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1. User Manual REA Series Diode Pumped Nd YAG Rod Laser Modules REA XX06 REA XX08 REA XX10 REA XX12 CEO UMAN 0022B DECEMBER 2012 Worldwide Technical Support and Product Information www northropgrumman com Search ceolaser Hours 8 00 a m to 5 00 p m Central time Service and Technical Support 636 916 4900 follow prompts for department directory Email st ceolaser info ngc com Cutting Edge Optronics Headquarters 20 Point West Blvd St Charles MO 63301 USA Sales Support 636 916 4900 follow prompts for department directory After office hours please leave a voice mail message Outside North America contact a Cutting Edge Optronics sales office or distributor see the Cutting Edge Optronics website for a list of offices 2006 2012 Cutting Edge Optronics a division of Northrop Grumman Corporation All rights reserved Northrop Grumman Corporation ji REA Series User Manual Important Information Warranty Summary Cutting Edge Optronics warrants that the products that it manufactures and sells will be free from defects in materials and workmanship for a period of one year from the date of shipment from an authorized Cutting Edge Optronics distributor If a product proves defective within the respective period Cutting Edge Optronics will provide repair or replacement as described in the complete warranty statement To arrange for service or obtain a copy of the complete warranty sta
2. Chapter 4 Installation and Operation 25 REA Series Laser Module Assembly and Connections 26 Closed Loop Water Chiller Assembly 28 Starting the Laser System 29 Northrop Grumman Corporation IK REA Series User Manual Standby Condition Turning Off the System Chapter 5 Maintenance Rod Removal and Replacement Rod Cleaning Leak Test Procedure Adjusting the Operating Current Cleaning the Chiller Chapter 6 Service Contacting Customer Service Return the Instrument for Repair Appendix A Customer Service Questions Appendix B System International Units Appendix C Acronyms Northrop Grumman Corporation 31 31 32 33 3 3 38 39 41 42 42 43 44 46 47 REA Series User Manual Table of Figures Figure 1 1 Exterior Components and Connections 1 Figure 1 2 Nd YAG Absorption Characteristics 2 Figure 1 3 Pump Light Absorption vs Pump Array Center Wavelength 3 Figure 1 4 Radial Pump Geometry 3 Table 1 1 REA Physical Configuration 4 Table 1 2 End of life Waste Heat 5 Table 1 3 REA Series Model Specifications 6 Table 1 4 REA Series General Specifications 7 Figure 2 1 Standard Safety Warning Sign 10 Figure 2 2 Radiation Control Drawing 11 Figure 2 3 Warning Labels 11 Figure 3 1 Reverse Bias Protection Diode Circuit 15 Figure 3 2 REA Series Electronic Timer 16 Table 3 1 Cooling System Requirements 19 Table 3 2 Avoid with Chillers 20 Figure 3 3 Constant Dew Point Lines for Ambient Tempera
3. REA4006 4 0 5 74 327 306 J15 6 20 or 40 REA4008 4 0 655 327 306 J15 8 20 or 40 REASOO6 5 0 5 74 3 27 306 J15 6 20 or 40 REASOO8 5 0 16 55 3 27 3 06 J15 8 20 or 40 REASO10 20 or 40 REASO12 20 or 40 REAG306 6 35 15 74 3 27 306 J15 6 20 or 40 REA6308 6 35 6 55 1321 306 J15 8 20 or 40 REA6310 20 or 40 REA6312 20 or 40 REA7006 7 0 5 74 3 27 3 06 15 6 20 or 40 REA7008 7 0 655 3 27 306 J15 8 20 or 40 REA7010 20 or 40 REA7012 20 or 40 REA8006 8 0 5 74 357 341 175 6 20 or 40 REA8008 8 0 655 357 341 175 8 20 or 40 REA8010 8 0 74 357 341 175 l0 20or40 REA8012 8 0 8 23 3 57 341 175 12 20 or 40 REA9006 90 574 357 341 175 6 20 or 40 REA9008 90 655 357 341 175 8 20 or 40 REA9010 90 74 357 341 175 l0 20 or 40 REA9012 9 0 8 23 357 341 175 12 20 or 40 REA10006 10 0 15 74 3 57 341 175 6 200r40 REA10008 10 0 6 55 3 57 341 175 8 Tab or 40 REA10010 20 or 40 REA10012 20 or 40 High Voltage DC Power Supply A high voltage DC power supply is required to provide the DC voltage to run the diode arrays in an REA Series module CEO will recommend a power supply based on the customer s application Closed Loop Re circulating Distilled Water Chiller Coolant flow direction is polarized on the REA Series pump module Inlet and Outlet hose barbs are marked on the pumphead Be sure to connect the coolant filter for the select
4. Circulate the cleaning solution through the system including the diode pump module for 40 minutes Drain the cleaning solution mixture from the chiller as detailed in steps 1 and 2 Northrop Grumman Corporation 39 REA Series User Manual Chapter 5 Maintenance 9 Refill and circulate distilled water for 5 minutes and drain Ensure that the cap of the chiller reservoir is loose or remove it completely to allow gas to escape from the system 10 Drain the chiller and dispose of the filter 11 Disconnect the chiller from the diode pump module and blow out water from the diode pump module coolant loop prior to refilling the chiller coolant reservoir 12 Reconnect the diode pump module coolant loop 13 Install new 5 micron filter into housing 14 Record cleaning date on sticker with a one month reminder to drain amp clean the system Affix sticker to chiller or cabinet 15 Refill the chiller reservoir with Optishield plus and distilled water coolant following the manufacturer s directions Run for 30 minutes with the cap loose to allow gas to escape from the system 16 Secure the reservoir cap It should have a 0 125 inch 3mm diameter hole in it to allow the cooling system to vent A hole should be drilled into the reservoir cap if one is not already present 17 Chiller ready to use Northrop Grumman Corporation 40 REA Series User Manual Chapter 6 Service At Northrop Grumman Aerospace Systems Cuttin
5. 1 2 Nd YAG Absorption Characteristics A single GaAlAs laser diode bar has a 2 nm FWHM distribution of output wavelengths However the process used in the manufacture of GaAlAs laser diodes results in a peak output wavelength for each diode that fits within a 10 nm distribution of wavelengths from 800 810 nm To match the diode output to an absorption peak of the laser medium diodes are selected with similar peak output wavelengths within the manufacturing range Temperature tuning is possible because GaAlAs diode characteristics are such that 0 25 nm of wavelength shift occurs for every 1 C change in temperature of the diode junction Cooling shortens the wavelength and heating lengthens it Figure 1 3 shows the percentage of pump light of different wavelengths absorbed by two passes through a 6 35 mm thick rod of 0 6 doped Nd YAG In CEO modules the laser diode center wavelength under normal operating conditions is near the absorption peak of the laser medium The operating temperature of closed loop chiller is carefully chosen to shift the diode temperature so that the wavelength matches the absorption peak The final test report included with each module indicates the optimum operation temperature for that module Northrop Grumman Corporation 2 REA Series User Manual Chapter 1 Introduction Modeled Pump Light Absorption vs Pump Array Center Wavelength c Spectral Width of Pump Array Ti nm fwhm lt m 2 fw 5 ae 4 n
6. Ban am gt eee TO REA INLET D Sona INLET cee a Geeta ear a COOLANT seat OPTISHIELD Plus KH x Pas dki CAPACITY 1 1 U S gallons Ya NPT Pad FROM REA to 3 8 3 8 reinforced oe wien 3 8 Female OUTLET barb Hose 8 ar Barb To eDrive a AAR l MD A Interlock ai 3 8 reinforced Hose 6 Figure 4 3 Chiller Assembly Drawing Closed Loop Water Chiller Assembly 1 Place the chiller on the floor near the REA Series laser module Refer to the chiller instruction manual for power requirements settings and instructions on how to set up the chiller 2 Attach the cooling lines included with the plumbing accessory kit to the hose barb fittings on the chiller and on the REA Series laser module Remember to attach the water filter between the chiller and the laser head The filter may be attached to the back of the chiller or to some other stable mounting point 1 e wall The standard plumbing arrangement for a typical closed loop chiller including hose diameters is shown in Figure 4 3 The input output coolant connections on the REA Series are polarized Coolant flow direction is important see Figure 1 1 for coolant inlet and outlet orientation for the REA Series module CAUTION Do not use de ionized DI water in the closed loop chiller based system If you must use DI water monitor the resistivity less than 1 0 MQ closely and avoid iron or aluminum parts in the coolant
7. No Aperture Label Label High Voltage each end Label Identifiaction amp Certification Label No User Servicable BeO Label Parts Within back side Label Void Label Figure 2 2 Radiation Control Drawing OTe aa pace Tochmadagy Cutting Edge Optronics Inc Cutting Edge Dpirarira 20 Point West Blvd St Charles MO 63301 PRODUCT MODEL NO AVOID EXPOSURE Wea following Patents Beryllium Oxide BeQ Alert This product contains BaO insulators BeO dusi can have HIGH VOLTAGE 5 913 108 toxic effects when inhaled Do not disassemble this unit Other US and Foriegn Patents Pending INVISIBLE LASER RADIATION IS EMITTED FROM THIS APERTURE This laser component does not include all of the safety features as required by CDAH It is sold solely to qualified manufacturers who in their end product will supply all interlocks indicators and will comply full with the provisions 21 CFA subchapter without appropriate training and precautions Figure 2 3 Warning Labels Safety Device Checklist 1 Verify that all labels are securely affixed 2 Verify that the safety interlock system is working properly Locate the module so that operation of laser and or adjustn electronics do not require exposure to laser radiation Northrop Grumman Corporation 11 REA Series User Manual Chapter 3 Module Details This chapter describes basic operation of your REA Series module This chapter di
8. a reverse protection diode This is another diode usually located in the module which forms a circuit across the laser diode arrays in the opposite flow direction Figure 3 1 In the event of the laser diode drive current being reversed the reverse bias protection diode will act like a short circuit allowing the electricity to flow for a brief time with no resistance However the reverse bias protection diode is not able to withstand the high currents that laser diodes require The protection diode will burn out after a brief time and the drive current will be sent through the laser diodes in reverse Northrop Grumman Corporation 14 REA Series User Manual REA Timer Chapter 3 Operation w Na ni N N i N ie NG a NS wS N N N NS N a if A D eal a NA a a a gd i Wd a a a ra PA Wa Wu Wi Reverse Protection Diode Terminals Figure 3 1 Reverse Bias Protection Diode Circuit NGAS CEO drive electronics are designed to detect the shorted reverse protection diode and suspend drive current before damaging the laser diodes Customers who use third party manufactured drive electronics must configure them for use with NGAS CEOs reverse bias protection diodes The driver should be able to detect the shorted condition because with a short across the array the full power supply voltage will suddenly be impressed across the driver control FETs For drivers which have a fixed power supply vol
9. amount of high power invisible laser radiation is emitted from the laser module Follow instructions contained in this manual for proper installation and safe operation of your laser We recommend the use of protective eyewear at all times selection depends on the energy and wavelength of the laser beam as well as operating conditions Consult ANSI ACGIH or OSHA standards for guidance WARNING Use of controls adjustments or performance of procedures other than those specified herein may result in hazardous radiation exposure WARNING At all times during installation operation maintenance or service of your laser avoid exposure to laser or collateral radiation exceeding the accessible emission limits listed in Performance Standards for Laser Products United States Code of Federal Regulations 21 CFR 1040 10 d ESD CAUTION The laser diodes in the REA Series are sensitive to Electro Static Discharge ESD Never handle the REA Series module without being properly grounded through the use of properly installed and maintained grounding wrist straps or other ESD control devices Subjecting the REA Series to static shock can seriously damage or destroy the diode bars and will void the product warranty ELECTRICAL WARNING The voltages in this system can be harmful or even lethal Whenever handling or servicing the laser always disconnect the power cord to the power supplies and drivers Use a voltmeter to verify all electronics are disc
10. eDrive shuts down Switch the main AC power switch on the external power supply located on the front panel to the OFF position Turn the AC power switch on rear of the eDrive to the OFF position Using a voltmeter verify voltage has discharged on module power lugs Allow chiller to run for a couple of minutes 1 2 minutes Switch the closed loop chiller to the OFF position Turn the key switch on the eDrive to the OFF position Remove the key Do not leave the laser accessible to people who are untrained in laser safety or operation WARNING Hazardous voltages are present in this system during normal operation Use a voltmeter to verify all electronics are discharged before touching or grounding of electrical connections Northrop Grumman Corporation 31 REA Series User Manual Chapter 5 Maintenance The chapter contains information in these sections Rod Removal and Replacement Rod Cleaning Leak Test Procedure Adjusting the Operating Current Cleaning the Chiller Northrop Grumman Corporation 32 REA Series User Manual Chapter 5 Maintenance Rod Removal and Replacement The only user serviceable part in the REA Series module is the Nd YAG rod which can be replaced by the user YAG rods rarely break frequent replacement may be a sign of another problem in the REA Series module Contact Cutting Edge Optronics if you have any further questions CAUTION The module is susceptible to damage due to electro sta
11. final test report delivered with the system During its early lifetime the laser diodes will deliver this specified power at or below 25 A of current for 1C2H modules or 45A for 1C4H modules Due to the high average powers of the diode bars used in your NGAS Cutting Edge Optronics laser module 1t is reasonable to expect the diode array to gradually degrade with use Determining when the current limit requires adjustment Make sure the temperature is at the correct set point If the temperature is incorrect low output power can result leading to unnecessary current increases Check to make sure the rod faces are clean If the rod faces are dirty low output power will result leading to unnecessary current increases Check to make sure the coolant and filter are clean If the coolant is dirty deposits accumulate on the Nd YAG rod which prevents absorption of diode light This results in low output power leading to unnecessary current increases If the temperature is correct and the rod faces and coolant are clean yet the output power is still low the operating current may need to be slightly raised Contact your NGAS Cutting Edge Optronics field service engineer if you have any doubts CAUTION Raising the current limit before it becomes necessary can severely shorten diode lifetime Adjusting the Temperature Set Point for the Re circulating Water Chiller The temperature set point for the water chiller was determined at NGAS CEO and i
12. loop 3 Fill the chiller reservoir and filter housing manually with coolant 10 Optishield PlusTM 90 distilled water It is made from DI water with additives to control the pH By using DI water in the solution scale will not form in the cooling loop It contains biocide to prevent algae growth and corrosion inhibitors Northrop Grumman Corporation 28 REA Series User Manual Chapter 4 Installation and Operation CAUTION Do not allow chiller to fill the filter housing as air can become trapped within the system 4 Power on the chiller Make sure no air remains trapped in the lines resulting in a positive back pressure when chiller is turned off Positive back pressure can hold the flow switch closed even though flow is not being supplied to the laser module Air is trapped in the lines if coolant level drops when chiller is turned on and then rises when turned off Failure to heed this warning may result in the destruction or serious damage to the device and will void the product warranty 6 Verify the pressure gauge located on the front panel of the chiller reads approximately 50 psi If it does not adjust the bypass valve on the rear of the chiller Minimum coolant flow is one gallon per minute See final test report for optimum flow rate which should be 2 gallons per minute 7 Verify the temperature located on the front panel of the chiller reads appropriately Optimum temperature is listed on the final test repo
13. number of hours the module has been operating If the number of hours exceeds 9999 then the display will scroll to the left to show the additional digits Second Readout Value The second value displayed in the sequence can be one of two values depending on the operating mode If the pump head is being operated in CW mode then the display will again report the number of operating hours If the module is being pulsed then the display will show the number of shots or pulses which the module has generated See the description below for an explanation of the meaning of the shot counter display Optional Third Readout Value The third value which is displayed is an optional value which is configured at the factory when the module is built Contact NGAS CEO for information about the values which can be selected If no value is selected this display value is skipped Northrop Grumman Corporation 17 REA Series User Manual Chapter 3 Operation and the display cycle starts over Typically the module will be programmed to display the on off cycle count in this third position After displaying all of these values the cycle will repeat with the display of the sequence start indicator Shot Count Display The shot counter display is capable of displaying a very large number of shots with 3 significant figures The first 3 digits of the shot count represent the first 3 digits of the number of shots The fourth digit represents the number of
14. risk to the laser diodes is minimized WARNING Do not operate the coolant system below air condensation temperature dew point at the laser head Condensation on the diode arrays can seriously damage the laser head and will void the warranty Consult a Cutting Edge Optronics field service engineer if you have any questions Air Condensation Temperature The air condensation temperature or dew point is the highest surface temperature that allows water to form from the ambient water vapor The dew point is dependent Northrop Grumman Corporation 20 REA Series User Manual Chapter 3 Operation on the surrounding air temperature and relative humidity If a surface such asa laser diode is cooled at or below the condensation temperature water may collect on that surface A formula for calculating dew point is given below along with a calculated table All temperatures are given in Celsius Condensation Temperature d _ 237 1xa T RH a T RH 17 27xT 22 17 27 a T RH 237 7 T 100 where T is the ambient air temperature in degrees Celsius 0 lt T lt 60 RH is the relative humidity in percent 1 lt RH lt 100 Ta is the air condensation temperature For example suppose your chiller is running at 22 C and the ambient air temperature near the laser is 28 C 82 F Referring to Figure 3 3 and Table 3 3 find the intersection of the 28 C air temperature and the curve for the 22 C diode temperatu
15. the end faces 6 Obtain two 007 white Viton O rings when using a 4mm diameter rod two 008 white Viton O rings when using a 5mm diameter rod or two 010 white Viton O rings when using a 6 35mm diameter rod 7 Place one of the corresponding O rings over one end of the rod Position the O ring inside the O ring groove on the end plate 8 Insert the opposite end of the rod into the corresponding hole in one end of the module until it protrudes from the hole in the opposite end Center the rod The rod is very fragile Be careful not to chip or scratch the rod while inserting it 9 Place one of the retainer caps over the end of the rod with the O ring Attach via the hardware removed during disassembly 10 Place the second white O ring over the opposite end of the rod Slide O ring along rod into O ring groove in endplate 11 Inspect this rod end for cleanliness If needed clean the end of the rod with methanol and cotton swabs 12 Attach the second retainer cap onto the pump module 13 Position the rod equidistant from each end of the pump module using the soft end of a cotton swab 14 Reinstall Macor shields Ensure that the gap is minimal between Macor shield and laser rod The Macor shields protect the retainer nut and O rings from stray laser radiation 15 Inspect both rod ends for cleanliness If necessary clean the ends of the rod with a puff of dry nitrogen or moisture free canned air 16 Leak test according to
16. 9006 REA9008 REA9010 REA9012 Table 1 3 REA Series Model Specifications Power Consumption i Bars per Watts Diode Bias Array per Bar Voltage 20 Watt bar 6 20or40 60 1920 3000 8 20or40 80 2560 4000 6 20or40 60 1920 3000 8 20or40 80 2560 14000 5000 6000 6 20or40 60 1920 3000 8 20or40 80 2560 4000 5000 6000 6 20or40 60 1920 3000 8 20or40 80 2560 4000 5000 6000 6 20or40 60 1920 30000 8 20or40 80 2560 4000 5000 6000 6 20or40 60 1920 3000 8 20or40 80 2560 4000 5000 6000 REA10006 6 200r40 60 1920 3000 REA10008 8 20or40 80 2560 4000 REA 10010 5000 REA 10012 6000 Northrop Grumman Corporation 6 Specifications subject to change without notice At end of life operating current is 32A for 1C2H and 50A for 1C4H Power Consumption 2 40 Watt bar REA Series User Manual Chapter 1 Introduction Table 1 4 REA Series General Specifications All REA Series Models Type CW Diode Pumped Nd YAG Rod Dopant Level Application Dependent Output Wavelength 1064 nm Polarization Random Cooling Closed Loop Recycling Coolant Coolant Flow gt 2 0 GPM Coolant Pressure 50 PSI Operating Temperature 20 30 C non condensing The Continuous wave diode arrays are sensitive to excessive thermal cycling Current should not be turned off completely and then restored to full operating current more than 6 times per day Current should be gradually 1A s ramp
17. Untreated tap water is not an acceptable coolant and may cause damage Optishield PlusTM is the recommended coolant It is made from DI water with additives to control the pH By using DI water in the solution scale will not form in the cooling loop It contains biocide to prevent algae growth and corrosion inhibitors to protect yellow metals and aluminum Optishield Plus is available from Opti Temp Inc http www optishield net home php cat 103 The filter should be capable of removing particles 5 um or larger 4 Every month or whenever the filter is changed the coolant should be drained The chiller should then be cleaned The filter should be changed more frequently if the chiller manufacturer recommends a shorter interval This ensures the cleanest coolest coolant passes through the diodes the most expensive component of most lasers When not using CEO drive electronics verify that flow sensor interrupts current to diodes less than 500 milliseconds after a low flow condition occurs Northrop Grumman Corporation 19 REA Series User Manual Chapter 3 Operation Table 3 2 Avoid with Chillers Avoid with Chillers Untreated De ionized water lron or aluminum parts in plumbing loop Operation below air condensation temperature CEO recommends chiller water have a resistivity of less than 1 0 MQ Deionized water can be used if the resistivity is closely monitored and the coolant loop does not have iron or alumi
18. al test report for initial recommended operating current This ramping process reduces thermal shock and helps prolong diode lifetime If the REA module is going to be installed in a system where quick transitions between lasing and non lasing are repeatedly required then drive current to the diodes should be maintained at 3 A below normal operating current when the system is not lasing This simmer current will keep the diodes at close to the operating lasing temperature and thereby reduce thermal shock The diode arrays within the REA Series module are aligned and sealed at the factory Other than the laser rod there are no user serviceable parts within the module Contact a NGAS CEO field service engineer for repairs Before lasing the operator should verify that rod faces are clean If necessary the rod faces can be cleaned by following the procedure in the maintenance section of this manual Reverse Bias Protection Diodes are polarized with respect to electrical flow A forward biased diode readily conducts while a reverse biased diode blocks conduction If sufficient voltage is applied in the reverse direction the diode is permanently damaged Laser diodes are the single most expensive component of a REA Series module so the customer should be careful to connect diode drive current correctly In order to provide the REA Series modules with some protection against reverse biasing all REA Series modules are equipped with
19. alth PRF Pulse Repetition Frequency PSI Pounds per Square Inch SHG Second Harmonic Generator TTL Transistor Transistor Logic VAC Volts Alternating Current Northrop Grumman Corporation 48 REA Series User Manual
20. ay a 4 digit software revision number This number will be underlined and the digits are decoded as follows Digit 1 Major Revision Level Digit 2 Minor Revision Level Digits 3 4 Build Number An example is shown below Version 1 0 25 Build Number 25 Minor Revision Level 0 Major Revision Level 1 Northrop Grumman Corporation 16 REA Series User Manual Chapter 3 Operation After 2 3 seconds the display will then display the number of power on off cycles which have occurred and the underline will be turned off This count is not the number of shots or pulses which have been generated by the module but instead 1s the number of times the module has gone from an inactive state to an active state This number is incremented each time the timer goes through its startup routines After a short delay the timer will transition to a repeating operational display mode This 1s described below Operational Display In this mode the timer displays a sequence start indicator followed by up to three timer values depending on the operating mode and the configuration which was applied at the factory These are described below Sequence Start Indicator In order to indicate the beginning of the display sequence the timer displays the Sequence Start Indicator The display briefly shows the following readout First Readout Value The next value displayed is the module hour counter This displays the
21. d skin ignite fires and vaporize substances The Laser Safety section Chapter 2 contains information and guidance about these hazards To minimize the risk of injury or expensive repairs carefully follow these instructions Do not open the factory packaging before carefully reading this complete operation and maintenance manual If you have any questions on the product which have not been discussed sufficiently within the manual contact the manufacturer for complete instructions Failure to heed this warning may result in the destruction or serious damage to the device and will void the product warranty The Service section is intended to help guide you to the source of problems Do not attempt repairs while the unit is under warranty instead report all problems to Northrop Grumman Aerospace Systems Cutting Edge Optronics NGAS CEO for warranty repair Use the form in Appendix A Customer Service to describe issues with the module We also suggest that you record information about the module such as power settings time and date Northrop Grumman Corporation vii REA Series User Manual About this Manual This manual describes the installation operation and service of the REA Series module The manual consists of the following chapters Chapter I Introduction provides a theory of operation description of the module and specifications Chapter 2 Laser Safety describes proper safety procedures you should understand b
22. e frequency force energy power electric current electric charge electric potential resistance inductance magnetic flux magnetic flux density luminous intensity temperature gram meter second Hertz Newton Joule Waitt Ampere Coulomb Volt ohm Henry Weber Tesla candela Kelvin Northrop Grumman Corporation 46 Prefixes REA Series User Manual Appendix C Acronyms Appendix C Acronyms ACGIH ANSI AR AO CDRH CEO CFR CW DC EO ESD FET FDA FWHM GaAlAs GPM HR HV IR KTP LBO MCC Nd YAG NGAS NIR Northrop Grumman Corporation Description American Council of Government Industrial Hygienists American National Standards Institute Anti Reflective Acusto Optical type of Q switch Center for Devices and Radiological Health U S Food and Drug Administration Cutting Edge Optronics Incorporated Code of Federal Regulations Continuous Wave Direct Current Electro Optical type of Q switch Electro Static Discharge Field Effect Transistor U S Food and Drug Administration Full Width Half Max Gallium Aluminum Arsenide Gallons Per Minute High Reflector High Voltage Infrared Potassium Titanyl Phosphate Lithium Triborate Meters Concave Neodymium doped Yttrium Aluminum Garnet Northrop Grumman Aerospace Systems Near Infrared 47 REA Series User Manual Appendix C Acronyms Acronym Description OSHA E el ia and He
23. ed chiller on the Inlet connection so only clean coolant from the filter flows through the pumphead Dirty coolant deposits dirt on the laser rod which results in low output power Northrop Grumman Corporation 4 REA Series User Manual Chapter 1 Introduction The module coolant loop is designed for an operating pressure of 50 psi The selected chiller must have a heat capacity of greater than the power consumption for the specific model of REA Series module Table 1 2 gives the CEO end of life operating current and power consumption waste heat Table 1 2 End of life Waste Heat 60 Hz Electrical Outlets Current Heat Capacity 1C2H 1C4H 1C2H 1C4H 1C2H 1C4H 1C2H 1C4H CEO 50 Hz Electrical Outlets Current Heat Capacity 1C2H 1C4H 1C2H 1C4H 1C2H REAXX10 50A 5000W Contact CEO Contact 1C4H CEO 1C2H REAXX 12 Contact CEO Contact 1C4H CEO Northrop Grumman Corporation 5 REA Series User Manual Chapter 1 Introduction Specifications REA Series modules are tested to exceed the following specifications The standard production test configuration consists of a 280 5 mm cavity utilizing a flat high reflector and a flat 70 reflective output coupler The modules are run at normal drive current of 25 A for 1C2H and 40 A for 1C4H Model Number REA4006 REA4008 REAS5006 REAS5008 REA5010 REA5012 REA6306 REA6308 REA6310 REA6312 REA7006 REA7008 REA7010 REA7012 REA8006 REA8008 REA8010 REA8012 REA
24. ed up when operating current restored See chapter 3 for more details CEO recommends Optishield Plusu distilled water coolant 10 Optishield Plusty 90 distilled water CEO modules are leak tested to 80 psi with Nitrogen gas CEO recommends 50 psi of chiller water for actual operation YLF configurations are available by special request Northrop Grumman Corporation 7 REA Series User Manual Chapter 2 Laser Safety Please read this section carefully before installing or operating your REA Series module We recommend that all service and repair operations be performed by a NGAS Cutting Edge Optronics service engineer If you do plan to service your laser module please follow the procedures in the Service section of this manual Sections included in this chapter provide the following information Caution amp Warning Statements Precautions for Safe Operation of Class IV Lasers Center for Devices and Radiological Health CDRH OEM Product Safety Device Checklist Northrop Grumman Corporation 8 REA Series User Manual Chapter 2 Laser Safety Caution amp Warning Statements gt be gt WARNING The NGAS Cutting Edge Optronics REA Series component when used as a laser oscillator is a Class IV High Power Laser whose beam is by definition a safety hazard Avoid eye or skin exposure to direct or scattered laser radiation Avoid direct viewing of the beam or its specular reflection When energized a large
25. efore operating the module Chapter 3 Module Details provides information about unpacking storing and proper environmental conditions for operation Chapter 4 Installation and Operation discusses how to setup your module and powering on your system for the first time Chapter 5 Maintenance provides information on proper maintenance of your module Chapter 6 Service provides resources to help fix problems with the REA Series module Appendix A Customer Service provides information to expedite any service request before contacting Cutting Edge Optronics Appendix B System International Units identifies commonly used units of measurement found in this manual Appendix C Acronyms provides a list of commonly used abbreviations and their descriptions used throughout this manual Northrop Grumman Corporation viii REA Series User Manual Table of Contents Chapter 1 Introduction 1 Theory of Operation 1 Temperature Tuning of Laser Diodes 2 REA Series Description 3 High Voltage DC Power Supply 4 Closed Loop Re circulating Distilled Water Chiller 4 Specifications 6 Chapter 2 Laser Safety 8 Caution amp Warning Statements 9 Precautions for Safe Operation of Class IV Lasers 9 Center for Devices and Radiological Health CDRH OEM Product 10 Safety Device Checklist 11 Chapter 3 Module Details 12 Unpacking your Module 13 REA Series Module 13 REA Timer 15 Closed Loop Chiller 19 High Voltage DC Power Supply 23
26. em should be monitored weekly The system should also be drained cleaned and refilled with clean coolant if any discoloration of the filter occurs Chemicals and Supplies Needed Cleaning Procedure 1 3 Hydrogen Peroxide solution sufficient to fill the system Optishield Plus and distilled water solution 10 Optishield Plus 90 distilled water Distilled water sufficient to fill the system Two replacement particle filters NGCEO part 37023165 Drain chiller and clean any residue or contamination in the reservoir with the use of a bottle brush or alcohol wipes Using a filter housing wrench dismantle the particle filter housing Empty the coolant trapped in the filter housing into a container for later disposal Dispose of the expired particle filter and clean any residue or contamination from the inside of the filter housing Install a new filter in the housing Refill with distilled water and circulate for 5 minutes 5 Drain system completely as detailed in steps 1 and 2 Fill the chiller with a 3 solution of Hydrogen Peroxide Care should be taken to ensure that the mixture completely fills to the top of the reservoir to ensure all wetted surface areas of the chillers are cleaned Cycle the chiller on and off Top off the reservoir as necessary to ensure it is full of the cleaning solution Ensure that the cap of the chiller reservoir is loose or remove it completely to allow gas to escape from the system
27. eries User Manual Chapter 3 Operation The chosen power supply should be capable of providing the end of life current mentioned in the specifications table 1 2 The power supply must also be capable of providing the voltage listed in table 1 3 with an additional 2 volts for FET turn on CEO Drivers can tolerate a large amount of ripple since the pass FET typically filters this out However ripple should not exceed 0 5 volt at full output current WARNING Hazardous voltages are present during normal operation Before removing the cover the power source should be disconnected and a period of 20 minutes allowed for the discharge of stored capacitance Use a voltmeter to verify all electronics are discharged before touching or grounding of electrical connections Northrop Grumman Corporation 24 REA Series User Manual Chapter 4 Installation and Operation NGAS CEO recommends using the eDrive diode drive electronics an external power supply and a Polyscience chiller to operate the REA Series module see Chapter for chiller capacities The following chapter contains step by step procedures detailing the installation and operation of the REA Series module with these peripherals This chapter covers REA Series Laser Module Assembly and Connections Closed Loop Water Chiller Assembly Starting the Laser System Pre start Conditions Turning on the Laser System Powering the REA Series Module Standby Condit
28. g Edge Optronics we are proud of the durability of our products Our manufacturing and quality control processes emphasize consistency ruggedness and high performance Nevertheless even the finest instruments break down occasionally We believe that the reliability record of our instruments compares favorably with that of our competition and we hope to demonstrate our superior service by providing dependable instruments and if the need arises service facilities that can restore your instrument to peak performance without delay When calling for service in the U S dial 636 916 4900 To phone for service in other countries contact your sales agent This chapter provides reference to types of customer service needs Contacting customer service Return the instrument for repair Northrop Grumman Corporation 41 REA Series User Manual Chapter 6 Service Contacting Customer Service To expedite your service needs please complete the questionnaire in Appendix A Customer Service before you contact Cutting Edge Optronics Customer Service Complete the questionnaire with as much detail as possible and retain a copy for your records E mail or fax the form to Cutting Edge Optronics refer to the second page of this manual for contact information and notify your customer service representative that it has been sent Return the Instrument for Repair A return merchandise authorization RMA is required prior to shipping any i
29. harged before touching or grounding of electrical connections Precautions for Safe Operation of Class IV Lasers Never look directly into the laser beam or at specular reflection even with protective eye wear on Always wear laser safety eye wear that is appropriate for the output power at the wavelengths of operation 808 nm pump light and 1064 nm fundamental Set aside a controlled access area for laser operation limit access to those trained in the principles of laser safety Post readily readable warning signs in prominent locations near the laser operation area Northrop Grumman Corporation 9 REA Series User Manual Chapter 2 Laser Safety Use safety interlocks on all entryways All NGAS CEO system control electronics are provided with interlock inputs to preclude operation with an open safety door NOTE when multiple interlocks are used they must be connected in SERIES for proper function Restrict access to laser areas to those who have been instructed in the necessary safety precautions Enclose beam paths wherever possible Set up experiments so the laser beam is below eye level Work in an area that is well lit to avoid dilation of pupils Set up a target for the beam Set up shields to prevent reflected beams from escaping the laser operation area The Q switched output power of the laser emits extremely high peak optical powers powers that can severely damage a wide array of optical compone
30. initial use See final test report for current Using an infrared viewer or phosphor card continue increasing the current checking for output at the laser threshold current indicated on the final test report Continue increasing the current until the desired output is obtained or until the current reaches approximately 5 A greater than the current used during the last time an acceptable laser output was achieved For initial use see final test report for current If you cannot achieve desired output within 5 A contact NGAS CEO for assistance Northrop Grumman Corporation 30 REA Series User Manual Chapter 4 Installation and Operation Standby Condition If you are finished using the module but want to use it again within the next hour it is best to go to standby To go to standby from a lasing condition press the EMISSION button on the eDrive Laser Controller In this condition the drive current to the laser diode shuts off but the closed loop chiller maintains the optimum diode temperature To resume lasing press the EMISSION button on the eDrive laser controller Again an audible warning will sound for approximately 4 seconds prior to firing the laser Turning Off the System 1 2 o as SS A 10 Press the EMISSION button to turn off drive current Close shutter if installed Press the main AC POWER switch of the eDrive located on the front panel Hold down for approximately 5 seconds until the
31. ion Turning Off the System The purchaser is responsible for any loss and injury during installation and use of the REA Series module NGAS CEO recommends that a qualified service technician install and maintain the laser If you intend to service the laser yourself please follow the following procedures Northrop Grumman Corporation 25 REA Series User Manual Chapter 4 Installation and Operation REA Series Laser Module Assembly and Connections CAUTION The module is susceptible to damage due to electro static discharge ESD Always use proper ESD control devices when handling the module See Module Connection Diagram figure 4 1 1 3 Check to make sure the AC power switch located on the rear panel of the eDrive Laser Diode Controller is in the OFF position Connect the Array Drive lugs from the rear of the eDrive to the power lugs on the side of the REA module Positive to positive and negative to negative ELECTRICAL WARNING The voltages in this system can be harmful or even lethal Whenever handling or servicing the laser always disconnect the power cord to the power supplies and drivers Use a voltmeter to verify all electronics are discharged before touching or grounding of electrical connections Connect the lab door interlock switch or other interlock used to the Interlock connector on the rear of the eDrive If multiple interlocks are needed be sure all interlocks are connected in SERIES to this po
32. m fwhm all a E 3 a E 6 35 mm z diameter rod 0 6 Nd YAG 2 pass absorption 790 795 800 805 810 815 820 Pump Array Center Wavelength nm Figure 1 3 Pump Light Absorption vs Pump Array Center Wavelength REA Series Description The REA Series module utilizes a radial longitudinal pump geometry to excite the solid state laser medium see Figure 1 4 This pump geometry results in excellent gain uniformity and lensing performance The reflector directs the divergent diode light back to the laser medium which is kept in a flow tube for coolant circulation The laser medium is a rod of neodymium doped yttrium aluminum garnet Nd YAG Both ends of the rod are optically polished and include anti reflection coatings at the lasing wavelength The ends of the rod may be curved to compensate for thermal lensing depending on module configuration 57 Diode Heat Exchanger i Diode Bar Weary ik Nd YAG Rod wi i ai Flow Tube i i x Wee SSL PEO ha OO C T 2 W May po A A Figure 1 4 Radial Pump Geometry The REA comes in various physical configurations per table 1 1 In addition each of the models listed consists of 5 arrays per module Northrop Grumman Corporation 3 REA Series User Manual Chapter 1 Introduction Table 1 1 REA Physical Configuration Model Rod Length Width Height Beam Bars per Watts Number Diameter Inches Inches Inches Height Array per Bar mm Inches
33. mpany or Institution Department Address Module Model Number Serial Number Chiller Model Number Serial Number External Power Supply Model Number Serial Number eDrive Model Number Serial Number Module Manufacture Date Total Module Lifetime hours Northrop Grumman Corporation 43 REA Series User Manual Appendix A Customer Service Questions What is the coolant flow rate GPM What is the set temperature on the chiller C What is the coolant pressure on chiller PSI What are the set current and actual current from eDrive A What is the external power supply voltage V What is the laser cavity configuration What is the measured CW power W When did the problem happen Have you changed any settings recently yes no Northrop Grumman Corporation 44 REA Series User Manual Appendix A Customer Service What are the changes made recently to the system Please describe the problem or module behavior as detailed as possible Suggestions Email or send to Northrop Grumman Cutting Edge Optronics Inc 20 Point West Boulevard Saint Charles MO 63301 USA Phone 636 916 4900 FAX 636 916 4994 Email st ceolaser info ngc com Northrop Grumman Corporation 45 REA Series User Manual Appendix B System International Units The following System International SI units abbreviations and prefixes are used throughout Cutting Edge Optronics user manuals Quantity mass length tim
34. nd on the endplate 13 Holding the insert up against the hose barbed endplate so it is flat and level place a gloved fingertip over the rod to keep it from being pushed out in step 14 14 With one hand held as stated in step 13 use the other hand to push the second insert onto the exposed rod end making sure the white o ring is not damaged as the rod passes through the center bore of the insert and the 28 black o ring faces the endplate 15 Once the inserts are pushed safely onto the rod ends they should lay flush with each of their endplates of the module with the 28 black o rings as the seal between the two pieces 16 Fasten each of the two inserts to their endplates with five 4 sized 3 8 SHC Screws and one 4 sized 3 8 BHC Screw that goes in the slotted hole shown in Figure 5 3 of each insert 17 Clean the rod ends at 50x with canned air and methanol soaked q tips 18 Reattach the Macor shields 19 Double check the rod ends with a microscope after the Macor shields are in place to ensure the rod ends are still clean Then replace the beam tube supports Northrop Grumman Corporation 36 REA Series User Manual Chapter 5 Maintenance Rod Cleaning CAUTION Ensure gloves or finger cots are worn during this procedure and that it is carried out in a clean environment preferably under a laminar flow hood 1 Blow optical surface with dry nitrogen 2 Remove four fasteners releasing Macor shields Using hemostat
35. ndicated on the Final Test Report Normally the temperature will not need adjustment It is possible however that this adjustment may be recommended by your Cutting Edge Optronics field service engineer during the later part of the laser diodes lifetime and after several current increases Increasing the diode drive current increases the heat load on the diode resulting in a shift in diode wavelength In order to compensate for this shift a slight adjustment most likely colder of the temperature set point on the recirculation water chiller may be required Changing the temperature set point will change the output wavelength of the laser diode this adjustment should be done in one degree Celsius increments Look for an increase in optical output power on an external power meter Wait a few minutes between each adjustment allowing the chiller to stabilize Continue until you obtain the maximum possible power Northrop Grumman Corporation 38 REA Series User Manual Chapter 5 Maintenance WARNING Do not operate coolant system below air condensation temperature dew point at laser head Condensation on the diode arrays can seriously damage the laser head and may void warranty Consult a CEO field service engineer if you have any questions Cleaning the Chiller The cooling fluid should run for a maximum period of month after which the system should be drained cleaned and refilled with clean coolant The filter on the closed loop syst
36. nstruments to Cutting Edge Optronics Contact Cutting Edge Optronics or your local distributor for RMA and shipping instructions CAUTION Failure to obtain proper shipping instructions may result in damage to the instrument Use the packing boxes supplied by Cutting Edge Optronics to ship your instruments If shipping boxes have been lost or destroyed replacements are available for a nominal charge from Cutting Edge Optronics Remove all coolant from module by blowing dry air through it for 20 minutes prior to packaging for shipment Place a shorting connector across the electrical connector see example Figure 1 1 Place module in a sealed bag inside shipping container Place some form of desiccant in bag with module WARNING Damage from residual water due to condensation or expansion can be catastrophic to the diode arrays or laser rod if not dealt with properly Such damage is excluded from warranty coverage Northrop Grumman Corporation 42 REA Series User Manual Appendix A Customer Service This form has been provided to encourage you to tell us about any difficulties you may have experienced while using your Northrop Grumman Cutting Edge Optronics instruments or user manuals Call or write our customer service department to bring attention to problems that you may not have personally experienced We are always interested in improving our products and manuals and we appreciate all suggestions Date Name Co
37. nts and detectors Know the limits of your components before exposing them to the Q switched beam View an infrared laser beam with a protected image converter at an oblique angle reflecting from a diffuse surface Do not use phosphorus cards in the Q switched beam Ensure that all electrical connections are made in a safe manner Where possible position equipment so that electrical connections are shielded from accidental touch No smoking eating or drinking should be allowed in laser areas Never leave an operating laser unattended INVISIBLE LASER RADIATION AVOID EYE OR SKIN EXPOSURE TO DIRECT i OR SCATTERED RADIATION Wavelength Power 790 820nm 10W 1064nm 150W CLASS IV Figure 2 1 Standard Safety Warning Sign Center for Devices and Radiological Health CDRH OEM Product The REA Series module is considered a component according to the Food and Drug Administration Code of Federal Regulations Title 21 Section 1002 1 b for use in Northrop Grumman Corporation 10 REA Series User Manual Chapter 2 Laser Safety an end system and therefore does not fully comply with all the requirements of the Code of Federal Regulations for laser based systems The REA Series module is capable of emitting Class IV radiation and extreme care must be exercised in its installation and operation Only persons familiar with the safety precautions and practices in this manual should operate the laser product Patent
38. num parts Operating the Chiller WARNING Do not operate module without cooling Inadequate heat dissipation will seriously damage the laser diodes and will void warranty If you notice coolant in the immediate vicinity of the module shut the laser system down immediately Check to see if the coolant is coming from the module If so return the module for repair If not repair the source of the leak and allow the module to dry thoroughly before resuming operation The REA Series module has a coolant loop to prevent thermal damage to the laser diodes The diodes should be kept at approximately 20 35 C See the final test report for optimum temperature and flow rate settings Operating the laser diodes for even a short period of time less than second without coolant will cause permanent damage To help prevent this all NGAS CEO drive electronics are equipped with a coolant interlock This interlock interrupts drive current to the diodes when coolant flow rate drops below set point For this to function properly a flow sensor must be used in the coolant loop It is a good idea to test the function of the flow sensor before firing when first setting up the laser system This can be accomplished by setting the drive current to a very low level 1 A then attempting to fire the laser with the chiller off In case interlock does not function correctly be prepared to manually turn off laser By testing the interlock with a minimal current the
39. o supply the required amount for the application Turn the AC power switch on rear of the eDrive to the ON position Turn the Key switch to the ON position Press the main AC POWER switch of the eDrive located on the front panel Before applying current to diodes shut off chiller to verify that the Coolant Fault interlock comes on within 1 second Restart the chiller Select Clear and verify the error display is no longer present Powering the REA Series Module 1 From the eDrive main menu select Channel Setup gt Channel 1 gt Set Current Limit Use the selection knob to set your maximum current amplitude to a value considered safe for the intended module The eDrive will not allow the current amplitude to be set higher than the limit REA 1C2H modules should never be run with more than 32 Amps and REA 1C4H should never be run at more than 50 A However to prevent premature diode degradation you may wish to set this limit at the beginning of module life to 5 Amps greater than the recommended operating current From the main menu select Channel Setup gt Channel 1 gt Set Current Use the selector knob to select a low current level of approximately 10A Press EMISSION After a few warning beeps approximately 4 second delay the eDrive begins to drive current to the module Slowly begin to adjust the current amplitude setting until the desired current level is achieved Rate increase in current should not exceed 3A s For
40. re At a relative humidity of 70 percent or greater condensation will form on the laser diodes Northrop Grumman Corporation 21 REA Series User Manual Chapter 3 Operation Constant Dew Point Lines for Ambient Temperature and Relative Humidity 12 C 16 C 70 C 24 C 28 oC 100 Relative Humidity 10 13 16 19 22 25 28 31 34 37 40 Temperature C Figure 3 3 Constant Dew Point Lines for Ambient Temperature and Relative Humidity Northrop Grumman Corporation 22 REA Series User Manual Chapter 3 Operation Table 3 3 Table of Air Condensation Temperature at Given Ambient Air Temperature Celcius and Relative Humidity percent Relative Humidity O NO O Oo 2 NO 2 N 2 Oo 3 If required to operate a laser in conditions near to the condensation temperature take precautions to keep the REA Series module dry The module should be operated inside an area that is purged with nitrogen No or encased in a sealed enclosure with a desiccant 4 High Voltage DC Power Supply The REA Series requires a high voltage DC power supply to provide electricity to the laser diodes The chosen power supply should be regulated Unregulated supplies tend to either drop below the minimum voltage required to maintain regulation or to sit at an unnecessarily high voltage at lower currents causing FET overheating Northrop Grumman Corporation 23 REA S
41. rn of our products for disposal When you are ready to reclaim the instrument you must properly transfer it according to local regulations concerning WEEE equipment Contact Cutting Edge Optronics or your local distributor for shipping instructions Please package the products as directed for a return for repair ROC ROHS Declaration In accordance with the Clause 6 2 of Marking for Control of Pollution Caused by Electronic Information Products SJ T11364 2006 for Measures for the Administration on Pollution Control of Electronic Information Products No 39 Order of the Ministry of Information Industry of the Peoples Republic of China Cutting Edge Optronics includes the following translation about our laser modules HELENE FAS SEE PE BRER Emi Northrop Grumman Cutting Edge Optronics difa ELE d 20 Pointe West Bivd St Charles MO 83301 USA hEN y Mirus Series Laser Systems Modals Mi xxx xxx xxxx amd AMIKEK KEN KANEKA ARASMARE RAR ABASRARLH o x mri SAEF Sm TH att EPAR Pb Hg Cd CrV PRB Pane ma ENE x if o a SM oF HEM X BAN Tema 0 HEH Bik x WANA PAS o WAH li 0 Mi m at Se BERS x aan eer eee a s 0 X Bria ROH Lo o o o o 0 0 PEAN KLELET UGI TT SJ T 11363 2006 MFM RLF X PANGGON eH eM aL S T 11363 2006 HAD R Northrop Grumman Corporation IV REA Series User Manual Conventions The following convention
42. rom its packaging and inspect end faces under 50X magnification Inspect rod o rings in the center of the inserts if no damage is found reuse the original o rings but if damage is found obtain two 10 white o rings if using a 6 35mm diameter rod two 8 white o rings if using a 5mm wide rod or two 7 white o rings if using a 4mm wide rod and replace the original o rings 8 Each insert has one large o ring groove on the surface near the edge of the insert this is the inside surface of the insert Figure 5 3 shows correct installation of the 28 black o ring into this groove 9 Lubricate both white o rings in the center of the inserts and both 28 black o rings with the syringe of methanol Northrop Grumman Corporation 35 REA Series User Manual Chapter 5 Maintenance 10 Place a 15 black medium o ring in the matching groove on the right endplate of the module as shown in Figure 5 3 that has the two hose barbs and then lubricate with the methanol syringe Figure 5 3 REA XXXX 002X O rings 11 Push the rod through the white o ring in the center bore of one insert from the inside surface side of the insert until it sticks past and out the other side about 1 8 making sure not to shave or cut the white o ring 12 Holding the rod with one insert on it carefully slide the end without the insert in to the center bore of the hose barbed end plate until the rod comes out the other end of the module being careful not to hit the rod e
43. rt If no remote interlocks are used short the connection to allow for normal laser operation Prior to connecting an external power supply check to make sure the AC power switch of the external power supply is in the OFF O position Then connect the output of the supply to the input power lugs of the eDrive located at the upper left of the rear panel Verify the eDrive has clear space in rear and on each side of unit to allow proper air flow Verify shroud over eDrive power lugs is in place to prevent human access to dangerous voltage Plug the eDrive and external power supply cords into the appropriate facility power Northrop Grumman Corporation 26 REA Series User Manual Chapter 4 Installation and Operation Host Computer Used only if optional external computer control is implemented RS XXX or CAN BUS External Power Laser Facility Power or Power m Input Power Array Output M eDrive Chiller Flow Switch fo Chiller Figure 4 1 Connection Diagram Power Supply Array Drive AC Power Remote Input Terminals Output Terminals Input Interlock 3202000200000000 Figure 4 2 eDrive Rear Panel Northrop Grumman Corporation 27 REA Series User Manual Chapter 4 Installation and Operation NPT 34 NPT 34 NPT to 3 8 to 3 8 to 3 8 CHILLER barb Tee barb Ba se ba a OUTLET mrs
44. rt but will be between 20 C 35 C 8 Connect coolant flow switch to coolant interlock on rear of eDrive diode driver When connecting the coolant flow switch make sure that it is connected to the return line of the chiller and the arrow located on the top of the switch is pointing in the direction of coolant flow Starting the Laser System Pre start Conditions 1 Wear laser safety goggles which protect user from1064 nm fundamental and 808 nm radiation 2 Position the REA Series module in a laser cavity such the output will be directed toward a safe target Verify that the system is correctly assembled 4 Verify that the rod faces are clean and not capped or covered Verify that the filter on the closed loop chiller is connected to the inlet hose barb 6 Switch the Closed Loop Chiller to the ON position Verify coolant flow from chiller WARNING Do not operate coolant system below air condensation temperature dew point at laser head Condensation on the diode arrays can seriously damage the laser head and may void warranty Consult a CEO field service engineer if you have any questions Northrop Grumman Corporation 29 REA Series User Manual Chapter 4 Installation and Operation Turning The Laser System On DH a ED Verify coolant temperature and flow rate are correct Turn power switch on external power supply to ON position Set the voltage to the voltage shown on the data sheet and set the current t
45. s and lens tissue wetted with acetone or methanol wipe the rod face in a circular motion from the center of the rod to the edges 4 Inspect the rod for cleanliness Reinstall Macor shields Ensure that the gap is minimal between Macor shield and laser rod The Macor shields protect the retainer nut and O rings from stray laser radiation Leak Test Procedure Laser diodes are very sensitive to water damage If you have access to pressurized nitrogen and a pressure gage you can test for leaks without exposing the diodes to water 1 Attach a nitrogen source to one of the coolant ports on the module being tested test article and attach the termination valve to the other coolant port on the test article 2 Close the termination valve Open the inlet valve and adjust the regulator to obtain 80 psi on the pressure gauge 4 Close the inlet valve Wait Return after 30 minutes and record pressure on the gauge Subtract this pressure from starting pressure of 80 psi to get the pressure drop over 30 minutes 6 Pass Fail requirements if the pressure drop is greater than 3 psi FAIL if the pressure drop is less than 3 psi PASS Test Article Water Ports Pressure Nitrogen Gauge Source Northrop Grumman Corporation 37 REA Series User Manual Chapter 5 Maintenance Figure 5 4 Nitrogen Leak Test Layout Adjusting the Operating Current The specification for laser module optical output is provided in the
46. s appear in this manual This icon denotes a caution or a warning which advise you of precautions to take to avoid injury data loss or a system crash Initial Capped The first letter in uppercase refers to menu options e g Phase Delay Pulse Width CAPS Front panel buttons knobs and connectors appear in all uppercase letters e g MENU CURRENT gt The gt symbol separates a sequence of button pushes e g MENU gt CHANNEL SETUP gt PULSE WIDTH means that you push the MENU button then push the CHANNEL SETUP soft key and then push the PULSE WIDTH soft key italic Italic text denotes references to other resources that may be helpful to you or to bring attention to important information This icon denotes a note which alerts you to important information Power Switch Position Symbols O I 0n O Off The following conventions may appear on the product DANGER An injury hazard immediately accessible as you read the marking WARNING A hazard not immediately accessible as you read the marking CAUTION A hazard to property including the product ESD Handle Appropriately Northrop Grumman Corporation V REA Series User Manual Laser Emission Use caution Shock Hazard Use caution Caution Risk of danger Refer to manual Chassis Ground Northrop Grumman Corporation vi REA Series User Manual General Safety Summary The REA Series module emits laser radiation that can permanently damage eyes an
47. scusses Unpacking your Module REA Series Module REA Timer Closed Loop Chiller High Voltage DC Power Supply Northrop Grumman Corporation 12 REA Series User Manual Chapter 3 Operation Unpacking your Module Your NGAS Cutting Edge Optronics Model REA Series module was carefully packed for shipment If the carton appears to have been damaged in transit have the shipper s agent present when you unpack CAUTION The module is susceptible to damage due to electro static discharge ESD Always use proper ESD control devices when handling the module CAUTION Do not open sealed package until package has normalized to room temperature Condensation can seriously damage the diode arrays in the laser module and may void warranty Inspect the unit as you unpack it looking for dents scratches or other evidence of damage If you discover any damage immediately file a claim against the carrier and notify your NGAS CEO representative NGAS CEO will arrange for repair without waiting for settlement of your claim Keep the shipping container If you file a damage claim you may need it to demonstrate that the damage occurred as a result of shipping If you need to return the unit for service the specially designed carton assures adequate protection A manual and a final test report should accompany each unit shipped REA Series Module Proper storage of the REA Series module involves four steps 1 Remove all coolan
48. t from module by blowing dry air through it for 20 minutes 2 Place a shorting connector across the module electrical contacts 3 Install rod end covers over both beam tube supports 4 Store module in a clean dry atmosphere relative humidity less than 30 If necessary place module in a sealed bag with some form of desiccant The approximate diode bias voltage for the different models of REA Series module can be found in the Specifications table at the end of chapter one The electrical system should deliver approximately 10 more volts depending on the FET used The final test report shipped with the REA Series module indicates the beginning of life current required to obtain the module s rated output power in a short cavity test NGAS CEO recommends users not exceed the listed current as overdriving the module reduces diode lifetime Northrop Grumman Corporation 13 REA Series User Manual Chapter 3 Operation The REA Series module connects to a diode driver in via power lugs on the base of the pumphead module REA Series module output is a result of the optical pump power from the continuous wave laser diodes These continuous wave diodes are sensitive to thermal shock from repeatedly applying and removing drive current Diodes should not be cycled on off more than 6 times a day When initially applying power to the module the current should be gradually increased 3 A s until the normal operating current is achieved see fin
49. tage a much larger voltage across the drive FETs will increase the heat load and cause a dramatic rise in their temperature For third party drivers which have the capability to servo the voltage to produce the necessary current a sudden decrease in output voltage should cause a corresponding large decrease in the voltage required internally within the driver which could be detected and reported If any of the conditions are detected the driver should suspend diode drive current and send the operator an error message The REA Series module includes an electronic timer circuit which monitors the operation of the pump head and tracks the number of hours of operation the number of pulsed shots and the number of on off cycles over the lifetime of the head These data may be displayed to the user on a 4 digit LCD display on the front of the module This timer is powered by the applied module operating voltage and will only be operational when the module is operating Northrop Grumman Corporation 15 REA Series User Manual Startup Display Chapter 3 Operation AME A Timer LCD Readout Figure 3 2 REA Series Electronic Timer When the module is powered on the timer will startup and displays two startup readings After these readings have been displayed the timer transitions into a looping operational display mode in which operating values are repeatedly displayed These modes are described below On startup the timer will displ
50. tement please contact your nearest Cutting Edge Optronics sales and service office EXCEPT AS PROVIDED IN THIS SUMMARY OR THE APPLICABLE WARRANTY STATEMENT CUTTING EDGE OPTRONICS MAKES NO WARRANTY OF ANY KIND EXPRESS OR IMPLIED INCLUDING WITHOUT LIMITATION THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PUPOSE IN NO EVENT SHALL CUTTING EDGE OPTRONICS BE LIABLE FOR INDIRECT SPECIAL OR CONSEQUENTIAL DAMAGES Copyright Under the copyright laws this publication may not be reproduced or transmitted in any form electronic or mechanical including photocopying recording storing in an information retrieval system or translating in whole or in part without the prior written consent of Cutting Edge Optronics Trademarks eDrive is a registered trademark of Northrop Grumman Corporation Patents Northrop Grumman Corporation products are covered by U S and foreign patents issued and pending Information in this publication supersedes that in all previously published material Specifications and price change privileges reserved Northrop Grumman Corporation iii REA Series User Manual Safety Information Product End of Life Handling Cutting Edge Optronics is committed to protecting the environment In accordance with the Waste Electrical and Electronic Equipment directive WEEE and Restriction of Hazardous Substances in the European Union RoHS EU directives Cutting Edge Optronics accepts the retu
51. the following procedure Alternately turn on the chiller and allow coolant to flow for approximately 20 minutes Examine pump module for leaks 17 If pumphead leaked first fix the leak then test again for leaks finally allow module to dry thoroughly before lasing Firing wet diodes will permanently damage them Northrop Grumman Corporation 34 REA Series User Manual Chapter 5 Maintenance REA XXXX 002X Configuration 28 Large O Ring amp Groove vA f A 15 Medium W Ila O Ring amp YAN aj Groove Macor Beam LY d Tube Shield Support fo A Gr to oS N d 4 NG Insert White N Cap Viton O Ring Figure 5 2 Rod Replacement Drawing REA XXXX 002X 1 Remove beam tube supports and the Macor shields from both ends of the rod CAUTION Use extreme caution during the remaining steps of this procedure to insure that the rod faces and or coatings are not damaged Never use a tool that can scratch the rod on the O rings 2 Starting with the end of the module without the hose barbs apply methanol to the rod o ring 3 Remove the six screws that hold the insert to the endplate and then slowly rotate and pull the insert off the rod 4 Moving to the other end of the module with the hose barbs remove the six screws holding the insert to the endplate and pull the insert and rod out of the module Apply methanol to the rod o ring and remove the second insert 6 Remove rod f
52. tic discharge ESD Always use proper ESD control devices when handling the module CAUTION Ensure gloves or finger cots are worn during this procedure and that it is carried out in a clean environment preferably under a laminar flow hood REA XXXX 001X Configuration YAG Rod Beam Tube Support White a Viton Macor O Ring ap Shield Figure 5 1 Rod Replacement Drawing REA XXXX 001X 1 Remove four fasteners releasing Macor shields 2 Remove the two retainer caps from the ends of the module CAUTION Use extreme caution during the remaining steps of this procedure to insure that the rod faces and or coatings are not damaged Never use a tool that can scratch the rod on the O rings 3 Extract one of the O rings that hold the rod in place using a dental pick or other similar tool Stick the sharp end of the dental pick into the O ring and pull away from the pump module New O rings will be used during the installation of the Northrop Grumman Corporation 33 REA Series User Manual Chapter 5 Maintenance new rod Be very careful not to damage the rod ends or barrel with the extraction tool 4 Remove the rod by applying slight pressure in order to break the O ring seal on the opposite end Partial extraction of the O ring on the opposite end may be needed If necessary loosen the O ring with the dental pick Once again be careful not to damage the rod ends or barrel 5 Unwrap the new rod and inspect
53. ture and Relative Humidity 22 Table 3 3 Table of Air Condensation Temperature at Given Ambient Air Temperature Celcius and Relative Humidity percent 23 Figure 4 1 Connection Diagram 27 Figure 4 2 eDrive Rear Panel 271 Figure 4 3 Chiller Assembly Drawing 26 Figure 5 1 Rod Replacement Drawing REA XXXX 001X 33 Northrop Grumman Corporation Ki REA Series User Manual Figure 5 2 Rod Replacement Drawing REA XXXX 002X Figure 5 3 REA XXXX 002X O rings Figure 5 4 Nitrogen Leak Test Layout Northrop Grumman Corporation xii 35 36 38 REA Series User Manual Chapter 1 Introduction This introduction provides the following information Theory of operation Temperature Tuning of Laser Diodes REA Series description High Voltage DC Power Supply Closed Loop Re circulating Chiller Specifications Northrop Grumman Corporation 1 REA Series User Manual Chapter 1 Introduction Theory of Operation The REA Series module was designed for use as a building block engine in the development or production of medium power rod laser systems or as a drop in replacement for arc lamp pump chambers in industrial lasers It is well suited for medium power applications such as laser marking and can provide high stability and beam quality for more precise micro machining and scientific applications Northrop Grumman Aerospace Systems Cutting Edge Optronics NGAS CEO diode pumped solid state lasers and p
54. ump modules use temperature tuned GaAlAs laser diodes These diodes replace arc lamps or incandescent light sources as the optical pump source The principal advantages of this approach include Longer lifetime More compact size More efficient operation The REA Series module uses arrays of solid state laser diodes to optically pump a neodymium doped yttrium aluminum garnet Nd YAG lasing medium The diode optical output power is radially coupled into the laser rod The Nd YAG laser rod has an anti reflection coating chosen for the highest gain wavelength of this material 1064 nm The REA Series module is constructed within a durable and rigid structure Exterior components and connections are shown in Figure 1 1 Timer Coolant Inlet Coolant Outlet Figure 1 1 Exterior Components and Connections Northrop Grumman Corporation 1 REA Series User Manual Chapter 1 Introduction Temperature Tuning of Laser Diodes The laser diodes are located within the REA Series module and tuned wavelength matched via the closed loop chiller For maximum efficiency the diode output wavelength must match the laser medium absorption characteristics see Figure 1 2 The output spectrum of a conventional pump source for Nd YAG operation the xenon arc lamp and 808 nm diode array is also shown Laser Diode Pump Wavelength 808 nm Xenon flash tube 1700 A cm mm Absorption spectrum of Nd YAG 300 K Wavelength um Figure
55. zeros to place behind this 3 digit number For example if the readout showed 8385 this would represent approximately 83 800 000 shots If the value shown has a line beneath it such as 1480 then the fourth digit should be increased by 10 to determine the number of zeros In this case the shot count would be approximately 1 480 000 000 000 Northrop Grumman Corporation 18 REA Series User Manual Chapter 3 Operation Closed Loop Chiller The single most common cause of laser module return for repair involves customer damage More than one third of all customer damaged laser modules involve cooling problems Coolant problems almost always require the replacement of the diode arrays the single most expensive component in NGAS CEO laser modules Read the following section carefully to avoid damaging arrays CAUTION Do not operate module without cooling Inadequate heat dissipation will seriously damage the laser diodes and will void warranty Table 3 1 Cooling System Requirements Chiller and Cooling System Requirements Optishield Plustm distilled water coolant 10 Optishield Plustm 90 distilled water Coolant circulated at 50 psi Filter connected between chiller and inlet on module Module first in coolant loop Chiller Heat Capacity gt Power Consumption Table 1 2 Flow sensor connected to coolant interlock on drive electronics 1 Clean coolant is important to keeping coolant lines from clogging

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