeNe ON differential signal
is input to receiver U19-13, where it is inverted and converted to five volt logic, then inverted again
by U16-12. The U16-12 output controls U27. U27 switches the 24 VDC return from the HeNe power
supply. When U16-12 output is low, U27 is off, and the HeNe supply is off. When U16-12 output is
high, U27 turns on, the return path for the 24 VDC is complete to the HeNe supply, and the HeNe
supply turns on.

0616-629-01 8/94 4-13
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Shutter in/out (5Q) - This signal operates the shutter. When the FTSWEN-H signal is high (the
footswitch is depressed), and this signal is high, NAND gate U33 outputs a low to differential driver
U15-10/11. The differential output goes to the Optics Bench PCB, where it enables drive to the shutter
solenoid. The solenoid energizes, pulling the shutter out of the beam path. (Refer to 8-12) At the
Optics Bench PCB, U19-3 converts the differential input from the Controller PCB to 5 volt logic, and
sends the result to pin 2 of OR gate U20-3. The other input to the OR gate is low whenever the
shutter is being energized, and then becomes a square wave once the shutter (or attenuator) is
energized and in place ( drops duty cycle of supply to solenoid, once shutter is in place, see "hold on/
off" below). A low out of the OR gate is inverted to a high by U16-6, which turns on Q1. Q1 on
completes the 24 VDC return path to the solenoid, and the solenoid will energize.
HOLDIN on/off (4Q) - This signal enables/disables a circuit on the Optics Bench PCB which reduces
the current to an energized shutter and/or attenuator solenoid. When either solenoid is commanded
to energize, the holdin on/off signal is kept off until the solenoid motion is complete. Once the
solenoid motion is complete, the microprocessor sets the holdin signal on, reducing the current
through the solenoid, while still keeping the solenoid in the energized position. The U15-2/3
differential output is sent to the Optics Bench PCB. (Refer to 8-12) On the Optics Bench PCB,
differential receiver U19-11 enables/disables timer U10. When enabled, the timer output is a 1KHZ
square wave (shutter and/or attenuator solenoids is/are energized), which interrupts the conduction
of Q1 and/or Q2 when the timer output is high (decreasing the duty cycle). When disabled, the timer
output is low.
ATTEN on/off (3Q) - This signal operates the attenuator. Differential driver U15-6/3 outputs to the
Optics Bench PCB, where is turns off/on supply voltage to the attenuator solenoid. The solenoid
energizes to move the attenuator out of the beam path, as would be used in WATTS or SUPERPULSE
mode. The solenoid de-energizes to place the attenuator in place when the laser is not firing, or the
laser is firing in MILLIWATT mode. (Refer to 8-12) At the Optics Bench PCB, U19-5 converts the
differential input form the Controller PCB to 5 volt logic, and sends the result to pin 4 of OR gate
U20-6. The other input to the OR gate is low whenever the attenuator is being energized, and then
becomes a square wave once the attenuator (or shutter) is energized and in place ( drops duty cycle of
supply to solenoid, once shutter or attenuator is in place, see "hold on/off" above). A low out of the
OR gate is inverted to a high by U16-4, which turns on Q2. Q2 on completes the 24 VDC return path
to the solenoid, and the solenoid will energize.
GAIN 1/2 (1Q and 2Q) - These two signals set the gain of the two programmable gain stages in the power
measuring and power seek circuit. The 1Q and 2Q outputs drive the gain stage on the Controller PCB (U48/
49) directly, and drive the gain stage on the Optics Bench PCB via differential driver U25-5/6, U25-2/3. See
4.4.7 for a detailed description of the power measuring and power seek circuitry.
U34:
Yellow HeNe on/off (1Q) - Turns on/off the Yellow HeNe supply. The microprocessor sets this
signal high to enable the 24VDC supply to the Yellow HeNe. (Refer to 8-6) The pin 2 output of U34
goes to differential driver U25-10/11. The differential output of U25-10/11 is sent to the Optics Bench
PCB. (Refer to 8-12) The YELL HeNe differential signal is input to receiver U9-3, where it is
converted to five volt logic, then inverted again by U16-12. The U16-12 output controls U27. U27
switches the 24VDC return from the HeNe power supply. When U16-12 output is low, U27 is off, and
the HeNe supply is off. When U16-12 output is high, U27 turns on, the return path for the 24VDC is
complete to the HeNe supply, and the HeNe supply turns on.
PSB enable/disable (2Q) - Not used.

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HeNe BLINK (3Q) - Enables/disables the "blink" mode of the aiming beam HeNe's. The
microprocessor sets this signal high/low to enable a timer chip on the Optics Bench PCB. (refer to 8-
12) The pin 7 output of U34 goes high/low to enable the blink mode, and is sent by differential driver
U6-6/5 to the Optics Bench PCB. U9 outputs a high to enable timer U10. While the timer is enabled, it
periodically interrupts the enable high to the opto couplers (U27, U28) for the HeNe and Yellow
HeNe. The opto couplers respond by turning off, opening the ground return lines for the HeNe's.
Fan on/off (4Q) - Not used.
STEN (5Q) - Control input to the safety circuit, this signal is used to enable the RF Amplifier during a
software initiated laser firing (self tests, power seek) when the shutter remains closed and the
footswitch is not depressed.
RF EXCITER RFDREN TP1

4
4
8
MICROPROCESSOR 8
TIMER TEMP
ERRSIG
4 ADC SEL
PWR SIG
CO2 DIGITAL
8
TUBE MULTIPLEXER
I/O
DAC COMMAND ERR SIG TP17
VOLTAGE TP15 TO MUX R31 INTEGRATED
2 ERR SIG TP19
GN0/GN1
3 7 7
VARIABLE
COMPARATOR INTEGRATION & GAIN
CIRCUIT
COMMAND DAC AMPLIFICATION
PWR SIG TP16

7
TO MUX
4 CONTROLLER PCB
SHUTTER 2
SOLENOID GN0/GN1 R41
1 DE-ENERGIZED VARIABLE
5 GAIN
CIRCUIT 6
SHUTTER
ENERGIZED
THERMOPILE 6
OPTICS BENCH PCB
POWER SEEK SEQUENCE SIMPLIFIED DIAGRAM

(REFER TO 4.X.X )

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220 on/off (6Q) - Not used on the systems with the Coherent 48 VDC Power Supply. It is used in the
earlier systems with the two commercial 48 VDC Power Supplies to turn on the supplies.
U17:
HeNe auto mode indicator on/off (1Q) - Controls the AUTO indicator light on the auxiliary control panel.
When "AUTO" is selected the HeNe is turned off for the duration of each treatment delivery. When "AUTO"
is not selected, the HeNe is always on. The output of differential driver U9-2/3 is sent to the auxiliary control
panel. (Refer to 8-20) Differential receiver U2-3 output is inverted by U1-4 to turn on (output low) or off
(output high) DS1.
Mast clock enable (2Q) - Enables/disables the clock signal to the 32 bit shift register for the mast display.
The clock is used to load serial data from the microprocessor into the shift register that drives the mast
display. The output of differential driver U9-5/6 is sent to the Optics Bench PCB. See topic 4.4.10 for a
complete description of the mast display circuit.
Clock enable (3Q) - Enables/disables the clock signal to the 72 bit shift register for the main control panel
display. The clock is used to load serial data from the microprocessor into the shift register that drives the
mast display. The output of differential driver U9-13/14 is sent to the Control Panel PCB. See topic 4.4.8 for a
complete description of the control panel.
Overheat indicator on/off - Controls the OVERHEAT indicator light on the auxiliary control panel. When
coolant temperature exceeds 115 ˚F, the indicator is turned on as an "overtemperature warning" (the system
continues to operate). At 125 ˚F, a fault code is displayed, and operation is disabled. The output of differen-
tial driver U9-10/11 is sent to the auxiliary control panel. (Refer to 8-16) U2-5 output is inverted by U1-6 to
turn the indicator on (output low) or off (output high) to differential driver U9-10/11. The differential output
goes to the auxiliary control panel to turn off or on the overheat indicator.
Keyboard reset (5Q) - Used during the power up initialization and self tests to initialize the serial
interface between the two keyboards (main control panel and auxiliary control panel) and controller.
The output of the differential driver U1-2/3 goes to the auxiliary control panel. At the control panel,
the reset causes the keyboard encoder to transmit an initialization signal back to the decoder on the
Controller PCB. If the initialization is not successful, a fault is displayed at the front panel.
(Refer to 8-16) At power up, the microprocessor momentarily sets the KYRST signal, which results in
a high out of differential receiver U2-11. The output of inverter U1-2 goes low, which drops the row
1/column 1 inputs to encoder U4 low. This simulates a "turn on" to the encoder, which outputs a
frequency modulated pulse at pin 14. The frequency modulated pulse is sent to differential driver U3-
2/3, which transmits the signal to the Controller PCB. (Refer to 8-5) The signal is received by U16-5,
which converts the differential signal to 5 volt logic, and sends the signal on to decoder U10 via U23-
6, U13-6, and U27-2. The decoder decodes the signal, places the information on the A/L lines, and
informs the microprocessor by interrupt (CHDAV & ADDAV) that a signal has been received. The
microprocessor will respond to the interrupt, and read in the signal information from U3. The "turn
on" signal indicates to the microprocessor that the serial interface circuit is operating, and the power
up initialization and self tests will continue. If the "turn on" signal is not received, the display will
indicate fault 20.
A/D read/convert (6Q) - To the R/ /C/ input of the AD converter U38. This signal enables a convert
or read cycle in the A/D converter.

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The remaining digital I/O output signals are processed by U35, U53, and U46. To write to these digital I/O
ports, the microprocessor places the appropriate address on the address bus, asserts ALE, and then places the
data on the data bus. The address decode circuit decodes the address, which results in WRPT34-L low. This
low clocks in the data (on the D inputs) to the Q outputs of a single FF in U53, and to 6 FF's in U35. The Q
outputs remain until a subsequent write cycle changes them. The following signals are generated:
U53:
LASEN, which is used as an enable for the RFDREN signal. The RFDREN signal turns on the RF
amplifier, which results in power out of the CO2 tube. See subsection 4.4.6.2 for a detailed description
of the circuitry which uses this signal.
U35:
HBEN-H, the microprocessor enables the heartbeat timer with this signal. When this line is high, the
heartbeat timer output will reset the microprocessor if the timer itself is not reset at its normal
interval. See subsection 4.4.6.1 for a detailed description of the heartbeat timer circuit.
ZERINT-L, which is used to reset (zero) the power seek loop integrator after each power seck
sequence. See subsection 4.4.7 for a detailed description of the power seek circuit.
NVRCE, which is used to clear the NVRAM. The clear is done upon completion of a successful
power calibration routine. After the NVRAM is cleared, it is loaded with the new values determined
during the calibration procedure.
1Q, 2Q, 3Q, which are sent on to decoder U46. U46 decodes these three lines to generate five signals,
as follow:
PWRSEL-L/FILSEL-L/TMPSEL-L/ERRSIG-L These are the four select signals to the

multiplexer U41 (refer to 8-8). The microprocessor sets any one of these lines to connect that
analog signal to the A/D conversion circuit. In this manner, the microprocessor can then use
the A/D conversion circuit to determine the value of the analog voltage. The TMPSEL-L
signal is the analog voltage from the coolant temperature detector, which is described in
detail in section 4.3. The remaining three signals are analog values associated with the power
measurement and power seek circuits. See subsection 4.4.7 for a detailed description of the
power measurement and power seek circuits.
ZERO-L - The microprocessor sets this signal low to "zero reference" the A/D circuit prior to
measuring the various sample analog voltages.

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4.4.6 Timer Circuits
(Refer to 8-5) U28 and U29 are programmable timers which operate under microprocessor control to provide
timed logic signals for:
U28:
Beeper - The beeper provides audible tones to draw the attention of the operator to some
operating condition (i.e., power seek complete, invalid operator input, etc.).
INT0-L TIMER - interrupts every .25 seconds to reset heartbeat timer, check CDRH (by
checking B supply), check shutter position, and decrement 5 minute inactivity timer.
U29:
Heartbeat timer - The heartbeat timer is a safety circuit which is kept in its nonfault state by
regular interval triggers from the software.
RF drive enable to the RF exciter - This signal, when low, turns on the RF exciter, which
results in power out of the CO2 tube. The relative duration of logic low and high pulses (the
duty cycle) determines the average power out of the tube. The microprocessor adjusts the
relative on and off time of this signal to control the average power out of the tube.
The microprocessor writes to the various timers to set the timer operating parameters. Each timer chip
actually contains 3 timers (Called timer 0, 1, and 2). In U28, timers 1 and 2 are used to control the beeper,
while timer 0 is used for the INT0-L. All three U28 timers use the 250 KHZ clock signal from U30. In U29,
timers 0 and 1 are used to generate the RFDREN signal, while timer 2 is the heartbeat timer. U29 Timers 0 and
1 are clocked at 6 MHz, and timer 2 is clocked at 1 MHz.
4.4.6.1 Heartbeat Timer
(Refer to 8-5) The output of the heartbeat timer is HBTIM-H. Once the timer is enabled, a software interrupt
occurs at regular intervals which resets the timer before it times out. If the timer is not reset within 66 milli-
seconds, it times out, and the HBTIM-H signal goes high. This high is seen as an input to NAND gate U13-3.
If the HBEN-H signal is also high (indicating the heartbeat timer circuit is enabled, which is true throughout
normal operation), the output of U13-3 goes low, driving the output of U13-8 high (resets the microprocessor)
and the output of U23-8 low (generates a power up reset).
4.4.6.2 RF Drive Enable Circuit
(Refer to 8-5) The timer 1 OUT signal and the LT50DUT-H signals are combined at XOR gate U32-3 to form
the signal which controls power out of the laser. As long as the LASEN-H input to U33-11 is high (laser is
enabled for firing), the XOR output is inverted and applied to differential driver U8-10/11, and is then sent to
the RF exciter. When the signal is low, the RF exciter is enabled. When enabled, the exciter pumps 81.36
MHz RF energy into the tube, causing the lasing action which results in the 10.6 micron wavelength energy
output from the tube. Pulse width modulation is used. During CW operation, the low enable pulses occur at a
3 KHz interval. The duration of the low pulse determines the "duty cycle". Maximum duty cycle is 40%, due
to limitations of the RF amplifier.
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POWER UP
INITIALIZATION
AND SELF
TEST
MAIN
PROGRAM
LOOP
WATT MILLWATT ULTRAPULSE

MODE MODE MODE
WATT MILLIWATT ULTRAPULSE

IDLE IDLE IDLE
ERROR TREATMENT POWER EXTERNAL &

ROUTINE FIRE SEEK OR READ .25 SEC.
INTERRUPTS
SERIAL SYSTEM
INTERRUPT CALIBRATION

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The operation of the timer for power seek, watt/milliwatts, and Ultrapulse operation is as follows:
POWER SEEK (WATTS & MILLIWATTS modes) - When a new power setting is selected, or the
system has been on a power setting for five minutes without firing, a power seek routine is initiated.
The purpose of the routine is to "seek" a pulse width for the RFDREN low enable pulses which results
in an average power out of the tube which matches the selected power.
WATT/MILLIWATT - When treatment power is delivered in either WATTS or MILLIWATTS mode,

the timer output will be of the pulse width and fixed frequency determined at the last power seek.
ULTRAPULSE - Ultrapulse mode allows the user to specify pulse width and repetition rate. When
the repetition rate or pulse width is changed, the system fires into the thermopile briefly at the new
setting. The power measuring circuit is read through the ADC to determine the average power for the
new setting, then the average power so found is displayed, and control is returned to the operator.
4.4.7 Power Measuring and Power Seek Circuits
The internal power measuring circuitry provides a means for the system to measure the power out of the CO2
tube. Periodically, the internal power measuring circuitry must be calibrated to an external power meter. The
power measuring circuitry is used in WATTS and MILLIWATTS modes as an input to the power seek circuit,
and in SUPERPULSE/ULTRAPULSE mode to determine the average power for the selected pulse duration
and repetition rate, for display at the control panel.
The power seek circuitry is used in WATTS and MILLIWATTS modes. Each time a new power setting is
selected (or after the system has remained at the same power setting for five minutes without firing) a
"power seek" routine is run. Note that the power seek routine runs previous to any treatment delivery at the
selected power setting.
This routine fires the laser into the internal power measuring circuitry and uses the power seek circuitry to
find the pulse width that results in power out of the tube which matches selected power. Once the power
seek is completed successfully, the system has determined the pulse width to use for any treatment delivery
at the current power setting. If the power setting is changed, or the laser is not fired for a period of 5 minutes,
a new power seek routine is done. The sequence of events in the power seek routine is as follows ( Refer to
the power seek routine diagram):
1.) The microprocessor maintains the shutter in the beam path, via the digital I/O, throughout the
power seek routine. Shutter position is controlled by the shutter solenoid. When the solenoid is de-
energized, the shutter is in the beam path. A convex mirror on the shutter will deflect any laser light
into the thermopile.
2.) The microprocessor writes to the digital I/O to set the gain of the two variable gain stages. The
circuits can be set to one of four gain settings. During calibration the system determines the
appropriate power range for each of the four gain settings. During normal operations, when the
selected power is in the lowest range, the gain of the first variable gain stage (Optics Bench PCB) is
set to the maximum gain setting, and the second variable gain circuit (on Controller PCB) is set to its
minimum gain setting. As selected power is moved up into the other three ranges, the gain of the first
variable gain stage is moved down, and the gain of the second stage is moved up (so that at the
highest power range, the first stage is at minimum gain, and the second stage at maximum). This
allows the entire output range of the DAC to be available to each of the four bands.

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3.) The microprocessor writes a digital value representing selected power to the command DAC. The
digital value is calculated from the selected power setting and calibration data stored in the NVRAM
during the last power calibration. The DAC outputs the corresponding voltage. This voltage will be
compared with a voltage representing actual measured power.
4.) The microprocessor writes to the timer to load it with a starting pulse duration of 15 µseconds and
a fixed pulse repetition rate, then starts the timer. The timer output is the RFDREN signal, which
enables/disables the RF exciter at the frequency and pulse duration loaded into the timer. The RF
output from the exciter is sent to the tube, resulting in power out of the tube.
5.) The power out of the tube is deflected by the shutter mirror onto the thermopile. The thermopile
PCB outputs a voltage proportional to the power of the laser energy from the tube, which is sent to
the optics bench PCB.
6.) At the optics bench PCB, the measured power signal is sent through the first variable gain stage,
through a dampening circuit (R41 is adjusted to minimize over/undershoot), then on to the controller
PCB.
7.) At the controller PCB, the voltage from the command DAC (desired power) is compared with the
voltage from the optics bench PCB (measured power). The error signal (TP17) is integrated and
dampened (R31 is adjusted to minimize over/undershoot), then sent through the second variable
gain stage to become one of the 4 multiplexer inputs (TP19).
8.) The microprocessor selects the error signal for input to the ADC, where the analog voltage is
converted to a digital value. The microprocessor reads in the digital value from the ADC.
9.) The microprocessor evaluates the error signal to determine if further adjustment of the pulse
width is necessary. The power detector reading must be within +/- 5% (or +/-15% for selected
powers within 15% of maximum power). If power is not within these limits, the microprocessor
computes a new pulse width and loads it into the timer.
This process continues until the power detector signal remains within limits for 1 second, at which time the
microprocessor retains the pulse width which resulted in the correct power and returns control to the opera-
tor. Each time the laser is fired, the frequency determined during the power seek is used. If the operator
changes power settings, or the system is not fired for five minutes, a new power seek is initiated. If the power
seek has not been completed after 7 seconds, the process is terminated and a fault 4 is displayed at the control
panel.
In ULTRAPULSE MODE the operator selects the repetition rate and pulse duration, which can then be loaded
directly into the timer. There is no need for a feedback loop. Each time a new Ultrapulse setting is selected,
the system fires once with the shutter closed, and then displays the resulting average power at the control
panel. Control is then turned over to the operator.

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4.4.8 Control Panel
The control panel is the primary operator input/output interface. It includes switched light bars for selective
illumination of panel graphics, seven segment LED's for numeric displays, and a ten key membrane for
operator input.
(Refer to 8-4) To update the control panel display, the microprocessor outputs a 72 bit serial data stream on its
P1.3 port, and a clock pulse on its P1.2 port. Differential transmitter U8-13/14 sends the data stream to the
mast display circuitry (the circuitry is on the optics bench PCB) and the control panel display circuitry. The
microprocessor enables one or the other (mast or control panel) to receive the data stream by sending a clock
enable signal (MCKEN or DSPCKEN via the digital I/O) to one or the other.
(Refer to 8-18) Differential receivers U20-13 and 5 accept the differential signals generated at the microproces-
sor (DSPCK and DSPDAT) and convert them to 5 volt logic. If the data being transmitted is meant for the
control panel display, the microprocessor will have also set the CKEN signal (via digital I/O) resulting in a
high at pin 5 of AND gate U14-6. This passes the clock signal into the CK (clock) inputs of a 72 bit serial input,
parallel output shift register made up of U2, U25, U27, U8, U10, U13, U17, U23, and U28. The clock pulses
load the 72 bit data word into the register, and the register parallel outputs drive the various LED's and light
bars.
The keyboard (10 button membrane) will output a row and column ground to uniquely identify a depressed
button. Encoder U5 transmits a frequency shift encoded representation of the key pushed. Differential
transmitter U24-10/11 sends the signal to the controller PCB.
(Refer to 8-5) At the controller PCB, the data is converted back to 5V logic (U16-3) and sent to AND gate U23-
6. The U16-13 (not used) input to U23-6 is always high. The U16-5 input to U23 is the data signal line from the
auxiliary keyboard. It is high when inactive (as is the control panel keyboard input). The keyboard serial data
is gated through U23-6, and AND gate U13-6 9 (data out line is not used, always high), then inverted by U27-
2 and sent to the data input of decoder U10. U10 /VA/ and DR outputs develop the ADDAV and CHDAV
signals, to notify the microprocessor of the receipt of a valid signal from the control panel (or aux control
panel). The microprocessor responds by reading in the data from latch U3.
4.4.9 Auxiliary Control Panel
The auxiliary control panel provides:
Operator inputs for HeNe "auto" on/off
Ultrapulse width
Ultrapulse rep rate
HeNe "color" and "blink" select
Indicator for HeNe "auto" on
Keyboard reset function, to initialize the circuit which transmits keyboard commands from the
control panel and aux control panel microprocessor.

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(Refer to 8-20) The auxiliary control panel keyboard (membrane) sends row/column inputs to encoder U4.
The encoder outputs a frequency shift encoded representation of the key pushed to differential transmitter
U3. The output of U3 is sent to the Controller PCB. Note that the row 5 and column 1 inputs to U4 are active
(low) when the KYRST signal is active. The microprocessor generates the KYRST signal (Digital I/O ) shortly
after power up, which causes encoder U4 to output the appropriate signal back to the controller via U3. This
signal acts to initialize the communication from the two keyboards (aux control panel and control panel) to
the controller.
(Refer to 8-5) At the controller, the AUXKY signal is handled in the same manner as the KYBD signal, which
was described in the previous subtopic.
4.4.10 Mast Display
(Refer to 8-21) The mast display consists of 6 seven segment (numeric) LED's and a series of light bars. The
numeric LED's provide power, exposure time, and Ultrapulse number. The light bars are turned on to
provide backlighting for mode indications (STANDBY, MILLI, CONTINUOUS, etc.). The mast display
components are controlled by the parallel outputs of a 32 bit shift register on the Optics Bench PCB. The
microprocessor loads the shift register to update the display.
(Refer to 8-7) To update the mast display, the microprocessor first sets MCKEN active (Digital I/O). Differen-
tial transmitter U25-5 output goes high:
(Refer to 8-13)
•To inverter U18-6, where it is inverted (active low) and sent to the BI input of each segment driver.
This blanks out the numeric LED's while the shift register is being updated.
• To inverter U4-12, where it is inverted (low) to disable the 20V output of regulator U26. This blanks
out the light bar indications while the shift register is being updated.
• To AND gate U14-8, where it gates the MSTCK signal through the AND gate, and out to each of the
74LS164 chips which form the shift register.
Once the MCKEN signal is active, the microprocessor outputs a clock (MSTCK) and data (MSTDAT) signal to
the shift register. Differential receivers U25-3 and 11 convert the signals to 5 volt logic. The data signal is
loaded into the 32 bit shift register (U2, U3, U8, U23) by the clock pulses. The U3 outputs drive the light bars.
U2, U8, and U23 output BCD to the segment drivers. The segment drivers output through resistor packs to
the numeric LED displays.
4.4.11 Safety Circuit & Audible Indicator
The safety circuit (also called the safety shutter circuit) and audible indicator circuit were added to later
production UltraPulse systems to meet approvals for ETL listing.
The safety circuit was first implemented as an add on circuit external to the 0617-040-01 controller PCB, then
was incorporated into the 0615-880-01 controller PCB. The 8-24 schematic shows the external circuit as used
with the "040" controller PCB. See 8-10 for the circuit as built in to the "880" controller PCB. The two circuits
are the same.
0616-629-01 8/94 4-23
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(Refer to 8-10) U3 is turned on to enable the RF amplifier (completing an interlock loop between J6-1 and 2).
U3 is turned on through Q1 turn on by U2-8. Note that the RFCNT-H and RFCNT-L signals allow the micro-
processor to monitor the status of the safety circuit enable. Nand gate U3-8 will turn on Q1 (enabling the RF
Amplifier) if either of its pin 9 or 10 inputs is low.
Nand gate U2-3 will enable the RF amplifier (low to U2-9) when the shutter is energized (out of the
beam path, SHTST-H is high)) and the footswitch is depressed (FTSW0-L is low). This is the enable
condition for a normal user requested exposure.
Nand gate U2-6 will enable the RF amplifier when the shutter is de-energized ( in the beam path,
beam path into power detector) and the STEN-L signal is low. The software uses the STEN-L signal to
enable the RF amplifier during the self test firings and power seek routines.
The audible indicator circuit produces a tone during treatment delivery. Q2 is turned off to enable timer U4.
Timer U4 output is sent through U5 to drive SP1. R8 adjusts tone volume.
Q2 is turned off (to produce the audible tone) when both the inputs to U55-3 are high. This occurs when the
footswitch is depressed and the shutter is energized.
4.5 RF EXCITER & TUBE
The RF exciter, RF cable, and tube are a matched set. When enabled, the exciter outputs an 81.36 MHZ RF
signal through a coaxial cable to the tube. At the tube, the RF is applied across the CO2 gas filled cavity
(capacitive coupling) to excite the gas. The result is 10.6 µm (or 11.1 µm) wavelength output from the tube.
The average power out of the tube is proportional to the duty cycle of the RF from the exciter. "Duty cycle"
refers to the percentage of time that the RF is on during the period of an exposure. For lower powers, the duty
cycle is low, and for higher powers, it increases. Maximum duty cycle is approximately 40%. The micropro-
cessor uses a programmable timer chip to control the duty cycle of the RF exciter (develops the RFDREN
signal, low to enable).
The RF exciter operates off of DC voltage from the 48 VDC Power Supply.
SUPERPULSE mode takes advantage of the ability of the tube to provide much higher peak powers than that
achieved in the CW modes if the tube is operated at a low duty cycle with short duration pulses of RF excita-
tion voltage. These short bursts of higher power typically result in a more dramatic effect on tissue, with less
thermal damage to surrounding tissue, than similar average power in the CW mode.
ULTRAPULSE provides the same short pulses of peak power, but with very short rise and fall times, allow-
ing the "peak power" portion of the pulse to be a much larger percentage of the entire pulse. Although the
peak power is a bit lower than in Superpulse, the total energy delivered per pulse in Ultrapulse is 4 to 5 times
more than in Superpulse delivery of the same average power. The result is an even better effect on tissue than
that of Superpulse, with very little thermal effect on surrounding tissue.
The tube is sealed, and has no adjustments. Maintenance is limited to the cleaning of the output coupler.

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4.6 OPTICS
The optics include all the components which operate on the HeNe (aiming) and CO2 (treatment) beams.
The aiming beam is provided by either or both of a red HeNe laser tube and yellow HeNe laser tube. Note
that the yellow HeNe is an option, not sold with all systems. A drawing of the optical paths for aiming and
treatment beams is included in section three. Systems with both HeNe's provide the operator with selection
for either or both aiming beams. When not selected, the power supply to the tube is turned off, so the tube
itself is off. Intensity is controlled by an attenuator glass on the mast which the operator turns directly.
The path for the treatment beam is:
CO2 Output coupler - The CO2 tube generates 10.6 µm (or 11.1 µm) energy in response to RF input
from the exciter.
Deflecting shutter - The shutter is operated by a solenoid. When the solenoid is de-energized, the
shutter is in the beam path, and a convex mirror on the shutter disperses the CO2 beam across the
surface of the thermopile. When the attenuator is energized, the shutter is out of the beam path.
Attenuator wheel - The attenuator is operated by a solenoid. When the solenoid is de-energized, the
attenuator is in the beam path, attenuating the beam to approximately 1/40th of its input power. The
attenuator is left in this position when the laser is not firing, and for MILLIWATT mode. For WATTS
and SUPERPULSE/ULTRAPULSE modes, the attenuator solenoid is energized to move the
attenuator out of the beam path.
NOTE: Adjustable dashpots are mechanically linked to both solenoids. The dashpots provide
dampening to the solenoid mechanical movement (minimizing "bounce"), but must still allow the
movement of the shutter or attenuator to be completed in under 50 mseconds. Both the shutter and
attenuator are monitored by slotted optical switches.
CO2 corrective optic & aperture - The corrective optic is adjusted to provide a circular beam shape,
and the aperture is positioned to eliminate any satellites or lobes on the CO2 beam.
Combiner - Places the treatment and aiming beams coincident.
Articulating arm - The seven knuckle arm delivers the CO2 and HeNe beams to the operating site via
a series of first surface mirrors within the arm. A manual beam stop is located on the base of the arm.
Delivery system - A variety of delivery systems are available for the XL/Ultrapulse, including fixed
and adjustable spot size hand pieces, colpascope adapters, etc..

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4.7 SOFTWARE
The USER software is permanently stored in the EPROM on the controller PCB. There is a different version of
software for each model type. The versions differ in the range of power that can be selected and delivered;
otherwise, all are very similar, and the sequence of events provided in this subsection is applicable to all.
Software updates are installed by replacing the EPROM (U21) with an EPROM containing the newer version
of software. See section 6 for part numbers of the various versions of the software.
Power initialization and self tests
1. Initialize the 8031 stack pointer and I/O port 2 and set up interrupt vectors.
2. Test data memory (RAM) for the correct read and write operation. If incorrect test results, system is halted,
and fault 7 is displayed.
3. Check coolant flow switch for inactivity. If active, halt system, display fault 22.
4. CRC the ROM memory. If incorrect CRC, halt system, display fault 6.
5. Turn on self test illumination.
6. Configure serial port, interrupt priorities and the heartbeat timer.
7. Enable 220VAC to the system (for early systems with the commercial power supplies only).
8. Turn on the yellow HeNe.
9. Measure A/D and D/A offset voltages.
10. Activate (for the early systems with commercial supplies only -energize relay K4) and check cooling
system . Fault 18 for flow switch error. Fault 3 for coolant temperature error.
11. Check attenuator operation. Fault 13 for failure to move into beam path. Fault 14 for failure to move out of
beam path.
12. Check shutter position. Halt and display fault 12 for failure.
13. Turn on the laser.
14. Check REFPOK signal. Halt and display fault 11 if low.
15. Check FRWPOK signal. Halt and display fault 17 if low.
16. Measure laser output. Halt and display fault 5 if less than 4 watts.
17. Test power detector gain circuitry. Halt and display fault 8 for failure.
18. Load default operational parameters.
19. Reset control panel. Fault 20 and halt if reset fails.
20. Configure tone generator timers.
21. Initialize power adjustment interrupt timer (8031 internal timer).
22. Obtain D/A power factors and 5% error factor data from NVRAM.
23. Configure the .25 second interrupt timer.
24. Test the footswitch. Fault 2 if shorted. Fault 1 if not present. Fault 19 if active.
25. Enable serial port interrupt.
26. Initialize control panel display to Ultrapulse 1.
27. Enter main program loop.
Main Program Loop
1. Reset the heartbeat timer.

2. Check if red or yellow HeNe is on.
3. Move attenuator out of the beam path.
4. If the operational mode is MILLIWATT, move attenuator into beam path and enter CW mode routine.
5. If the operational mode is SUPERPULSE/ULTRAPULSE, enter SUPERPULSE/ULTRAPULSE routine.
6. If the operational mode is WATTS , enter CW mode routine.

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Watt mode loop

2. Disable laser power adjustment interrupt timer and turn off the laser.
3. Call watt power parameter routine to calculate the values for the power adjustment routine, based on
current watt power value.
4. Enable power adjustment interrupt timer to interrupt in 1 microsecond.
5. Check operation mode. If not Watt mode, return to main program loop.
6. Check operation status for the standby/ready and continuous/pulsed. Enter the related routine and
remain in that routine until the operating status is changed.

2. Disable laser power adjustment interrupt timer and turn off laser.
3. Check operation mode. If not WATT or MILLIWATT, return to main program loop.
4. Enter CW idle routine.
Milliwatt mode loop

2. Disable laser power adjustment interrupt timer and turn off the laser.
3. Call milliwatt power parameter routine to calculate the values for the power adjustment routine, based on
current milliwatt power value.
4. Enable power adjustment interrupt timer to interrupt in 1 microsecond.
5. Check operation mode. If not milliwatt mode return to main program loop.
6. Check operation status for standby/ready and continuous/pulsed. Enter the related routine and remain in
that routine until the operating status is changed.
Ultrapulse mode loop

2. Disable laser power adjustment interrupt timer and turn off laser.
3. Load modulation timers with ultrapulse rep rate and pulse width values. Set power detector gain to zero.
4. Enable Ultrapulse power measurement interrupt timer to interrupt in 50 milliseconds.
5. Check operation mode. If not Ultrapulse, return to main program loop.
6. Check operation status for standby/ready and continuous/pulsed. Enter the related routine and remain in
that routine until the operation status is changed.

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Operating state loop
1. Reset heartbeat timer and update display.

2. If system is in continuous, watt, standby, and 2 watt power setting; then enable serial interrupt for calibra-
tion.
3. Check control panel for an active push-button.
4. Call the appropriate routine, or take the appropriate action to service the control panel input. In every
operating state some push-buttons are inactive. Only the beeper sounds to acknowledge button depression,
but no action is taken.
5. Monitor the footswitch for off to on transition. If in ready mode, call pulsed lase or continuous lase routine.
6. In standby the footswitch depression is ignored and the shutter remains closed.
7. In standby mode, when the ready push-button is depressed, the footswitch status is checked before the
system can go to ready. If the footswitch is active, system remains in standby until the footswitch is released.
Error code is displayed if the footswitch is defective.
8. The flow switch and coolant temperature are monitored. If the flow switch is inactive, system is halted and
fault code is displayed. If the coolant temperature rises to warning limit of about 46˚C, the temperature
warning LED is lit on the auxiliary control panel. If the temperature goes above the maximum limit of about
53˚C, the laser is turned off, the system is halted, and fault code is displayed.
Treatment fire routine
1. Reset heartbeat timer.

2. Activate shutter solenoid. Allow maximum of 50 milliseconds for the shutter to open. Check footswitch
status and shutter position. If shutter does not open in 50 milliseconds, display shutter did not activate error.
If the footswitch is inactive., do not open the shutter. Display fault code is footswitch is defective.
3. Turn on laser.
4. Display lase annunciator.
5. Turn off HeNe is auto mode is active.
6. Continue monitoring footswitch status. Stop laser firing, close shutter and turn off lase annunciator if
footswitch is inactive.
7. If in pulsed lasing mode fire the laser for the exposure time duration and repeat rate.
8. Monitor coolant temperature. Display temperature warning if in warning range. If above high temperature
level, close shutter, stop firing and display fault code. System operation is not allowed until the coolant
temperature drops to below high temperature level. Warning LED goes off when the coolant temperature
drops below warning limit.
9. Reset the 5 minute laser power readjust timer to interrupt if the laser is not fired in five minutes.

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Clock interrupt routines
timer 0 interrupt - This interrupt is activated as needed when a new power level is selected.
1. Disable timer 0 interrupt and reset heartbeat timer.
2. If in watt or milliwatt mode, call power adjust routine.
3. If in Ultrapulse mode, call power adjust routine.
4. Turn off laser if on and go into standby.
5. Delay until power detector reads less than 1 watt of power. If gain 3 is selected delay until power detector
reads below .25 watts.
6. Load modulation timers with fixed frequency of 3000 Hz and minimum pulse width of 25 microseconds.
7. Check shutter. If open, display fault and halt. If closed fire laser into the detector.
8. Adjust the pulse width until the power detector reading is within ±5% of the selected power for 1 second
(allow ±15% for power levels within 15% of watt limit). Allow 7 seconds for this adjustment to occur. Display
fault 4 if seven seconds is exceeded.
9. In Ultrapulse mode, read detector and display watt value.
10. When power is found, beep and turn off laser.
11. If system is in ready mode when the interrupt happened, check footswitch and if not active go to ready. If
footswitch is active, keep monitoring the footswitch until it is released, then allow the system to go to ready.
timer 3 interrupt - This interrupt is caused by external timer every .25 seconds.
1. Reset heartbeat timer.
2. Test shutter solenoid operation.
3. If system is not in Superpulse mode of operation, and if footswitch is not active, and if low laser power
fault code is not active, decrement the 5 minute power re-adjust counter. If expired, enable timer 0 interrupt
to activate in 1 microsecond to readjust power.
System error routine
This routine is called when a fault condition is detected.
1. Disable all interrupts.

2. Disable heartbeat timer.
3. Blank all displays.
4. Display fault code only.
5. Go idle.

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Power calibration routine
The power calibration routine is entered when the field data terminal is attached, and the system is set to 2
watts, standby, continuous. An external power meter and field data terminal are required to do the calibra-
tion.
1. Reset the heartbeat timer and disable all interrupts.

2. Clear all displays.
3. Move shutter into beam path.
4. Load D/A with 5 volts.
5. Enable timer 0 interrupt for power adjustment.
6. For each gain level fire laser and measure error signal (TP17).
7. Transmit the error signal to the calibration computer.
8. Allow laser to be fired into an external meter.
9. Calibrate for watt and milliwatt mode.
10. The attenuator is moved into the beam path for milliwatt measurement.
11. Get 5% error factors and D/A factors calculated by the program in the calibration computer from the
computer.
12. Save factors in the system NVRAM.
13. Restore system operation to 2 watts- continuous- standby.

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5.0 TROUBLESHOOTING & REPAIR
5.1 OVERVIEW
5.1.1 Service Philosophy
UltraPulse systems are designed to require few service technician adjustments, and to detect and report most
hardware malfunctions by a displayed fault code. In most cases field failures are repaired by changing out a
field replaceable unit (FRU). FRU's are built specifically to support field repair, consisting of a part or group
of parts determined to be suitable for field replacement. When a part fails that is a part of a FRU, the FRU is
replaced, not the individual part.
Corrective and preventive maintenance must only be accomplished by a Service Engineer who has success-
fully completed a Coherent certification training course on the UltraPulse series.
Field calibration and adjustment is covered in detail in Section 3. Special purpose tools are required to
maintain the UltraPulse; these tools are listed in Section 3. Coherent part numbers for ordering the special
purpose tools are provided in Section 6.
After power up, and before the system moves to the standby condition, the software performs a series of self
tests. Self test failures result in fault codes displayed at the control panel. These fault codes provide an
indication of what malfunction was detected, which should point to a specific area of the system for further
investigation. Explanations of the fault codes are included in this section.
During normal operation the software continues to monitor for system malfunctions, and to report any
detected malfunctions via the control panel.
The UltraPulse series is supported by three service software routines. Each routine is contained in a separate
EPROM. To use one of these service routines the EPROM for that service routine must be installed in place of
the user software EPROM on the controller PCB.
ULTRAPULSE SERVICE MANUAL TROUBLESHOOTING & REPAIR

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5.1.2 Safety Precautions
Lethal voltages and laser emission are the primary dangers to the servicing engineer. In addition to the
general safety precautions which always apply when working on electronics and lasers, the servicing engi-
neer must be aware of the following specific precautions:
Only Coherent certified UltraPulse Service Engineers should attempt any service on this system.
Even with the key switch in the "OFF" position there are potentially lethal voltages present inside
the console.
Storage capacitors inside the system are capable of holding a lethal charge, even after power has
been removed from the unit. Before contacting any capacitor, disconnect the system from primary
power and use a shorting probe to discharge the capacitor to ground.
The 10.6µm (or 11.1 µm for "L" systems) laser light is invisible to the human eye. Because the
energy can not be seen, there is no visible indication of the primary or reflected beam. Eye protection
that attenuates the treatment wavelength to a safe level must be worn by all persons in the area of the
laser system whenever the laser is being serviced.
The 10.6 µm (or 11.1 µm for "L" systems) laser light and its reflections are potential burn hazards
and can ignite flammable materials. Use extreme caution when operating the system with covers
opened or removed. The covers contain the beam and reflections safely within the console. Only
those persons required should be present during servicing, and eye protection that safely attenuates
these wavelengths must be worn by all present.
The 10.6µm (or 11.1 µm for "L" systems) laser light and its reflections are potential hazards to the
eye. Use extreme caution when operating the system with the covers opened or removed. The covers
contain the beam and reflections safely within the console. Only those persons required should be
present during servicing, and eye protection that safely attenuates the system treatment wavelength
must be worn by all those present.
Use caution when operating the unit with any of the mast covers removed, the articulating arm
removed or disassembled, or when test firing the system. Before firing, confirm that the beam will
be safely terminated, and that all persons present are wearing protective polycarbonate goggles with
side shields that safely attenuate the laser treatment wavelength (10.6µm for UltraPulse systems, 11.1
µm for UltraPulse "L" systems).
During firing, be alert for any indication of reflection or misdirection of the treatment beam.
Consult the instructions for interior access (Topic 5.2) before attempting to remove any of the
covers. When loosening the screws to lower the panel power assembly (behind left side cover), be
prepared to support and swivel the heavy panel power assembly into its lowered position.
Excessive duty cycle will damage the RF Amplifier. Never ground the RFDREN line (TP1 on the
Controller PCB). Unlike the XL40/50/60 series, the UltraPulse systems must never operate at a duty
cycle above approximately 40%.
TROUBLESHOOTING & REPAIR ULTRPULSE SERVICE MANUAL

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5.2 INTERIOR ACCESS
The console has a top cover, left and right side covers, a front cover, a cover which surrounds the operating
controls, and a light bar/handle. The mast has four covers.
TOP COVER - Removal of the top cover is necessary to allow removal of the side covers or operating panel
area cover, and to gain access to most of the controller PCB for troubleshooting
To remove the top cover, open the rear storage door and remove the two hex screws (3/32") located
above the calibration port "D" connector. Note that the emergency off button is located on the
panel, and that the wires to it can be disconnected once the cover is lifted up. The top cover will
swivel up from the back, and lift off. This unlocks the top of both side covers, and exposes two of
the screws which hold the operating panel area cover in place.
MANUAL
SHUTTER ARTICULATING
ARM
MAST
EMERGENCY OFF
PUSH BUTTON
CONTROL
PANEL
KEYSWITCH
AUXILARY
CONTROL
PANEL
LEFT SIDE RIGHT SIDE
CIRCUIT BREAKER
DS1
BRH PLUG
DS2
POWER CORD
FRONT OF UNIT

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LEFT SIDE COVER - The left side cover (side with the mast) is removed to gain access to the two hex screws
which allow the panel power assembly to be lowered into its maintenance position. This allows access to the
controller PCB, isolation transformer and all the power panel components. The power panel includes the "C"
and 48 VDC Power Supplies, CON1, CON2, T2, TB1, R1, R2, and VR1.
To remove the left side cover, first remove the top cover,
as described above, then loosen two hex screws (9/64")
which hold the black "L" bracket located along the
bottom underside of the cover. The cover sits on the
bracket. Once the bracket is loosened the cover can be
lifted up slightly and swiveled out from the rear to free it
from inserts along the inside of the front panel.
Once the left side cover is removed, the power panel

assembly can be dropped down to gain access to the
assemblies inside.
TB1 R1 THR1 R2
WATER COOLING
C SUPPLY LINES
48VDC SUPPLY
VR1 CON1 CON2 T2

POWER PANEL DETAIL
ACCESSING THE POWER PANEL AREA
TRAY
CONTROLLER PCB
SAFETY CIRCUIT PCB HEAT EXCHANGER/FANS
FLOWSWITCH
TB FOR TAPPING TRANSFORMER FAN CONTROLLER PCB
THR1
ISOLATION TRANSFORMER
CIRCUIT BREAKER
DS1
DS2
LEFT SIDE INTERIOR VIEW
BRH
(POWER PANEL DOWN)
POWER CORD

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To drop the power panel, Be prepared to support the heavy power panel in its closed position as you
remove two hex head screws (9/64") in the upper corners of the power panel assembly. The top of the
assembly can then be swiveled out and down to the floor, exposing the interior of the unit.
RIGHT SIDE COVER - Remove the right side cover to access the cooling system motor, pump, flow switch,
temperature sensor, and the RF amplifier.
To remove the cover, first remove the top cover, as described above, then loosen two hex screws
which hold the "L" bracket along the bottom inside of the cover. The cover sits on the bracket.
Once the bracket is loosened, the cover can be swiveled out from the rear to free it from inserts
along the inside of the front panel.
EMERGENCY OFF
BUTTON.
EXTERNAL CAL
RF AMP
CONNECTOR
FLOW SWITCH
RESERVIOR
TEMP SENSE
PCB IS LOCATED
HERE
PUMP
HEAT EXCHANGER
PUMP MOTOR
THREE COOLANT
LINES REJOIN UV LIGHT
BEFORE ENTERING P/S
HEAT EXCHANGER
RF OUTPUT
D CONNECTOR
WATER LINES (2)
GROUND
48VDC INPUT
BOTTOM VIEW, RF AMPLIFIER

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MAST COVERS - Remove the main mast cover to access the optical components, Optics Bench PCB, Mast
Display, and the laser tubes (HeNe ad CO2). Remove the three smaller mast covers, as necessary, to remove/
replace the articulating arm, etc..
Four phillips head screws hold the main mast cover in

place. Remove the articulating arm from the storage clamps
on the cover, remove (unscrew) the HeNe intensity control
lever from the black wheel, then remove the four screws.
The panel will slide off towards the rear of the unit.
The remaining smaller panels are also secured with phillips head Manual Shutter
screws. To remove the top cover, the manual shutter knob must be
removed. To remove the collar cover, the articulating arm must be
removed.
FRONT COVER - To remove the front cover, first remove the side
covers, then loosen 2 hex screws which screw into the bottom of the
panel from the underside of the unit. Swivel the panel out from the
bottom (A bracket on the inside of the panel catches under the lip of
the control panel area cover).
LIGHT BAR - To remove the light bar, first remove the two side
covers, then remove the 4 hex screws (two on each end) which
Attenuator stick
secure the bar to the panel cover. Note that the supply cable enters
through the left end of the bar. Using caution not to damage the
supply cable, slide the right end of the bar out.
CONTROL PANEL - The main Control Panel PCB and Membrane

Switch Assembly are both located inside the two piece plastic
control panel. The control panel is secured to the system with two
hex head screws. The two sides of the plastic control panel cover are
glued together. The two sides of the cover can be pried apart (be
careful not to damage the plastic) to access the control panel PCB
and membrane switch assembly.
CONTROL PANEL AREA COVER - To remove the control panel

area cover, first remove the side covers, front cover, control panel,
and light bar. Next, remove two screws that secure the front of the
cover to the front side (top) of the system, and two screws that secure the back of the cover to the top of the
system. Note that there is cabling to the key switch and axillary control panel.

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5.3 FAULT ISOLATION
Failures/malfunctions fall into the following general categories:
•␣ The system fails to turn on properly, or turns off when it should not. (see 5.3.1)
•␣ The system turns on, but the control panel display or operating controls do not respond properly,
and no fault code is displayed. (see 5.3.2)
• During power up tests, or during operation, the system displays a fault indication. A fault code
number will be displayed to reference one of the write ups in subtopic 5.3.3, except that most systems
do not actually display the "4" if a fault 4 occurs (instead, the fault light is illuminated and the power
display flashes - see the fault 4 write up). (see 5.3.3)
Following is a description of the normal power up and self test sequence for the system (refer to 8-2):
•CB1/CB2 on, key switch off; indicator DS2 on.
Key switch turned to START (II) position:
•The CON1 contactor closes, applying the AC to T1 primary. The contactor closing is audible, and
visible if the power panel is in its open position. At this point, the soft start resistors are in the AC
path, and only the 48 VDC Power Supply is being supplied from the T1 secondary (CON2 is de-
energized).
•The CON2 contactor will close as soon as the 48 VDC Power Supply has charged the capacitor bank
past a minimum level. The contactor closing is audible, and visible if the power panel is in the open
position. The CON2 closing will lag the CON1 closing by several seconds, if the machine is cold, but
will close immediately behind CON1 on a unit that has been off for only a brief period.
•When CON2 closes, AC is applied throughout the system. The light bar illuminates, the fans and
coolant pump turn on. At this point, the C power supply begins providing the DC voltages required
throughout the system. The microprocessor on the controller PCB begins running its start up
sequence.
•During the start up sequence the Self Test indicator is illuminated, the shutter is tested, and the unit
fires twice into the Thermopile.
•At the end of the self test sequence the system moves to Standby, first doing a power seek routine to
establish the pulse width for the current operating selections.

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5.3.1 Turn On/Shutdown Problems
If the unit fails to turn on with the key switch, check the circuit breaker and AC supply. If DS1 is on, AC
power is available to the unit and the circuit breaker is on. DS2 illuminates once the main contactor is closed.
If DS2 illuminates when the key switch is held in the "start" position, but then turns off when the key is
released, check the two thermal fuses and the 48VDC power supply U2 (must be on).
If DS2 fails to illuminate at all, check the key switch, T2, CON1 and the emergency off switch.
If the unit shuts down, check for circuit breaker trip, or a failure in the power distribution circuits.
5.3.2 "No Fault Code Reported" Fault Isolation
Some system malfunctions cannot be reported at the control panel. These include those malfunctions which
interfere with the operation of the microprocessor, malfunctions in the hardware that drive the display which
reports the faults, and miscellaneous circuits/functions which are not directly monitored by the software.
If the malfunction is associated with a particular function (e.g., the system doesn't respond to the footswitch,
or to some control panel control), troubleshoot that function, referring to the circuit descriptions in Section 4.
If the system turns on, but the malfunction is more general (e.g., the self test sequence doesn't run, control
panel does not respond to operator input) check for proper DC supply voltages, interconnection problems, or
for some problem with the microprocessor (Is it running?/EPROM installed?/DC voltages to the Controller
PCB good?). If the problem cannot be isolated to a particular circuit, replace the Controller PCB.
5.3.3 Fault Codes
Microprocessor detected faults are displayed at the control panel. Some faults will clear when the condition
causing the fault is corrected (e.g., no footswitch connected causes fault 1- connect the footswitch, fault 1 goes
away). Other faults are caused by an actual hardware failure (e.g., ROM memory error causes fault 6)), and
will not clear until repairs are accomplished. The following list provides a description of each fault code, and
recommended corrective action. In every case, check supply voltages and connections to the circuit(s)
associated with the fault.
FAULT 1 - FOOTSWITCH NOT PRESENT. The microprocessor monitors the FTSW0-l and FTSW1-H
signals via digital I/O U45. The footswitch always grounds one line or the other (see table below). If the
microprocessor sees both lines high at the same time, it displays FAULT 1. This is typically an indication that
the footswitch is not connected, but could be caused by an open in the footswitch cable wiring, poor connec-
tions between controller J10 and the footswitch cable, U33, U45, or the components on the FTSW0-L or
FTSW1-H lines (R8, R6, etc.).
FOOTSWITCH FOOTSWITCH
RELEASED DEPRESSED
FTSW0-L 5V ground
FTSW1-H ground 5V
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FAULT 2 - FOOTSWITCH SHORTED. This fault indicates that the microprocessor sees logic lows on both
the FTSW0-L and FTSW1-H lines. Normally, the footswitch grounds one line or the other (see table above).
Since the footswitch is not depressed when this check occurs, it is likely that the FTSW0-L line is grounded or
the 5 V via R9 is not present. Check the footswitch first, then check for grounds to the FTSW-L line (C59, U33,
U45, or a short in wiring into J10-1).
FAULT 3 - COOLANT OVERTEMPERATURE/CDRH. Fault three can occur due to a coolant

overtemperature condition or an open CDRH connection.
The voltage from the temperature sense PCB, as measured by the ADC circuit on the controller, indicates
coolant temperature has exceeded 125˚ F . The cooling system is designed to allow continuous duty cycle
operation of the system at any mode/exposure time combination without overheating in a typical "operating
room" environment. The CDRH plug connects the temperature sensor PCB voltage output to the Controller
PCB. Note that the temperature sense PCB "pulls down" the TMP-A line (+15 VDC ) through R20. When the
BRH plug is pulled out, it opens the Temp Sense input to the controller TMP-A line, allowing the TMP-A line
to rise to +15 VDC. This looks like an overtemperature condition to the software, which responds with a fault
3.
Check CDRH. Check the coolant system reservoir level (should be near top - uses water - add with system
running to within 1 inch of top). If the level is OK, the problem could be in the cooling system itself, or in the
temperature sensor circuitry. Measure the coolant temperature. If the temperature is less than 125˚F ( 38˚C),
check the temperature sense circuitry (see next paragraph). If the temperature is 125 ˚ F or more, check the
fans, pump, and for any restrictions in the coolant flow or air flow.
The temperature sense PCB outputs a voltage proportional to the temperature of the coolant. R2 is adjusted
so that the voltage out (monitor the temp sense PCB output at TP14 on the controller PCB, use TP7, 8, or 9 for
ground reference) is:
VTP14 = Coolant temp in degrees C (.129)

NOTE: (C˚*1.8)+ 32 = F˚
If the correct voltage can not be obtained, troubleshoot/replace the temperature sense PCB, controller PCB.
FAULT 4 (MOST SYSTEMS DO NOT DISPLAY A "4", INSTEAD THE POWER DISPLAY FLASHES) -
LASER COULD NOT FIND REQUESTED POWER. When a power seek routine fails to find the selected
power in seven seconds, the fault 4 occurs. Changing the power or energy setting will clear the fault.
During a power seek routine the power measured via the thermopile did not remain within +/-5% (+/-15%
for power levels within 15% of max power ) for 1 second, i.e., the attempt by the microprocessor to find a
pulse width to achieve the selected power out of the CO2 tube has failed.
Note the power setting at which the fault occurred, turn the system off, then back on. This forces the system
to go through self tests, and may result in a fault 5 or fault 8. If so, troubleshoot the problem as a fault 5 or
fault 8 (see below). If the system comes up without a fault 5 or fault 8, the tube is making power. Check the
centering of the thermopile (as described in Section 3). If the fault persists, do the power gain loop adjust-
ments (as described in Section 3 ). If the fault still persists, do the power calibration (as described in Section 3).
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If all adjustments are correct, and the fault persists, troubleshoot the power seek loop circuit. The fault occurs
when the software power seek routine fails to find a pulse width that provides the selected power as mea-
sured at the thermopile. The power seek routine runs in WATTS and MILLIWATTS MODES, when the
power setting is changed, and after five minutes of no footswitch depression at the same power setting.
When a power seek is run, the microprocessor leaves the shutter in the beam path, which places the convex
mirror in the CO2 beam path. The mirror is positioned to direct the CO2 beam into the thermopile. The
microprocessor then selects the appropriate gain setting at the optics bench PCB (U12) and controller PCB
(U49), and loads a digital value into controller PCB DAC U43. The digital value represents the voltage
expected from the thermopile for the power setting being checked. The digital value comes from a table of
values kept in NVRAM (the table is built during the laser calibration routine). The microprocessor fires the
laser, monitoring the error signal at TP19 of the Controller PCB via multiplexer U41 and the A/D converter
U38. It varies the modulation frequency to the RF exciter to increase/decrease power out of the tube, until the
IRDDLV signal from the thermopile/optics bench PCB matches the reference voltage out of the DAC. When
the two signals are equal, the TP19 voltage will go to zero, and the power loop sequence is complete. The
microprocessor uses the pulse width as determined by the power seek for subsequent treatment firings.
If the fault can not be isolated to a particular component in the power measuring and power seek circuits,
attempt to isolate to the controller PCB, optics bench, thermopile/detector assembly, or the interconnections
between them.
FAULT 5 - NO LASER POWER DETECTED AT LIGHT OFF. The laser output, as measured via the
thermopile, indicates less than 4 watts (less than 800 mv at TP16 on controller PCB at tube light off). This test
is done during the first laser firing of the power up initialization and self test sequence. Check the output
coupler and shutter mirror for contamination/damage. Check for modulation signal to the RF exciter/
amplifier (TP1 on the controller), and the 48 VDC power supply output.
CAUTION: Do not ground TP1 on the controller PCB to check the tube (this was an acceptable quick
check of the tube for some earlier model High Power CO2 systems). This will damage the RF
amplifier.
If the signals to the tube and tube output are good, troubleshoot the thermopile/detector and power measur-
ing circuitry on the optics bench PCB and controller PCB.
FAULT 6 - ROM MEMORY ERROR. controller PCB ROM has failed a CRC check, at power up. Replace
the EPROM, controller PCB.
FAULT 7 - RAM MEMORY ERROR. The RAM has failed the power up self test. Replace the controller
PCB.
FAULT 8 - DETECTOR GAIN STAGE FAILURE. A self test of the power seek circuit, at each of the four
gain settings, has failed. The test is performed during the power up initialization and self tests. Troubleshoot
the gain stage circuits. Replace the controller PCB.
FAULT 9 - RF POWER SUPPLY GOOD SIGNAL INACTIVE WHEN CHECKED (+48 VDC). The follow-
ing signals should be checked:

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• +48 VDC power supply output with light-off software installed.

• REFPOK signal with light-off software in.
• FRWPOK signal with light-off software in.
If the fault persists, replace the RF power supply.
FAULT 10 - RF AMP GOOD SIGNAL INACTIVE WHEN CHECKED. Checked all items applicable to
Fault 9, corrective actions remain the same as well.
FAULT 11 - REFLECTED POWER BAD. The microprocessor has read the REFPOK signal from the exciter
and found it low (fault condition). Reflected power is an indication of the effectiveness of the energy transfer
from the exciter to the laser tube, i.e., the impedance match between the source (exciter/amplifier) and load
(laser tube).
High reflected power is typically detected because of a poor connection of the coax between exciter and laser
tube or a failure in the tube or exciter. It is less likely that a false detection of reflected power has occurred.
When this fault occurs, check the RF connection between the exciter and tube. If the connection is good, the
fault is either in the tube, exciter, or is a false detection of the reflected power condition.
Since the tube and exciter are replaced as a pair, there is no reason to determine if one or the other is at fault.
Instead, jumper U36 pin 6 of the controller PCB to TP2 (5 VDC) , then run the system through its turn on
sequence. The jumper prevents the reflected power signal from occurring. A fault 4, 5, or 17 tends to confirm
that the exciter/tube pair have a problem, and should be replaced. If no fault occurs, the tube is passing the
self test firings, and the reflected power problem is probably a false indication; troubleshoot the controller
PCB (U36, U37, U45) digital I/O circuits which process the REFOK signal.
FAULT 12/15 - SHUTTER DID NOT DE-ACTIVATE/SHUTTER DID NOT ACTIVATE. When the
shutter solenoid is de-energized, the shutter is closed, placing a convex mirror in the treatment beam path.
Firing the CO2 laser with the shutter closed results in the convex mirror directing the treatment beam into the
thermopile, the output of which is monitored by the power seek circuitry. When the shutter is energized, the
shutter opens, and the path is not blocked. The shutter is opened only during treatment firing (future soft-
ware releases may incorporate a self test which opens the shutter during self test. The laser would, of course,
be off during this self test).
The microprocessor controls the shutter via the digital I/O and Optics Bench PCB. A low out of U33-8 is the
"energize" command, ( NAND gate U33 ensures that the shutter energize command is sent only if the
footswitch is depressed and U22-12 is high) sent to differential driver U15-10/11. The differential enable
results in a low out of U19-3. This low is switched through U20-3 and inverter U16-6 to turn on Q1. Q1
completes the ground return to the shutter solenoid (other side of solenoid is (24 VDC) when it is on. Note
that once the shutter has moved out of the beam path the HOLDEN signal enables timer U10. The U10 output
is a square wave which turns Q1 off and on at a 50% (1KHZ) duty cycle. This is sufficient to hold the solenoid
in while decreasing the heat generated by the solenoid.
The solenoid position is sensed by a slotted optical switch mounted near the solenoid. When the solenoid is
de-energized, the slot is clear, and the switch output is 5 VDC. When the solenoid energizes, a tab is rotated
into the slot, turning the switch off.
For fault 12 (shutter sense indicates shutter is not closed, and it should be) , check the shutter mechanics,
slotted optical switch, shutter drive circuitry, and shutter position sense circuitry.

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For fault 15 (shutter sense indicates shutter is closed when it should be open), check the shutter mechanics,
shutter drive circuitry, slotted optical switch, and position sense circuitry. Use an oscilloscope to check for
proper timing of the position sense circuitry (at optics bench PCB, U19-3 is shutter enable, U15-10 shutter
sense). The signal must change states within .5 seconds of the "shutter enable" command. If it does not, adjust
the dampening of the dashpot (turn screw CCW to decrease dampening).
FAULT 13/14 - ATTENUATOR DID NOT ACTIVATE. ATTENUATOR DID NOT DEACTIVATE. When
the attenuator solenoid is de-energized, the attenuator is in the treatment beam path. Firing the CO2 laser
when the attenuator is in the beam path results in greatly reduced output power. When energized, the
solenoid rotates the attenuator out of the beam path. The attenuator is used to drop the output down to the
range of values available in the milliwatt mode. The attenuator is kept out of the beam path except when the
system is in MILLIWATTS mode.
The solenoid position is sensed by a slotted optical switch mounted near the solenoid. When the solenoid is
de-energized the slot is clear, and the switch output is 5 VDC. When the solenoid energizes, a tab is rotated
into the slot, turning the switch off.
For fault 13, (shutter sense indicates attenuator is in the beam path when it should be out), check the attenua-
tor mechanics, attenuator drive circuitry, slotted optical switch, and position sense circuitry. Use an oscillo-
scope to check for proper timing of the position sense circuitry (at optics bench PCB, U19-5 is the attenuator
enable, U15-10 attenuator position sense). The signal must change states within .5 seconds of the "attenuator
enable" command. If it does not, adjust the dampening of the dashpot (turn screw CCW to decrease dampen-
ing).
For fault 14 (attenuator sense indicates attenuator is not in the beam path, and it should be) , check the
shutter mechanics, slotted optical switch, shutter drive circuitry, and shutter position sense circuitry.
FAULT 16 - D/A VALUE OUT OF RANGE. Check the beam centering on thermopile, attempt to re-
calibrate. Troubleshoot the power measurement signal path, from the detector to the A/D conversion circuits.
FAULT 17 - FORWARD POWER BAD. The RF exciter has indicated that forward power of the RF signal
from the exciter to the CO2 laser tube is low. Check for proper DC voltages to the exciter, coax connection
between exciter/amplifier and tube, and for the modulation signal. Confirm that the FRWPOK signal from
the exciter is actually low ( not a shorted signal wire). The check is made during the power up initialization
and self test sequence. If the modulation is present, and DC voltages to the exciter are present, replace the
tube/exciter pair.
FAULT 18 - FLOWSWITCH INACTIVE. The coolant flowswitch indicates insufficient flow. Check for low
coolant level at reservoir; add coolant if necessary. Check the flowswitch signal (U45-4 on controller PCB,
high indicates flow, low indicates insufficient flow ). If U45-4 is high, and fault continues, replace the control-
ler PCB. IF U45-4 is low, check for mechanical failure (blockage, pump, flowswitch), supply voltage to pump.
Check flowswitch by disconnecting unit from power, carefully unscrewing/removing top of flowswitch, then
removing internal spring and plastic plunger. Check for blockage or stretched spring.
FAULT 19 - FOOTSWITCH ACTIVE AT POWER ON. The footswitch was depressed ( NO line grounded,
NC line open) when checked during the power up initialization and self tests. This could be operator error, a
bad footswitch, or a failure on the controller PCB.

5-12 0616-629-01 8/94
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FAULT 20 - CONTROL PANEL DID NOT RESET. During the power up initialization and self test
sequence, a reset signal (KYRST high) from the controller (U1-2) is sent to the axillary keyboard encoder (U4).
The encoder should respond by sending a signal back to the controller PCB, to decoder U10. Troubleshoot the
keyboard circuits on the controller and axillary keyboard PCBs.
FAULT 22 - FLOW SWITCH ACTIVE WHEN IT IS NOT SUPPOSED TO BE - The software checks the
condition of the flowswitch signal early in the start up sequence, before the pump has had a chance to begin
circulating the coolant. The flowswitch should be inactive at this time. This check will detect a flowswitch
which is stuck closed. Note that this fault can occur if the system is turned off, and then back on without
allowing time (30 seconds) for the coolant flow to stop.
FAULT 99 - VALID D/A VALUE NOT CALCULATED. This error indicates some problem with the data
stored in the NVRAM. It commonly occurs when a new controller PCB is installed and calibration is not
done. Try to calibrate, replace the controller PCB.
5.4 CHANGE NOTES
It is typical for design changes to occur throughout the life of a product. The UltraPulse series has seen a
number of changes incorporated into new production to enhance product performance, improve reliability
and to improve the ease and cost of manufacture.
The major changes of interest to service are discussed below.
•␣OLD AND NEW STYLE TUBES - When the "L" wavelength tube was developed, improved optics
were incorporated into its design, resulting in a slightly different set of supporting optics. The result
is three different CO2 optical schemes; one for the old style tubes (SL600 tubes with part numbers
ending in "-00"), one for the systems retrofitted with new style tubes (SL611 "L" technology tubes and
SL600 tubes ending in "-01"), and one for systems produced with the new style tubes. The differences
are noted and illustrated in Section 3.
• HENE OPTICS REMOVED - All systems with s/n > xx300 were produced with a HeNe diameter
much larger than the previous systems (a few lower serial number units were also produced with the
larger diameter HeNe). The change was made to improve HeNe delivery through a
micromanipulator. The change was made by removing the HeNe diverging and collimating optics. A
dust window is installed in the diverging optics position.
•␣DUAL HENE - The UltraPulse can be ordered with a dual HeNe (red and yellow) or single HeNe
(red). Note that the Excelase 1000, 2000, and 3000 systems use either of two aux control panels
depending on the HeNe option (see Section 6 for p/n's).
•␣MILLIJOULE CONTROL PANEL - The addition of a millijoule display at the control panel required
a controller PCB microprocessor with a larger internal memory (an 8032 instead of 8031), and a
different mast display. See Section 6 for part numbers.
•␣PULSE WIDTH CONTROL PANEL - A few systems have been produced with a pulse width
display on the control panel. See Section 6 for the part number.

0616-629-01 8/94 5-13
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•␣SAFETY CIRCUIT - The safety circuit monitors a logic signal from the controller (STEN), the
shutter position slotted optical switch, and the footswitch normally open contact. It controls an optical
switch in an enable loop from the RF amplifier. The RF amplifier will respond to modulation from the
controller PCB only when the enable loop is complete (the safety circuit electronic switch closed).
The safety circuit was first incorporated into the design as a small add on PCB that mounted to the
0617-040-01 controller PCB. On the add on board, a jumper (W1) was included to jumper out the
circuit. This allowed the circuit to be disabled on systems with software that does not support the
circuit.
The 0615-880-01 controller PCB (this PCB is newer than the "0617" PCB) includes the safety circuit on
the board.
• AUDIBLE INDICATOR CIRCUIT - This circuit, like the safety shutter circuit, was first incorporated
as an "add on" PCB with the 0617-040-01 controller PCB. The circuit is built onto the new 0615-880-01
controller PCB. The circuit simply produces an audible tone during treatment beam delivery.
• OPTICS BENCH PCB - There are two interchangeable optics bench PCBs, 0615-374-01 (old) and
0617-523-01 (newer). The newer PCB is a new fabrication layout with different component
numbering, but is essentially the same circuitry.
• AXILLARY CONTROL PANEL - The aux control panel on the UltraPulse systems with no
millijoule control panel (0003-2282) included an overtemperature indicator. The new aux control
panel (0616-149-01) does not have the overtemperature indicator.
5.5 TEST POINTS
CONTROLLER PCB:
TP1 Modulation signal from the controller to RF exciter. A low turns on the exciter, resulting in power
out of the tube. A high turns off the exciter, and the tube. The average power of the treatment beam
is controlled by the on and off time of this signal. The on/off time is varied by changing the pulse
width of the low "on" signal. In CW modes the frequency is 3000 Hz for settings above 10 Watts
(or 100 milliwatts in milliwatts mode) and 1500 Hz for power settings below.
TP2 5 VDC from C supply.
TP3/4/5 5 VDC return.
TP6 +15 VDC from C supply.
TP7/8/9 +/-15 VDC return.
TP10 -15 VDC from C supply.
TP11 24 VDC
TP12 20 VDC
TP13 24 VDC return.

5-14 0616-629-01 8/94
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TP14 Analog input from temperature detector PCB.
TP15 Command output from microprocessor for watt selection.
TP16 Conditioned power detector input signal from the optics bench PCB.
TP17 Error signal from output of summing junction
TP18 Output of multiplexer to A/D converter.
TP19 Gain stage input to multiplexer.
C SUPPLY VOLTAGES:
TB1-9 5 VDC, ± 25 V, ripple <.1V (TB1-8 ref)
TB1-3 +15 VDC, ±.25 V, ripple < .1V (TB1-6 ref)
TB1-5 -15 VDC, ± .25 V, ripple < .1V (TB1-6 ref)
TB1-4 +24 VDC, ±.25 V, ripple < .1V (TB1-7 ref)
5.6 PERIODIC MAINTENANCE REQUIREMENTS
The systems require the following periodic maintenance:
ANNUALLY:
Cooling system level check. The cooling system reservoir is located behind the right side cover. Use
water, with the system running, to bring the coolant level up, to within about one inch the top of the
reservoir (no closer).
Calibration and adjustment:
Thermopile centering and loop gain dampening adjustment (see Section 3)
Power calibration (see Section 3)
Temperature sense calibration (see Section 3)
AS REQUIRED:
Cleaning of the internal optics (see section 5.6)
Optical Alignment (see section 3)

0616-629-01 8/94 5-15
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5.7 CLEANING OPTICS
This section assumes the reader is familiar with and experienced in cleaning optics associated with lasers, and
provides considerations specific to the UltraPulse system.
The few HeNe specific optics (don't contact the CO2 beam) can be cleaned as necessary to maintain proper
transmission of the HeNe beam, using acetone, cotton swabs, and lens tissue. These optics are less likely to be
damaged by cleaning than the optics which come into contact with the CO2 beam.
The CO2 optics have soft coatings, and should be cleaned only when observed to be contaminated with some
significant foreign material on the surface. Foreign material on a lens can lower the transmission of the 10.6
micron energy and promote failure of the lens coating. Lowered transmission can effect the delivered power
and accuracy of the power calibration. Excessive cleaning ( too often or too rigorous) can damage or remove
the coatings, lowering the transmission of the 10.6 wavelength radiation. To determine if cleaning is neces-
sary, examine the surface of the optic under light (a dental examining mirror is necessary to examine the
output coupler). Look for foreign materials on the surface of the optic. This could be dried pieces of the
compound used to lock down screws, flakes of the coating itself, etc.. Note that any foreign particle on the
optic is being subjected to extreme heating each time the laser fires, and may be "baked on" the lens surface
(in which case, it will probably not come off). Try removing particles with dry air first. If this fails, and the
lens must be cleaned, use acetone on a cotton swab or piece of lens tissue (use swab or tissue for one swipe,
then discard and use a clean one). The lenses mounted to face upwards (output coupler, CO2 far mirror,
combiner) are more likely to require cleaning.

5-16 0616-629-01 8/94
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6.0 PARTS LIST
The Bill of Materials for each model of the UltraPulse is maintained under document control at Coherent
Medical Group, Palo Alto, California. The following list is provided for convenience. Always confirm the P/
N for a given part through technical support before ordering.
SPECIAL TOOLS
ANGULAR RON OUT TOOL 0612-497-01

HENE ALIGNMENT DISK 0614-154-51
POSITIONAL RUNOUT TOOL
OLD STYLE ((small HeNe diameter) 0620-052-51
NEW STYLE (larger HeNe diameter) 0622-955-51
RUNOUT TOOL REPLACEMENT RETICLE
OLD STYLE 0620-053-01
NEW STYLE 0622-955-51
FIELD DATA TERMINAL 0620-408-01
FIRST SURFACE HENE
ALIGNMENT MIRROR available from scientific supply outlets (e.g., Edmund
Scientific, part order number 40041)
LAPAROSCOPE ALIGNMENT TOOL 0619-087-01
MAJOR SUB ASSEMBLIES
UV LIGHT POWER SUPPLY 4001-0189

FOOTSWITCH 0619-370-01
2 WAY DASHPOT 2207-0003
YELLOW HENE TUBE 5701-0054
YELLOW HENE P/S 5701-0055
HENE TUBE (RED) 5701-0048
HENE P/S (RED) 4001-0154
"C" POWER SUPPLY 4001-0146
48VDC POWER SUPPLY ASSEMBLY 0615-807-01
ARTICULATING ARM 0619-960-01 (new style arm)
48 VDC POWER PANEL 0615-807-01 (208 VAC ETL version)
SL600 TUBE/EXCITER 0162-410-01
SL611 TUBE/EXCITER 0163-336-00
SL600 "00" TO "01" REPLACEMENT FRU 0618-049-01
ULTRAPULSE SERVICE MANUAL PARTS LIST

0616-629-01 8/94 6-1
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ELECTRICAL COMPONENTS
CIRCUIT BREAKER 5108-0120

ISOLATION TRANSFORMER:
NON-ETL (not tapable for 117 mains) 0615-042-01
ETL (tapable for 117 mains) 0616-759-01
200 WATT SENSOR 0210-796-00
ROTARY SOLENOID 2204-0127
LOCKING PHONE JACK 0614-008-01
BUS PLATE MOSFET 4801-0385
BUS PLATE DIODE 0615-089-01
BRIDGE RECTIFIER 0615-967-01
SS RELAY 240 VAC/ 40A 4501-0392
SS RELAY 120 VAC/ 10A 5601-0153
24 VAC TRANSFORMER (T2) 5601-0153
POWER CONVERSION KIT, NON-ETL 0617-329-01
POWER CONVERSION KIT, ETL 0618-166-01
SOFTWARE
• Systems without the millijoule display on the control panel:

UltraPulse 4000 0616-290-01
UltraPulse 5000 0616-294-01
Use the following service software for these systems:

Loop Gain 0615-830-01
Power Detector 0615-831-01
Light Off 0615-832-01
• Systems with the millijoule control panel and safety shutter circuit, but the safety shutter circuit is jumpered
out (does not operate):
UltraPulse 4000 (60W) 0617-135-01
UltraPulse 4000 (100 W) 0616-900-01
UltraPulse 5000 0616-901-01

Loop Gain 0617-114-01
Light Off 0617-116-01
• Systems with the millijoule control panel and the safety shutter circuit produced with the old style milli-
watts mode (attenuator moves into place only in milliwatts mode) should be upgraded as outlined in FSB #
21R2, retrofit 2Z02. Once upgraded, these systems will use the software as provided below.
• Systems with the millijoule control panel, operational safety shutter circuit, the new style milliwatts mode
(attenuator moves into place at 2 Watts or below, attenuator has two attenuator lenses), but does not use the
new Controller CPU (p/n 0615-880-01):
UltraPulse 1000/XL 1000 0618-234-01
UltraPulse 3000 117 VAC 0618-237-01
UtraPulse 3000L 0618-237-01
XL-2000 0618-237-01
PARTS LIST ULTRAPULSE SERVICE MANUAL

6- 2 0616-629-01 8/94
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UltraPulse 3000 208 VAC 0618-240-01

XL-3000 0618-240-01
UltraPulse 5000 208 VAC 0618-243-01
UltraPulse 5000 117 VAC 0618-249-01
UltraPulse 5000L 208 VAC 0618-246-01
UltraPulse 5000L 117 VAC 0618-252-01

Loop Gain 0617-194-01
Light Off 0618-254-01
• Systems produced with the new Controller PCB p/n 0615-880-01 (these units have the millijoule control
panel, safety shutter circuit, new style milliwatts mode, as well as the new controller PCB):
UltraPulse 5000 117 VAC 0623-569-01
UltraPulse 5000 208 VAC 0623-570-01
UltraPulse 5000L 117 VAC 0623-571-01
UltraPulse 5000L 208 VAC 0623-572-01
UltraPulse 3000 117 VAC 0623-573-01
UltraPulse 3000 208 VAC 0623-574-01
UltraPulse 3000L 0623-575-01

Loop Gain 0617-194-01
Light Off 0618-254-01
PRINTED CIRCUIT BOARDS
POWER DETECTOR PCB 0615-843-01

TEMPERATURE SENSE PCB 0616-467-01
MAST DISPLAY PCB:
no millijoule display 0615-856-01
millijoule display 0616-284-01
MAIN CONTROL PANEL PCB:
no millijoule display 0612-934-01
millijoule display (no pulse width display) 0615-959-01
millijpoule display (and pulse width) 0615-959-02
AUX CONTROL PANEL PCB:
no millijoule display 0003-2282
with millijoule display 0616-149-01
OPTICS BENCH PCB:
Old style (discontinued, will work with
with any UltraPulse) 0615-374-01
Current production (will work with
any UltraPulse) 0617-523-01
LAMP HANDLE PCB 0003-2867
DC CONTROLLER PCB 0614-944-01 ( water cooled P/S)
AUDIBLE INDICATOR PCB 0616-252-01
SAFETY SHUTTER PCB

0616-629-01 8/94 6-3
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JUMPERED MODEL
(jumper W1 across J1-17 & 18) 0615-655-01
ACTIVE MODEL 0617-355-01
FAN SPEED CONTROL PCB 2601-0025
CONTROL PANEL OVERLAY:

XL-1000, 2000, 3000 0616-240-01
UltraPulse, no millijoule display 0614-996-01
millijoule display (no pulse width display) 0616-092-01
millijoule display (with pulse width) 0615-889-01
AUX CONTROL PANEL OVERLAY:

UltraPulse with no millijoule display 0614-966-01
UltraPulse with millijoule display 0616-397-01
XL-1000, 2000, 3000 W/O yellow 0616-451-01
XL-1000, 2000, 3000 with yellow 0616-397-01
CONTROLLER PCA:
0615-703-01: Used with systems that do not have the millijoule display. It is essentially the XA/XL system
"strip line" controller PCB modified to support control of the added yellow HeNe and with the "A" and "B"
supply overvoltage inputs wired out.
0616-352-01: Used with systems that have the millijoule display but do not have the enabled safety shutter
circuit. It differs from the "703" PCB above in that it uses an 8032 controller chip instead of 8031.
0617-040-01: Used with systems that have the millijoule display and safety shutter circuit but do not have the
"syncronized firing" capability. It differs from the "352" PCB above in that it supports the external audible
indicator board and external safety shutter circuit.
0615-880-01: Used in systems that support "syncronized firing". It differs from the "040" PCB in that it has the
safety shutter circuit and audible indicator cirucits built into it and adds two enable signals sent to the RF
Amplifier to enable the synchronous firing. Note that the PCB has different component numbering and
layout.
INTEGRATED CIRCUITS
2114A 3133-0195
26LS31 3135-0055
26LS33 3135-0050
8031 microprocessor 3133-0190
MC1488P 3135-0020
MC1489LP 3135-0025
X2444 NVRAM 3133-0185
OPTICAL INTERRUPTOR 3703-0020
PHOTOSENSOR CABLE ASSY 0620-078-01
PARTS LIST ULTRAPULSE SERVICE MANUAL

6- 4 0616-629-01 8/94
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FRAME, MAST
SWIVEL CASTOR 1407-0141

FIXED TRACK LOCK CASTOR 1407-0140
CORD WRAP 0001-8160
ARM CAP COVER 0003-2247
CONTROL PANEL LOWER COVER 0612-921-01
CONTROL PANEL UPPER COVER 0003-2286
FRONT COVER 0615-047-01
EMEERGENCY OFF SWITCH GUARD 0615-500-01
ARM RETAINER (old) 0615-170-01
VELCRO STRAP 0614-128-01
REAR COVER 0614-946-01
REAR LOUVERED COVER 0615-168-01
LEFT SIDE COVER (DC Supply side) 0614-170-01
RIGHT SIDE COVER (RF Supply side) 0614-169-01
TOP COVER (the one with emergency off switch) 0614-945-01
STORAGE DOOR 0615-169-01
CONTROL PANEL WELL COVER 0003-2230
MANUAL SHUTTER KNOB 0619-711-01
KEY 5105-0050
WHITE COVER SCREWS (8-32x5/16") 2801-0149
HANDLE, HENE ATTEN ASS'Y 0614-824-01
ARM RETAINER 0619-561-01 (new style)
SHARK FIN CLIP 0613-703-01 (old style arm)
ARM DIRECTION LABEL (up arrow) 0618-761-01
COOLING SYSTEM
MAG DRIVEN PUMP 3501-0025

FAN SPEED CONTROLLER PCB 2601-0127
.5 GPM FLOW SWITCH 5106-0074 (larger flowswitch, black)
.5 GPM FLOW SWITCH 5106-0068 (blue green flowswitch)
PLUMBING FRU 0616-449-01 ("00" upgrade)
FITTING ADAPTOR 2519-0186 (for the smaller flowswitch)
PLASTIC HOSE BARB 2518-0054
OPTICS
HENE COMBINER 0615-510-01

HENE COLLIMATOR 0615-512-01
HENE DIVERGENCE LENS 0615-511-01
HENE DUST COVER 0621-739-01
HENE & CO2 COMBINER 0615-560-01
HENE ATTENUATOR FRU 0622-869-01

0616-629-01 8/94 6-5
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8.0 SCHEMATICS & DRAWINGS
8.1 LIST OF SCHEMATICS:
TITLE FROM PAGE

DRWG #: #:
DC POWER SUPPLY 0614-942-01 8-2
OPTICS BENCH INTERCONNECT 0616-762-01 8-3
CONTROLLER PCB 0617-040-01 8-4, 5, 6, 7, 8
CONTROLLER PCB 0615-880-01 8-9, 10, 11
OPTICS BENCH PCB 0615-374-01 8-12, 13, 14, 15
OPTICS BENCH #2 PCB 0617-523-01 8-16, 17, 18
MAIN CONTROL PANEL 0615-959-XX 8-19, 20
AUXILARY CONTROL PANEL 0616-149-01 8-21
MAST DISPLAY 0616-284-01 8-22
LAMP HANDLE 0003-2361 8-23
TEMP SENSE 0003-2274 8-24
SAFETY CIRCUIT 0615-655-01 8-25
POWER DETECTOR PCB 0615-843-01 8-26
DUAL DC SUPPLY VERSION

POWER PANEL 0615-878-01 8-27
TRANSFORMER DRAWINGS 0615-042-01 &

0616-759-01 8-28
ULTRAPULSE SERVICE MANUAL SCHEMATICS

0616-629-01 8/94 8-1
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CONTROLLER #3 PCB 0625-928-01 8-29, 30, 31, 32, 33
CPG CONTROL PCB 0625-272-01 8-34, 35, 36
CPG DISPLAY PCB 0625-270-01 8-37
SCHEMATICS ULTRAPULSE SERVICE MANUAL

8-2 0616-629-01 8/94

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* PRA CTICAL LIMIT CLASS IV LASER PRODUCT

2400 Condensa Street

Please direct all inquiries about this manual to:

© Coherent Inc. 06/91, 11/94, 06/95, 02/97

UltraPulse Service Manual Disclaimer 0616-629-01 02/97

SECTION 1 All pages, 08/94

SECTION 2 All pages, 08/94

SECTION 3 All pages, 08/94

SECTION 4 All pages, 08/94

SECTION 5 Pages 5-10, 11, 02/97

SECTION 6 All pages, 08/94

SECTION 8 Pages 8-1, 06/95

UltraPulse Service Manual 0616-629-01 02/97

UltraPulse Service Manual Table of Contents 0616-629-01 02/97

4.7 SOFTWARE .......................................................................................................................................... 26

1.0 GENERAL INFORMATION

1.1 USE OF THIS MANUAL

1.2 CONVENTIONS USED IN THIS MANUAL

1.3 SYSTEM DIFFERENCES

The UltraPulse product line includes the following models:

ULTRAPULSE SERVICE MANUAL GENERAL INFORMATION

1.4 DELIVERY SYSTEMS

Standard delivery systems include .2mm and 1.0 mm hand pieces.

GENERAL INFORMATION ULTRAPULSE SERVICE MANUAL

2.1 INSTALLATION INSTRUCTIONS

117 VAC ± 10% 20 A, 50/60 Hz single phase.

2. Check the shipping crates (2) for any damage.

3. Remove the console and accessories from the crates.

ULTRAPULSE SERVICE MANUAL INSTALLATION

4. Roll the console to the installation site.

6. Connect the footswitch.

7. Fill the cooling reservoir with water.

9. Plug the system into the AC power source.

12. Verify the power calibration.

13. Replace all covers.

14. Verify system operation with all accessories on hand.

15. Demonstrate system operation to the user.

INSTALLATION ULTRAPULSE SERVICE MANUAL

3.0 CALIBRATIONS, ADJUSTMENTS &

3.1.1 Overview Of The Procedures

The procedures are:

ULTRAPULSE SERVICE MANUAL CALIBRATIONS & ADJUSTMENTS

3.1.2 Safety Precautions

CALIBRATIONS & ADJUSTMENTS ULTRAPULSE SERVICE MANUAL

3.2 OPTICAL CHECK OUT

2. Check the CO2 to HeNe coincidence at the arm output.

3. Check the CO2 to HeNe coincidence 2 feet from the arm.

4. Check the burn.

5. Measure the positional run out.

Install the positional run

ULTRAPULSE SERVICE MANUAL CALIBRATIONS & ADJUSTMENTS

6. Check the positional error of the HeNe.

7. Check the angular run out of the HeNe.

CALIBRATIONS & ADJUSTMENTS ULTRAPULSE SERVICE MANUAL

ULTRAPULSE SERVICE MANUAL CALIBRATIONS & ADJUSTMENTS

CALIBRATIONS & ADJUSTMENTS ULTRAPULSE SERVICE MANUAL

3.3 OPTICAL ALIGNMENT

yellow (red) HeNe

ULTRAPULSE SERVICE MANUAL CALIBRATIONS & ADJUSTMENTS

(Beam shape adjustment)

3. Tape a burn card on the wall in the beam path.

(Satellite/lobe adjustment for systems with the old style tube)

If no lobes or satellites are observed, no further adjustment is necessary.