Manual 0546-396-OE Rev B

CP SERIES
LASER MANUAL
Convergent Laser, Inc. Administration: Sales: Service:

711 East Main St T: 413-598-5200 T: 800-527-3760 T: 800-722-1133
Chicopee, MA 01020 F: 413-598-5201 F: 413-598-5367 F: 413-598-5201
http://www.prima-na.com
DISCLAIMER
All drawings, schematics, and illustrations in this manual are only representative of the objects
they depict. They should not be considered as exact replications of the actual objects. The
information in this manual is presented as accurately as possible. It is, however, subject to
change without notice. The information is presented “as is” and Convergent Prima makes no
representations or warranties of any kind regarding this material including implied warranties.
Convergent Prima will not be held responsible for errors, omissions, or damage, whether direct,
indirect, incidental or consequential, in connection with any part of this material.
Copyright © 2005 Convergent Lasers All rights reserved. No part of this book may be
reproduced or transmitted in any form, by any means (electronic, photocopying, recording, or
otherwise) without the prior written permission of Convergent Lasers.
0546-396-OE Rev B Page 1

INDEX
INDEX
OPERATOR MANUAL.................. 7
1. SAFETY 7
1.1. CONTACT INFORMATION............................................................................... 7
1.2. INTRODUCTION TO SAFETY.......................................................................... 7
1.3. ELECTRICAL HAZARDS.................................................................................. 9
1.3.1. SAFETY INTERLOCKS 9
1.3.2. HIGH VOLTAGE DC HAZARDS 10
1.3.3. HIGH VOLTAGE AC HAZARDS 10
1.3.4. SAFETY DISCONNECTS 11
1.4. OPTICAL RADIATION HAZARDS .................................................................. 12
1.4.1. CORNEAL-RETINAL BURNS 12
1.4.2. DIRECT SKIN BURNS 13
1.4.3. IN-DIRECT SKIN BURNS 13
1.5. MATERIAL PROCESSING HAZARDS ........................................................... 13
1.5.1. Flammable and Explosive Reactions 13
1.5.2. Toxic Reactions 13
1.5.3. Material Temperature Burns/Cuts 13
1.6. DELIVERY APERTURE DIRECTION ............................................................. 14
1.7. CDRH COMPLIANCE ..................................................................................... 14
1.7.1. PROTECTIVE HOUSINGS 14
1.7.2. REMOTE INTERLOCKS 14
1.7.3. E-STOP 14
1.7.4. MAIN POWER KEY SWITCH 14
1.7.5. CNC MAIN POWER KEY SWITCH AND SHUTTER KEY SWITCH 15
1.7.6. LASER EMISSION INDICATORS 15
1.7.7. SHUTTER CONTROL 15
1.7.8. EXTERNAL SHUTTER INTERLOCKS 16
1.7.9. SAFETY LABELS 16
1.7.10. BEAM DELIVERY APERTURE DIRECTION 16
1.7.11. ACCIDENTAL RADIATION OCCURENCES (ARO’s) 16
1.7.12. Reporting Of Accidental Radiation Occurrences 16
1.8. SAFETY LABELS ........................................................................................... 17
1.8.1. SAFETY LABEL LOCATIONS 20
1.9. Training Courses............................................................................................. 21
2. SPECIFICATIONS 22
2.1. CP SERIES CO2 LASER SPECIFICATIONS.................................................. 22
2.2. CP SERIES CO2 LASER UTILITIES SPECIFICATIONS ................................ 22
2.3. CP SERIES CO2 LASER PHYSICAL DIMENSIONS ...................................... 23
3. OPERATING PROCEDURES 24
3.1. START UP PROCEDURES ............................................................................ 24
3.2. SHUT DOWN PROCEDURES........................................................................ 24
3.3. CP PANEL SOFTWARE ................................................................................. 24
3.3.1. Getting Started 25
3.3.2. Installing The Display Panel 25
3.3.3. Starting The Display Panel 25

INDEX
3.3.4. Starting The Display Panel in DEMO mode 27

3.3.5. Closing The Display Panel 27
3.4. Accessing The Online User Guide .................................................................. 27
4. FAULTS and WARNINGS 29
4.1. General Information ........................................................................................ 29
4.1.1. Types Of Faults And Warnings 29
4.1.2. Viewing Fault And Warning Messages 31
4.1.3. Clearing Fault And Warning Messages 31
4.2.............................................................................................................................. 33
4.3. MCR Faults ..................................................................................................... 33
4.3.1. MCR 001 CO2 Gas Pressure Low - Line Pressure Below 60 PSI 34
4.3.2. MCR 002 N2 Gas Pressure Low - Line Pressure Below 60 PSI 34
4.3.3. MCR 003 He Gas Pressure Low - Line Pressure Below 60 PSI 34
4.3.4. MCR 004 34
4.3.5. MCR 005 Main Contactor State Fault 35
4.3.6. MCR 006 Vac Pump Contactor State or Circuit Breaker Tripped Fault 35
4.3.7. MCR 007 Frequency Inverter Circuit Breaker Tripped Fault 35
4.3.8. MCR 008 Phase Detector Fault 35
4.3.9. MCR 009 High Voltage Softstart Circuit Breaker Tripped Fault 36
4.3.10. MCR 010 Door Interlock Fault 36
4.3.11. MCR 011 Frequency Inverter Fault 36
4.3.12. MCR 012 Shutter Water Flow Fault < 5.5 LPM 36
4.3.13. MCR 013 Safety Relay Interlock Fault 37
4.3.14. MCR 014 Cabinet Temp Fault > 45 deg C 37
4.3.15. MCR 015 Turbine Motor Bearing Temp Fault > 85 deg C 37
4.3.16. MCR 016 Turbine Bearing Temp Fault > 85 deg C 37
4.3.17. MCR 017 Turbine Gas Temp Fault > 120 deg C 38
4.3.18. MCR 018 Water Temp High Fault > 25 deg C 38
4.3.19. MCR 019 Turbine Pressure Low Limit Fault < 45 Torr 38
4.3.20. MCR 020 Exceeded Max Time to Start Pressure > 10 Min – 38
4.3.21. MCR 021 10 Minute Limit on Continuous Pumpdown Exceeded 39
4.3.22. MCR 022 Laser Pressure Outside Limits to Operate Turb. (P<50 or P>95 Torr) 39
4.3.23. MCR 023 Temperature Monitor Low Fault - Check Analog Temperatures 39
4.3.24. MCR 024 HV Contactor Not OFF in Allotted Time > 300 msec 39
4.3.25. MCR 025 40
4.3.26. MCR 026 40
4.3.27. MCR 027 Turbine Starting Time Exceeded 90 Sec - Shutting Down Laser 40
4.3.28. MCR 028 Main Laser Key Is OFF 40
4.4. HV Faults ........................................................................................................ 40
4.4.1. HV 001 41
4.4.2. HV 002 Lane Over-Voltage Fault 41
4.4.3. HV 003 HV Power Supply Fault 41
4.4.4. HV 004 Transformer Tank Temp Fault > 70 degC 41
4.4.5. HV 005 Lane Imbalance 10 Times in 2 Min Fault - Lane x 42
4.4.6. HV 006 Laser Cavity Pressure Fault (+/- 5 Torr from Set Point) 42
4.4.7. HV 007 Turbine Speed Fault < 380Hz 42
4.4.8. HV 008 42
4.4.9. HV 009 Pulser Watchdog Fault 42
4.4.10. HV 010 Water Temp LOW Fault < 12 degC 43
4.4.11. HV 011 Lane Monitor Fault 43
4.4.12. HV 012 Power Monitor Fault 43
4.4.13. HV 013 Air Pressure Fault - Line Pressure Below 60 PSI 43

INDEX
4.4.14. HV 014 HV Circuit Breaker Fault 43

4.4.15. HV 015 HV Contactor Not ON in Allotted Time > 25 Sec 44
4.5. Shutter Faults.................................................................................................. 44
4.5.1. SHTR 001 44
4.5.2. SHTR 002 Shutter Blade Temp > 60 degC or Beam Dump Temp > 82 degC 44
4.5.3. SHTR 003 Beam Tube Interlock Not Satisfied 44
4.5.4. SHTR 004 Shutter Moved Out of OPEN/CLOSED Position w/o Command 45
4.5.5. SHTR 005 Shutter Timing Fault (Not OPEN or CLOSED within 0.3 sec) 45
4.5.6. SHTR 006 Shutter Logic Fault (OPEN and CLOSED State Simultaneously) 45
4.5.7. SHTR 007 Lane Imbalance with Shutter Open Fault - Lane x 45
4.6. PLC Faults ...................................................................................................... 46
4.6.1. PLC 001 Low Battery 46
4.6.2. PLC 002 CPU Hardware Problem 46
4.6.3. PLC 003 Configuration Mismatch 46
4.6.4. PLC 004 Corrupted RAM 46
4.6.5. PLC 005 Unrecoverable Software Error 47
4.6.6. PLC 006 PLC Fault Table Entry 47
4.6.7. PLC 007 I/O Fault Table Entry 47
4.7. Warnings......................................................................................................... 47
4.7.1. WARN 001 CO2 Gas Pressure Low - Line Pressure Below 60 PSI 48
4.7.2. WARN 002 N2 Gas Pressure Low - Line Pressure Below 60 PSI 48
4.7.3. WARN 003 He Gas Pressure Low - Line Pressure Below 60 PSI 49
4.7.4. WARN 004 Laser start Delayed While Turbine Winding Down to Below 30Hz 49
4.7.5. WARN 005 Lane Anomaly PCB Warning - Lane ID Signals Missing 49
4.7.6. WARN 006 49
4.7.7. WARN 007 49
4.7.8. WARN 008 Main Contactor Delay - Wait 30 Seconds 49
4.7.9. WARN 009 50
4.7.10. WARN 010 HV Inhibited, Not In Pressure Window (P < 80 Torr or P > 90 Torr) 50
4.7.11. WARN 011 BEAM ON Without High Voltage ON (Cycle BEAM OFF) 50
4.7.12. WARN 012 HV Inhibited, Re-enable HV ON (After HV Fault Reset) 50
4.7.13. WARN 013 HV Inhibited, CLOSE Shutter (After HV Fault Reset) 50
4.7.14. WARN 014 Shutter Inhibited, Laser Warming Up, Close Shutter 51
4.7.15. WARN 015 Water Flow < 5.5 LPM or Water Temp. < 12 degC or > 25 degC 51
4.7.16. WARN 016 Purge Inhibited - Gas Pressure Low 51
4.7.17. WARN 017 - WARN 032 51
4.7.18. WARN 033 Change Vacuum Pump Oil 51
4.7.19. WARN 034 Turbine Maintenance Required 52
4.7.20. WARN 035 Max Time For Backfill Exceeded ( > 3 Min) 52
4.7.21. WARN 036 Laser Didn't Pump Down to Start Press. in Allotted Time ( > 5 min) 52
4.7.22. WARN 037 Max Time for Overnight N2 Exceeded ( > 10 Min Total) 52
4.7.23. WARN 038 Discharge Anomaly Repeat on Lane 1, Check Output Coupler 53
4.7.24. WARN 039 Three Consecutive Discharge Anomalies - Lane x 53
4.7.25. WARN 040 Start Pressure Bypassed by User 53
4.7.26. WARN 041 Exceeded Max Turbine Starting Time - Restarting Laser 53
4.7.27. WARN 042 Turbine Bearing Overtemp Warning > 70 degC for 90 min 53
4.7.28. WARN 043 Turbine Motor Bearing Overtemp Warning > 70 degC for 90 Min 54
4.7.29. WARN 044 Water Flow High > 15 LPM, Check PCB output 54
MAINTENANCE MANUAL ......... 55

5. INSTALLATION 55
5.1. ON-SITE RECEIVING INSPECTION.............................................................. 55

INDEX
5.2. LIFTING THE CP SERIES LASER ................................................................. 55

5.3. LASER REQUIREMENTS .............................................................................. 57
5.3.1. FLOOR SPACE REQUIREMENTS 57
5.3.2. ELECTRICAL POWER REQUIREMENTS 57
5.3.3. COOLING WATER REQUIREMENTS 57
5.3.4. GAS AND AIR REQUIREMENTS 57
5.4. WHEN SERVICE REQUIREMENTS HAVE BEEN MET ................................ 58
5.5. UNPACKING AND INSPECTION ................................................................... 58
5.5.1. REMOVE SHIPPING BOLTS 59
5.5.2. REMOVE KINEMATIC MOUNT SHIM 59
5.6. LEVEL THE LASER........................................................................................ 60
5.7. INSTALL GLASS ELBOWS ............................................................................ 61
5.8. INPUT VOLTAGE CONFIGURATION ............................................................ 61
5.8.1. CONNECTING POWER 62
5.8.2. MAIN INPUT TRANSFORMER XFMR1 62
5.8.3. PHASE DETECTOR AND PHASING 62
5.9. CONNECTING THE LASER GASES.............................................................. 62
5.10. CONNECTING THE COOLING CIRCUIT ................................................... 63
5.11. INTERFACING ............................................................................................ 63
5.12. RUNNING THE LASER UP......................................................................... 64
6. CP SERIES LASER INTERFACE 65
6.1. CP SERIES LASER INTERFACING............................................................... 65
6.2. EXTERNAL AND SAFETY INTERLOCKS...................................................... 65
6.3. LASER INTERFACE CONNECTIONS ........................................................... 66
6.4. CONTROLLING THE LASER ......................................................................... 71
6.4.1. CONTROLLING THE SHUTTER 71
6.4.2. PULSING 71
6.4.3. ANALOG COMMAND 71
6.4.4. CNC 24 VDC 71
7. LASER DESCRIPTION 71
7.1. GENERAL DESCRIPTION AND FEATURES................................................. 71
7.2. BASIC LASER THEORY AND THE CP SERIES LASER ............................... 72
7.3. RESONATOR ................................................................................................. 75
7.3.1. ELECTRICAL DISCHARGE SYSTEM 75
7.3.2. OPTIC SYSTEM 75
7.3.3. CENTER TUBE 76
7.4. TURBINE ASSEMBLY.................................................................................... 76
7.4.1. FREQUENCY INVERTER ASSEMBLY 76
7.4.2. UPSTREAM AND DOWSTREAM HEATEXCHANGERS 77
7.4.3. PRESSURE REGULATION SYSTEM 77
7.5. VACUUM PUMP ASSEMBLY......................................................................... 78
7.5.1. FAST PUMPDOWN SOLENOID 79
7.5.2. PRESSURE RELIEF VALVE 79
7.6. GAS MIXER ASSEMBLY................................................................................ 80
7.6.1. LASING GASES 80
7.6.2. BACKFILL SOLENOID 80
7.6.3. DRY AIR SYSTEM 81
7.7. HIGH VOLTAGE POWER SUPPLY ............................................................... 81

INDEX
7.7.1. HVPS INVERTER 81

7.7.2. HV TANK WITH QUAD ASSEMLIES 82
7.8. SHUTTER ASSEMBLY................................................................................... 82
7.8.1. DIODE POINTER ASSEMBLY 83
7.9. ELECTRICAL SYSTEM .................................................................................. 84
7.9.1. THREE-PHASE POWER DISTRIBUTION 84
7.9.2. 230 VAC POWER DISTRIBUTION 84
7.9.3. 24 VDC POWER DISTRIBUTION 84
7.9.4. +/- 15 VDC POWER DISTRIBUTION 84
7.10. CIRCUIT BOARDS...................................................................................... 84
7.10.1. WATER MONITOR 84
7.10.2. POWER METER DRIVER CIRCUIT 85
7.10.3. 8-CHANNEL ANALOG MULTIPLEXER 86
7.10.4. LANE ANOMALY AND CURRENT SENSE BOARD 87
7.10.5. QUAD RTD PCB 88
7.11. CONTROL SYSTEM ................................................................................... 89
7.12. COOLING SYSTEM .................................................................................... 89
7.13. AIR SYSTEM............................................................................................... 89
8. PREVENTATIVE MAINTENANCE 90
8.1. OVERVIEW..................................................................................................... 90
8.2. MAINTENANCE SCHEDULE ......................................................................... 90
8.3. VACUUM PUMP MAINTENANCE .................................................................. 90
8.3.1. VACUUM PUMP OIL CHANGE 91
8.3.2. OIL MIST ELIMINATOR FILTER REPLACEMENT 93
8.4. TURBINE MAINTENACE................................................................................ 94
8.4.1. Bearing Maintenance 94
8.4.2. Turbine Maintenance 94
8.4.3. TURBINE BEARING BREAK-IN PROCEDURE 95
8.5. OPTICS MAINTENANCE................................................................................ 96
8.5.1. Optics replacement 96
8.5.2. Resonator tuning 96
8.6. POWER METER CALIBRATION .................................................................... 96
9. WARRANTY 97
9.1. BASIC WARRANTY........................................................................................ 97
9.2. RETURNS AND ADJUSTMENTS................................................................... 98
9.3. EXCLUDED PRODUCTS ............................................................................... 98
9.3.1. Internal Optics 99
9.3.2. Water Cooled Products 99
10. MANUAL CRITIQUE FORM 100
10.1. Place an “X” in the appropriate box ........................................................... 100
11. SERVICE ORDER / RMA FORM 103
12. List of Schematics 106
12.1. 0546-303-03 Rev A – Standard Schematics ............................................. 106
12.2. 0546-303-41 Rev A – Standalone Schematics.......................................... 106

1. SAFETY
OPERATOR MANUAL
1. SAFETY
1.1. CONTACT INFORMATION
This manual was written as an aid in understanding and using the CP Series Lasers in a safe
manner. In case of any questions, please do not hesitate to contact the Convergent Lasers, Inc.
Worldwide Service Headquarters in Chicopee, MA. USA, at one of the following numbers:
Telephone: 1-800-722-1133 (Domestic U.S. only)

Telephone: 1-413-598-5200
Fax: 1-413-598-5201
Email: service@convergentlasers.com
1.2. INTRODUCTION TO SAFETY

The CP Series lasers generates an invisible high-power energy beam. It is extremely dangerous if
improperly used. Additionally, any service performed on the laser can lead to injury or death if
improperly serviced. Operators and maintenance personnel should read this manual carefully and
ensure that they understand all safety issues. If there are any problems or questions, please
contact the Convergent Lasers, see section 1.1 CONTACT
CAUTION: To protect operating personnel, this safety section should be

thoroughly reviewed after system installation and again before operation.
WARNING: Failure to observe operating procedures and warnings can

result in blindness, serious bodily injury, laser beam burns, or death from
electrical hazards.
1.2.1 Safety Considerations
Since the CP Series laser is a Class IV laser product, the user should be aware of certain dangers
and precautions prior to operating the product. While some of the dangers are internal to the
product, there are other dangers related to the delivery and application of the laser. A brief list of
dangers below will be described in more detail in the following sections.

1. SAFETY
ELECTRICAL HAZARDS
o SAFETY INTERLOCKS
o

1. SAFETY
HIGH VOLTAGE DC HAZARDS

o HIGH VOLTAGE AC HAZARDS
OPTICAL RADIATION HAZARDS
o CORNEAL-RETINAL BURNS
o DIRECT SKIN BURNS
o IN-DIRECT SKIN BURNS
MATERIAL PROCESSING HAZARDS
o Flammable and Explosive Reactions
o Toxic Reactions
o Material Temperature Burns/Cuts
1.3. ELECTRICAL HAZARDS
WARNING: Do not touch any electrical part that hasn’t been grounded by the
provided grounding stick or by another means. An ungrounded power supply
may have lethal high voltages present at unexpected locations and is a serious
personnel hazard.
Due to the levels of voltage used in the CP Series lasers, well-trained, technically qualified
personnel only should undertake service and maintenance. This equipment is designed to
prevent accidental exposure to hazardous voltages. Use caution during service and maintenance.
Interlocks are incorporated to ensure safe operation. Voltages used in this laser are high enough
to endanger life. Before any internal maintenance is undertaken, ensure that the laser has been
isolated from the electrical service.
1.3.1. SAFETY INTERLOCKS

Door interlock switches are used to ensure safe laser system operation.
WARNING: Do not override or tamper with any interlock or safety circuit in

any way. The result could prove fatal. Convergent Lasers accepts no liability if
safety circuits have been tampered with or modified.

1. SAFETY
1.3.2. HIGH VOLTAGE DC HAZARDS
WARNING: Failure to turn off all power prior to working on or near high
voltage components could result in severe electrical shock or fatality.
Additionally, all circuits should be grounded using the provided grounding
stick.
A DC Fast Axial Flow Laser uses high voltage when generating a CO2 laser beam. The voltage
used in the CP Series lasers can exceed 25,000 volts DC and is high enough to endage life. DO
NOT perform any electrical service inside the CP Series laser without the proper training or
assistance.
High Voltage Precautions

Always observe the following safety precautions when working near the high voltage areas of
the Laser:
1) Do not work on the high voltage areas alone or when you are tired.
2) Do not work on the high voltage areas when you are perspiring (your body resistance can be
lowered significantly when it is wet).
3) Do not carry metal objects in your pockets or wear metal belt buckles. Also, remove all
jewelry (I.E watches, rings, and necklaces).
4) Be sure to have someone nearby that is trained in CPR in case of electrical shock.
1.3.3. HIGH VOLTAGE AC HAZARDS
WARNING: Failure to turn off all power prior to working on or near high
voltage AC components could result in severe electrical shock or fatality.
The CP Series lasers have electrical components which require 230 VAC and 400-480 VAC.
These voltage levels and current levels from these components are elevated enough to cause
injury or death by electrocution. DO NOT perform any electrical service inside the CP Series
laser without the proper training or assistance.
Follow similar precautions to the High Voltage Precautions listed above.

1. SAFETY
1.3.4. SAFETY DISCONNECTS

The CP Laser provides electrical disconnects for both safety and maintenance purposes.
Main Disconnect Switch
The MAIN DISCONNECT SWITCH (MCB1) (See Figure 1.1) is located on the upper left-
hand side of the control panel. In the ON (red/1) position, electrical power is available to operate
the laser. In the OFF (green/0) position, the entire laser, high voltage power supply, and control
system are shut down. This disconnect should be used when performing any maintenance inside
the laser.
Figure 1.1, Main Disconnect Switch
Emergency Stop Button
The CP Series Laser is typically used a part of a total system. In most cases, the system
manufacturer provides a Emergency Stop (E-Stop) button. However the CP Series Laser does
have an option in which a Emergency Stop is provided with the laser.
In the event of an emergency, the operator should engage the E-Stop button to shut the
machine/laser down. Pressing either button will shut down electrical power to the entire laser
and cease laser emission. Only the PLC Input Control Voltages will remain active. Restarting the
laser can only be achieved by manual release of the EMERGENCY STOP buttons, resetting
(optional keys) KEY1 (CNC Main Power Key Switch), KEY2 (Shutter Key Switch), and KEY3
(Main Power Key Switch), followed by the normal laser PC controlled start up procedure. The
danger to personnel from the high voltage circuits far exceeds that possible from the laser beam.

1. SAFETY
Appropriate and adequate interlock safeguards are therefore an integral part of the laser system
for the protection of operators and maintenance personnel.
WARNING: Capacitors used in the power supply system are capable of

storing electrical charge for extended time periods. Discharge circuits are
provided in the laser units but as a safety precaution a qualified technician
must assure that all voltages have been discharged before entering the laser
unit.
1.4. OPTICAL RADIATION HAZARDS

1.4.1. CORNEAL-RETINAL BURNS
The CP Series Lasers have actually 2 lasers emerging from their output. One is an invisible CO2
Class IV laser beam, which is the main function of the laser. The second is a visible Class II
diode laser beam used for coarse beam alignment and process positioning.
Corneal Burns
The CO2 laser beam is a high powered infrared laser beam operating at a 10.6 µm wavelength.
This energy and wavelength of this laser beam can severely damage the cornea of the
unprotected eye. It should be noted the eye can be damaged by both a direct or reflected beam.
The best protection from this type of injury can be prevented when the user is wearing protective
eyewear whenever they are in the presence of the laser and laser work piece.
Retinal Burns
Unlike the CO2 laser beam, the Class II diode laser generates a laser beam at 635 nm, which is
inside the visible light spectrum. Although the laser beam is not powerful enough to burn skin,
the user should take care not to directly look into the beam or reflected beam. The visible
wavelength of the laser allows the lens a person’s eye to focus the beam onto the back of the
retina creating enough energy to damage the retina.
Protective Eyeware
The CP Series laser is a Carbon Dioxide (CO2) Class IV laser with an invisible output beam that
has a wavelength of 10.6 micrometers. Proper safety glasses must be worn. Eyewear should
meet the standards of ANSI Z87.1-1968, which specifies the protective properties for laser
eyewear such as impact resistance as well as protection from laser beam exposure at the specific
wavelength.
References
American National Standard: ANSI Z87.1-1989, “Practice for Occupational and Educational Eye
and Face Protection.
American National Standard: ANSI Z136.1-2000, “for the safe use of lasers.”

1. SAFETY
Laser Institute of America: “Guide for the Selection of Laser Eye wear."
WARNING: Never, under any circumstances, look directly or indirectly into

the beam. Severe burns or blindness will result!
1.4.2. DIRECT SKIN BURNS

The concentrated optical energy from a Class IV CO2 laser is strong enough to severly burn skin
upon direct contact. Only trained personnel should work around the system when beam
protective devices have been removed for service purposes. Users should ensure that a
protective screen or enclosure is used at all times around the work area to absorb any reflected
energy from the work piece when the laser shutter is open and the beam is in use. Keep hands
and limbs clear of the laser beam at all times.
1.4.3. IN-DIRECT SKIN BURNS

The user should also be aware that the energy from a Class IV CO2 laser is strong enough that
reflective energy from several reflective materials, is strong enough to burn skin upon contact.
1.5. MATERIAL PROCESSING HAZARDS

1.5.1. Flammable and Explosive Reactions
The energy delivered from a Class IV CO2 laser is enough to generate flammable reactons with
most materials. Therefore, it is important to keep the area around the laser process clear of
combustible materials such as paper, flammable chemicals (acetone, alcohol, etc) and oily rags.
CAUTION: Use caution when handling flammable materials in close

proximity to the laser beam. Ventilation is the responsibility of the end user.
1.5.2. Toxic Reactions

Some materials processed can release harmful gases, which can be hazardous. The user should
be aware of the gases released from the materials they are processing and make sure they are
properly exhausted.
1.5.3. Material Temperature Burns/Cuts

Some materials will be extremely hot immediately after processing. The user should take care
not to directly handle the material until it cools to an appropriate temperature to avoid burns.
Additionally, some parts may have sharp edges or dross, the user should use gloves and handle
the material carefully to avoid cuts.

1. SAFETY
1.6. DELIVERY APERTURE DIRECTION

EXTREME CAUTION should be used near all beam delivery systems,
especially when beam tubes or optics have been removed. Beam stops,
shielding or enclosures must be used to ensure safety of surrounding personnel
and the environment. Therefore, alignment of the Laser beam through the
beam delivery system should only be performed by a Laser engineer or
certified operator.
1.7. CDRH COMPLIANCE

Statement Of Compliance
This product complies with FDA performance standards for laser products except for deviations
pursuant to laser notice NO. 50, dated July 26, 2001.
CAUTION: Use of controls or adjustments or performance of procedures

other than those specified in this manual may result in result in hazardous
radiation exposure.
1.7.1. PROTECTIVE HOUSINGS

The laser beam is totally enclosed within the laser and no access is possible during operation
except at the output aperture from the head when the shutter is operated. In a typical system the
beam will then be totally enclosed within beam delivery tubes all the way to the final focus lens.
1.7.2. REMOTE INTERLOCKS

The ability to wire external interlocks (I.E. work area access doors, safety shields/screens or
other devices intended to protect personnel working around the laser) into the laser safety circuits
has been provided. When activated, the external interlock will shut down the laser, remove
power from the shutter circuits and disable the high voltage power supply. Operation of the laser
may only be resumed through a normal reset of the fault condition and start up from the laser PC
control device.
1.7.3. E-STOP
Provisions have been made for installation of an External E-Stop. Connections can be made at
PJ3 (on 0546-303-03 Rev A – Standard Schematics, Sheet 6). An optional Cabinet E-STOP can
be ordered.
1.7.4. MAIN POWER KEY SWITCH
An optional key lock switch interface is provided at J3, pins 1 and 3 (0546-303-03 Rev A –
Standard Schematics, Sheet 6). This acts as the Main Power Control Switch (KEY 3). The key is

1. SAFETY
removable in the OFF position only, and the laser is not operable with the key removed. This key
prevents use by untrained operators and should only be available to trained personnel.
Subsequent control of the High Voltage is carried out by the PC control and is determined by the
status of the interlocks used in the laser as well as other status conditions.
1.7.5. CNC MAIN POWER KEY SWITCH AND SHUTTER KEY SWITCH
The optional customer supplied CNC Main Power Key Switch (KEY 1) and Shutter Key Switch
(KEY 2) must also be turned on to operate the laser. They also provide resetting capability for
the Safety Relay SRL1 (0546-303-03 Rev A – Standard Schematics, Sheet 6) at T33 and T34.
WARNING: If the remote interlocks, E-STOP LOOP, or SAFETY LOOP are

activated, or if a power loss occurs, operation of the CP4000 laser cannot
automatically occur upon restoration of power, or de-activation of the
interlock. To start the laser again the Safety Relay Reset Loop Keys (CNC
Main Power KEY 1 and Shutter KEY 2) must be turned OFF and back ON to
reset the safety relay SLR1. Main Power Key Switch (KEY3) must also be on
to allow safe laser restart.
1.7.6. LASER EMISSION INDICATORS

LASER EMISSION identification on the CP Laser is provided be means of a red indicator lamp
located on the top of the laser. When the lamp is OFF the Laser is OFF. The indicator is ON
STEADY when the laser is running with the High Voltage OFF. The indicator will FLASH at a
1 Hz interval when the High Voltage is turned ON. There is also an optional stack light
assembly on the laser. The AMBER lamps on the stack will be ON when the laser is READY
FOR HIGH VOLTAGE to be enabled. After the warm-up cycle is complete and the laser is
READY FOR THE BEAM ON COMMAND, the GREEN lamp will be ON. If there is a laser
FAULT, the RED lamp will be OFF. This provides an easily identifiable indication of laser
status. There is also a BEAM ON indicator on the CP Display Panel.
1.7.7. SHUTTER CONTROL

There is a user controlled, shutter blade-type device used in the laser to interrupt the beam under
certain circumstances. The shutter is electrically operated and controls output of the laser beam.
If this shutter is closed a mirror deflects the beam into a water-cooled dump. If the shutter is
open, the beam is allowed to exit the laser. Operation of the shutter is dependent on various
conditions being met and is under full control by the laser PLC control unit. The shutter can be
opened or closed at any time but High Voltage cannot be enabled until the shutter is closed.
Additionally, the shutter cannot be opened until all interlocks, safety loops, and E-stops loops
have been satisfied (see 0546-303-03 Rev A – Standard Schematics, Sheets 6 and 19).

1. SAFETY
1.7.8. EXTERNAL SHUTTER INTERLOCKS

External Shutter Interlocking is available at the CNC connector J3 pins 2 and 4. This circuit
gives the capability for the Laser to monitor the in-line safety circuits of the workstation and
inhibit the shutter drive if those conditions are not satisfied. This signal is required for proper
operation of the shutter and for beam extraction.
WARNING: Convergent Lasers assumes no liability if the interlocks provided

on this product are disabled for any reason.
1.7.9. SAFETY LABELS

The laser is labeled to certify compliance with CDRH standards. The labels indicate the lasing
medium (CO2), the power level (practical upper limit), the classification of the laser (Class IV),
and the location of the output aperture. Figures are provided at the end of this chapter that clearly
show label location, type, and part numbers should labels ever need to be replaced.
1.7.10. BEAM DELIVERY APERTURE DIRECTION
EXTREME CAUTION must be taken with all beam delivery systems that
point the laser beam other than straight down or away from the operator. When
carrying out maintenance procedures, beam stops, shielding, enclosures or
other means must be used to ensure safety of surrounding personnel and
environment
NOTE: Suitably qualified maintenance or other service personnel should only

perform adjustment of beam delivery equipment for pointing angle and
alignment.
1.7.11. ACCIDENTAL RADIATION OCCURENCES (ARO’s)

Accidental Radiation Occurrences that take place on a customer’s site must be immediately
reported to Convergent Lasers. Convergent Lasers will then notify the CDRH as stipulated in the
FDA handbook on Accidental Radiation Occurrences. The following is an excerpt from that
publication:
1.7.12. Reporting Of Accidental Radiation Occurrences

a) Manufacturers of electronic products shall, where reasonable grounds for suspecting that
such an incident has occurred, immediately report to the Director, Bureau of Radiological
Health, all accidental radiation occurrences reported to or otherwise known to the
manufacturer and arising from the manufacturing, testing, or use of any product introduced

1. SAFETY
or intended to be introduced into commerce by such manufacturer. Reasonable grounds

include, but are not necessarily limited to, professional, scientific, or medical facts or
opinions documented or otherwise, that conclude or lead to the conclusion that such an
incident has occurred.
b) Such reports shall be addressed to the Director, Bureau of Radiological Health, 5600 Fishers
Lane, Rockville MD20857, and the reports and their envelopes shall be distinctly marked
“Report on section 1002.20” and shall contain all of the following information where known
to the manufacturer:
• Nature of the accidental radiation occurrence.

• Location at which the accidental radiation occurrence occurred.
• Manufacturer, type, and model number of the electronic products involved.
• Circumstances surrounding the accidental radiation occurrence, including causes.
• The number of persons involved, adversely affected, or exposed during the accidental
radiation occurrence, the nature and magnitude of their exposure and/or injuries and if
requested by the Director, Bureau of Radiological Health, the names of the persons
involved.
• Actions, if any, which may have been taken by the manufacturer, to control, correct,
or eliminate the causes and to prevent reoccurrence.
• Any other pertinent information that can be obtained about the accidental radiation
occurrence should be included.
1.8. SAFETY LABELS

1. SAFETY

1. SAFETY

1. SAFETY
1.8.1. SAFETY LABEL LOCATIONS
2
7
4
6
8
Figure 1.2, Safety Label Locations, Front View
2
4
Figure 1.3, Safety Label Locations, Rear View
Figure 1.4 Label Locations, Output View

1. SAFETY
1.9. Training Courses

Convergent Lasers offers full training in the maintenance and operation of all of its laser
products. Contact the service training facility at 1-800-722-1133 or 413-598-5200 for course
schedules and itineraries.

3. LASER DISPLAY PANEL DESCRIPTIONS
2. SPECIFICATIONS
2.1. CP SERIES CO2 LASER SPECIFICATIONS
CP 3000 CP 3500 CP 4000
Average Power 200W - 3000W 200W - 3500W 200W - 4000W
Peak Power Up to 6 kW Up to 7kW Up to 10kW
Wavelength 10.6 micrometers
Beam propagation factor M2 < 2.4 (typical 2.1 to 2.3)
Beam Divergence 1.5 mrad half angle
Beam Diameter at Output 14.5mm 1/e2, 19mm full beam
Pulsing Pulse Rep.Rate 0 - 2kHz.
Pulse Width >250 microseconds, 70 µsec Resolution
Pointing Stability +/- 150 µradians
Operating Conditions
Ambient Temperature Max 40 Degrees C
Min 10 Degrees C
Relative Humidity <95% Non Condensing
Diode Laser
Wavelength 635 nanometers
Power Output <1 milliwatt
2.2. CP SERIES CO2 LASER UTILITIES SPECIFICATIONS

CP 3000 CP 3500 CP 4000
Electrical Power 28 kW 31 kW 34 kW
Voltage 400VAC - 460VAC, 3-Phase,
Cooling Required cooling capacity 34 kW 36 kW 40 kW

Flow Rate 133 LPM (35 GPM)
Inlet Temperature 18 - 20 Degrees C
Maximum Inlet Pressure 6 Bar
Nominal Inlet Pressure 3 Bar
Pressure Differential 1.5 Bar
Fluid Distilled Water w/ 35% Dowfrost HD
Filter Requirements 100 micron
Gas Type Purity Gas Mix Consumption: 20 SLPH - 70 SLPH Variable

He 99.996% 67.7% 13.4 SLPH - 46.8 SLPH
CO2 99.995% 4.1% 0.9 SLPH - 3.0 SLPH
N2 99.996% 28.2% 5.8 SLPH - 20.2 SLPH
Less than 10 ppm water vapor, hydrocarbons, and oxygen
Air Dry – Dew Point < 2 Degrees C Dependent upon shutter usage
Manual P/N: 0546-396-2E Page 22 / 106

3. LASER DISPLAY PANEL DESCRIPTIONS
2.3. CP SERIES CO2 LASER PHYSICAL DIMENSIONS
Dimensions Width 855 mm

Height 883 mm
Length 3105 mm
Weight 1200 kg (2650 lbs)
Connections Water 1.25" Hose Barb (x2)
Gas Inlet 6mm Tube Fitting (x4)
Exhaust 0.5” Tube Fitting
Drain 8mm Tube Fitting
Manual P/N: 0546-396-2E Page 23 / 106

4. OPERATING PROCEDURES
NOTE: The following procedures are based upon normal CNC startup
procedures instigated from a OEM control source.
3.1. START UP PROCEDURES

Step 1: Turn the laser on by turning the Laser Start Key on the CNC. The following
sequence will occur:
a. Fast Pump Down Solenoid, Pressure Regulator Solenoids and Vacuum Pump will
turn on and Laser will evacuate to 4 Torr.
b. At 4 Torr, the Fast Pump Down Solenoid and Pressure Regulating Solenoids will
turn off and the Gas Solenoids will turn on filling the Laser to 85 Torr.
c. At 50 Torr the Frequency Drive Inverter will start ramping the Turbine up to the
operating frequency.
d. At 75 Torr the operator can enable the HVPS.
Step 2: Turn the HV ON (it will not turn on until laser reaches 85 Torr).
a. HVPS will come on after a 30 second soft start.
b. The laser will go through the Warm-up Cycle (unless it is bypassed).
c. Laser will go into Simmer (or whatever level the Standby Command is set to).
St Step 3: Start the program on the CNC.
3.2. SHUT DOWN PROCEDURES

1. Stop the CNC program.
2. Turn High Voltage OFF.
3. Turn laser Start Key OFF.
4. Backfill the Laser.
5. Leave Power On to the laser with N2 On to allow for Overnight Backfill.
3.3. CP PANEL SOFTWARE
The CP laser also comes with a software package, which allows the customer to interact directly
to the laser through a PC either supplied by the OEM or a PC purchased on their own.
Manual P/N 0546-396-OE Rev B Page 24 / 106

On the same CD-Rom, which you used to open this manual, there is also a setup program as
shown in Figure 3.1.
Figure 3.1 CP Panel Software Setup
3.3.1. Getting Started

This section describes how to install and setup the CP-Series Software Display Panel, as well as
how to start and stop the Panel software
The following topics are covered in this section:
• Installing The Display Panel

• Starting The Display Panel
• Starting The Display Panel in DEMO mode
• Closing The Display Panel
3.3.2. Installing The Display Panel

The CP-Series Software Display Panel is installed from a single Setup file located on the
Software and Documentation CD. The installation program is straight-forward and simple to use.
To run the installation program, perform the following procedure.
Installing the CP4000 Software Control Panel:

1. Insert the CP-Series CD into your CD drive.
2. Using the Windows Explorer, navigate to the Display Panel Install directory.
3. Double-click on the CP Series Setup v2.10.x.x.exe file to initiate the install.
4. Follow the prompts to complete the installation.
3.3.3. Starting The Display Panel

To start the CP-Series Software Display Panel, simply double-click its shortcut icon. The icon
can be found by Clicking Start>Programs>CP-Series Laser. An icon may also have been
placed on the Desktop for easy access.
CP-Series Panel Icon

While the Panel is loading, a splash screen is displayed showing information about the panel, its
version number and its author. During this time, the Panel reads the CP4000.ini file and sets
up the options, preferences, etc. as read from the file.
When the Panel is finished loading, it will display the Information page, showing the Panel
software version number and revision date, the Laser software version number, and information
on how to contact the author.
After the Information page is displayed, the Panel will attempt to establish serial
communications with the Laser. This process can be monitored on the Communications Status
box, located at the lower left of the Panel.
Communication Status Display
A green, blinking indicator shows communication with the Laser. A red, non-blinking indicator
shows a communications fault, and is accompanied by an appropriate fault message.
NOTE: If any fault occurs, it is displayed on the Message page, which can be accessed by clicking on the F6
button on the Panel or by simply pressing the F6 key on the keyboard. Also, the Panel options may be set to
force the Message page at the occurrence of any fault or warning. See the section of this User Guide for
information about each fault or warning message, and instructions on how to clear the message and reset the
Laser.
If serial communications with the Laser are established, the Panel is then ready to receive input
from the user. To learn more about using the Display Panel, see the appropriate sections of this
document. To learn more about operating the CP-Series Laser, see the CP-Series manual.

3.3.4. Starting The Display Panel in DEMO mode
What is DEMO mode?

DEMO mode allows the user to run the CP-Series Display Panel software without actually being
connected to a Laser. This allows the user to `play' with the controls and become familiar with
the Panel while not actually controlling a Laser.
In DEMO mode, all serial commands to and from the Laser's PLC are ignored, and instead are
read and acted upon by a special routine which simulates the operation of the CP-Series Laser.
Separate Log and Data Recorder files are used while in DEMO mode, so as not to modify or
change any `real' files which may be on the PC at the time the Panel is run in DEMO mode.
These files are clearly marked as DEMO files in the filename. They are stored in the same
directories as the true CP-Series Display Panel files.
NOTE: Some features of the CP-Series Laser are not simulated at this time due to the need for a hardwired
control panel to turn the Laser components ON and OFF.. Others are simulated, but due to the nature of the
Laser's thermal response times and the simulation software's relatively fast response, are not accurate in
timing.
Starting the Display Panel in DEMO Mode

To start the CP-Series Software Display Panel in DEMO mode, simply double-click its shortcut
icon labeled DEMO The icon can be found by Clicking Start>Programs>CP-Series Laser. An
icon may also have been placed on the Desktop for easy access.
CP4000 Panel DEMO Icon
While running in DEMO mode, the word DEMO is displayed in place of the word Connected in
the Communications Status display at the lower left of the Panel.
3.3.5. Closing The Display Panel

To close the Display Panel, simply click on the in the upper right corner of the Panel
Window. Communications with the Laser will be terminated and the Panel will be closed.
NOTE: If the Software Function Buttons are grayed out, indicating that they are disabled, the panel cannot
be shut down. Finish the current task to re-enable the Buttons, then close the Panel.
3.4. Accessing The Online User Guide

Once the CP Panel software is loaded and operational, the user can click on the Help
file Icon for further information on the CP panel software and the fault codes listed
below.

The Online User Guide is in the standard Windows HTML Help format. Anyone familiar with
Windows software will feel right at home in the User Guide. To access the Guide, simply click
on the Icon, which is a pad of paper with a yellow question mark, located at the upper right of the
Display Panel in the Logo bar.
User Guide Icon shown in Logo bar
Once open, the User Guide can be resized or maximized if desired.

4. FAULTS and WARNINGS

This section of the User Guide covers topics related to the Fault and Warning Messages.
Note: The descriptions in this section refer to the operation of the CP-Series Laser. For more detailed
information on the Laser itself, and on basic trouble-shooting procedures, refer to the CP-Series Laser
Manual.

• General Information
• MCR Faults
• HV Faults
• Shutter Faults
• PLC Faults
• Warnings
4.1. General Information

The CP-Series Display Panel makes trouble-shooting the Laser much easier by displaying the
Laser's built-in diagnostic status.
Fault and Warning messages are clearly displayed. This section describes how to view and reset
these messages, as well as the meaning and probable cause of each message displayed.

• Types Of Faults And Warnings
• Viewing Fault And Warning Messages
• Clearing Fault And Warning Messages
4.1.1. Types Of Faults And Warnings
Faults in the CP-Series laser are grouped into four types.

• MCR Faults
• HV Faults
• SHUTTER Faults
• PLC Faults
All Fault Messages are displayed in Red on the Message page and require the user to manually
clear them before further operating the Laser.
All Warnings are displayed in Yellow on the Message page and are self-resetting.

MCR Faults
The MCR Faults are serious faults which could cause major damage to the Laser or operator.
The Laser will shut itself down if any of the MCR faults occur, and will prevent the user form
starting again until the fault is rectified and the message is cleared.
NOTE: If any MCR fault occurs before the Laser is started, the word WARN will be displayed before the
message on the Message page, and the fault will not be logged in the Fault Log. The fault will then only
prevent the user from starting the Laser until the fault is rectified and the Message is cleared.
HV Faults
The HV Faults are less serious faults but could still cause major damage to the Laser or operator.
The Laser will remain ON if it is ON when the fault occurs, but the HV will be shut down. The
user will be prevented form turning the High Voltage ON again until the fault is rectified and the
message is cleared.
NOTE: If any HV fault occurs before the HV is turned ON, the word WARN will be displayed before the
message on the Message page, and the fault will not be logged in the Fault Log. The fault will then only
prevent the user from turning the High Voltage ON until the fault is rectified and the Message is cleared.
SHUTTER Faults
The SHUTTER Faults are less serious than the MCR or HV faults, but could still cause harm to
the operator. The Laser and High Voltage will remain ON if they are ON when the fault occurs,
but the Safety Shutter will be CLOSED. The user will be prevented form OPENING the Safety
Shutter again until the fault is rectified and the message is cleared.
NOTE: If any SHUTTER fault occurs before the Safety Shutter is OPENED, the word WARN will be
displayed before the message on the Message page, and the fault will not be logged in the Fault Log. The
fault will then only prevent the user from OPENING the Safety Shutter until the fault is rectified and the
Message is cleared.
PLC Faults
The PLC Faults are different from the other types of faults. These faults are generated by the
PLC controller hardware itself, and not by the Laser's built-in diagnostics logic. If a PLC fault
should occur, the message will be displayed in Red on the Message page. The Laser may or may
not be shut down, depending on the severity of the PLC fault.
Warnings
The Warnings are not indications of serious conditions, but rather exist to alert the user to certain
conditions which may develop into more serious faults if not tended to, or which may prevent the
user from performing various operations on the Laser. The Warning messages are displayed in
Yellow on the Message page and are self re-setting when the condition which caused the
Warning is corrected.

4.1.2. Viewing Fault And Warning Messages

The Fault and Warning Message text is displayed on the Message page. The page is accessed by
clicking the F6 Message button on the main Display Panel screen, or by pressing the F6 key on
the Keyboard.
Fault and Warning Messages displayed on the Message page
The Message page can be displayed at any time and at any user level, as long as the Function
Keys are enabled.
NOTE: The Display Panel can be set up to automatically show the Message page any time a Fault or
Warning Message is displayed, by selecting the appropriate options on the Setup page.
4.1.3. Clearing Fault And Warning Messages

The Fault and Warning Messages can be cleared either by using the CNC Hardware Fault Clear
input or by following the procedure below for clearing the Messages using the Display Panel.
The Fault and Warning Messages can be cleared at any time and at any current user level, as
long as the Function Keys are enabled.
Clearing the Fault and Warning Messages involves three easy steps:
1. Display the Message page and read any existing Fault or Warning text.
2. Make sure that the condition which caused the Fault or Warning has been corrected.
3. Initiate a Laser Reset.
The following section describes the procedure for clearing Fault and Warning Messages.
Step 1. Display the Message page

Using the Mouse or the Touch Screen, click on the F6 Message button on the lower part of the
Display Panel, or press the F6 key on the Keyboard. This will display the Message page.

Message page showing current Fault and Warning messages
Step 2. Correct the Fault or Warning condition

For information on the Fault and Warning messages, such as what the message means, what
most likely caused the Fault or Warning condition, and how to correct the problem, see the
appropriate message later in this section.
For more information on the Laser and its operation, see the CP-Series User Manual.
Step 3. Initiate a Laser Reset

Using the Mouse or the Touch Screen, click on the Fault Clear button on the lower part of the
Message page, or press the C key on the Keyboard. This will initiate a Laser Reset and clear any
Fault or Warning messages. After one second, it the Fault or Warning condition still exists, the
message will be re-displayed.
Message page showing the Fault Clear button

NOTE: Warnings are not actually cleared by the user. They are self-re-setting in the Laser PLC. The
message display itself, however will be cleared and the Warning message will be redisplayed if the Warning
still exists.
4.2.
4.3. MCR Faults
The following is a list of all MCR Faults which may occur in the CP-Series Laser.
• MCR 001 CO2 Gas Pressure Low - Line Pressure Below 60 PSI
• MCR 002 N2 Gas Pressure Low - Line Pressure Below 60 PSI
• MCR 003 He Gas Pressure Low - Line Pressure Below 60 PSI
• MCR 004
• MCR 005 Main Contactor State Fault
• MCR 006 Vac Pump Contactor State or Circuit Breaker Tripped Fault
• MCR 007 Frequency Inverter Circuit Breaker Tripped Fault
• MCR 008 Phase Detector Fault
• MCR 009 High Voltage Softstart Circuit Breaker Tripped Fault
• MCR 010 Door Interlock Fault
• MCR 011 Frequency Inverter Fault
• MCR 012 Shutter Water Flow Fault < 5.5 LPM
• MCR 013 Safety Relay Interlock Fault
• MCR 014 Cabinet Temp Fault > 45 degC
• MCR 015 Turbine Motor Bearing Temp Fault > 85 degC
• MCR 016 Turbine Bearing Temp Fault > 85 degC
• MCR 017 Turbine Gas Temp Fault > 120 degC
• MCR 018 Water Temp High Fault > 25 degC
• MCR 019 Turbine Pressure Low Limit Fault < 45 Torr
• MCR 020 Exceeded Max Time to Start Pressure > 10 Min - Check Vac Pump and/or Perform Leak Test
• MCR 021 10 Minute Limit on Continuous Pumpdown Exceeded
• MCR 022 Laser Pressure Outside Limits to Operate Turbine (P < 50 Torr or P > 95 Torr)
• MCR 023 Temperature Monitor Low Fault - Check Analog Temperatures
• MCR 024 HV Contactor Not OFF in Allotted Time > 300 mSec
• MCR 025
• MCR 026
• MCR 027 Turbine Starting Time Exceeded 90 Sec - Shutting Down Laser
• MCR 028 Main Laser Key Is OFF

4.3.1. MCR 001 CO2 Gas Pressure Low - Line Pressure Below 60 PSI
DESCRIPTION: CO2 gas pressure at input to Laser has dropped below 60 PSI for more than 5 minutes. This is a Fault if
condition occurs before regulated pressure mode. While in regulated pressure mode, 5 minutes will be
provided to allow for gas cylinder replacement before the Fault occurs.
POSSIBLE CO2 gas cylinder low - Check that regulator is set to 80 PSI. Change cylinder if necessary.
CAUSES:
CO2 supply line not connected to Laser or not turned ON - Connect supply line and OPEN supply valve.
NOTES: For the first 5 minutes below 60 PSI, a warning is displayed.
4.3.2. MCR 002 N2 Gas Pressure Low - Line Pressure Below 60 PSI
DESCRIPTION: N2 gas pressure at input to Laser has dropped below 60 PSI for more than 5 minutes. This is a Fault if
POSSIBLE N2 gas cylinder low - Check that regulator is set to 80 PSI. Change cylinder if necessary.
CAUSES:
N2 supply line not connected to Laser or not turned ON - Connect supply line and OPEN supply valve.
4.3.3. MCR 003 He Gas Pressure Low - Line Pressure Below 60 PSI
DESCRIPTION: He gas pressure at input to Laser has dropped below 60 PSI for more than 5 minutes. This is a Fault if
POSSIBLE He gas cylinder low - Check that regulator is set to 80 PSI. Change cylinder if necessary.
CAUSES:
He supply line not connected to Laser or not turned ON - Connect supply line and OPEN supply valve.
4.3.4. MCR 004

NOTES: This Fault Message is no longer used..

4.3.5. MCR 005 Main Contactor State Fault

DESCRIPTION: Main Contactor is not CLOSED when it should be CLOSED, or not OPEN when it should be OPEN.
Contactor should be OPEN or CLOSED within 300ms after the command.
POSSIBLE Contactor Overload tripped

CAUSES: Contactor contacts stuck closed
NOTES:
4.3.6. MCR 006 Vac Pump Contactor State or Circuit Breaker Tripped
Fault
DESCRIPTION: Vacuum Pump Contactor is not CLOSED when it should be CLOSED, or not OPEN when it should be
OPEN or the Vacuum Pump Circuit Breaker has tripped. Contactor should be OPEN or CLOSED within
300ms after the command.
POSSIBLE Contactor Overload tripped

CAUSES: Contactor contacts stuck closed
NOTES:
4.3.7. MCR 007 Frequency Inverter Circuit Breaker Tripped Fault

DESCRIPTION: Frequency Inverter Circuit Breaker tripped
POSSIBLE Circuit Breaker tripped from momentary overload

CAUSES:
NOTES:
4.3.8. MCR 008 Phase Detector Fault

DESCRIPTION: Main 3-phase voltage supply to Laser not phased properly
POSSIBLE Input line wires to Laser not phased properly.

CAUSES:
NOTES: See Troubleshooting section of CP-Series Manual.

4.3.9. MCR 009 High Voltage Softstart Circuit Breaker Tripped Fault
DESCRIPTION: High Voltage Softstart Circuit Breaker Tripped.
POSSIBLE Circuit breaker tripped due to momentary overload.

CAUSES:
NOTES: .
4.3.10. MCR 010 Door Interlock Fault

DESCRIPTION: Power Supply Cabinet door interlock OPEN
POSSIBLE One of the Laser Power Supply Cabinet doors is not CLOSED completely
CAUSES:
Faulty switch or wiring on Door Interlock switch
NOTES:
4.3.11. MCR 011 Frequency Inverter Fault

DESCRIPTION: The Frequency Inverter has detected and internal fault
POSSIBLE Fault internal to the Frequency Inverter - See Frequency Inverter Manual
CAUSES:
NOTES:
4.3.12. MCR 012 Shutter Water Flow Fault < 5.5 LPM
DESCRIPTION: Water flow to the Shutter Dump has dropped below 5 liters/minute
POSSIBLE Water Chiller not ON or not adjusted properly

CAUSES:
Restriction in Cooling lines to the Shutter Dump
NOTES: This is a WARNING before the Turbine is turned ON and a FAULT when the Tubine is
running

4.3.13. MCR 013 Safety Relay Interlock Fault

DESCRIPTION: Safety Relay interlock string OPEN
POSSIBLE E-Stop button pressed

CAUSES:
Problem with Safety Interlock String
NOTES: See Troubleshooting section of CP-Series Manual
4.3.14. MCR 014 Cabinet Temp Fault > 45 deg C

DESCRIPTION: The Temp in the Laser Cabinet has exceeded 45 deg C
POSSIBLE Cooling Water Supply Flow Low

CAUSES:
Cabinet Circulating Fans not working properly
Water flow restriction in Cabinet Heat Exchanger
Possible faulty temperature probe
NOTES:
4.3.15. MCR 015 Turbine Motor Bearing Temp Fault > 85 deg C
DESCRIPTION: Turbine Motor Bearing Temp has exceeded 85 degC for over 10 sec.
POSSIBLE Low Cooling Water Flow to Bearing Loop

CAUSES:
Worn or deteriorated Bearing
NOTES:
4.3.16. MCR 016 Turbine Bearing Temp Fault > 85 deg C

DESCRIPTION: Turbine Bearing Temp has exceeded 85 degC for over 10 sec.
POSSIBLE Low Cooling Water Flow to Bearing Loop

CAUSES:
Worn or deteriorated Bearing
NOTES:

4.3.17. MCR 017 Turbine Gas Temp Fault > 120 deg C
DESCRIPTION: Temperature of the Gas at Outlet of the Turbine has exceeded 120 deg C
POSSIBLE Improper Gas Mixture

CAUSES:
Turbine Cooling problem
Improper Turbine program settings
4.3.18. MCR 018 Water Temp High Fault > 25 deg C

DESCRIPTION: Cooling Water Temp in the Laser has exceeded 25 deg C
POSSIBLE Water Chiller Temp Regulator not set correctly

CAUSES:
Ambient Room Temp too high for the Chiller to function properly
NOTES: This is a WARNING before the Turbine is turned ON and a FAULT when the Turbine is
running.
4.3.19. MCR 019 Turbine Pressure Low Limit Fault < 45 Torr
DESCRIPTION: Cavity pressure dropped below 45 Torr during Turbine startup.
POSSIBLE Fast pump down valve or pressure regulation valves open when they shouldn't be.
CAUSES:
Gas fill stopped.
NOTES:
4.3.20. MCR 020 Exceeded Max Time to Start Pressure > 10 Min –
Check Vac Pump and/or Perform Leak Test
DESCRIPTION: Time to base or start pressure for Laser Start, Leak Test or Gas Mix Calibration has exceeded ten
minutes.
POSSIBLE Vacuum leak

CAUSES:
Faulty vacuum pump
Faulty pump down valve(s)
NOTES: Try Performing the Leak Test using the Start Pressure Bypass function.

4.3.21. MCR 021 10 Minute Limit on Continuous Pumpdown Exceeded

DESCRIPTION: Continuous pump down exceeded ten minute time limit
POSSIBLE Failure to terminate Continuous Pump down mode within ten minute limit.
CAUSES:
NOTES:
4.3.22. MCR 022 Laser Pressure Outside Limits to Operate Turb. (P<50 or P>95 Torr)
DESCRIPTION: Laser cavity pressure dropped below 50 Torr or went above 95 Torr.
POSSIBLE Pressure regulation valves not operating properly

CAUSES:
Gas Consumption values set too low
Gas Mixer not operating properly
Fast Pumpdown valve open when it shouldn't be
Vacuum Pump not operating properly
NOTES:
4.3.23. MCR 023 Temperature Monitor Low Fault - Check Analog Temperatures
DESCRIPTION: Temperature reading is below 1 degC for Turbine bearing(s), Turbine Gas or Laser Cabinet
POSSIBLE Printed circuit board communication cable disconnected

CAUSES:
Poor connection or broken wire(s) from temperature sensor(s)
NOTES: Check the Analogs page on the Display Panel to determine if a sensor may be faulty.
4.3.24. MCR 024 HV Contactor Not OFF in Allotted Time > 300 msec
DESCRIPTION: High Voltage Enable command is removed and HV contactor failed to OPEN within 300 mSec.
POSSIBLE High Voltage contactor not operating properly

CAUSES:
NOTES:

4.3.25. MCR 025

4.3.26. MCR 026

4.3.27. MCR 027 Turbine Starting Time Exceeded 90 Sec - Shutting Down Laser
DESCRIPTION: Turbine failed to reach 380Hz within 90 seconds
POSSIBLE Improper Turbine program settings

CAUSES:
Improper Gas Mix
NOTES: This will be a Warning the first time it happens, a Fault the second time..
4.3.28. MCR 028 Main Laser Key Is OFF

DESCRIPTION: Main Laser Key is OFF for systems with an external key interlock. 24VDC signal missing at the PLC for
systems without an external key interlock.
POSSIBLE Key in wrong position

CAUSES:
24VDC missing
NOTES:
4.4. HV Faults
The following is a list of all HV Faults which may occur in the CP-Series Laser.
• HV 001
• HV 002 Lane Over-Voltage Fault
• HV 003 HV Power Supply Fault
• HV 004 Transformer Tank Temp Fault > 70 degC
• HV 005 Lane Imbalance 10 Times in 2 Min Fault - Lane x
• HV 006 Laser Cavity Pressure Fault (+/- 5 Torr from Set Point)
• HV 007 Turbine Speed Fault < 380Hz
• HV 008
• HV 009 Pulser Watchdog Fault

• HV 010 Water Temp LOW Fault < 12 degC

• HV 011 Lane Monitor Fault
• HV 012 Power Monitor Fault
• HV 013 Air Pressure Fault - Line Pressure Below 60 PSI
• HV 014 HV Circuit Breaker Fault
• HV 015 HV Contactor Not ON in Allotted Time > 25 Sec
4.4.1. HV 001
4.4.2. HV 002 Lane Over-Voltage Fault

DESCRIPTION: An Over-Voltage condition has been detected on one or more discharge lanes.
POSSIBLE High Voltage wires disconnected

CAUSES:
Improper Gas Mix
Signal missing at PLC
NOTES:
4.4.3. HV 003 HV Power Supply Fault

DESCRIPTION: The HVPS has shut down due to an internal fault.
POSSIBLE Internal HVPS problem. Check HVPS display for Fault description
CAUSES:
4.4.4. HV 004 Transformer Tank Temp Fault > 70 degC

DESCRIPTION: The Transformer Tank temperature has exceeded 70 deg C
POSSIBLE Cooling Water temp too HIGH - Check Chiller settings

CAUSES:
Insufficient water flow to Transformer Tank - Check Cooling Lines
NOTES:

4.4.5. HV 005 Lane Imbalance 10 Times in 2 Min Fault - Lane x

DESCRIPTION: Discharge lane voltage imbalances have been detected ten times within a two minute
period while the Shutter was CLOSED.
POSSIBLE Improper Gas Mix

CAUSES:
Vacuum leak
Output Coupler damaged
NOTES:
4.4.6. HV 006 Laser Cavity Pressure Fault (+/- 5 Torr from Set Point)
DESCRIPTION: Laser Pressure is not within the allowed window for High Voltage (+/- 5 Torr from Set Point). The High
Voltage cannot be enabled until the pressure is within 5 Torr of the safe Set Point to prevent damage to
the Laser (Typically 85 +/- 5 Torr).
POSSIBLE High Voltage commanded while the Laser Pressure was not within the allowed window.
CAUSES:
NOTES:
4.4.7. HV 007 Turbine Speed Fault < 380Hz

DESCRIPTION: The Turbine Speed is too LOW (Inverter Frequency below 380 HZ)
POSSIBLE Leak in the Gas system

CAUSES:
Gas mix problem
Turbine problem
Frequency Inverter problem
NOTES:
4.4.8. HV 008
NOTES: This Fault Message is no longer used.
4.4.9. HV 009 Pulser Watchdog Fault

DESCRIPTION: Optional Beam Pulser watchdog signal failed to toggle in the appropriate time perieod.
POSSIBLE The software on the Optional Beam Pulser has halted. If this Fault persists, Remove Power from the
CAUSES: Laser at the Main Disconnect and re-Apply to Reset the Optional Beam Pulser.
NOTES:

4.4.10. HV 010 Water Temp LOW Fault < 12 degC

DESCRIPTION: Water Temp is below 12 deg C
POSSIBLE Water Chiller not set correctly

CAUSES:
Ambient Temp too LOW for Chiller to perform correctly
NOTES:
4.4.11. HV 011 Lane Monitor Fault

DESCRIPTION: One or more discharge lane voltages were out of balance or in an over-voltage condition

CAUSES:
Improper Gas Mix
NOTES: This Fault is only used in laser systems without the Discharge Anomaly PCB
4.4.12. HV 012 Power Monitor Fault

DESCRIPTION: The Laser Power drifted outside of the user-defined window while the Power Monitor was ACTIVE
POSSIBLE Power Command changed while Power Monitor was ACTIVE

CAUSES:
Laser Power drifted due to various reasons. Check Laser Operating conditions such as Pressure and
Temperature. Also check for Leaks in the Gas system. Check Internal Optics.
4.4.13. HV 013 Air Pressure Fault - Line Pressure Below 60 PSI

DESCRIPTION: The Air Pressure dropped to below 60 PSI
POSSIBLE Air Supply LOW or OFF

CAUSES:
Restriction in Air Supply line
NOTES:
4.4.14. HV 014 HV Circuit Breaker Fault

DESCRIPTION: The High Voltage Circuit Breaker has tripped
POSSIBLE Malfunction in the HVPS

CAUSES:
NOTES: See Troubleshooting section of CP-Series Manual.

4.4.15. HV 015 HV Contactor Not ON in Allotted Time > 25 Sec

DESCRIPTION: The High Voltage Power Supply did not enable within 25 seconds of the HV ON command
POSSIBLE Faulty HV Contactor

CAUSES:
HVPS problems
NOTES:
4.5. Shutter Faults

The following is a list of all Shutter Faults which may occur in the CP-Series Laser.
• SHTR 001
• SHTR 002 Shutter Blade Temp > 60 degC or Beam Dump Temp > 82 degC
• SHTR 003 Beam Tube Interlock Not Satisfied
• SHTR 004 Shutter State Fault (Moved Out of OPEN/CLOSED Position Without Command)
• SHTR 005 Shutter Timing Fault (Not OPEN or CLOSED within 0.3 sec After Command)
• SHTR 006 Shutter Logic Fault (OPEN and CLOSED State Simultaneously, Faulty Switch)
• SHTR 007 Lane Imbalance with Shutter Open Fault - Lane x
4.5.1. SHTR 001

4.5.2. SHTR 002 Shutter Blade Temp > 60 degC or Beam Dump Temp > 82 degC
DESCRIPTION: The Shutter Blade Temperature has exceeded 60 degC or the Beam Dump Temperature has exceeded 82
degC
POSSIBLE Water Chiller Temp or Flow not set correctly

CAUSES:
Restriction in the Cooling lines to the Shutter and Beam Dump Assemblies
Debris or contaminate buildup on the Shutter Blade
NOTES:
4.5.3. SHTR 003 Beam Tube Interlock Not Satisfied

DESCRIPTION: The interlock switch on the Beam Tube inside the Laser is OPEN
POSSIBLE Check the positioning of the Internal Beam Tubes

CAUSES:
Check the wiring of the Beam Tube Interlock switches
NOTES:

4.5.4. SHTR 004 Shutter Moved Out of OPEN/CLOSED Position w/o Command
DESCRIPTION: Shutter actual position does not agree with the Commanded position
POSSIBLE Air Pressure LOW

CAUSES:
External Shutter Interlock OPEN
Shutter Blade or Switches Stuck
NOTES:
4.5.5. SHTR 005 Shutter Timing Fault (Not OPEN or CLOSED within 0.3 sec)
DESCRIPTION: Shutter has taken more than 300ms to OPEN or CLOSE
POSSIBLE Air Pressure LOW

CAUSES:
Shutter hardware problem or obstruction
Check operation of Shutter Position switches
NOTES:
4.5.6. SHTR 006 Shutter Logic Fault (OPEN and CLOSED State Simultaneously)
DESCRIPTION: Shutter is being sensed as both OPEN and CLOSED at the same time
POSSIBLE Check operation of Shutter Position switches

CAUSES:
Wiring problem
NOTES:
4.5.7. SHTR 007 Lane Imbalance with Shutter Open Fault - Lane x
DESCRIPTION: A discharge lane voltage imbalance was detected while the Shutter was OPEN

CAUSES:
Improper Gas Mix
NOTES:

4.6. PLC Faults

The following is a list of all PLC Faults which may occur in the CP-Series Laser.
• PLC 001 Low Battery
• PLC 002 CPU Hardware Problem
• PLC 003 Configuration Mismatch
• PLC 004 Corrupted RAM
• PLC 005 Unrecoverable Software Error
• PLC 006 PLC Fault Table Entry
• PLC 007 I/O Fault Table Entry
4.6.1. PLC 001 Low Battery

DESCRIPTION: The Battery in the Lasers PLC is LOW
POSSIBLE Battery is OLD and may need replacing

CAUSES:
NOTES: The state of the PLC Battery is not important, as the program and important data is stored in
EEPROM, and is not dependent on the state of the Battery
4.6.2. PLC 002 CPU Hardware Problem

DESCRIPTION: A problem with the PLC hardware was detected by the PLC's internal diagnostic routines
POSSIBLE Bad Connection between a PLC module and the mounting rack
CAUSES:
Bad I/O module, CPU module, or the Mounting Rack
NOTES:
4.6.3. PLC 003 Configuration Mismatch

DESCRIPTION: The software configuration does not match the hardware settings
POSSIBLE This is displayed only when a new program is downloaded to the PLC, and the settings in the program do
CAUSES: not match the hardware set
NOTES:
4.6.4. PLC 004 Corrupted RAM

DESCRIPTION: There is a problem in the PLC's RAM memory
POSSIBLE Power Line surge or momentary drop-out

CAUSES:

NOTES:
4.6.5. PLC 005 Unrecoverable Software Error

DESCRIPTION: An error has occurred from which the PLC cannot recover, and the unit has shut down
POSSIBLE Power Line surge or momentary drop-out

CAUSES:
NOTES:
4.6.6. PLC 006 PLC Fault Table Entry

DESCRIPTION: An entry has been made in the PLC's internal Fault Table by its built-in, real-time diagnostics routine
POSSIBLE Problem in the PLC CPU or one of its I/O modules

CAUSES:
NOTES:
4.6.7. PLC 007 I/O Fault Table Entry

DESCRIPTION: An entry has been made in the PLC's internal I/O Table by its built-in, real-time diagnostics routine.
POSSIBLE Problem in one of the PLC's I/O modules

CAUSES:
NOTES:
4.7. Warnings
The following is a list of all Warnings which may occur in the CP4000 Laser.
• WARN 001 CO2 Gas Pressure Low - Line Pressure Below 60 PSI
• WARN 002 N2 Gas Pressure Low - Line Pressure Below 60 PSI
• WARN 003 He Gas Pressure Low - Line Pressure Below 60 PSI
• WARN 004 Laser start Delayed While Turbine Winding Down to Below 30Hz
• WARN 005 Lane Anomaly PCB Warning - Lane ID Signals Missing
• WARN 006
• WARN 007
• WARN 008 Main Contactor Delay - Wait 30 Seconds
• WARN 009
• WARN 010 HV Inhibited, Not In Pressure Window (P < 80 Torr or P > 90 Torr)
• WARN 011 BEAM ON Without High Voltage ON (Cycle BEAM OFF)

• WARN 012 HV Inhibited, Re-enable HV ON (After HV Fault Reset)

• WARN 013 HV Inhibited, CLOSE Shutter (After HV Fault Reset)
• WARN 014 Shutter Inhibited, Laser Warming Up, Turn OFF Open Shutter Command
• WARN 015 Water Flow < 5.5 LPM or Water Temperature < 12 degC or > 25 degC
• WARN 016 Purge Inhibited - Gas Pressure Low
• WARN 017 - WARN 032
• WARN 033 Change Vacuum Pump Oil
• WARN 034 Turbine Maintenance Required
• WARN 035 Max Time For Backfill Exceeded ( > 3 Min)
• WARN 036 Laser Didn't Pump Down to Start Pressure in Allotted Time ( > 5 Min)
• WARN 037 Max Time for Overnight N2 Exceeded ( > 10 Min Total)
• WARN 038 Discharge Anomaly Repeat on Lane 1, Check Output Coupler
• WARN 039 Three Consecutive Discharge Anomalies - Lane x
• WARN 040 Start Pressure Bypassed by User
• WARN 041 Exceeded Max Turbine Starting Time - Restarting Laser
• WARN 042 Turbine Bearing Overtemp Warning > 70 degC for 90 Min
• WARN 043 Turbine Motor Bearing Overtemp Warning > 70 degC for 90 Min
• WARN 044 Water Flow High > 15 LPM, Check PCB output
4.7.1. WARN 001 CO2 Gas Pressure Low - Line Pressure Below 60 PSI
DESCRIPTION: CO2 Gas Pressure at input to Laser has dropped below 60 PSI
POSSIBLE CO2 Gas cylinder LOW - Check that regulator is set to 80 PSI. Change cylinder if necessary
CAUSES:
CO2 supply line not connected to Laser or not turned ON - Connect supply line and OPEN supply valve
NOTES: After 5 minutes below 60 PSI, a fault is displayed.
4.7.2. WARN 002 N2 Gas Pressure Low - Line Pressure Below 60 PSI
DESCRIPTION: N2 Gas Pressure at input to Laser has dropped below 60 PSI
POSSIBLE N2 Gas cylinder LOW - Check that regulator is set to 80 PSI. Change cylinder if necessary
CAUSES:
N2 supply line not connected to Laser or not turned ON - Connect supply line and OPEN supply valve

It is normal for this Warning to display during a Backfill cycle, as the heavy flow of N2 into the
Laser sometimes causes the pressure to temporarily drop below the normal operating range.

4.7.3. WARN 003 He Gas Pressure Low - Line Pressure Below 60 PSI
DESCRIPTION: He Gas Pressure at input to Laser has dropped below 60 PSI
POSSIBLE He Gas cylinder LOW - Check that regulator is set to 80 PSI. Change cylinder if necessary
CAUSES:
He supply line not connected to Laser or not turned ON - Connect supply line and OPEN supply valve
4.7.4. WARN 004 Laser start Delayed While Turbine Winding Down to
Below 30Hz
DESCRIPTION: Laser Start delayed while the turbine winds down. After Turbine winds down
Laser will Start
POSSIBLE Turbine still running

CAUSES:
NOTES:
4.7.5. WARN 005 Lane Anomaly PCB Warning - Lane ID Signals Missing
DESCRIPTION: The four signals indicating discharge lane number for Fault reporting are missing
POSSIBLE Check cable from Discharge Anomaly PCB

CAUSES:
NOTES:
4.7.6. WARN 006

NOTES: This Warning Message is no longer used..
4.7.7. WARN 007

4.7.8. WARN 008 Main Contactor Delay - Wait 30 Seconds

DESCRIPTION: Waiting 30 Seconds after the Main Contactor is turned OFF before re-enabling. This is to prevent damage
to the Frequency Inverter soft-start components. The Frequency Inverter can only be cycled OFF and ON
twice per minute, resulting in the need for a 30 sec. delay for the Main Contactor.
POSSIBLE Frequency Inverter has not been OFF for the required 30 seconds
CAUSES:
NOTES: See the CP-Series Manual

4.7.9. WARN 009

4.7.10. WARN 010 HV Inhibited, Not In Pressure Window (P < 80 Torr or P > 90 Torr)
DESCRIPTION: HV commanded while Laser Pressure not within the allowed window for High Voltage (80-90 Torr)
POSSIBLE Laser Pressure was not within the allowed window

CAUSES:
4.7.11. WARN 011 BEAM ON Without High Voltage ON (Cycle BEAM OFF)
DESCRIPTION: The Beam was commanded ON while the High Voltage was OFF or the High Voltage turned OFF while
the Beam was ON
POSSIBLE High Voltage not ON - Wait for HV ON before commanding the Beam ON
CAUSES:
4.7.12. WARN 012 HV Inhibited, Re-enable HV ON (After HV Fault Reset)

DESCRIPTION: The HV has been turned OFF by the Laser due to a Fault or other internal Laser condition. Before the HV
can again be enabled, the HV command from the CNC or user input must be cycled OFF and then ON.
This is a safety feature of the CP-Series Laser
POSSIBLE Laser has turned the High Voltage OFF because of a fault or some user action and the HV command from
CAUSES: the CNC or user input is still active
NOTES: Any HV Fault must be Reset before this Warning will clear
4.7.13. WARN 013 HV Inhibited, CLOSE Shutter (After HV Fault Reset)

DESCRIPTION: The HV was commanded ON while the Shutter was OPEN. For Safety reasons, the HV cannot be
commanded ON while the Safety Shutter is OPEN. The user must first CLOSE the Shutter, turn HV ON,
then re-OPEN the Shutter if desired.
POSSIBLE Shutter not CLOSED before commanding the HV ON

CAUSES:
HV turned OFF while the Shutter was OPEN
NOTES: Any HV Fault must be Reset before this Warning will clear

4.7.14. WARN 014 Shutter Inhibited, Laser Warming Up, Close Shutter
DESCRIPTION: The Shutter has been commanded OPEN before the Laser has completed it's warm-up cycle
POSSIBLE Shutter commanded OPEN too early - Wait for the warm-up cycle to complete
CAUSES:
NOTES: Remove the Shutter Open Command
4.7.15. WARN 015 Water Flow < 5.5 LPM or Water Temp. < 12 degC or > 25 degC
DESCRIPTION: The Cooling Water Flow to the Laser is below 5.5 Liters Per Minute or the Water Temperature is out of
the correct operating range (12 - 25 degC)
POSSIBLE Water Chiller not turned ON

CAUSES:
Restriction in Cooling Lines to the Laser
Chiller Temp Regulator not set correctly
Ambient Temperature too hot or too cold for Chiller to operate correctly
NOTES:
4.7.16. WARN 016 Purge Inhibited - Gas Pressure Low

DESCRIPTION: Gas Purge Cycle inhibited due to LOW Gas Pressure
POSSIBLE One or more of the Laser Gas pressures are LOW

CAUSES:
NOTES:
4.7.17. WARN 017 - WARN 032

NOTES: These Warning Messages are not used..
4.7.18. WARN 033 Change Vacuum Pump Oil

DESCRIPTION: This message will be displayed once the Vacuum Pump exceeds 1000 hours run-time since the Timer
was last Reset.
POSSIBLE This is a Normal Maintenance feature of the CP-Series Laser.

CAUSES:
NOTES: After Changing the Vacuum Pump Oil, be sure to Reset the Timer on the Timers page.

4.7.19. WARN 034 Turbine Maintenance Required

DESCRIPTION: This message will be displayed once the Turbine exceeds 8000 hours run-time since the Timer was last
Reset.
POSSIBLE This is a Normal Maintenance feature of the CP-Series Laser.

CAUSES:
NOTES: Service both Turbine bearings. After servicing, Reset the Turbine Maintenance Timer on the
Timers page.
4.7.20. WARN 035 Max Time For Backfill Exceeded ( > 3 Min)
DESCRIPTION: The Initial Backfill to atmospheric pressure (+0.5 psi) exceeded the three minute time limit
POSSIBLE Positive pressure leak

CAUSES:
Faulty Backfill valve
Blockage in Gas line
NOTES: Warnings WARN 033 - WARN 048 get logged in the Fault Log file.
4.7.21. WARN 036 Laser Didn't Pump Down to Start Press. in Allotted Time ( > 5 min)
DESCRIPTION: Laser Failed to pump down to the Start Pressure within the allotted five minutes

CAUSES:
Faulty Vacuum Pump
Faulty Pumpdown valves
NOTES: Try Performing a Leak Test using the Start Pressure Bypass Function
Warnings WARN 033 - WARN 048 get logged in the Fault Log file.
4.7.22. WARN 037 Max Time for Overnight N2 Exceeded ( > 10 Min Total)
DESCRIPTION: Secondary Backfill on demand exceeded ten minutes total on-time
POSSIBLE Positive pressure leak

CAUSES:
Gas line leak

4.7.23. WARN 038 Discharge Anomaly Repeat on Lane 1, Check Output Coupler
DESCRIPTION: Three consecutive Discharge Lane imbalances have occurred on lane 1
POSSIBLE Damaged Output Coupler

CAUSES:
Vacuum leak related to lane 1
NOTES: Multiple imbalances on lane 1 often indicate a damaged Output Coupler
Warnings WARN 033 - WARN 048 get logged in the Fault Log file.
4.7.24. WARN 039 Three Consecutive Discharge Anomalies - Lane x

DESCRIPTION: Three consecutive Discharge lane imbalances have occurred on lane x (x-indicates lane number)
POSSIBLE Vacuum leak related to lane x

CAUSES:
HVPS problem related to lane x
4.7.25. WARN 040 Start Pressure Bypassed by User

DESCRIPTION: User has bypassed the normal Start Pressure using the Start Pressure Bypass Function
POSSIBLE User chose to bypass the Start Pressure

CAUSES:
4.7.26. WARN 041 Exceeded Max Turbine Starting Time - Restarting Laser
DESCRIPTION: Turbine failed to reach 380Hz within 90 seconds. The Laser will be Shut Down, then Restarted
POSSIBLE Improper Gas Mix

CAUSES:
Improper Turbine program settings
4.7.27. WARN 042 Turbine Bearing Overtemp Warning > 70 degC for 90 min
DESCRIPTION: Turbine bearing temperature exceeded 70 degC continuously for 90 minutes or more
POSSIBLE Low cooling water flow to bearing loop

CAUSES:
Worn or deteriorated bearing

4.7.28. WARN 043 Turbine Motor Bearing Overtemp Warning > 70 degC for 90 Min
DESCRIPTION: Turbine motor bearing temperature exceeded 70 degC continuously for 90 minutes or more
POSSIBLE Low cooling water flow to bearing loop

CAUSES:
Worn or deteriorated bearing
4.7.29. WARN 044 Water Flow High > 15 LPM, Check PCB output
DESCRIPTION: Water Flow reading is higher than 15 lpm. This indicates a problem with the signal
POSSIBLE Check the printed circuit board, located on the Water Flow Sensor, and it's associated wiring
CAUSES:

7. LASER DESCRIPTION
MAINTENANCE MANUAL
5. INSTALLATION
Note: ON-SITE RECEIVING INSPECTION and LASER REQUIREMENTS are the
responsibility of the customer.
Installation assistance can be obtained from a trained Convergent Lasers Service Engineer or an
OEM designated System Installer. Installation instructions are provided in this section.
5.1. ON-SITE RECEIVING INSPECTION

Upon receipt of the laser system, check all containers for signs of damage. If there are any
visible signs of damage, notify both the freight carrier and Convergent Lasers immediately (See
9. WARRANTY). The containers should also be checked against the consignment papers to
confirm that you have received the correct number of boxes. If the equipment is to be stored for
any length of time prior to use, ensure that adequate protection against damage, corrosion and
environmental elements has been taken.
5.2. LIFTING THE CP SERIES LASER

The CP Laser has four tapped holes size M20 holes tapped to provide lifting points for the laser.
The user must provide the hardware to integrate this option. When lifting the laser with the
lifting bolt option, please take care that the straps or chains are rated for the weight specifications
of the laser.
Also, it is important that the lifting hardware never be at less than a 45-degree angle from the top
of the laser. Anything less can be both dangerous and cause damage to the laser.
Figure 5.1: Mounting Hole Locations

WARNING: It is important that the vertical struts mounted inside the frame
remain mounted when lifting the laser frame with the eyebolt method. The
vertical struts are part of the frame support.
Additionally, Figure 5.2 shows the lifting points for using a forklift or other device to move the
CP Series Laser.
Figure 5.2: Forklift Lifting Points

5.3. LASER REQUIREMENTS
The following sections provide the user with the minimum requirements for operating the CP
SERIES lasers:
FLOOR SPACE REQUIREMENTS

ELECTRICAL POWER REQUIREMENTS
COOLING WATER REQUIREMENTS
GAS AND AIR REQUIREMENTS
5.3.1. FLOOR SPACE REQUIREMENTS

A minimum of 1.5m (5 feet) should be left clear around the laser for maintenance purposes. The
floor should be level, smooth, and free of vibrations from other machinery. In certain cases, the
area should be vibration isolated.
5.3.2. ELECTRICAL POWER REQUIREMENTS
A three-phase source with ground is required. Input Voltage may be from a Wye or Delta source,
and input voltage range may be from 400 to 460 VAC +/- 10%. The capacity of this power
source must be from 28 to 34 kW, depending on the model.
WARNING: The ground wire in the input power cable must be electrically
connected to the ground terminal STD5 of the laser cabinet located next to the
main circuit breaker (MCB1).
5.3.3. COOLING WATER REQUIREMENTS

A water feed and drain must be supplied that is capable of providing coolant that meets the
SPECIFICATIONS Section of this manual. There is approximately a 15-PSI drop in pressure
across the laser.
It is important to use clean plumbing materials without ferrous material in any of the components
in the cooling circuit. The cooling circuit should also be filtered with a 100- micron filter.
5.3.4. GAS AND AIR REQUIREMENTS

Gas purity is very important for laser efficiency, optic lifetime and power stability. The gas
purity specifications are listed in the SPECIFICATIONS Section of this manual.
Great care should be taken in the design of the gas delivery system to ensure that the purity of
the gas in the bottles is not compromised. The high purity gases in the gas cylinders can be
contaminated when passing through the gas delivery system, which may not be clean. It should
also be noted that certain plastic materials have properties that allow moisture and contaminants

to permeate into the gas delivery system. If plastic tubing is to be used, polyethylene is both the
cheapest and has the best permeation qualities and therefore should be used.
If stainless steel or copper tubing is used make sure the following conditions are meet to
minimize gas contamination:
• Tubes should be cleaned with a chemical solvent so that grease and dirt are removed. The
ends of the tubes should be plugged until assembly takes place.
• Use orbital TIG welding for stainless steel. Backing gas should be used inside the tubes
during the weld.
• Braze copper tubes using backing gas inside the tubes to prevent formation of copper oxides,
which could form a source of particles that can cause damage to the internal mirrors of the
laser.
• Compression-type fittings are acceptable for both stainless and copper tubes.
NOTE: It should be noted that the supplied DRY AIR should also be both
clean and oil free. In addition to operating the shutter, the dry air is also used
as a cooling aid to the output coupler and in many cases the external optics.
Any oil or moisture can have permanent damaging effects to these optics.
5.4. WHEN SERVICE REQUIREMENTS HAVE BEEN MET

When preparations are complete, call Convergent Lasers to schedule installation of the laser. A
Convergent Lasers Service Engineer, trained representative, or OEM system installer will carry
out the installation.
Number Connects you with Direct Fax Number

1-413-598-5200 Main Switchboard
1-800-722-1133 Service Department 1-413-598-5201
1-800-527-3760 Sales Department 1-413-598-5201
5.5. UNPACKING AND INSPECTION
Upon unpacking the Laser you will find two keys that are tie-wrapped to the CNC Interface
connector at the back end of the Laser. Use the keys to open the three panels on the access side
of the Laser. You will find the documentation package and the glass exhaust elbow assemblies
(which are removed from the resonator prior to shipment) inside the Laser. There is also a small
bag of foam plugs that are used to plug the Laser mounting holes after it is installed to help seal
the cabinet.

The documentation contains the manuals on a CDROM for the CP Series Laser. This package
should always be kept together and contains all of the important information necessary to operate
and maintain the Laser. For now, this package should be set aside and will be referred to later
when the interface is ready to be completed. The glass elbow assemblies should be unpacked
and set aside.
5.5.1. REMOVE SHIPPING BOLTS
Remove the four bolts (Figure 5.3) that secure the turbine for shipping as shown below.
Figure 5.3: Turbine shipping bolts
Figure 5.4: Heat Exchanger Shipping Bolts
Each heat exchanger is secured using one bolt (Figure 5.4). Remove these and store them with
the four from the turbine in case the Laser has to be shipped at a later date.
5.5.2. REMOVE KINEMATIC MOUNT SHIM
There is also a bright orange plastic shim as shown in Figure 5.5 on the following page is used
to protect the kinematic mount of the resonator. It is located at the rear of the Laser between the
endplate and the central supply tube (on the corner mirror end of the resonator). To remove the
shim it is necessary to apply a little force upward on the endplate while pulling on the shim.

Figure 5.5: Kinematic Shim
5.6. LEVEL THE LASER

Using a level and the diagrams below, level the Laser at its operating location.

5.7. INSTALL GLASS ELBOWS

To install both glass exhaust elbows Figure 5.6 perform the following: First, remove all shipping
cover plugs on the open ports. Verify that there is no debris or residue left on the parts and if
necessary, clean them with alcohol or another suitable solvent. Loosen the screws on the flanges
and put the elbows in place. Care must be taken so as not to chip or break the glass during its
installation. Tighten the screws while holding the elbows in place.
Figure 5.6: Glass Elbows and Universal Joint
WARNING: The clear heat shrink material must be left on the universal joints
as shown to reduce the risk of shock. Please make sure when installing the
glass that this heat shrink is not accidentally removed.
5.8. INPUT VOLTAGE CONFIGURATION

Use the following procedure for configuring this laser for the proper input electrical voltage.
This procedure will include phase checks for proper rotation of 3 phase motors and pumps.
WARNING: The ground wire in the input power cable must be electrically
connected to the ground terminal STD1 of the laser cabinet located next to the
main circuit breaker MCB1.

WARNING: Make sure that the main supply voltage is DISCONNECTED

before proceeding.
5.8.1. CONNECTING POWER

Remove the cover panel on the electrical cabinet at the rear of the Laser. The 3-phase power
cable should be routed through the strain relief at the bottom of the electrical cabinet, up along
the left side, and connected to the top terminals of the main disconnect (MCB1). The ground
wire must also be securely connected to the ground stud provided. All connections must be tight
before power is applied.
5.8.2. MAIN INPUT TRANSFORMER XFMR1

Locate TB4 at the bottom of the electrical panel (see 0546-303-03 Rev A – Standard Schematics,
Sheet 4). Jumper TB4 for site power requirements listed on the Primary Voltage Table for
XFMR1.
TB 4
Figure 5.7: TB4 Input Voltage Jumper
5.8.3. PHASE DETECTOR AND PHASING

Once the 3 phase input power is connected to the laser and the input transformer is properly
configured. Turn on the main supply voltage, Circuit Breaker CB4, and the Main Circuit Breaker
MCB1. Physically check the phase detector to ensure the LED is lit indicating proper phasing.
If the LED is not lit, turn off Main Circuit Breaker MCB1, TURN OFF MAIN POWER
DISCONNECT TO THE LASER and reverse two of the three-phase legs at the input of
MCB1. Turn on the Main Power Disconnect to the Laser and the Main Circuit Breaker MCB1
and check the phase detector to ensure that the LED is on before applying power to the vacuum
pump or turbine. You can now turn on all circuit breakers.
5.9. CONNECTING THE LASER GASES
There are four separate gasses required to run the CP SERIES Laser (three gasses and a supply
of dry, clean, oil-free air). Lasers are very sensitive to the purity and cleanliness of these gasses
so these connections must be made properly to ensure that the gas supply remains pure and

uncontaminated when it is plumbed to the Laser. Ensuring a clean, leak-free gas supply will
reduce gas usage, minimize discharge problems, and prolong optics life.
The gas connections on the CP SERIES Lasers are connected to the fittings at the bottom of the
electrical panel. It is very important to use polyethylene tubing (do not use polyurethane tubing
because of its poor permeability properties). Make all tubing connections at the gas bottles first
and label the ends of each gas line at the Laser end to avoid confusion when making the final
connections.
When making each gas line connection, first make a clean, square cut at the end of the tube and
slide the nut for the fitting onto the tube. Go to the gas bottle and set the regulator to around 15
psi (around 1 bar). Open the output valve to flush the gas line for around 10 seconds. Close the
output valve at the gas bottle, slide the tubing onto the fitting and tighten the nut until snug.
Open the output valve again and check for leaks. Finally, set the gas pressure to 80 psi. Repeat
this procedure for each gas connection.
5.10. CONNECTING THE COOLING CIRCUIT

The CP SERIES Laser cooling system is designed to operate with high flow and a low-pressure
drop. It requires a coolant mixture containing 30% Dowfrost and the balance of distilled water.
The chiller should be equipped with a suitable high-flow 100-micron filter on the coolant supply
line and should be plumbed to the laser using 1.25” hoses. The chiller should also be able to
supply the flow specifications discussed in the SPECIFICATIONS table discussed in Section 2.
When the coolant supply and return hoses are connected to the laser, the chiller should be set to
18 degrees Celsius. It should then be jogged on and off while checking for leaks which may
have developed during shipping. After the Laser has been filled with coolant, it may be
necessary to add more coolant to the chiller reservoir.
5.11. INTERFACING
The control interface for the CP Laser is explained in detail in the CP SERIES LASER
INTERFACE section of this manual and only the most important general topics will be discussed
here. For wiring and individual signal explanations, also refer to the INTERFACING section of
this manual.
Connect the CNC Interface Connectors to J1, J2, HDW INTLK J3, and the serial cable J4.
The most important aspect on the interface is where the 24 VDC supply voltage for the interface
signals is coming from (either the laser or the CNC). The CP Series Lasers can be configured
with the use of jumpers to operate either way. These jumpers are located on the main terminal
block (TB2). One jumper is between TB2-8 and TB2-9 and the other jumper is between TB2-14
and TB2-15 (See 0546-303-03 Rev A – Standard Schematics., sheet 3).

If the Laser is connected to a Prima System or with another OEM system there should be a
jumper in TB2-14 & TB2-15 only. If the Laser is being operated stand-alone or with a service
test box there should be jumpers between TB2-8 & TB2-9 and TB2-14 & TB2-15.
5.12. RUNNING THE LASER UP

Now that all the utilities and interfacing have been completed, it is time for the initial run-up of
the Laser. At this point, it is important that the technician is familiar with all the controls and
operation of the Laser. Routines will only be referred to here and it is assumed that the
technician understands how to perform these operations
Use the CP Panel to perform a Leak Test. Since the Laser cavity has been exposed to the
environment, it can be expected that the leak rate will not be perfect at first. Moisture and out-
gassing will affect the leak rate and prevent the Laser from achieving a real good leak rate at this
time. The purpose of this Leak Test is to verify that there is not a “gross” leak due to the exhaust
glass assembly or shipping. A full 15-minute Leak Test is not necessary at this point and a
reasonable reading can be obtained by stopping the test after 2 minutes. An acceptable leak rate
at this point would be less than 0.06 Torr/minute.
The laser can now be started. Pump the Laser down to 2 Torr and backfill the Laser 2 or 3 times.
Then start the laser and allow the laser to follow through with its normal sequence to the HV
point.
Using the CP panel software Bypass the Warm-up Cycle BEFORE turning the high voltage
on. Set a command level to 1000 watts and turn the beam on. The technician should tune the
output coupler and rear mirror for maximum power. Set the Laser gas consumption to Max Gas
and let the Laser run for 30 minutes.
After the Laser has run for 30 minutes the Laser should be shut down and another Leak Test
should be performed. Turn off the high voltage for a couple of minutes to allow the resonator to
cool down. Then shut the Laser down allowing the turbine to come to a complete stop. Perform
the Leak Test. The leak rate should now be below 0.02 Torr/min.
The Laser can now be run-up again and the power should be gradually increased over the next
several hours of operation. As you increase the power of the laser, tuning for maximum
power should be performed to prevent the laser beam from clipping inside the resonator.
The Laser can also be operated under normal gas consumption, though some power loss can be
expected until the Laser cavity is completely free of contamination. As the power is increased,
the output power should be observed to make sure it is within acceptable limits. After several
hours of operation, the Laser should be able to operate at full power under normal gas
consumption.
When the mode and power are verified, all of the laser panels should be installed to keep the
inside of the cabinet free from contamination and moisture. The Laser is now fully
commissioned.

6. CP SERIES LASER INTERFACE

6.1. CP SERIES LASER INTERFACING
This chapter discusses the interfacing details needed to integrate the Laser into a machine tool.
These details include external interlocks, the computer numeric control (CNC) and the serial
control interface. The signals and wiring discussed in this chapter are accessible on the CNC
Electrical Interface Panel as shown in Figure 6.1. The connections can be seen in the schematics
supplied on the CD Rom Manual and briefly shown in section 6.3 LASER INTERFACE
CONNECTIONS
Figure 6.1: Panel Connections
6.2. EXTERNAL AND SAFETY INTERLOCKS

Connecting a work enclosure to the laser’s internal safety system is done using the CNC
Connector J3, pins 2 and 4 (See 0546-303-03 Rev A – Standard Schematics, Sheet 19). External
interlocking is intended to prevent the Laser’s shutter from opening when the external interlock
string is not satisfied.
WARNING: External Interlocking of the shutter is provided to ensure safe

operation of the laser when used with a workstation. Tampering with this
safety measure presents a very UNSAFE condition. Convergent Prima
assumes no liability if the safety circuits have been tampered with by any
means.
Additionally, the workstation’s E-Stop button is interfaced using the CNC Connector J3, pins 1
& 3 and 5 & 7 (See 0546-303-03 Rev A – Standard Schematics, Sheet 19). The optional Cabinet
E-Stop is connected to TB2 pins 41 & 42 and 43 & 44. These connections allow the operator to
completely shut down the Laser in the event of an emergency.

Commands from the CNC to operate the Laser in addition to status signals from the Laser to the
work station are routed through the CNC (parallel) connector J1 (See 0546-303-03 Rev A –
Standard Schematics, Sheet 17). These are also explained below.
NOTE: Jumpers on Pins 8 & 9 and 14 & 15 of TB2 must be removed for External CNC 24
VDC. Jumpers on Pins 41 & 42 and 43 & 44 of TB2 must be removed for use of Optional
Cabinet E-STOP.
The CNC interface connectors and the Safety Relay SRL1 provide safety interlocking. Refer to
the tables below for information on the interface connectors in addition with 0546-303-03 Rev A
– Standard Schematics (CP SERIES Laser Safety Loop & E-Stop Loop) for the Safety Relay.
The connections required for the Safety Relay (SRL1) to enable operation of the Laser are as
follows: Cabinet Doors, Safety Loop, CNC E-Stop and Optional E-Stop strings, and the
following key switches: Customer supplied CNC Main Power Key switch (KEY1) and Shutter
Key switch (KEY2).
The cabinet doors on the high voltage power supply side of the Laser have safety switches
implemented so that Laser operation is not permitted with the doors open.
The safety loop string looks for the normally closed auxiliary contacts (contactor NOT pulled in)
on the Main Contactor (CON1 pins 21 & 22), Vacuum Pump Contactor (CON2 pins 21 & 22),
and the HV Contactor (CON3 pins 31 & 32).
The Safety Relay also requires connection between T33 and T34. These connections provide for
optional Key Switches KEY1 (CNC Main Power) and KEY2 (Shutter Key Switch), which are
customer supplied.
6.3. LASER INTERFACE CONNECTIONS
Table 6-1: CNC Connector, J1
Pin No. Wire No. To Signal Description
1 801 TB2 23D Analog Command In +
2 802 TB2 24D Analog Command Out -
3 803 MOD4 B3 Shutter Open/Close Command
4 804 TB3 10D Beam On Command
5 805 TB3 9D Pulse Mode Command
6 806 TB3 8D
7 807 TB3 11D Pulse Train Signal
8 808
9 809 MOD4 B4 CNC / Local Command
10 810 MOD4 B1 Laser On/Off Command
11 811 MOD4 B2 HV On/Off Command
12 812 TB3 15D CNC 24VDC
13 813


14 814 MOD4 B5 Fault Reset
15 815 MOD4 B6 Backfill Command
16 816 TB3 19D CNC Shutter Open Signal
17 817 TB101 22 Laser Power Meter Return
18 818 TB101 21 Laser Power Meter Signal
19 819 TB3 17D CNC 24 VDC Return
20 820 TB3 14D CNC 24 VDC
21 821 TB3 20D CNC Shutter Closed Signal
22 822
23 823 Chiller Enable
24 824 MOD4 B16 General Warning
25 825
26 826
27 827
28 828
29 829 TB3 6D Laser Ready for High Voltage
30 830 TB3 7D Laser Ready for Beam
31 831
32 832
33 833 TB3 5D General Fault
34 834 MOD4 B7 Laser Diode Disable
35 835 MOD4 B8 Max Gas Enable
36 836 TB101 23
37 837 TB101 24
Table 6-2: CNC Connector, J2

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15

16 856 CBL-80 Optical Path +

17 857 CBL-80 Optical Path -
18
19
20 860 TB101-23 Analog Mux Bd. Cavity Pressure Meter +
21 861 TB101-24 Analog Mux Bd. Cavity Pressure Meter -
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
Table 6-3: Connector, J3

1 881 TB3-1D Emergency Stop Input Contact
2 400A TB2-47D External Shutter Interlock
3 883 TB3-2D Customer E-Stop PB1
4 401 TB2-48D External Shutter Interlock
5 885 TB3-3D End User Box E-Stop
6
7 887 TB3-4D Customer E-Stop Ext
8 J3-10 Jumper
9
10 J3-8 Jumper
11
12
13
14

Figure 6.2, RS 232 Pin-Out
ANALOG COMMAND – A 0 to 10V signal that controls the Laser output power from 0% to
100% of the lasers’ rated power. If the Laser is pulse mode, the analog control signal will set the
“base” power, or amplitude of the pulse. The input impedance for the signal is 10 kOhms.
ANALOG CONTROL RETURN – The return for the Analog Control.
SHUTTER OPEN COMMAND – Supplying 24 volts to this pin will open the Laser Shutter
(beam will exit the Laser cabinet). Zero volts will close the shutter.
BEAM ON COMMAND – Supplying 24 volts to this pin will turn ON the Laser beam in any of
the operational modes. Zero volts will turn the beam OFF.
PULSE MODE COMMAND – Supplying 24 volts to this pin will logically place the Laser in
gated pulse mode.
PULSE TRAIN SIGNAL – This signal serves to “trigger” the Laser when it is used in any of
the pulse modes. The trigger signal must supply 24 volts to the input during the “ON” time, and
ground it or leave it floating during the “OFF” time. The frequency and duty cycle of the pulses
are provided by the user’s pulse generator.
CNC/LOCAL COMMAND – Supplying 24 volts to this pin will place the Laser in CNC
Command Mode. In this mode the CNC has control of the output power using the Analog
command. Supplying a low to this input will place the laser in Local Command Mode. In this
mode the laser’s power is controlled internally by the PLC’s Standby setting.

LASER ON COMMAND – Supplying 24 volts to this pin will initialize the Laser’s automatic
start-up sequence and the Laser will continue to operate if the pin remains at 24 volts. Zero volts
will stop the Laser or prevent it from starting.
HIGH VOLTAGE ON COMMAND – Supplying 24 volts to this pin will turn the High
Voltage ON.
FAULT RESET – Supplying 24 volts to this pin will for at least 200 milliseconds will reset any
faults that were monitored within the Laser.
BACKFILL COMMAND – If the LASER ON signal is not present, momentarily supplying 24
volts to this pin for a minimum of 200 milliseconds will initialize the backfilling of the Laser
cavity.
SHUTTER OPEN – This is a normally closed contact, which will open when the shutter is
open. This signal has a separate return.
POWER INDICATION SIGNAL RETURN – The return for the power indication signal.
POWER INDICATION SIGNAL – This is a 0 to 10 VDC signal which represents the Laser
output power.
24 VOLT RETURN – The return, or ground for all the digital control signals.
24 VOLT – This pin supplies the common 24 volts to the Laser PLC.
SHUTTER CLOSED – This signal is a normally open contact that will close when the Laser
shutter is closed.
CHILLER ON ENABLE – This signal will be 24 VDC when at the turbine on point indicating
that it is safe to turn the chiller on in automatic mode.
PRESENT – 24 VDC = No warning is present in the Laser.
LOW = A warning is present in the Laser, but the Laser can continue to operate for 5 minutes
maximum. (After 5 minutes the Laser will send the General Fault Present Signal.)
LASER READY FOR HIGH VOLTAGE – This signal will 24 VDC when the laser is ready to
have the high voltage turned ON by the CNC.
LASER READY FOR BEAM – This signal will be 24 VDC when the HV is ON and the Laser
is ready for the BEAM ON command.
GENERAL FAULT PRESENT – 24 VDC = No fault is present in the Laser. LOW = A fault
is present in the Laser. The fault descriptions will be sent to the CP Display Panel through the
serial communications port.

6.4. CONTROLLING THE LASER

Laser mode control is done using Laser Start Command (J1 pin 10), HV On Command (J1 pin
11) and Beam On Command (J1 pin 4). It is not permissible to simultaneously turn on these
inputs to the asserted state; the inputs must be asserted in the proper order so that the Laser can
change operating modes properly. However, it is permissible to negate these lines
simultaneously to power down the laser quickly.
Feedback from the laser about the operating mode of the laser is provided with the output lines.
After the main power has come on, the laser will assert Laser Ready For High Voltage (J1 pin
29) and Laser Ready For Beam (J1 pin 30) .
To turn the beam on you have to enable the Beam On Command (J1 pin 4).
6.4.1. CONTROLLING THE SHUTTER
Shutter control is accomplished using the Shutter Open Command (J1 pin 3). Once asserted, the
shutter will open. The Shutter Open 1 (J1 pin 16) and the Shutter Closed (J1 pin 21) will go low.
When the shutter closes, these signals will go to 24 VDC.
6.4.2. PULSING
Pulse Mode Command (J1 pin 5) puts the Laser into Gated Pulse Operation. The Pulse Train
Signal (J1 pin 7) sets up the frequency and duty cycle of the pulse as commanded by the CNC.
6.4.3. ANALOG COMMAND

The Analog Command + (J1 pin 1) and Analog Command – (J1 pin 2), control the output power
of the Laser by providing a 0 to 10 VDC analog input through the Control Relay (CR1) to the
High Voltage Power Supply (see 0546-303-03 Rev A – Standard Schematics, sheet 4).
6.4.4. CNC 24 VDC
The CNC supplied 24 VDC is connected to J1 pin 20 (+24 VDC) and pin 19 (24 VDC Return).
The jumpers on TB2 8 & 9 must be removed for this configuration. (See 0546-303-03 Rev A –
Standard Schematics, Sheet 1).
7.1. GENERAL DESCRIPTION AND FEATURES
The CP Series CO2 Laser produces a high quality beam for material processing. It was designed
utilizing the latest technology and with a basic philosophy that stresses simplicity and high
reliability. The final result is a rugged industrial Laser that is inexpensive to operate, extremely
reliable, and very easy to use.
All aspects of the Laser’s operational costs were considered in the CP SERIES LASER design.
To reduce electrical costs, very efficient resonator and power supply designs were chosen.

Consequently, the CP SERIES LASER has an overall plug wall efficiency of over 11%. This
high efficiency creates the added benefit of reducing the operating cost of the Laser chiller since
there is less waste heat that it has to dissipate.
The Laser’s gas consumption has been minimized with close attention to detail in the design of
the vacuum and gas delivery systems. All seals were optimized to create a very tight and reliable
vacuum system. Materials were chosen for their cleanliness and compatibility. A simple and
dependable gas mixer was designed with a unique control scheme, which proportions the gas
consumption for the power level required.
The costs associated with maintenance and down time were also addressed in every aspect of the
CP SERIES LASER design. Every component in the CP SERIES LASER was diligently
specified and tested for its durability. The cooling system was designed with plenty of margin to
keep all components and the cabinet air temperature well below specified values. Mechanical
design features and fine particle filters have been incorporated into the Laser to improve optics
life. Unavoidable downtime due to scheduled maintenance can also be more efficiently
scheduled and managed through the special features available in the customer interface panel.
The CP SERIES LASER customer interface panel was designed based on feedback from many
Laser owners and operators. The resulting interface is very easy to use and contains many added
features which simplify the maintenance and control of the Laser such as:
• User level password protection for access control.

• Status indicators and fault and warning reporting.
• Date and time stamped logbooks which log all faults, leak tests, operational setting changes,
and notes.
• A display of all digital and analog values used by the control software.
• Embedded elapsed time meters for all of the major operational modes.
• An automated leak test subroutine and gas mix calibration.
• A data recorder and charting subroutine.
• A Power monitor function.
• Special Laser tuning screens.
• The ability to change gas consumption parameters.
7.2. BASIC LASER THEORY AND THE CP SERIES LASER

The CP SERIES LASER is a fast-axial flow CO2 Laser. This type of Laser is characterized by
its ability to achieve reliable high power levels with good mode quality in a relatively small
package. The principle of operation is to flow the Laser gas out of the discharge region at very
high velocities, which maintains a very high gain within the optical cavity. The gas flows in the
same axis as the optical cavity, which helps maintain the mode quality

The main subsystems of the Laser are listed below:
RESONATOR
o ELECTRICAL DISCHARGE SYSTEM
o OPTIC SYSTEM
o CENTER TUBE
TURBINE ASSEMBLY
o FREQUENCY INVERTER ASSEMBLY
o UPSTREAM AND DOWSTREAM HEATEXCHANGERS
o PRESSURE REGULATION SYSTEM
Purge Valves
Pressure Transducer
Atmospheric Pressure Switch
VACUUM PUMP ASSEMBLY
o FAST PUMPDOWN SOLENOID
o PRESSURE RELIEF VALVE
GAS MIXER ASSEMBLY
o LASING GASES
o BACKFILL SOLENOID
o DRY AIR SYSTEM
HIGH VOLTAGE POWER SUPPLY
o HVPS INVERTER
o HV TANK WITH QUAD ASSEMLIES
SHUTTER ASSEMBLY
o SHUTTER ASSEMBLY
o DIODE POINTER ASSEMBLY
ELECTRICAL SYSTEM
o THREE-PHASE POWER DISTRIBUTION
o 230 VAC POWER DISTRIBUTION
o 24 VDC POWER DISTRIBUTION
o +/- 15 VDC POWER DISTRIBUTION
CIRCUIT BOARDS
WATER MONITOR
POWER METER DRIVER CIRCUIT
8-CHANNEL ANALOG MULTIPLEXER
LANE ANOMALY AND CURRENT SENSE BOARD
QUAD RTD PCB


CONTROL SYSTEM
COOLING SYSTEM
AIR SYSTEM

7.3. RESONATOR
The resonator is the subsystem of the laser where the actual beam is created. As such, many of
the other subsystems either directly or indirectly interact with the resonator.
The Resonator Assembly itself consists of all the parts supporting the glass discharge tubes and
optics. The resonator is mounted with an optical support structure, which is kinematically
mounted to a central tube, also acting as the gas supply manifold to the discharge tubes. The
kinematically mounted resonator design also results in a rugged design that produces exceptional
high power mode quality and pointing stability.
The discharge tubes were designed with integral electrodes and gas orifices. The gas flow
orifices create turbulent flow conditions in the discharge region. This is important in creating a
nice evenly distributed electrical discharge. The internal electrodes create superior electrical
isolation and eliminate several difficult seals. The electrodes themselves are designed to
minimize sputtering and trap any sputtered cathode material.
7.3.1. ELECTRICAL DISCHARGE SYSTEM
The discharge system consists of 12 glass tubes (See Figure 7.1), with anodes and cathodes, the
gas medium, and the high voltage power supply. The high voltage power supply provides
approximately -17 Kilovolts to the cathode. The electrical discharge is fired from the cathode to
the anode of each discharge lane against the circulating gas flow.
ANODE CATHODE
GAS FLOW
-17 kV
Figure 7.1 Discharge Tube and Gas Flow System
7.3.2. OPTIC SYSTEM

The optical support is constructed of two stiff endplates, which are used to mount the optical
components. These endplates are held parallel to each other and kept in alignment using three
carbon fiber tubes, which have very low and equal thermal growth characteristics. The two
structures are then precisely aligned to each other at the factory.
The optic system consists of a series of four mirrors:

Output Coupler
o This optic is partially transmissive allowing a percentage of generated laser beam
to exit the resonator.

Rear Mirror
o Almost 100% reflective for generation of the laser beam. However a very small
percentage “leaks” through this optic into the power sensor. Using this
percentage, we can calibrate the power readings based upon the amount of
proportional power, which “leaks” through this optic.
Two Corner Mirrors
o These two optics are 100% water directly water-cooled optics used for bending
the resonator into our small cabinet.
7.3.3. CENTER TUBE
Underneath the glass portion of the resonator is an aluminum manifold referred to as the center
tube. This manifold is designed to evenly distribute the gas medium through the discharge lanes.
The center tube is also stable support for the alignment of the resonator and a support structure
for the kinematic mounting of the resonator.
7.4. TURBINE ASSEMBLY
The Turbine Assembly (see Figure 7.2: Turbine Assembly) is mounted to the resonator with
connections through heat exchangers. The gas medium is circulated through the glass discharge
tubes at 2400 m3/h. The electrical motor is integrated into the turbine assembly is powered by a
frequency converter. The frequency converter converts the three-phase 380 to 460 VAC (at
50/60 Hz) input voltage to a three-phase nominal 380 VAC at 440 Hz.
Figure 7.2: Turbine Assembly
7.4.1. FREQUENCY INVERTER ASSEMBLY

The Frequency Inverter Assembly uses the supplied 60 hz or 50 hz 3 phase voltage and
converts the frequencies to the necessary 440 hz frequency used by the turbine motor.

7.4.2. UPSTREAM AND DOWSTREAM HEATEXCHANGERS

On the upstream side of the turbine assembly there are two water-cooled heatexchangers
used for cooling the compressed gas exiting the turbine into the center tube and resonator
prior to laser excitation.
On the downstream side of the turbine assembly there are two water-cooled
heatexchangers used for cooling the excited gas exiting the resonator prior to entering the
turbine assembly.
7.4.3. PRESSURE REGULATION SYSTEM

Purge Valves
There are 3 valves mounted directly to the turbine assembly also seen in Figure 7.2. These
valves are used for regulating the system working pressure at 85 Torr. Used in conjunction with
the vacuum pump assembly, the upper and lower valves cycle as needed to maintain the working
pressure. When they are open, the vacuum pump pulls vacuum through the bearing assemblies
of the turbine. The middle valve is used to keep a constant vacuum on the bearings when the
other two valves are closed. With the used of orifices in series, the middle valve only removes
16 lpm of gas while the other two valves are closed.
Pressure Transducer
The Pressure Transducer (Figure 7.3) measures the working pressure in the resonator and
provides that information the PLC. When the working pressure reaches 85 Torr, the PLC sends a
command to open the purge valves mention above to allow the vacuum pump to remove more
gas.
The signal is also fed to the 8-Channel Analog Multiplexer PCB for isolation amplification and
sent to the CNC.
Figure 7.3: Pressure Transducer
Atmospheric Pressure Switch

The atmospheric pressure switch (Figure 7.4) is located in front and down on the right-hand side
of the turbine and attached to the pressure transducer. This switch is used during the backfill
operation of the laser. When the backfill command is given, the backfill solenoid is opened and

nitrogen enters the resonator filling it with gas. The atmospheric pressure switch, once the gas
pressure reaches 0.5 psi above atmospheric pressure, will open signaling that the resonator is full
of gas. This signal is sent to the PLC that will, in turn, shut OFF the backfill solenoid on the gas
mixer to keep from over-pressurizing the laser cavity.
Figure 7.4: Atmospheric Pressure Switch
7.5. VACUUM PUMP ASSEMBLY

The vacuum pump maintains the resonator’s pressure of approximately 85 Torr with use of the
pressure regulation solenoids, the pressure transducer, and PLC as mentioned in the previous
paragraphs. The vacuum pump (Figure 7.5) also pumps the laser down to 4 Torr during start-up
to remove contaminants and moisture that may have entered into the resonator cavity during shut
down or servicing.
Figure 7.5: Vacuum Pump

7.5.1. FAST PUMPDOWN SOLENOID

The fast pumpdown solenoid (Figure 7.6) connects to the bottom of the center allowing quicker
pumpdown of the resonator during startup by opening the larger ½” polyflow line connecting the
resonator to the vacuum pump. When pumping down the laser this solenoid bypasses the line
from the pressure regulating solenoids and turbine pump out solenoid (which have orifices
connecting them) that would take a long time to pump down through.
Figure 7.6: Fast Pump Down Solenoid
7.5.2. PRESSURE RELIEF VALVE

The pressure relief valve (Figure 7.7) is strictly used as protection against over pressuring the
resonator during backfill. If a valve should stick open allowing the resonator pressure increase
above 1.0 psi, the mechanical pressure relief valve will open allowing some excess pressure to
escape.
Figure 7.7: Pressure Relief Valve

7.6. GAS MIXER ASSEMBLY

The proportioning of the gases for producing the Laser’s active medium depends upon the setting
of the regulators on the gas mixer, which is located behind the vacuum pump. The regulators
located at the gas bottle supplying gas to the Laser (and the gas mixer) should be set to 80 PSI.
The gas mix is factory set. The user does have the ability to check the gas ratio using the CP
Panel software. For further information on the gas calibration check, please refer to the help files
on the CP Panel Software.
Figure 7.8: Gas Mixer Assembly
7.6.1. LASING GASES

The CP Series Laser uses 3 gases as the active medium inside the resonator. The standard gas
mixture consists of 4.1% CO2, 28.2% N2, and 67.7% He. The laser chamber is initially
evacuated to a pressure of 4 Torr before being back-filled with the active medium gas to the
regulated operational pressure of 85 Torr. The percentage of the gas mixture is critical to Laser
operation. Any deviation of these percentages will affect Laser operation.
7.6.2. BACKFILL SOLENOID

The backfill solenoid valve, also located on the gas mixer, is used to backfill the laser resonator
for a prolonged laser shut down or for service requirements when the resonator chamber needs to
be opened to atmospheric pressure. The backfill bypasses the N2 orifice to allow faster
backfilling with nitrogen only.

Mounted at the center tube with the fast pump down valve, the 1.0 psi pressure relief valve will
help prevent overpressure in the vacuum system during backfill. If there is a malfunction with
the atmospheric pressure switch, the pressure relief valve will open allowing some gas to escape
in an attempt to prevent overpressure of the resonator.
7.6.3. DRY AIR SYSTEM

Clean Dry Air must to be supplied to the Laser using a commercial air drying system to keep
contaminants out of the Laser. This compressed air is supplied to the laser at 80 PSI. It is routed
through a regulator (0546-303-03 Rev A – Standard Schematics, Sheet 22), on the gas mixer
where it is set to 50 PSI. This air is used to run the shutter and to purge the output coupler.
DRY AIR POSITIVE PRESSURE VALVE
Also installed on the gas mixer is a dry air positive pressure valve. In humid environments, the
dry air positive pressure valve can be opened to fill the cabinet with dry air and add a positive
pressure into the cabinet to keep out the humidity. In colder months or dry climates, the user
should keep this valve closed.
7.7. HIGH VOLTAGE POWER SUPPLY

The High Voltage Power Supply is made up of two assemblies. The first assembly is the HVPS
inverter (Figure 7.9). The second assembly is the HV tank. These two assemblies work together
to provide a nominal -18 kV to each individual lane generating the excitation of the gas for laser
beam.
7.7.1. HVPS INVERTER
The HVPS Inverter (Figure 7.9) takes the 400-460 VAC 3 phase 60 hz electrical voltage supplied
by the customer and converts it to 3 individual single phase 17 khz electrical voltages. The peak
to peak voltages are depended up the customer input voltage (used to create the DC bus). The
period (on time) of the output phase is dependent upon both the customer input voltage and the
analog power commanded to the laser. The software used in the inverter takes into account the
input voltage and the requested power output to generate the output to the HV tanks. The higher
the power commanded the longer the on time of the pulse delivered.

Figure 7.9: HVPS Inverter
7.7.2. HV TANK WITH QUAD ASSEMLIES

The HV tank (Figure 7.10) contains 3 individual Quad Assemblies. Each Quad Assembly is
responsible for delivering HV to 4 discharge tube groups. Each Quad assembly transforms one
of the single phase high frequency pulsed outputs from the HVPS which is then transformed and
rectified to the DC high voltage supplied to the discharge tubes on the resonator. Typically,
these voltages range from –20 kV to –16 kV depending upon the power commanded from the
CNC and current supplied to the discharge tubes.
Figure 7.10: HVPS Quad Assemblies in the Tank
7.8. SHUTTER ASSEMBLY

The purpose of the shutter assembly is to allow safe extraction of the Laser beam out to the work
piece. When the shutter is closed it directs the Laser’s beam into a “beam dump” which provides
safe absorption of the beam. When commanded by the CNC, the PLC opens the shutter allowing
extraction of the beam to the work piece, provided that the External Shutter Interlock is satisfied.
The shutter (Figure 7.11) provides feedback information by use of proximity switches to tell the
PLC whether it is open or closed.

Additionally, the shutter also has shutter blade and beam dump temperature switches that will
disable the laser beam in an over-temperature condition if for some reason they exceed their fault
temperatures.
The beam tube switch ensures that the Laser cannot be operated without the beam tube in place.
Figure 7.11: Shutter Assembly

7.8.1. DIODE POINTER ASSEMBLY
A diode pointer is mounted on the side of the shutter next to the inspection plate. The diode
pointer is used to point coaxial with the CO2 laser beam. This pointer can be used to assist with
external beam alignment and as a pointer locater through the cutting lens.
WARNING: Please be aware that the diode laser is a Class II laser and all
OPTICAL RADIATION HAZARDS regarding a Class II laser should be
observed.

7.9. ELECTRICAL SYSTEM

Refer to Schematic 0546-303-03 Rev A – Standard Schematics, Sheets 1 – 5 for the layout of the
electrical system. Basically, 3-phase power drives the following subsystems: turbine (after being
conditioned by the frequency converter), vacuum pump and high voltage power supply. XFMR1
converts 3-phase power to 230 VAC to power the following: PLC, 24 VDC power supply, + and
- 15 VDC power supply, cabinet cooling fans and the high voltage power supply. The 24 VDC
and 15 VDC power supplies supply power for the printed circuit boards, the PLC and other
associated equipment.
7.9.1. THREE-PHASE POWER DISTRIBUTION

Three-phase power enters the Laser through the Main Disconnect Breaker MCB1 (80 AMP) and
passes through the Main Line Filter FLTR1. From there, three phase power is routed through the
appropriate circuit breakers and contactors to the following assemblies: Frequency Driver DVR1
(powers the turbine motor), Vacuum Pump MOT2, High Voltage Power Supply, and an optional
Air Conditioning Unit. In addition, two phases (legs 1 and 2) are fed to the Main Input
Transformer XFMR1, which drops the input voltage down to 230 VAC. (See the Installation
Section MAIN INPUT TRANSFORMER XFMR1 of this manual and Schematic 0546-303-03
Rev A – Standard Schematics, Sheet 1 for proper transformer configuration.)
7.9.2. 230 VAC POWER DISTRIBUTION

230 VAC comes off of the secondary of the Main Input Transformer XFMR1 and is protected by
CB4. It is used to power the following circuits: PLC, 24 VDC power supply, +/- 15 VDC power
supply, the five cooling fans for the cabinet heat exchanger, and the High Voltage Power Supply.
7.9.3. 24 VDC POWER DISTRIBUTION
The 24 VDC Power Supply provides power for the following circuits: Safety Relay SRL1, Lane
Monitor, Power Meter, Multiplexer, and the PLC.
7.9.4. +/- 15 VDC POWER DISTRIBUTION
The +/- 15 VDC Power Supply provides power to the pressure transducer, diode laser power
supply, and the Quad RTD, Analog Multiplexer, and Water Monitor printed circuit boards.
7.10. CIRCUIT BOARDS

7.10.1. WATER MONITOR
The Water Flow Monitor board (Figure 7.12) provides two signals to the 8-Channel Analog
Multiplexer Board:
1. Water Temperature 0V (0ºC) to 10V (50ºC) or 5ºC/V
2. Water Flow 0V(0 lpm) to 10V (20 lpm) or 2 lpm/V

Figure 7.12: Water Monitor PCB with Paddle Wheel
Water Temperature Monitoring

The temperature-sensing element is an RTD mounted at the shutter beam dump assembly
mounted to the shutter. To check the RTD the user can use the following calculations.
PT100 CALCULATIONS:
To calculate the RTD resistance knowing the temperature:
(ºC * 0.385) + 100 =Ω
To calculate the temperature knowing the resistance:
(Ω-100) ÷ 0.385 = ºC
Water Flow Monitoring

The water flow sensor is a paddle wheel with magnet elements. As the paddle wheel spins
relative to the water flow, the magnets generate a pulse frequency also proportional to the flow
rate. This can be measured on the water flow board if the user needs to check the flow
calibration.
7.10.2. POWER METER DRIVER CIRCUIT
The Power Meter Driver (Figure 7.14) receives a .5mV per Watt signal from the Thermopile
(Figure 7.13) on Pins 1 and 2. It amplifies that signal to a 500 Watt per volt signal for the PLC
MOD2 A9 and A10. The signal is also fed to the Analog Mux PCB, which provides isolation
and an output to the CNC interface.

Figure 7.13: Thermopile
Figure 7.14: Power meter amplifier
7.10.3. 8-CHANNEL ANALOG MULTIPLEXER

The Analog Multiplexer circuit board (Figure 7.15) scans the four inputs from the Quad RTD
circuit board and the two inputs from the Water Monitor board and provides a single output to
the PLC for status monitoring. It also provides a visual indication of which channel is being
scanned by the LEDs 3,4, and 5 in a binary arrangement (see Figure 7.16). In addition, the board
provides Laser Output Power and Cavity Pressure analog outputs to the CNC for display
purposes. The six analog inputs are scanned and then provided to the PLC in a multiplexed
output to be de-multiplexed by the PLC and used in the PLC calculations, fault monitoring and
user information.
Figure 7.15: Analog Mux Board

CHANNEL 0 1 2 3 4 5 6 7
LED5
= ON
LED4
= OFF
LED3
Figure 7.16: Binary LED Display
7.10.4. LANE ANOMALY AND CURRENT SENSE BOARD

The Lane Anomaly Board (Figure 7.17) measures a proportional voltage of each discharge.
The voltages of each discharge region are averaged creating an average discharge voltage. The
averaged discharge voltage is then used to create a high and low limit (+/- 20% for CW operation
and +/- 45% for pulse operation). All discharge voltages are then compared to this operational
window to determine if the discharges are operating safely. If a discharge voltage is outside of
the determined operational window, the laser is shutdown with a discharge anomaly fault. If a
particular lane is outside of the window, that discharge will be identified and displayed with the
fault on the fault message page.
If there are more than one lane at fault, only the first lane identified will be displayed. However,
the operator can see the other lanes at fault on the circuit board itself. The other lanes will be
identified with the corresponding LED identifying the lane.
Additionally LED2 on the Discharge Anomaly board will be lit indicating a discharge anomaly
fault. It also turns off the Fiber Optic Link to the High Voltage Power supply to provide for fast
shutdown of the High Voltage Power Supply.
Figure 7.17: Lane Anomaly Board and Current Sense Board

Additionally, the discharge anomaly board also monitors for overvoltage on any particular lane.
The highest voltage on any lane is labeled the High Lane. If this High Lane exceeds 31.5 kV for
more than 50 microseconds the HV will be inhibited. Any discharge created in the discharge
tubes should reduce this voltage to a normal voltage of approximately 20 kV. If after 100ms the
voltage on the “High Lane” is greater than 28.8 the laser will shut down on an over voltage fault
and LED 1 will be lit.
This lights LED2 on the Lane Monitor PCB indicating a High Voltage Fault. It also turns off the
Fiber Optic Link to the High Voltage Power supply to provide for fast shutdown of the High
Voltage Power Supply. In addition, a High Voltage Output Fault is sent to the PLC via P1, Pins
9 &10.
CURRENT SENSE BOARD
The current sense board allows the user to measure the current and discharge voltage safely on
the test points provided. Additionally, it averages the three quad current to assist the HVPS is
regulating the current.
7.10.5. QUAD RTD PCB

The Quad RTD (Figure 7.18: Quad RTD Board) printed circuit board provides four
thermocouple readings to the 8-Channel Analog Multiplexer Board:
1. Turbine Gas Temperature 0V (0ºC) to 10V (150ºC) or 15ºC/V
2. Turbine Bearing Temperature 0V (0ºC) to 10V (150ºC) or 15ºC/V
3. Turbine Motor Bearing Temperature 0V (0ºC) to 10V (150ºC) or 15ºC/V
4. Cabinet Temperature. 0V (0ºC) to 10V (50º) or 5ºC/V
Figure 7.18: Quad RTD Board

7.11. CONTROL SYSTEM

The Laser is controlled using a General Electric PLC utilizing a PC interface. All inputs and
outputs required to operate the Laser are processed and executed by this system.
Figure 7.19: PLC
7.12. COOLING SYSTEM

The CP Series lasers need chilled water (18 degrees Celsius) supplied to the Laser by an external
chiller system to remove heat from the Laser Once the chilled water enters the cabinet it
branches off to several manifolds (See 0546-303-03 Rev A – Standard Schematics, Sheet 21).
The water is used to cool the following items:
• The turbine
• Upstream and Downstream heatexchangers
• Turbine bearings
• Cabinet heat exchangers
• Optics, and plates and power head
• Shutter blade and beam dump
• High voltage power supplies and tank.
7.13. AIR SYSTEM
Clean Dry Air must to be supplied to the Laser using a commercial air drying system to keep
contaminants out of the Laser. This compressed air is supplied to the laser at 80 PSI. It is routed
through a regulator (See 0546-303-03 Rev A – Standard Schematics, Sheet 22), on the gas mixer
where it is set to 50 PSI. This air is used to run the shutter and to purge the output coupler.

9. MAINTENANCE
8. PREVENTATIVE MAINTENANCE
8.1. OVERVIEW
The following section describes routine maintenance required to keep the CP SERIES Laser in
proper operating condition. Close attention must be made to these procedures to ensure proper
operation of equipment, prevention of damage to the Laser’s components, or severe injury or loss
of human life.
WARNING: Before performing any maintenance on the CP SERIES Laser,

be sure that the machine is powered down (High Voltage Power Supply Circuit
Breaker CB3 and Main Circuit Breaker MCB1 are turned off) and the CNC
has been powered down. Use the grounding rod to ground the HVPS
electrodes on the discharge lanes. Failure to do so could result in severe injury
or death by electrocution.
8.2. MAINTENANCE SCHEDULE
1000 8000
500 HOURS AS NEEDED
MAINTENANCE TASK HOURS HOURS
VACUUM PUMP AIR INLET FILTER
X
CLEANING
VACUUM PUMP OIL CHANGE 1ST ALL OTHERS
VACUUM PUMP MESH FILTER CLEANING X X
VACUUM PUMP DEMISTING FILTER
X
CHANGE
TURBINE BEARING CHANGE X
TURBINE REFURBISHMENT 16’000 h
OPTICS CLEANING/REPLACEMENT X
8.3. VACUUM PUMP MAINTENANCE

WARNING: Before performing maintenance on the vacuum pump be sure to
turn off both the Main Circuit Breaker MCB1 and the Vacuum Pump Circuit
Breaker CB2. It is imperative that the unit cannot be restarted during the
maintenance operation.
Manual P/N: 0546-396-OE Rev B Page 90 / 106

9. MAINTENANCE
WARNING: The vacuum pump, under normal operating conditions, can

produce dangerous temperatures in the lubricant and operating parts. Allow
sufficient time for cooling before performing maintenance or burns may result.
8.3.1. VACUUM PUMP OIL CHANGE

The oil level should be checked on the site gauge regularly. The top of the gauge is the
maximum fill level and the bottom of the gauge is the minimum fill level. The first oil change
will be performed just before Laser shipment. Oil changes after that should be every 1000
(Vacuum Pump Oil P/N is 0546-276-00) hours or sooner if the application is dusty/dirty. Upon
oil change, reset the vacuum pump oil change time on the Maintenance Information Screen.
WARNING: The only oils that should be used are DIN1506 group VC/VCL
or synthetic vacuum pump oil that can be obtained from Convergent Lasers
P/N 0546-276-00. Viscosity must correspond to ISO-VG 46 according to DIN
51519. Recommended oil type is SUPER-LUBE 46 (synthetic oil).
WARNING: Dispose of oil in accordance with safety and environmental

regulations and laws.
1. Place a small drain pan under the vacuum pump drain plug as shown in Figure 9-4.
Figure 9-4: Vacuum Pump With Drain Pan
2. Open the oil fill cap (black) on top of the vacuum pump.
3. Using a #11 hex key, open the red drain plug (See figure 9-4) and drain the oil into the
pan.

9. MAINTENANCE
4. Replace seal in drain plug with P/N 2505-3320.

5. Reinstall the red drain plug.
6. Unscrew the plugs as shown in Figures 9-5 and 9-6. Clean the mesh filters with alcohol
and dry.
Figure 9-5: Mesh Filter Figure 9-6: Mesh Filter
7. Replace the mesh filters and plugs in reverse order.

8. Go to paragraph 9.3.c and follow the procedure for replacing the oil mist eliminator filter
(demisting filter) before replacing the vacuum pump oil.
9. Fill pump with oil up to the top of the sight gauge (See Figure 9-7) and replace the black
fill cap on top of the vacuum pump.
Figure 9-7: VACUUM PUMP SIGHT GAUGE

9. MAINTENANCE
8.3.2. OIL MIST ELIMINATOR FILTER REPLACEMENT
WARNING: Blocked filter elements cause backpressure on the vacuum

pump, oil discoloration, and increased operating temperature that can damage
the pump.
The oil mist separator element will become contaminated and caused increased pump operating
temperatures and pump overload. Hence, it should be replaced every 1000 operating hours.
First, remove the two screws holding on the exhaust cover (See Figure 9-8).
Figure 9-8: Exhaust Cover Figure 9-9: Spring Washer Screw

Remove the screw holding the spring washer to the filter (See Figure 9-9). Remove the spring
washer and demisting element (See Figure 9-10). Replace the demisting filter element (and
demisting filter O-rings, if necessary) and reassemble in reverse order. The Convergent Prima
Part Number for the filter is 2603-3336.

9. MAINTENANCE
Figure 9-10: Demisting Filter
8.4. TURBINE MAINTENACE

WARNING: Only factory-trained personnel are authorized to perform turbine
bearing cartridge replacement or turbine assembly replacement.
8.4.1. Bearing Maintenance

In accordance with the manufacturer’s recommended maintenance schedule, the bearings inside
the CP Series laser need to be replaced every 8000 hours for continued proper run conditions. If
the turbine is not maintained properly Convergent Lasers voids all warranty claims respective to
the turbine.
8.4.2. Turbine Maintenance

In accordance with the manufacturer’s recommended maintenance schedule, the turbine needs to
be replaced every 16,000 hours. At this time, the bearings have also run their respective
maintenance schedule and of course will be replaced with the replacement of the turbine. If the
turbine is not maintained properly, Convergent Lasers voids all warranty respective to the
turbine.

9. MAINTENANCE
8.4.3. TURBINE BEARING BREAK-IN PROCEDURE

NOTE: For instructions on programming the Frequency Inverter refer to the frequency manual
supplied on the CD-Rom supplied with this laser.
At times due to grease build up or other normal factors, it may be required to perform a bearing
break-in procedure to reduce the bearing temperatures prior to a full bearing replacement. Please
use the following set point to break in the bearings. If the user is not familiar with programming
the frequency inverter, he either may contact Convergent Lasers or refer to the Frequency
Inverter manual provided with the CD Rom supplied with the laser.
RUN THE TURBINE AT 100 Hz

1. Program the Frequency Inverter Parameter Set 2, Basic Parameters, Maximum Frequency to
100 Hz.
2. Program the Frequency Inverter Parameter Set 2, Control Clamps, Relay 2 Frequency to 80
Hz.
3. Start the Laser and run the Turbine at 100 Hz.
4. Monitor the Turbine Bearing and Turbine Motor Bearing temperatures on the Analogs Screen
of the CP Panel. After each temperature stabilizes (to within +/- 3 degrees Celsius), turn the
laser off and proceed to step 9.8.2.
RUN THE TURBINE AT 300 Hz

300 Hz.
Hz.
of the CP Panel. After each temperature stabilizes (to within +/- 3 degrees Celsius), turn off the
laser and proceed to step 9.8.3.
RUN THE TURBINE AT ITS ORIGINAL FREQUENCY OF 400 Hz

441 Hz.
Hz.
of the CP Panel. After each temperature stabilizes (to within +/- 3 degrees Celsius), run the laser
as normal.

9. MAINTENANCE
8.5. OPTICS MAINTENANCE

It is not recommended to clean the optics (mirrors) until a reduction of output power or beam
quality degradation is observed.
NOTE: Never touch the alignment of the corner mirrors
8.5.1. Optics replacement
NOTE: After replacing the rear mirror or the output coupler a power meter calibration is
required, because of some small variations in the transmission of those optics.
8.5.2. Resonator tuning
NOTE: Never touch the alignment of the corner mirrors
NOTE: It is important that the CP Panel Software be on the “TUNING” screen on the
maintenance page before tuning. Otherwise the user will not be able to tune properly due to
certain functions inside the laser and the user can cause damage by burning the glass and
contaminating the optics.
NOTE: After replacing the rear mirror or the output coupler a power meter calibration is
required, because of some small variations in the transmission of those optics.
NOTE: The laser should be set on Max Gas for proper tuning. For reference on setting the laser
in Max Gas, please refer to the CP Panel help icon for assistance in operating the CP panel
software.
8.6. POWER METER CALIBRATION

1) Let the Laser cool off for around twenty minutes.
2) Connect BLK (-) lead to TP3, which is the WHITE Test Point and is ground. Connect RED
(+) lead to TP7 (OUTPUT). Set DVM to VDC and adjust OFFSET POT (POT2) for 0.00 VDC.
3) Turn on Laser, HV, and let the Laser warm-up for around 15 minutes.
4) Take an external power measurement of the beam with a calorimeter or labmaster.
5) Take the external reading you get and divide it by 500. (I.E. 4000 watts divided by 500 =
8V).
6) Adjust POT3 for the result you get in step five. (500 Watts/Volt).

12. WARRANTY
9. WARRANTY
9.1. BASIC WARRANTY
Convergent Lasers warrants to the original purchaser only and at its original location that the
Laser will be free from defects in material and workmanship for a period of twelve months from
the date of installation.
CP Series Laser Products

The Laser will be free from defects in material and workmanship for a period of twelve (12)
months or two thousand (2,000) hours following installation of the laser at the end-user site, or
thirteen (13) months from date of shipment from Convergent Laser, whichever comes first.
Major subsystems manufactured by other firms but integrated into the laser are covered by the
original manufacturer’s warranty only. The liability of Convergent Lasers under valid warranty
claims is limited to repair or replacement at Convergent Lasers plant or purchaser’s place of
business, all at the option of Convergent Lasers. Warranty claims must be made promptly after
occurrence of circumstances giving rise thereto and must be received within the applicable
warranty period by Convergent Lasers. In no case should more than thirty (30) days elapse after
discovery of defect. Before any products are returned for repair and/or adjustment, authorization
from Convergent Lasers must be obtained. In all cases, Convergent Lasers has sole
responsibility for determining the cause and nature of failure, and determination with regard
thereto shall be final.
Adjustments or modifications to the Laser other than those described in the maintenance section
without the expressed permission of the factory will void the warranty. Customer caused
damages are non-warranted; failure to maintain the equipment, failure or damage resulting from
misuse, negligence or accident are non-warranted.
The liability of Convergent Lasers under valid warranty is limited to repair or replacement at our
factory or at the purchaser's place of business, all at the option of Convergent Lasers.
This warranty is valid only for Lasers installed or relocated by a qualified Convergent Lasers
representative.
This warranty is exclusive and in lieu of all other warranties, whether written, oral or implied and
shall be the buyers sole remedy and Convergent Lasers sole liability on contract or warranty or
otherwise for the product. Convergent Lasers disclaims any implied warranty or merchantability
or fitness for purpose. In no event shall Convergent Lasers be liable for any incidental or
consequential damages arising out of or in connection with the use of or the performance of the
goods delivered hereunder.
Voiding of Warranty
The warranty will be considered void if any of the following actions are taken:
Manual P/N: 0546-396-OE – Rev B Page 97 / 106

12. WARRANTY
1) Internal adjustments or modifications of the Laser without the express (written) permission of
CONVERGENT LASERS.
(Note: Instructions on adjustments necessary during installation which are contained in the
Installation and/or Operation section of this manual are allowed).
2) Damage caused by the end-user.
3) Damage due to misuse, negligence or accident.
9.2. RETURNS AND ADJUSTMENTS

Warranty claims must be made promptly after occurrence of circumstances giving rise thereto
and must be received within the applicable warranty period by Convergent Lasers. In no case
should more than thirty days elapse after discovery of defect. Such claims should give the
product serial number, the date of installation and a full written description of the circumstances
giving rise to the claim.
Before any products are returned for repair and/or adjustment, the RMA authorization form must
be completed and returned to Convergent lasers for the return authorization number and
instructions as to how these products should be returned. Any product or component returned for
examination and/or warranty repair shall be sent via insured pre- paid transportation specified by
Convergent Lasers.
Convergent Lasers reserves the right to reject any warranty claim on any item that has been
shipped by unacceptable means of transportation. The buyer and its shipping agency shall be
responsible for all damage incurred to parts or products as a result of improper packing or
handling and for loss in transit, notwithstanding any defect or non conformity in the product. In
all cases Convergent Lasers has sole responsibility for determining the cause and nature of
failure, and Convergent Lasers determination with regard thereto.
If it is found that Convergent Lasers product has been returned without cause and is still
serviceable, the buyer will be notified and the product will be returned at the buyer's expense.
Additionally, a charge for testing and examination may, at the discretion of Convergent Lasers,
be made.
The customer has agreed to stock spare parts, especially those items recommended by
Convergent Lasers.
9.3. EXCLUDED PRODUCTS

Focusing Lenses - Lenses are specifically excluded from warranty. The warranty does not cover
cleaning of contaminated optics and adjustments of reflectors.
Lasers supplied under OEM agreement may be specifically excluded from this warranty.

12. WARRANTY
9.3.1. Internal Optics

Optics included with the Laser are specifically excluded from warranty.
9.3.2. Water Cooled Products

Convergent Laser does not warranty any of its water cooled products against contingent or
subsequent damage resulting from negligence in providing the required water cooling or from
unexpected events which cause the required water cooling to be interrupted during operation of
the equipment. Convergent Lasers water cooled products include protective devices designed to
deactivate the product in the event that the flow of required cooling water is interrupted.
However, Convergent Lasers liability in the event of a protective device failure is limited to
repair or replacement of the protective device and any Convergent Lasers water-cooled product
damaged as a result of the protective device failure at Convergent Lasers plant or the purchaser’s
place of business, all at the option of Convergent Lasers.
The foregoing warranty is exclusive and in lieu of all other warranties, whether written, oral or
implied and shall be buyer’s sole remedy and Convergent Lasers sole liability on contact or
warranty or otherwise for the product. Convergent Lasers disclaims any implied warranty of
merchantability or fitness for purpose.

13. MANAUL CRITIQU FORM
10. MANUAL CRITIQUE FORM
Our goal at Convergent Prima is to provide our customers with the best possible documentation
with our products. To help us to accomplish this, please take time to fill out the following
information and return the form to:
CONVERGENT LASERS Voice: 800-722-1133
Service Department Fax: 413-598-5200
711 East Main St. www.convergentlasers.com
Chicopee, MA 01020
10.1. Place an “X” in the appropriate box
Needs Meets Exceeds
CP SERIES LASER Improvement Expectations Expectations
READABILITY
COMPLETENESS
ORGANIZATION
ACCURACY
SAFETY INFORMATION
GRAPHICS
APPEARANCE
USEFULNESS
MAINTENANCE PROCEDURES
INSTALLATION PROCEDURES
TROUBLESHOOTING
SCHEMATICS
CONTENTS
OVERALL IMPRESSION

NAME: POSITION:
COMPANY:
ADDRESS:
TEL / FAX / EMAIL:
If any areas above were marked “Needs Improvement,” please explain:
How could we improve this manual?
Further Remarks:

REPORT MANUAL DISCREPANCIES

Page Explain Discrepancy

14. RMA FORM
11. SERVICE ORDER / RMA FORM

14. RMA FORM
HOW to FILL OUT A

SERVICE ORDER / RMA FORM
TO BE USED FOR DEPOT REPAIR, ADVANCE REPLACEMENT, SERVICE INVENTORY RETURN,
CREDIT & NON-CREDIT RETURN AND DEMO EQUIPMENT RETURNS
DATE
Enter today’s date.
RMA Type Check the appropriate RMA box. Check one (1) box only!
• Depot Repair (complete sections 1-7) This is a repair and return of the same unit sent to the
factory for warranty or billable repairs from the customer.
• Advance Replacement (complete sections 1-8) Factory will send a warranty/billable
replacement to customer in advance and customer will send failed unit to Factory on a Service
Order/RMA.
• Non Credit Return (complete sections 1-7) Failed unit/part returning from customer, No
replacement or Credit required.
• Credit Return (complete sections 1-7) Unused part returning from customer for credit/restock.
• Service Inventory Return (complete sections 1-6) Used for Coherent Field reps only.
• Demo Equipment Return (complete sections 1-6) Loaner/Demo equipment (Factory owned)
returning to factory from customer.

14. RMA FORM
Requestor Information
Provide all of requestor’s and ship to address information. Provide reference number if
applicable.
System Information
Provide system product number, system serial number and hours of operation.
Note: Enter “None” for Service Inventory Returns
Return Part(s) Information

Provide the part number, description, serial number (if applicable) and quantity of
returned part(s).
Failure Information/ Comments

Provide failure details or explain why the part(s) is being returned.
Note: Return for credit: If box is open, but parts are unused, please indicate.
Financial Information – FOR DEPOT REPAIR ADVANCE REPLACEMENT & CUSTOMER CREDIT
RETURN
Indicate if part(s) is in or out of warranty/contract, the warranty/contract end date and
P.O. number for ordering replacement parts, and head/tube hours (if available). Please attach a
hard copy of the reference P.O. for Warranty/ Billable Depot Repair and Advance
Replacement RMAs to the form prior to faxing. Indicate if a Credit Memo is required for
Return/Restock.
Advance Replacement Part(s) Request

“Replacement Part(s) Information” required for Advance Replacement/RMA requests.
Fax the completed form to 413-598-5201 or

E-mail form to ksmith@convergetlasers.com
OA-3.13, 12/06/99, pg 2

15. LIST OF SCHEMATICS
12. List of Schematics

12.1. 0546-303-03 Rev A – Standard Schematics
See separate document on CD delivered with the machine.
12.2. 0546-303-41 Rev A – Standalone Schematics

See separate document on CD delivered with the machine.

Manual 0546-396-OE Rev B

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Manual 0546-396-OE Rev B

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CP SERIES

Convergent Laser, Inc. Administration: Sales: Service:

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3.3.4. Starting The Display Panel in DEMO mode 27

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4.4.14. HV 014 HV Circuit Breaker Fault 43

MAINTENANCE MANUAL ......... 55

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5.2. LIFTING THE CP SERIES LASER ................................................................. 55

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7.7.1. HVPS INVERTER 81

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Telephone: 1-800-722-1133 (Domestic U.S. only)

1.2. INTRODUCTION TO SAFETY

CAUTION: To protect operating personnel, this safety section should be

WARNING: Failure to observe operating procedures and warnings can

1.2.1 Safety Considerations

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HIGH VOLTAGE DC HAZARDS

1.3. ELECTRICAL HAZARDS

1.3.1. SAFETY INTERLOCKS

WARNING: Do not override or tamper with any interlock or safety circuit in

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1.3.2. HIGH VOLTAGE DC HAZARDS

High Voltage Precautions

1.3.3. HIGH VOLTAGE AC HAZARDS

Follow similar precautions to the High Voltage Precautions listed above.

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1.3.4. SAFETY DISCONNECTS

Main Disconnect Switch

Figure 1.1, Main Disconnect Switch

Emergency Stop Button

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WARNING: Capacitors used in the power supply system are capable of

1.4. OPTICAL RADIATION HAZARDS

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WARNING: Never, under any circumstances, look directly or indirectly into

1.4.2. DIRECT SKIN BURNS

1.4.3. IN-DIRECT SKIN BURNS

1.5. MATERIAL PROCESSING HAZARDS

CAUTION: Use caution when handling flammable materials in close

1.5.2. Toxic Reactions

1.5.3. Material Temperature Burns/Cuts

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1.6. DELIVERY APERTURE DIRECTION

1.7. CDRH COMPLIANCE

CAUTION: Use of controls or adjustments or performance of procedures

1.7.1. PROTECTIVE HOUSINGS

1.7.2. REMOTE INTERLOCKS

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WARNING: If the remote interlocks, E-STOP LOOP, or SAFETY LOOP are

1.7.6. LASER EMISSION INDICATORS

1.7.7. SHUTTER CONTROL

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1.7.8. EXTERNAL SHUTTER INTERLOCKS

WARNING: Convergent Lasers assumes no liability if the interlocks provided

1.7.9. SAFETY LABELS

1.7.10. BEAM DELIVERY APERTURE DIRECTION

NOTE: Suitably qualified maintenance or other service personnel should only

1.7.11. ACCIDENTAL RADIATION OCCURENCES (ARO’s)

1.7.12. Reporting Of Accidental Radiation Occurrences

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