Diamond E-150 OEM RevAC

OEM Manual
DIAMOND™ E-150 Laser
5100 Patrick Henry Drive

Santa Clara, CA 95054
DIAMOND E-150 OEM Manual
This document is copyrighted with all rights reserved. Under the copyright
laws, this document may not be copied in whole or in part or reproduced in
any other media without the express written permission of Coherent, Inc.
Permitted copies must carry the same proprietary and copyright notices as
were affixed to the original. This exception does not allow copies to be
made for others, whether or not sold, but all the material purchased may
be sold, given or loaned to another person. Under the law, copying
includes translation into another language.
Coherent, the Coherent Logo, DIAMOND, ModeMaster and LabMax are

registered trademarks of Coherent, Inc.
Every effort has been made to ensure that the data given in this document
is accurate. The information, figures, tables, specifications and schematics
contained herein are subject to change without notice. Coherent makes no
warranty or representation, either expressed or implied with respect to this
document. In no event will Coherent be liable for any direct, indirect,
special, incidental or consequential damages resulting from any defects in
its documentation.
Technical Support
In the USA:
Should you experience any difficulties with your laser or need any
technical information, please visit our web site www.Coherent.com.
Additional support can be obtained by contacting our Technical Support
Hotline at 800-367-7890 (408-764-4557 outside the U.S.) or by E-mail
(Product.Support@Coherent.com). Telephone coverage is available
Monday through Friday (except U.S. holidays and company shutdowns).
If you call outside of our office hours, your call will be taken by our
answering service and will be returned when the office reopens.
If there are technical difficulties with your laser that cannot be resolved by
support mechanisms outlined above, please E-mail or telephone Coherent
Technical Support with a description of the problem and the corrective
steps attempted. When communicating with our Technical Support
Department, via the web or telephone, the model and Laser Head serial
number of your laser system will be required by the Support Engineer
responding to your request.
Outside the USA:
If you are located outside the United States, visit our web site for technical
assistance or contact, by phone, our local Service Representative.
Representative phone numbers and addresses can be found on the
Coherent web site, www.Coherent.com.
Coherent provides telephone and web technical assistance as a service to

its customers and assumes no liability thereby for any injury or damage
that may occur contemporaneous with such services. These support
services do not affect, under any circumstances, the terms of any warranty
agreement between Coherent and the buyer. Operation of any Coherent
laser with any of its interlocks defeated is always at the operator's own risk.
ii
Table of Contents
TABLE OF CONTENTS
Preface ................................................................................................................................. vii
U.S. Export Control Laws Compliance ............................................................................... vii
Symbols Used in This Manual and on the Laser System ................................................... viii
Chapter One: Description and Specifications................................................ 1-1

Introduction......................................................................................................................... 1-1
Purpose of This Manual ...................................................................................................... 1-1
Laser Head .......................................................................................................................... 1-4
Tube ........................................................................................................................... 1-4
Simmer Circuit........................................................................................................... 1-6
RF Amplifier.............................................................................................................. 1-6
Beam Shaping Unit .................................................................................................... 1-6
Chapter Two: Laser Safety ....................................................................................... 2-1

Optical Safety ..................................................................................................................... 2-1
Viewing Distance................................................................................................................ 2-1
Electrical Safety .................................................................................................................. 2-4
Laser Head ................................................................................................................. 2-4
Laser Safety Requirements ................................................................................................. 2-4
Safety Interlocks ........................................................................................................ 2-5
Radiated Emission Compliance .......................................................................................... 2-5
Interference Potential of the System .......................................................................... 2-5
Maintenance of the System........................................................................................ 2-5
Simple Measures to Correct Interference .................................................................. 2-6
Compliance to Standards Relevant to CE Mark ................................................................. 2-6
Labels and Label Placement ............................................................................................... 2-6
Waste Electrical and Electronic Equipment (WEEE, 2002)............................................... 2-9
Chapter Three: Utility Requirements and

System Installation ................................................................................................. 3-1
Utility Requirements........................................................................................................... 3-1
Electrical Service ....................................................................................................... 3-1
DC Power Supply ............................................................................................. 3-1
Main Power Disconnect.................................................................................... 3-1
Cooling Water............................................................................................................ 3-1
Selecting The Correct Cooling Water Temperature .................................................. 3-2
Optics Purge............................................................................................................... 3-4
Installation .......................................................................................................................... 3-5
Preparing the Facility for Installation ........................................................................ 3-5
Receiving Inspection.................................................................................................. 3-5
Unpacking .................................................................................................................. 3-6
Mounting the Laser System ....................................................................................... 3-6
Output Aperture Dust Cap ......................................................................................... 3-9
iii
Attaching External Delivery System to Beam Shaping Unit..................................... 3-9

Purge Gas Quality ...................................................................................................... 3-9
Water Line Connections .......................................................................................... 3-10
DC Power Connections............................................................................................ 3-13
Chapter Four: Control Interface ........................................................................... 4-1

Introduction......................................................................................................................... 4-1
RF Amplifier Control Connector Interface......................................................................... 4-1
Input Signal Requirements......................................................................................... 4-1
Drive Circuit for RF Amplifier .................................................................................. 4-2
Output Signal Recommendation ................................................................................ 4-4
Output Signal Description ......................................................................................... 4-7
Monitoring Circuit Example ...................................................................................... 4-7
Test Function Operation ............................................................................................ 4-9
Output Signal Waveforms ....................................................................................... 4-10
Chapter Five: Operation ............................................................................................. 5-1

Introduction......................................................................................................................... 5-1
Startup Procedure................................................................................................................ 5-1
Adjusting the E-150 Output ................................................................................................ 5-2
Shutdown Procedure ......................................................................................................... 5-13
Chapter Six: Maintenance and Troubleshooting ........................................ 6-1

Introduction......................................................................................................................... 6-1
Preventive Maintenance...................................................................................................... 6-1
Water System Inspection ........................................................................................... 6-1
Optics Inspection and Cleaning ................................................................................. 6-1
Purge Gas Filter Panel (option) ................................................................................. 6-2
Electrical Inspection .................................................................................................. 6-3
Troubleshooting .................................................................................................................. 6-4
Replacement Procedure .................................................................................................... 6-14
Appendix A: Parts List................................................................................................ A-1

Appendix B: Accessories .............................................................................................B-1
Power Meters and Sensors ..................................................................................................B-1
Coherent’s Recommendation.....................................................................................B-1
Purge Gas Filter Panel Assembly .......................................................................................B-2
Appendix C: Warranty ................................................................................................C-1

DIAMOND E-150 Laser Warranty ....................................................................................C-1
Conditions of Warranty ......................................................................................................C-1
Responsibilities of the Buyer ..............................................................................................C-1
Limitations of Warranty......................................................................................................C-2
Glossary ..................................................................................................................... Glossary-1
iv
Table of Contents
Index ................................................................................................................................. Index-1
LIST OF ILLUSTRATIONS
1-1. DIAMOND E-150 OEM Laser System with Beam Shaper Optics................................. 1-1
1-2. Simplified System Block Diagram .................................................................................. 1-4
1-3. Laser Head Diagram ........................................................................................................ 1-5
1-4. Laser Tube ....................................................................................................................... 1-5
2-1. Nominal Ocular Hazard Distance (NOHD)..................................................................... 2-2

2-2. Label Placement............................................................................................................... 2-7
2-3. Product Labels ................................................................................................................. 2-7
2-4. Waste Electrical and Electronic Equipment Label .......................................................... 2-9
3-1. Laser Head Dimensions and Mounting Hardware Locations .......................................... 3-7
3-2. Alternative Laser Head Mounting Hardware Details ...................................................... 3-8
3-3. Laser Head Mounting and Connection Detail ............................................................... 3-12
4-1. Input Circuit of RF Amplifier .......................................................................................... 4-4

4-2. Typical Drive Circuit for RF Amplifier........................................................................... 4-5
4-3. Output Circuit of RF Amplifier ....................................................................................... 4-6
4-4. Typical Monitoring Circuit .............................................................................................. 4-8
4-5. Interface for Test Function .............................................................................................. 4-9
4-6. RF Amplifier Output Signals - Normal Operating Conditions...................................... 4-11
4-7. RF Amplifier Output Signal - DIGITAL REFLECTED Active During Failed State ... 4-12
4-8. RF Amplifier Output Signal - DIGITAL FORWARD Active During Failed State ...... 4-13
4-9. RF Amplifier Output Signal - VSWR Active During Failed State................................ 4-14
4-10. RF Amplifier Output Signal - DUTY CYCLE LIMIT Active During Failed State...... 4-15
5-1. Typical Pulse/Modulation................................................................................................ 5-3

5-2. Laser Tube Forward and Reflected Voltage Waveforms ................................................ 5-4
5-3. Example of Changing Laser Power ................................................................................. 5-6
5-4. Typical DIAMOND E-150 Laser Output Power Plots .................................................... 5-7
5-5. Instantaneous Laser Output Power Showing Rise and Fall Times .................................. 5-8
5-6. Effective Processing Power vs. Pulse Width ................................................................... 5-9
5-7. Typical Power Stability at Different Duty Cycles ......................................................... 5-10
5-8. Typical Near-field Beam Profile at 70% Duty Cycle .................................................... 5-11
5-9. Typical Beam Divergence at 70% Duty Cycle .............................................................. 5-12
B-1. Power Meter and Thermal Sensor ...................................................................................B-1

B-2. Purge Gas Filter Panel Assembly ....................................................................................B-2
v
LIST OF TABLES
1-1. DIAMOND E-150 Specifications and Utility Requirements .......................................... 1-2
3-1. Recommended Minimum Inlet Cooling Water Temperature

for Celsius Temperature Scale ......................................................................................... 3-3
3-2. Recommended Minimum Inlet Cooling Water Temperature
for Fahrenheit Temperature Scale.................................................................................... 3-4
3-3. Equipment Required for Installation................................................................................ 3-6
3-4. Laser Head Indicators and Connectors .......................................................................... 3-13
4-1. Summary of RF Amplifier Control and Indicator Signals............................................... 4-2

4-2. RF Amplifier DB25 Connector Pinouts........................................................................... 4-3
4-3. Examples of Line Drivers Meeting RS-422A.................................................................. 4-5
4-4. Examples of Line Receivers Meeting RS-422A.............................................................. 4-8
5-1. Laser Turn-on Functions.................................................................................................. 5-2

5-2. Control Unit Settings for Laser Shutdown .................................................................... 5-13
6-1. System Faults and Warning Indications .......................................................................... 6-4
A-1. Parts List ......................................................................................................................... A-1
LIST OF CHARTS
1. Laser Does Not Start (No Output Beam)............................................................................ 6-6
2. Low Output Power.............................................................................................................. 6-8
3. Unstable Output Power ..................................................................................................... 6-10
4. Degraded Mode Quality.................................................................................................... 6-12
vi
Preface
Preface This manual provides operating and maintenance instructions for the
DIAMOND™ E-150 OEM system. It is recommended that the user
read this manual, especially Chapter Two, Laser Safety, before oper-
ating the laser.
Caution — use of controls or adjustments or performance of

procedures other than those specified in this manual may result
in hazardous radiation exposure.
U.S. Export It is the policy of Coherent to comply strictly with the U.S. export
control laws.
Control Laws
Compliance Export and re-export of lasers manufactured by Coherent are subject
to the U.S. Export Administration Regulations administered by the
Department of Commerce, Bureau of Export Administration.
The applicable restrictions vary depending on the specific product
involved, intended application, and the product destination. In some
cases, an individual validated export license is required from the
U.S. Department of Commerce prior to resale or re-export of certain
products. If you are uncertain about the obligations imposed by U.S.
law, obtain clarification from Coherent.
vii
Symbols Used in
This Manual and
on the Laser
System
This symbol is intended to alert the operator to the presence of

dangerous voltages associated with the laser that may be of suffi-
cient magnitude to constitute a risk of electric shock.
This symbol is intended to alert the operator to the presence of

important operating and maintenance instructions.
This symbol is intended to alert the operator to the danger of

exposure to hazardous visible and invisible laser radiation.
This symbol identifies DIRECT CURRENT electrical potential.
viii
Description and Specifications
CHAPTER ONE: DESCRIPTION AND SPECIFICATIONS
Introduction The DIAMOND E-150 laser is an RF excited, sealed-tube industrial

CO2 pulsed laser. The system (Figure 1-1) consists of a 150 watt
laser resonator and solid-state RF amplifier integrated within an
all-metal enclosure. Operation requires water cooling, 48 VDC
input power, drive signals (interlock & control), and an optical beam
delivery to the work piece.
The E-150 can operate in many pulse formats, and with a user-
supplied control system, allows user control of the output power.
The DIAMOND E-150 has an output power range of 20 to
150 watts. Specifications are listed in Table 1-1. A simplified
system block diagram is shown in Figure 1-2.
Figure 1-1. DIAMOND E-150 OEM Laser System with Beam Shaper Optics
Purpose of This manual is designed to assist the original equipment manufac-

turer during the integration of the DIAMOND E-150 OEM laser. It
This Manual contains information on the performance and operation of the laser
as well as installation and control methods.
1-1
Table 1-1. DIAMOND E-150 Specifications and Utility Requirements
PARAMETER SPECIFICATION
LASER PERFORMANCE
Average output power (1) 150 watts
M2 – Transverse mode quality (2) ≤1.2
System warranty time 2 year
Tube shelf life >1 year
Peak effective power 375 watts
Average power range (3) 20 to 150 watts
Pulse energy range 5 to 315 mJ
Pulse period (minimum) 10 µs (equivalent to a

frequency of 100 kHz)
Pulse Frequency Single shot to 100 kHz
Output power stability (4) <± 7%
Beam diameter at 60 cm (5)(6) 4.6 mm ± 1 mm
Beam waist diameter (1/e2) (2) 2.2 mm ± 0.6 mm
Beam divergence (full angle) 6.6 mrad - typical
Beam waist asymmetry (2) <1.3:1
Beam ellipticity at 60 cm (5)(6) 1.3 (Wy/Wx)
Divergence asymmetry (5)(6) 1.2 (Wy/Wx)
Beam polarization (parallel to base plate) Linear >100:1
Modulation pulse width range 2 to 1,000 µs
Optical pulse fall time (7) 35 to 65 µs
Wavelength 10.2 to 10.8 µm
Laser head assembly weight 36 lbs. (16.3 kg)
The above specifications subject to change without notice.

(1) Guaranteed at 0.7–100 kHz at 70% duty cycle with the inlet cooling water at 25°C. Allow a 1%/°C power derating for inlet
cooling water to a temperature of 35°C.
(2) ModeMaster measurement at 40 kHz, 35% duty cycle.
(3) Stability specification may not be met at low powers or acoustic resonant frequencies. Refer to Figure 5-7 for typical
performance.
(4) Measured at 10 kHz, 70% duty cycle with coolant temperature regulated to 25°C ± 1°C. Stability defined as
± (Pmax–Pmin)/2Pmax.
(5) Beam mode quality specifications may not be met at low powers or at acoustic resonant frequencies.
(6) Refer to Figure 5-8 and Figure 5-9 for typical performance.
(7) Typical value at 1 kHz and 35% duty cycle.
1-2
Table 1-1. DIAMOND E-150 Specifications and Utility Requirements (Continued)
PARAMETER SPECIFICATION
LASER HEAD ELECTRICAL REQUIREMENTS
DC input voltage(8) 48 VDC ± 1%
Maximum DC current 55 Amps
Peak current 100 Amps
ENVIRONMENTAL REQUIREMENTS
Ambient temperature (operational) 5°C to 40°C (41°F to 104°F)
Operating altitude <6,500 feet (<2,000 meters)
Relative humidity <95% non-condensing at inlet coolant temperature
Tube gas consumption None
Optional laser head purge 6 STD cubic feet/hour (2.8 liters per minute) of N2 99.95%
purity, or 99.995% oil-free air filtered with particle air filter
to < 1 micron and dew point 10°C (18°F) lower than inlet
cooling water temperature
Water(10)
Cooling water flow rate (minimum) (10) 1.5 gpm (5.7 lpm)
Cooling water temperature (9) 10°C to 35°C (50°F to 95°F)
Coolant temperature stability < ± 1°C (< ± 1.8°F)
Inlet pressure(11) 30 to 75 psi (207 to 517 kPa)
Cooling water hardness (equivalent to CaCO3) (10) <250 mg/liter
Maximum pressure drop at required flow rate (12) 30 psi (207 kPa)
Heat load (13) 2.5 kW
Hardness (equivalent to CaCO3) <250 mg/liter
pH 5 to 9
Particulate size <200 microns in diameter
The above specifications subject to change without notice.

(8) DC input voltage to the laser head which consists of the RF amplifier and laser tube.
(9) Do not operate at or below dew point.
(10) These requirements are for facility tap water. If facility tap water is used, an in-line water filter is also recommended. If a
closed loop system is used, it must meet the water requirements listed in this table. Also refer to the paragraph titled
Cooling Water, located in this chapter for additional information including discharge of cooling water.
(11) Inlet pressure is based on 30 foot water lines. If different lengths are used, the difference must be taken into account when
determining the inlet pressure.
(12) Between the inlet and return water lines. Pressure differential is based on 30 foot water lines. If different lengths are used,
the difference must be taken into account when determining the pressure differential.
(13) If a closed-loop cooling system is used, it must have sufficient capacity to handle heat loads of 2.5 kW in addition to
meeting the other water requirements listed in this table.
1-3
COOLING
WATER
SUPPLY CUSTOMER
SUPPLIED
WATER FLOW
SWITCH
CUSTOMER CONTROL
SUPPLIED ELECTRONICS
OUT
OPTIONAL/
CUSTOMER SUPPLIED IN LASER TUBE
and
FACILITY POWER RF AMPLIFIER
DC
POWER
SUPPLY 48 VDC
48 V RETURN
Figure 1-2. Simplified System Block Diagram
Laser Head The laser head consists of an aluminum housing with two sections.
The upper section contains the RF circuitry, and the lower section
contains a sealed laser cavity. All necessary components reside
within this housing to provide reliable, maintenance-free operation
with full control and diagnostics.
Tube The laser housing is sealed with all metal seal. The aluminum
housing has high thermal conductivity, resulting in a thermally
stable laser cavity.
Within the laser cavity are 2 liquid-cooled electrodes which provide
excitation for the gas mixture and waveguide surfaces for the optical
cavity. Coils are positioned along the length of these electrodes to
ensure a uniform discharge.
Attached to the housing end pieces are 2 mirrors which are 100%
reflective and designed for the necessary optical cavity. The inherent
design of this laser cavity produces a high quality beam, with stable
output power and the highest power per unit volume.
1-4
RF AMPLIFIER
LASER
OUTPUT
LASER TUBE
BEAM
SHAPING
UNIT
Figure 1-3. Laser Head Diagram
OUTPUT WINDOW
OUTPUT
CAVITY OPTICS CONFIGURATION

100% REFLECTING 100% REFLECTING
SPHERICAL END MIRROR SPHERICAL END MIRROR
COILS COILS
RF INPUT
ELECTRODES WAVEGUIDE
RESONATOR STRUCTURE
Figure 1-4. Laser Tube
1-5
Simmer Circuit The simmer circuit generates short duration RF pulses to the cavity
gas, in order to promote rapid starting after periods of being turned
off. The simmer pulse is automatically generated to ensure
instant-on operation, but is not powerful enough to cause laser
action. When the laser is commanded with modulation pulses, the
simmer circuit is inhibited.
RF Amplifier The integrated RF amplifier provides pulsed RF power to the laser

cavity to ionize the gas mixture in the tube. A modulation signal
applied to the laser head controls the output pulse width and period.
The RF amplifier produces up to 3 kW of RF output power.
The RF amplifier has the following features:
• Provides protection from duty cycles above 70%.
• Limits the pulse width to less than 1 msec.
• Monitors forward and reflected RF power to and from the laser
cavity.
• Provides a connection for an external safety interlock circuit
which will shut down the laser when activated.
• Contains a factory set VSWR limit that limits duty cycle to less
than 10% for faults typically related to the cavity.
• Provides over temperature and system test functions.
Beam Shaping Unit A beam shaping assembly is factory installed on all E-150 laser
heads. The beam shaping assembly contains a cylindrical lens
designed to make a near round beam with equal divergence in the
vertical to horizontal planes.
1-6
Laser Safety
CHAPTER TWO: LASER SAFETY
Optical Safety The DIAMOND E-150 has undergone extensive testing to ensure
that, with proper usage, it is a safe and reliable device.
Laser light, because of its special properties, poses safety hazards
not associated with light from other sources. The safe use of lasers
requires that all laser users and everyone near a laser be aware of the
dangers involved in laser operation.
DANGER! Class 4 laser product. Avoid eye or skin exposure to

direct or scattered radiation.
Viewing The E-150 produces optical power levels that are dangerous to the
eyes and skin if exposed directly or indirectly. This product must be
Distance operated only with proper eye and skin protection at all times. Never
view directly emitted or scattered radiation with unprotected eyes.
When viewing the laser during operation, the operator must main-
tain the Nominal Ocular Hazard Distance (NOHD) between the laser
or scatter radiation and the operator's eyes. Figure 2-1 summarizes
the NOHD for the power range of the E-150 for both direct viewing
and direct viewing with OD5 laser safety eyewear. The NOHD in
this figure is based on the Maximum Permissible Exposure (MPE)
level for each power condition as specified in IEC 60825-1-2007.
Direct eye contact with the output beam from the laser will cause
serious eye damage and may cause blindness.
All personnel in the same room as the laser or anyone who may be
exposed to the laser beam should be informed that a laser is in oper-
ation. All personnel must wear laser safety glasses which protect
against the wavelengths in use.
2-1
Figure 2-1. Nominal Ocular Hazard Distance (NOHD)
Exercise caution to protect against specular reflections since

reflections at the DIAMOND E-150 wavelength are invisible.
Eye safety is a great concern when using a high-power laser such as

the DIAMOND E-150. There are often many secondary beams
present at various angles near the laser. These beams are specular
reflections of the main beam from polished surfaces. While weaker
than the main beam, such beams may still be sufficiently intense to
cause eye damage.
Laser beams are also powerful enough to burn skin, clothing or
paint. They can ignite volatile substances such as alcohol, gasoline,
ether, and other solvents and can damage the light-sensitive
elements in video cameras, photomultipliers, and photodiodes.
Coherent provides the following recommendations to promote the
safe use of the DIAMOND E-150. Operators are advised to adhere
to these recommendations and employ sound laser safety practices
at all times.
2-2
Laser Safety
• Use protective eyewear when operating the laser and guard

against inadvertent exposure to skin or clothing. Select
eyewear which is suitable for use with the wavelengths and
radiation intensity that the laser emits. Refer to the Guide for
Selection of Laser Eye Protection, Laser Institute of America
(6th Edition), 2007.
• Do not remove the protective covering over the beam path.
During normal operation, internal reflections are confined
within the laser head and pose no safety hazard.
• Never look directly into the laser output port when the power
is on.
• Set up the laser and all optical components used with the laser
away from eye level. Provide enclosures for the laser beam.
• Use the laser in a room with access controlled by door inter-
locks. Post warning signs. When operating the laser, limit
access to the area to individuals who are trained in laser safety.
• Avoid operating the laser in a darkened environment.
• Do not use the laser in the presence of flammables, explosives,
or volatile solvents such as alcohol, gasoline, or ether.
For additional information on laser safety, refer to the following
publications:
• American National Standard for the Safe Use of Lasers,
Z136.1-2007, American National Standards Institute, 2007.
• Performance Standards for Laser Products, United States
Code of Federal Regulations, 21 CFR 1040 10 (d).
• Laser Safety Guide, Laser Institute of America. (11th Edition).
Orlando, FL 2007.
• D. Sliney and M. Wolbarsht. Safety with Lasers and Other
Optical Sources,. Plenum Publishing Company, New York,
NY, 1980.
Many of these documents on laser safety are available through the

Laser Institute of America, 13501 Ingenuity Drive, Suite 128,
Orlando, FL 32826. Call them at 800-345-2737, or visit their web
site: www.laserinstitute.org.
2-3
Electrical Safety The E-150 laser head requires a +48 VDC supply. This voltage is
provided by commercially available power supplies from various
manufacturers. The typical input voltage to these power supplies is
208 or 240 VAC, single phase with ground. These voltages can be
lethal. Every portion of the electrical system should be treated as if
it is at a dangerous voltage level. All the metal parts of the laser
system should be considered extremely dangerous.
The DC power supply and laser head covers should never be
removed. There are no user serviceable components inside.
The “48 VDC RETURN” terminal is electrically common with

the laser head metal housing.
Laser Head High voltages are present in the laser head when the power is on.
Please read the appropriate manual chapters carefully before
attempting any maintenance of components housed in the laser head.
Laser Safety This laser is an OEM component and as such does not conform to
the United States Government requirements for laser safety. In the
Requirements United States, it is the responsibility of the buyer that the product
sold to the end user complies with all laser safety requirements prior
to resell. These laser safety requirements are contained in 21 CFR,
Sub Chapter J and are administered by the Center for Devices and
Radiological Health.
The text of this federal law is available from the U.S. Government
Printing Office Bookstore located in most major cities in the U.S. as
well as Washington, D.C. A report detailing how the laser product
complies with the Federal law is required before the product is
shipped. The form of this report is covered in a pamphlet entitled:
Guide for Preparing Product Reports for Lasers and Products
Containing Lasers, HHS Publication FDA 86-8259. This pamphlet
is available at no cost from:
U.S. Department of Health and Human Services
Public Health Service
Food and Drug Administration
Center for Devices and Radiological Health
Division of Small Manufactures Assistance
Rockville, MD 20857
2-4
Laser Safety
Voice phone: (800) 638-2041

For reports provided by FAX, call: (301) 433-9435
For jurisdictions outside of the United States, it is the responsibility
of the buyer of this laser device to ensure that it meets the local laser
safety requirements.
Safety Interlocks The laser head cover and optional DC power supply covers are not
interlocked. These covers should never be removed. There are no
user serviceable components inside.
Use of controls or adjustments, or performance of procedures

other than those specified herein, may result in hazardous radi-
ation exposure.
Radiated The DIAMOND E-150 laser has been tested and verified that it is in
compliance with the radiated emission limits of FCC Rules
Emission contained in 47 CFR Part 18 Subpart C for industrial, scientific, and
Compliance medical equipment.
The following information to the user is provided to assist the OEM
in complying with radiation safety standards. (47 CFR 18.213).
Interference In our testing in a variety of laboratory and industrial settings, we

Potential of have not found any significant electrical interference that can be
traced to the DIAMOND E-150 laser. The DIAMOND E-150 laser
the System is excited by an RF power supply operating at 81.36 MHz. The RF
power is modulated at the same pulse width and pulse period
selected in operating the laser.
Maintenance of In order to have the DIAMOND E-150 laser operate properly, all
the System external connections to the laser must always be kept tight. We
recommend checking these connections on a monthly interval to
ensure that they are tight.
2-5
Simple Measures If the DIAMOND E-150 laser is determined to be the source of

to Correct interference with other equipment the following steps can be taken
to minimize this interference:
Interference
1. Check all the connections at the control cable connections to
the laser head, power module, and remote control unit.
2. Use shielded cables including control cables to the unit expe-
riencing the interference problem. The shield should be
grounded.
Compliance The DIAMOND E-150 OEM laser is a component and thus the
system integrator is responsible for meeting the applicable standards
to Standards for CE mark.
Relevant to
As part of the testing program, the DIAMOND E-150 OEM laser
CE Mark powered by a compliant DC power supply has been shown to be
compliant with the relevant requirements of the electromagnetic
compatibility directive and low voltage directive pertaining to elec-
trical and laser safety (IEC60825-1:2007/ EN60823-1:2007). The
tests shows compliance with radiated emissions and conducted line
emissions (EN 55011 (1998) Class A, Group 2), electrostatic
discharge (EN 61000-4-2 (1995) Level 3 air, Level 2 contact), radi-
ated immunity (EN 61000-4-3 (2002) Level 3, electrical fast tran-
sients (EN 61000-4-4 (2004) Level 3), conducted RF immunity
(EN 61000-4-6 (1996), surge immunity (EN61000-4-5 (1995),
Criteria B), magnetic field immunity (EN61000-4-8 (1993), Criteria
A), and voltage dips & interrupts (EN61000-4-11 (2004)).
Compliance to the applicable standards for a particular laser system
incorporating the DIAMOND E-150 OEM laser must be demon-
strated by the manufacturer of the laser tool. By testing the
DIAMOND E-150 OEM laser independently, it is shown that this
step is possible. The primary issue for the system integrator is to
show compliance with specific covers, routing of the electrical
cables, laser safety standards, as well as other applicable standards.
Labels and Figure 2-2 and Figure 2-3 show the positions and detail of product
labels.
Label
Placement
2-6
Laser Safety
Figure 2-2. Label Placement
1. Important Information Label
Figure 2-3. Product Labels
2-7
2. Product Nameplate & Compliance Label
3. Laser Classification Label
4. Aperture Label
Figure 2-3. Product Labels (Continued)
2-8
Laser Safety
Waste Electrical The European Waste Electrical and Electronic Equipment (WEEE)
Directive (2002/96/EC) is represented by a crossed-out garbage
and Electronic container label. The purpose of this directive is to minimize the
Equipment disposal of WEEE as unsorted municipal waste and to facilitate its
(WEEE, 2002) separate collection. Properly dispose/recycle this product.
Figure 2-4. Waste Electrical and Electronic Equipment Label
2-9
2 - 10
Utility Requirements and System Installation
CHAPTER THREE: UTILITY REQUIREMENTS AND

SYSTEM INSTALLATION
Utility The DIAMOND E-150 laser requires 48 VDC power, facility

cooling water, and optics purge. Electrical power, environment,
Requirements cooling water and optics purge must meet the specifications
provided in Table 1-1.
Electrical Service
DC Power Supply Any DC power supply selected for use with the DIAMOND E-150
must be able to supply the output voltage and both RMS and peak
currents specified in Table 1-1.
Main Power A main power disconnect must be located on the equipment housing
Disconnect the laser or near the equipment. The disconnecting device should be
labeled as such and be located within easy reach of the operator.
Consult applicable local electrical codes to select this hardware.
Cooling Water The DIAMOND E-150 laser requires a flow of cooling water.
Because the properties of the cooling water are important for laser
performance, ensure that the conditions remain within the tolerance
limits listed in Table 1-1 at all times.
Although not recommended, it is possible to use facility tap or
process water for cooling. Check local and state regulations which
may control use of city water for cooling applications. Some regula-
tory codes will not allow the discharge of cooling water into the
sewer system. Running cooling water down the drain adds to the
cost of operation. Also, tap water temperature and pressure can vary
with the time of day and season of the year.
For best results, a closed-loop cooling system should be used to
obtain consistent laser performance.
3-1
Selecting The The cooling water of the DIAMOND E-150 laser can condense
Correct Cooling moisture from the air when the temperature of the cooling water is
lower than the dew point of the air. The system must not operate
Water under these conditions since it will lead to catastrophic failure in
Temperature both the laser head and the RF power supply. When failures occur in
either the optics or the RF power supply it must be returned to the
factory for repair. Under most conditions, it is recommended to
select the inlet cooling water temperature at room temperature or at
least 25°C (77°F). This following information provides recommen-
dations for operating conditions outside of the normal temperature
and humidity range.
The conditions that lead to a situation where there can be condensa-
tion are warm and humid weather combined with water that is cooler
than the surroundings. High risk conditions which will lead to
condensation are:
• Operating the laser in a room that is not air conditioned in high
humidity conditions
• Using cooling water that is not temperature controlled
• Leaving the cooling water on when the laser is not operating
for extended time periods
The information required to determine if the cooling water temper-
ature will lead to condensation is:
• Room temperature
• Relative humidity
Since the weather conditions change, these factors need to be peri-
odically checked, especially in the spring and summer seasons. In
environments that are air conditioned, we recommend setting the
cooling water temperature to 25°C (77°F). As explained below for
conditions that are not air conditioned, we recommend that the
cooling water temperature be increased to the air temperature to
avoid condensation in humid climates.
The recommended inlet cooling water temperature is provided in
Table 3-1 and Table 3-2 for the complete operating temperature
range of the DIAMOND E-150 laser system. Note that the first table
is for temperature on the Celsius scale and the second is for temper-
atures on the Fahrenheit scale. To use this chart, find the row with
the closest room temperature. Next read across until you find the
column with the nearest relative humidity for the room with the
laser. The number in the box is the recommended temperature for the
inlet cooling water. If a closed loop cooling system is being used
then select this temperature as the temperature set point. As an
3-2
example, if the current room temperature is 28°C and the relative

humidity is 68%, then the recommended inlet cooling water temper-
ature is 35°C and the nearest relative humidity is 70%.
Table 3-1. Recommended Minimum Inlet Cooling Water Temperature

for Celsius Temperature Scale
AMBIENT (ROOM) MAXIMUM RELATIVE HUMIDITY

TEMPERATURE
(°C) 30% 40% 50% 60% 70% 80% 90% 95%
5 20 20 20 20 20 20 20 20
10 20 20 20 20 20 20 20 20
15 20 20 20 20 20 20 20 20
20 20 20 20 20 25 25 25 25
25 25 25 25 25 30 30 30 30
30 30 30 30 30 35 35 35 35
35 35 35 35 35 35 35 35 35
40 35 35 35 35 35 N/A N/A N/A
1. The minimum inlet cooling water temperature should account for variations in cooling water temperature with
the thermal load, temperature stability of the cooling water system, and seasonal variations in cooling water
temperature.
2. N/A indicates operation under these conditions is not acceptable since condensation will occur on the laser
system. Either the ambient temperature must be reduced or the relative humidity must be reduced before oper-
ating the laser.
Selecting the cooling water temperature must also take into account
changes in the cooling water temperature. For a closed loop cooling
water system, there can be variations in the water temperature due to
changes in the thermal load and the response time of temperature
controller. The number given by the table will be the minimum water
temperature that should be observed for the current room tempera-
ture and humidity conditions.
In many climates, the cooling water temperature should be changed
due to seasonal variations in the ambient conditions. For example in
times of high relative humidity and high room temperatures, the
cooling water temperature will have to be increased to avoid prob-
lems with condensation. Under extreme conditions of temperature
and humidity, the laser should not be operated as noted in Table 3-1
and Table 3-2. This can be solved by air conditioning the room with
the laser to reduce both the room temperature and the humidity.
3-3
Table 3-2. Recommended Minimum Inlet Cooling Water Temperature

for Fahrenheit Temperature Scale
AMBIENT (ROOM) MAXIMUM RELATIVE HUMIDITY

TEMPERATURE
(°F) 30% 40% 50% 60% 70% 80% 90% 95%
41 68 68 68 68 68 68 68 68
50 68 68 68 68 68 68 68 68
60 68 68 68 68 68 68 68 68
70 70 70 70 70 77 77 77 77
80 77 77 77 77 86 86 86 86
90 86 86 86 86 95 95 95 95
95 95 95 95 95 95 95 95 95
104 95 95 95 95 95 N/A N/A N/A
1. The minimum inlet cooling water temperature should account for variations in cooling water temperature with
the thermal load, temperature stability of the cooling water system, and seasonal variations in cooling water
temperature.
2. N/A indicates operation under these conditions is not acceptable since condensation will occur on the laser
system. Either the ambient temperature must be reduced or the relative humidity must be reduced before oper-
ating the laser.
When using tap water as cooling source, seasonal variations in the

water temperature often can lead to conditions that will produce
condensation. In this case, mixing some hot water with the inlet
cooling water will be required to eliminate condensation or alterna-
tively reducing the room temperature and humidity with an air
conditioning system.
Optics Purge The DIAMOND E-150 laser is used in a wide range of material
processing which often has by-products of dust, smoke, fumes, oil
and various gases. These by-products can cause contamination on
the output window as well as the beam delivery optics. Build up of
contaminants will eventually degrade the system performance and
can lead to permanent damage of optical components. Passing a
purge gas through the beam shaping optics then into the customers
beam delivery optics can prevent optics damage. Also under some
conditions of high humidity, the laser beam can be distorted by
optical absorption of the laser beam by water vapor. This effect can
also be totally eliminated by a proper gas purge.
3-4
The gas purge in the E-150 laser enters in front of the output window
and flows through the beam shaping optics out the exit aperture of
the beam shaping optics. The beam tube provides a convenient
connection to the beam delivery optics while maintaining a gas seal
at this junction.
Installation Installation consists of:

• Preparing the facility for installation
• Performing a receiving inspection
• Unpacking and inspecting system components
• Mounting the laser system components
• Connecting water lines
• Connecting the electrical cables
• Turning on the laser system
Preparing the Ensure facility electrical and water are adequate for laser operation
Facility for as described below.
Installation The facility connection or outlet for the DC power supply must be
protected by a fuse or circuit breaker with the appropriate rating.
Consult a qualified electrician to discuss the electrical requirements,
including component selection, wire size and fusing.
Refer to the paragraph titled “Cooling Water” in this chapter, and to
Table 1-1 for water requirements.
Receiving Before unpacking the DIAMOND E-150, inspect all shipping

Inspection containers and note any damage. Any indication of damage should
be noted on the bill of lading. The shipping carrier is responsible for
damage in transit. Immediately report damage to the shipping carrier
and to Coherent.
3-5
Table 3-3. Equipment Required for Installation
EQUIPMENT QUANTITY USE

Provides +48 VDC power to the RF amplifier
+48 VDC power supply 1
and to the laser head.
Secures DC power supply to a base.

Mounting hardware for DC power supply – Refer to the installation instructions provided by
the power supply manufacturer.
Mounting hardware for laser head 2 See Figure 3-1 and Figure 3-2 for details.
Adapts the 1/4 inch NPT pipe thread on the laser

Water hose fittings (barb to pipe thread) 2
head to accept a 3/8 inch ID cooling water hose.
Provides cooling water to the laser head.

Cooling water hoses 2 3/8 inch I.D. nylon PVC cooling water hoses are
recommended up to a total length of 50 feet.
Auxiliary cooling water inlet/outlet 2 0.125 inch NPT pipe thread.
Purge gas keeps output optics clean and dry. Use

Purge gas tubing 1
1/4 inch OD Teflon or PE tubing
Unpacking To avoid equipment damage, exercise care when removing wrap-

ping materials.
To minimize the risk of functional or cosmetic damage, unpack the
laser system at the installation site. While unpacking the
DIAMOND E-150 laser, verify that all items on the packing list have
been received. Save all containers and packing material including
the water line end caps. They will be required if it becomes neces-
sary to re-ship the equipment.
Mounting the Laser The laser head has provisions for permanent mounting. Refer to
System Figure 3-2 and Figure 3-3 on the following pages for overall dimen-
sions, location of the mounting holes and mounting dovetails, and
depth of mounting bolts.
The laser head can be mounted in any orientation. If mounted verti-
cally with the output window up, ensure no dust or other particulates
fall on the collimating optic during installation. Leave the dust cap
on the output beam tube during installation.
3-6
982.4mm
38.68in
69.6mm
2.74in
127mm
5.00in
77.5mm
50.8mm 3.05in
2.00in
3X 6.73mm 508mm - 635mm 187.2mm

.265in 20.00in - 25.00in 7.37in
3X 19.9mm
.79in
3-7
88.9mm
3.50in
PURGE FITTING
3mm [.125] MALE
HOSE BARB
184.1mm
7.25in
57mm±1
2.24in±.04
59.6mm±1
2.35in±.04
139.7mm
CONTROL INTERFACE CONNECTOR 5.50in
Figure 3-1. Laser Head Dimensions and Mounting Hardware Locations

25 POSITION (PINS)
48 VDC POSITIVE (+) CONNECTION
5.5mm [#12-32] STUD 48 VDC RETURN CONNECTION
4.8mm [#10-32] STUD
44.45 mm
(1.75 in)
6.35 mm
HOUSING CENTERLINE
3.96 mm 171.45 mm
(0.16 in) (0.25 in)
(6.75 in)
Output
Beam
Axis
76.20 mm
(3.00 in)
(6 PLACES)
44.45 mm
(1.75 in)
30.48 mm 6.35 mm
(1.20 in) (0.25 in)
60°
Figure 3-2. Alternative Laser Head Mounting Hardware Details
3-8
Output Aperture To keep the final lens in the beam shaper clean during shipment and
Dust Cap handling, a protective slip-on dust cap is installed on the output end
of the beam shaper assembly.
Remove this dust cap before operating the laser!
Remove the dust cap from the output end of the beam shaper
assembly before operating the laser! Operating the laser with
the dust cap in place will permanently damage the beam shaper
output window.
Retain this cap and re-install it prior to storage or shipment.
Attaching External E-150 lasers have a factory installed beam shaper assembly that
Delivery System to produces a round laser output.
Beam Shaping Unit The beam shaper assembly is designed for integrator supplied
0.88 inch OD beam tubing. Also a gas purge port
(3 mm/0.125 inch OD hose barb) is supplied on the index block for
clean dry gas purge. The integrators beam tubing should be designed
to seal and allow this gas flow around optical components and
exhaust from the system.
Purge Gas Quality The quality of the purge gas is extremely important factor for trouble
free operation of the DIAMOND E-150 laser system. The preferred
purge gas is nitrogen with a purity of 99.95%. In many facilities,
nitrogen of the purity level is provided from a nitrogen boil of a
liquid nitrogen source.
If nitrogen is not available, then the alternate source is oil-free and
dry compressed air. Compressed air is available in many facilities,
but it is typically contaminated with water and oil vapors. The purity
requirements for the compressed air are:
1. Filtered to remove particles larger than 1 micron.

2. Dried so that dew point is 10°C (18°F) lower than the inlet
cooling water temperature to the DIAMOND E-150 laser
system.
3. Oil free to better than 99.995%.
3-9
An optional purge gas filter panel assembly can be installed to obtain

this quality of air. See “Purge Gas Filter Panel Assembly” on
page B-2. Fittings should be sealed with Teflon tape only. The
output of the filter assembly is attached to the laser at the inlet fitting
labeled PURGE using 3 mm (1/8 inch) ID Teflon or PE tubing.
It is the responsibility of the customer to provide nitrogen or

compressed air that meets the specifications stated above. If
appropriate purge is not used while operating the laser, the
warranty of the laser is voided and the customer is responsible
for all cost of repair or damage to the laser.
See the “Chapter Six: Maintenance and Troubleshooting” for the

routine maintenance required for the purge gas filters.
Water Line Refer to Figure 3-3 for the location of laser head water hose connec-
Connections tors.
The cooling water source can be facility water or a closed-loop
cooling system. If facility water is used, ensure that the water meets
the requirements listed in Table 1-1. Refer to the paragraph titled
“Cooling Water” in this chapter for additional information.
The recommended hose for cooling water consists of 3/8 inch
(9.5 mm) ID nylon reinforced PVC water hose. Water cooling lines
longer than 30 feet may require larger diameter lines to provide
sufficient water flow. Use 1/4 inch NPT thread to connect main
cooling lines to the laser head. The 1/8 inch NPT are for cooling
lines to accessories such as water cooled shutters.
After connecting the water hoses, verify that there are no water leaks
as follows:
• Open the valve in the water drain line.
• Slowly open the valve in the water supply line.
With the water supply pressure and water line differential pressure
in accordance with Table 1-1, check all connections for leaks.
3 - 10
This page intentionally left blank.
3 - 11
2
4
1. Mounting dovetails (both sides) 3. Dust cap (remove before operation)

2. Purge gas port (3 mm or 1/8” hose barb) 4. Laser beam exit aperture (when dust cap is
removed)
5
CONTROL INTERFACE CONNECTOR
8 25 POSITION (PINS)
48 VDC POSITIVE (+) CONNECTION
5.5mm [#12-32] STUD 48 VDC RETURN CONNECTION
9
4.8mm [#10-32] STUD
COOLANT SUPPLY COOLANT RETURN

6
(INLET) (OUTLET) 7
1/4 NPT FEMALE 1/4 NPT FEMALE
5. DB 25 Control cable connector 8. DC positive (+) terminal

6. Coolant inlet 9. DC negative (–) return terminal
7. Coolant outlet
Figure 3-3. Laser Head Mounting and Connection Detail
3 - 12
Table 3-4. Laser Head Indicators and Connectors
ITEM CONTROL FUNCTION

Can be used for mounting laser to system and also for mounting laser beam
1 Mounting dovetails
delivery hardware. See Figure 3-2 for dovetail mounting details.
6 STD cubic feet/hour (2.8 liters per minute) Nitrogen 99.95% purity or
2 Purge gas port 99.995% oil free air filtered with particle air filter to <1 µm and dew point
10°C (18°F) lower than inlet cooling water temperature.
Laser beam exit aper-

3 The output beam exits the laser head from this aperture.
ture
Ensure pin on beam shaping unit engages fully with this slot to ensure correct
4 Index slot
alignment.
Connector for a DB25 interconnection cable. This connector supplies control

DB25 control cable and input modulation signals to the RF amplifier within the laser head, and
5
connector supplies status information from the RF amplifier. Refer to Chapter Four for a
complete description of signals at this connector.
Connection for water hose (supply). Cooling water must meet specifications
6 Cooling water inlet listed in Table 1-1. Refer to “Selecting The Correct Cooling Water Tempera-
ture” in this chapter for additional guidelines.
Connection for water hose (return). Cooling water must meet specifications
7 Cooling water outlet listed in Table 1-1. Refer to “Selecting The Correct Cooling Water Tempera-
ture” in this chapter for additional guidelines.
Connects +48 VDC from the DC power supply to the laser head. For connec-
8 48 VDC IN (+) tions to the power supply, refer to the installation instructions provided by the
power supply manufacturer.
Connects to the DC supply negative terminal. For return current. This terminal
9 48 VDC RETURN (–)
is electrically common with the laser head metal housing.
DC Power The primary DC power connection that must be made is between the
Connections DC power supply and the laser head.
The “48 VDC RETURN” terminal is electrically common with

the laser head metal housing.
3 - 13
Input power to the laser head is made at the terminals labeled

+48 VDC and 48 VDC RETURN which are for the +48 VDC input
and the return respectively. The lug labeled +48 VDC should be
connected to the positive terminal of the DC power supply. The lug
with the 48 V RETURN label connects to the negative terminal on
the DC power supply. The maximum cable length recommended for
the DC power supplies is 18 inches (45 cm). Twisting together the
two wires between the DC supply and the laser head will minimize
the inductance in these leads.
3 - 14
Control Interface
CHAPTER FOUR: CONTROL INTERFACE
Introduction This chapter describes the interface required to operate the

DIAMOND E-150 OEM laser system. Critical signals which control
laser power are the pulse width and pulse period to the RF amplifier
in the laser head. Typical laser output power for various operating
pulse widths and periods is shown in Chapter Five, Operation.
RF Amplifier The RF amplifier control and indicator signals are summarized in

Table 4-1 and are accessed through a DB25 connector on the rear of
Control the laser head. To operate the laser, two input signals are required, as
Connector indicated in Table 4-1. In order to monitor the condition of the
Interface system, six output signals are provided and recommended for use in
the control system. There are two test signals that are also available
and which can be used to test the integrity of the input circuitry. The
test function provides a pulse width of 100 µs at a pulse period of
1,000 µs which also could be used to test the performance of the
laser. Detailed descriptions and pinouts of the control connector
interface are provided in Table 4-2.
Input Signal The two inputs required to operate the laser are the ENABLE and
Requirements MODULATION signals. Figure 4-1 shows the schematic of the
input circuit of the RF amplifier interface circuit.
The ENABLE signal is typically used in safety circuits and also
provides an very easy channel to enable and disable the laser. It
could be connected with such faults as the water flow interlock or a
safety interlock to disable laser operation when some other opera-
tion is taking place. Connecting this input to the RETURN will
enable the RF amplifier thus allowing laser operation when the DC
power supply is also enabled.
The second function required to operate the laser is the MODULA-
TION signal. This signal will determine the laser “on” interval typi-
cally called the pulse width. The time interval between the start of
successive “on” periods is called the pulse period. The pulse width
must be in the range of 2 µs to 1,000 µs. MODULATION pulse
widths longer than 1,000 µs will automatically be limited to
1,000 µs by the protection circuit in the RF amplifier. The duty cycle
must be limited to no more than 70%. The duty cycle is the ratio of
the pulse width divided by the pulse period and then multiplied by
4-1
Table 4-1. Summary of RF Amplifier Control and Indicator Signals
IDENTIFICATION BRIEF DESCRIPTION CONNECTION

INPUT SIGNALS
Controls laser average output power through input of pulse width

MODULATION Required
and pulse period.
ENABLE Enables laser operations. Can be used in safety circuit. Required
TEST ENABLE Activates the test modulation output. Test function
OUTPUT SIGNALS
Warning indicating that the system has exceeded the maximum

DUTY CYCLE LIMIT Recommended
duty cycle.
Warning indicating error conditions related to tube or RF cable

VSWR LIMIT Recommended
problem.
DIGITAL FORWARD Warning indicating low RF power from the RF amplifier. Recommended
DIGITAL REFLECTED Warning indicating high reflected power from tube or RF cable. Recommended
ANALOG FORWARD Signal proportional to the forward RF voltage. Recommended
ANALOG REFLECTED Signal proportional to the reflected RF voltage. Recommended
Provides modulation signal for testing laser and input circuitry at

TEST MODULATION Test function
10% duty cycle.
OVER TEMPERATURE Signal that indicates excessive inlet water temperature Recommended
100. If either the duty cycle or the pulse width exceeds these limits
a warning will occur on the DUTY CYCLE output. A more
complete description of this signal and typical waveforms follow
later in this chapter.
Drive Circuit for An example of a drive circuit to interface to the inputs described in
RF Amplifier the previous paragraph is shown in Figure 4-2. Suitable input
devices are shown in Table 4-3.
The DIAMOND E-150 input interface shown in Figure 4-1 is
designed to be driven by a differential line driver meeting the
requirements of EIA Standard RS-422A. Common mode voltage on
the driver signals should be kept as low as possible and cannot
exceed ±15V relative to the laser system ground. Examples of suit-
able line drivers are indicated in Table 4-3.
4-2
Control Interface
Table 4-2. RF Amplifier DB25 Connector Pinouts
PIN
FUNCTION DESCRIPTION
NUMBER(S)
ANALOG FORWARD Analog output signal representing forward voltage from the RF
1
voltage output signal amplifier to the laser head. +5V full scale.
ANALOG
Analog output signal representing reflected voltage from the tube.
2 REFLECTED voltage
+5 V full scale.
output signal
Connecting this pin to return enables the RF amplifier. This pin can
ENABLE also be used for external safety interlock. If an over-temperature
3
input signal fault occurs, this pin will need to be disconnected from return then
re-connected to return to reset the enable signal.
6 — Not currently used on this product.
5 (+) and TEST MODULATION Differential output signal that produces a 100 µs pulse width at a
18(–) —output signal pulse period of 1,000 µs. See TEST ENABLE.
Differential input signal that controls the laser output. Laser output
7 (+) and MODULATION
power will be present for the duration of this pulse only. Pulse widths
20 (–) —input signal
should be in the range of 2 to 1,000 µs at <70% duty cycle.
Differential signal that does not change state when the RF amplifier
8 (+) and DIGITAL REFLECTED
is modulated on. If this signal does change state, this indicates a
21 (–) power—output signal
failed laser tube, RF cable, or RF connector.
Differential signal that changes state when the RF amplifier is modu-

9 (+) and DIGITAL FORWARD
lated on. Under a failed condition of the RF amplifier, this signal will
22 (–) power—output signal
not change states.
Differential signal that does not change state unless the modulation
10 (+) and DUTY CYCLE LIMIT
pulse is on for more than a 70% duty cycle or a modulation pulse
23 (–) —output signal
width longer than 1 ms.
Differential signal that does not change under normal operating

11 (+) and VSWR LIMIT conditions. It will turn on during modulation if there is a tube fault
24 (–) —output signal that causes an excessive mismatch between the laser tube and the RF
amplifier.
TEST ENABLE Enables the TEST MODULATION output signal when connected to
12
—input signal the RETURN.
13, 19 and 25 — Not currently used on this product.
14, 15, 16 RETURN Reference for pin 1, 2, and 3.
Differential signal changes state (pin 4 goes low and pin 17 goes
high) when cooling water exceeds 60°C limit. When this limit is
OVER
4 (+) and exceeded, modulation of the laser is stopped until water temperature
TEMPERATURE
17 (–) is reduced. The water temperature must be lowered to less than 40ºC
—output signal
and the ENABLE signal must be cycled to enable the modulation
again.
4-3
332 ohm +5 V
MOD (–), PIN 20
1N4148
100 pF HCPL 2601
MOD (+), PIN 7 2 3
1 Kohm 0.1 pF
1
8
7 6
4
CUSTOMER INTERFACE
+5 V
HCPL 2630 GND
8
INTERFACE
CONNECTOR
1 Kohm
+5 V
INTERFACE
3 BOARD
6 LOGIC
432 ohm
4
5
470 pF 1N4148
ENABLE, PIN 3
GND +5 V
14
15 ENABLE RETURN
PINS 14, 15, OR 16 4.7 Kohm
16
TEST ENABLE GND

PIN
Figure 4-1. Input Circuit of RF Amplifier
Output Signal There are six output signals from the RF amplifier that indicate the
Recommendation status of the RF amplifier and laser tube. These six outputs provide
useful information to the user on the function of the laser system.
Figure 4-3 shows a schematic of the output circuits located in the RF
amplifier interface circuit. Although monitoring of these six outputs
is not required, it is strongly recommended for the overall ease of use
of the complete system.
Their purpose is to warn the user of potential faults and can assist in
the diagnosis of several types of operating problems. Some common
situations when these warnings are useful is when noisy input
signals, incorrect pulse widths or pulse periods have been selected.
4-4
Control Interface
+5 V
0.1 µF
GND
TO MOD (+), PIN 7
PULSE
GENERATOR
TO MOD (–), PIN 20
DIFFERENTIAL
LINE DRIVER
GND SN75172 OR
EQUIVALENT
TO ENABLE, PIN 3
SAFETY
OR ENABLE SAMPLE
CIRCUIT 14 SIGNAL
1 Kohm 1 Kohm WAVEFORMS
TO RETURN 15
2N2222
PINS 14, 15, OR 16 16
IN4733 IN4002
CABLE TO
RF AMP
GND INTERFACE
CUSTOMER CIRCUIT CONNECTOR
Figure 4-2. Typical Drive Circuit for RF Amplifier
Table 4-3. Examples of Line Drivers Meeting RS-422A
DEVICE PART NUMBER DESCRIPTION MANUFACTURER

SN75172
AM26LS31C
MC3487 Quad Driver Texas Instruments
SN75174
SN55ALS194
One example would be selecting a duty cycle of 75% and the user
observing unstable laser performance. The warning indicator DUTY
CYCLE LIMIT will show the error and make it possible to rapidly
correct this problem.
4-5
+5 V
AM26C31
16
0.1 µF GND
INTERFACE 1
2 DUTY CYCLE (+), PIN 10
BOARD 3 DUTY CYCLE (–), PIN 23
LOGIC
6
7 VSWR (+), PIN 11
5
10 VSWR (–), PIN 24
9
11 DIGITAL FWD (+), PIN 9
14
15 DIGITAL FWD (–), PIN 22
13
+5 V DIGITAL REFL (+), PIN 8
4 DIGITAL REFL (–), PIN 21
EN
12 5
EN GND
+5 V
AM26C31 GND
16
0.1 µF
2 GND TEST MOD (+), PIN 5
1
3 TEST MOD (–), PIN 18
7
6 OVER TEMP (+), PIN 4
5 OVER TEMP (–), PIN 17
10
9
11
14
+5 V 15
13
4
EN
12 5 14
EN GND
RETURN 15
PIN 14, 15, OR 16 16
1.5 K 2K
GND GND
–
100 ohm ANALOG FWD, PIN 1
+
GND
LMH6644
1.5 K 2K
GND – 100 ohm ANALOG REFL, PIN 2

+
LMH6644 RF AMP INTERFACE
RF AMP INTERFACE CIRCUIT CONNECTOR
Figure 4-3. Output Circuit of RF Amplifier
4-6
Control Interface
Output Signal The DUTY CYCLE LIMIT and the VSWR LIMIT warnings indi-
Description cate when the control circuitry in the RF amplifier is activated and
limiting the operation of the RF amplifier. When these functions are
activated, the output power of the laser can be unstable or much
lower than expected. If there is a DUTY CYCLE LIMIT warning,
then check the MODULATION pulse width and pulse period to
ensure that they are not exceeding maximum duty cycle limit or
1,000 µs pulse width.
The VSWR LIMIT indicates that the ratio of the reflected RF
voltage to the forward RF voltage has exceeded a preset limit. This
typically indicates a problem with the tube. In some transient
starting situations, the VSWR LIMIT warning will be activated. We
recommend checking the status of this indicator about 100 ms after
starting the MODULATION signal. If the warning signal persists
during stable operation, the most likely source is a problem with the
laser tube. The unit should be replaced if the laser power is low.
The DIGITAL FORWARD warning indicates that the forward RF
voltage is below a preset limit. As with the VSWR limit, it is recom-
mended to start monitoring this warning 100 ms after starting the
laser MODULATION signal. If the warning persists during contin-
uous operation of the laser, then the source of the problem is the laser
head. The unit should be replaced if the laser power is low.
The DIGITAL REFLECTED warning indicates that the reflected RF
voltage is above a preset limit. As with the DIGITAL FORWARD
and DUTY CYCLE LIMIT warnings, it is recommended to monitor
this indicator about 100 ms after starting the MODULATION signal.
If the warning persists during continuous operation of the laser, then
the source of the problem is the laser head. The unit should be
replaced if the laser power is low.
Monitoring Circuit An example of a monitoring circuit that can be connected to the

Example output of the RF amplifier interface circuit is indicated in Figure 4-4.
Suitable input devices are shown in Table 4-4.
The DIAMOND E-150 output circuits shown in Figure 4-3 is
designed to use line receivers meeting the requirements of EIA Stan-
dard RS-422A. Common mode voltages on the drive signals should
be kept as low as possible and cannot exceed ±15 volts relative to the
laser system ground. Examples of line receivers are shown in
Table 4-4. It is recommended that the OVER TEMP outputs also be
monitored.
4-7
+5 V
LINE
2.7 Kohm
2.7 Kohm
2.7 Kohm
2.7 Kohm
RECEIVER
+5 V
SN75173
DUTY CYCLE (+), PIN 10

0.1 µF
DUTY CYCLE (–), PIN 23 GND
50 V
2
VSWR (+), PIN 11 3
1
VSWR (–), PIN 24 6 SYSTEM
5 INTERFACE
DIGITAL FWD (+), PIN 9 7 ELECTRONICS
DIGITAL FWD (–), PIN 22 10
11
9
DIGITAL REFL (+), PIN 8
14
13
DIGITAL REFL (–), PIN 21 15
+5 V
RF AMP INTERFACE
4
2.7 Kohm
2.7 Kohm
2.7 Kohm
2.7 Kohm
EN
12 8
EN
GND CUSTOMER CIRCUIT GND
Figure 4-4. Typical Monitoring Circuit
Table 4-4. Examples of Line Receivers Meeting RS-422A
DEVICE PART NUMBER DESCRIPTION MANUFACTURER

SN75173
AM26LS32A
Quad Receiver Texas Instruments
MC3486
SN75175
4-8
Control Interface
Test Function The test function provides a method to check the operation of the
Operation input circuit of the RF amplifier interface. Enabling the test function
provides a pulse width of 100 µs at a pulse period of 1,000 µs. Using
this test function will operate the RF amplifier and make it possible
for laser operation. Ensure that when this function is used that all
personnel are in a safe location and that the laser beam is suitably
blocked.
When using the test circuit ensure that all personnel are not in
the beam path and that the laser beam is suitably blocked.
A schematic of the test circuit and connections that will enable its
operation are shown in Figure 4-5. Both the ENABLE and the TEST
ENABLE functions must be connected to the RETURN for the laser
to operate. For purposes of safety one of these switches should be a
momentary switch.
RF AMP INTERFACE
CONNECTOR TEST HARDWARE — CUSTOMER SUPPLIED
MOD (+), PIN 7

MOD (–), PIN 20
ENABLE, PIN 3
RF AMP INTERFACE CIRCUIT
RETURN, PIN 14
RETURN, PIN 15
TEST MOD (+), PIN 5
TEST MOD (–), PIN 18
TEST ENABLE, PIN 12
ANALOG FWD, PIN 1
ANALOG REFL, PIN 2
TO OSCILLOSCOPE
RETURN, PIN 16
Figure 4-5. Interface for Test Function
4-9
The test function provides a reliable method to check the function of

the RF amplifier interface circuit, the output of the RF amplifier, and
the output of the laser. If there is a problem with the interface
circuitry, then the RF amplifier and the laser will not operate when
the test circuit is connected as shown in Figure 4-5. The output of the
RF amplifier can be monitored by observing the ANALOG
FORWARD signal. It should be as shown in Figure 4-6 with peak
voltage of 4.0V when observed on a oscilloscope.
Output Signal The output waveforms of the DUTY CYCLE LIMIT, VSWR
Waveforms LIMIT, DIGITAL FORWARD, and DIGITAL REFLECTED are
shown in Figure 4-6 through Figure 4-10 along with the ANALOG
FORWARD output and the MODULATION input signals. The
ANALOG FORWARD signal is shown to clearly indicate when RF
power is being delivered to the laser tube under a variety of condi-
tions. The first set of waveforms is for normal operation without any
warnings activated and the following three set are warnings in the
active condition. All of these signals are at the noted pinout indi-
cated beside the figure and referenced to ground. An active VSWR
LIMIT is shown in Figure 4-9 and notes that the ANALOG
FORWARD signal shows that the tube is operating at 10% duty
cycle when MODULATION signal is at a 30% duty cycle. A similar
situation is shown in Figure 4-10 for a DUTY CYCLE LIMIT in the
active state. The MODULATION signal is at a 75% duty cycle while
the tube is actually operating at an average of 70% duty cycle.
Similar limiting of the pulse width will also occur when the pulse
width is longer than 1,000 µs.
It is recommended to sense the status of the output signals from the
RF amplifier on the trailing edge of the MODULATION signal. All
of the output signals are present for 1 to 5 µs after the MODULA-
TION(+) signal makes the transition from the TTL high to the TTL
low state. There are transient starting conditions that will activate
these warnings. If possible, design the monitoring system of the
these warning signals to neglect the first 100 ms of operation after
the laser has been off for a period of time longer than a few seconds.
This will minimize the number of false warnings.
4 - 10
Control Interface
Modulation (+): Input

pin 7 (reference pin 14)
Pulse Width = 100µs
Pulse Period = 300µs
Duty Cycle = 33%
Laser is ON when modulation signal is high
0V
1V/DIV 100µS/DIV
Analog Forward: Output

Analog Forward signal is high anytime the modulation signal is
active (high) and within specification.
0V
1V/DIV 100µS/DIV
Digital Reflected (+): Output

pin 8 (reference Pin 14)
Digital Reflected signal is high anytime the modulation signal is
inactive (low), and high anytime modulation is active (high) and
the reflected RF power is in the normal range.
Duty Cycle Limit (+): Output

pin 10 (reference pin 14) and
VSWR Limit (+): Output
0V
1V/DIV 100µS/DIV Both DC Limit and VSWR Limit signals are low anytime the
modulation signal is active (high) and neither is out of range.
Digital Forward (+): Output

Digital Forward signal is low anytime the modulation signal is
active (high) and the forward RF power is in the normal range.
0V
1V/DIV 100µS/DIV
Figure 4-6. RF Amplifier Output Signals - Normal Operating Conditions
4 - 11

Duty Cycle = 33%
0V
1V/DIV 100µS/DIV

0V
1V/DIV 100µS/DIV
Digital Reflected (+) Output

Digital Reflected signal shown at left is in a failed state. If the
level of the Digital Reflected signal is low whenever the modula-
tion signal is active (high), the reflected RF power is not within
the normal range.
0V
1V/DIV 100µS/DIV
Figure 4-7. RF Amplifier Output Signal - DIGITAL REFLECTED Active During Failed State
4 - 12
Control Interface

Duty Cycle = 33%
0V
1V/DIV 100µS/DIV

0V
1V/DIV 100µS/DIV
Digital Forward (+): Output

Digital Reflected signal shown at left is in a failed state. If the
level of the Digital Forward signal is high whenever the modula-
tion signal is active (high), the forward RF power is not within the
normal range (forward RF power is too low).
0V
1V/DIV 100µS/DIV
Figure 4-8. RF Amplifier Output Signal - DIGITAL FORWARD Active During Failed State
4 - 13

Duty Cycle = 33%
0V
1V/DIV 100µS/DIV

The Analog Forward signal should follow the Modulation signal.
Analog Forward signal shown at left is low for 2 pulses (that were
suppressed by a VSWR fault condition) and then recovers.
0V
1V/DIV 100µS/DIV
VSWR Limit (+): Output

A high VSWR Limit signal while the Modulation signal is active
(high) indicates the RATIO of reflected to forward RF power is
too high.
The ratio can be too high if the forward RF is too low or if the
reflected RF is too high.
0V
1V/DIV 100µS/DIV
Figure 4-9. RF Amplifier Output Signal - VSWR Active During Failed State
4 - 14
Control Interface
Modulation (+) Signal: Input

Duty Cycle = 75% (above the 70% limit!)
Laser is ON when modulation signal is high and within legal
0V limits.
1V/DIV 200µS/DIV

The Analog Forward signal follows the Modulation signal, but in
this case the Analog Forward signal is limited by the laser
controller and limits the Duty Cycle to the maximum of 70%.
0V
1V/DIV 200µS/DIV
Duty Cycle Limit (+): Output

The Duty Cycle Limit signal goes high for the portion of the input
command (Modulation signal) that exceeds the 70% limit.
0V
1V/DIV 200µS/DIV
Figure 4-10. RF Amplifier Output Signal - DUTY CYCLE LIMIT Active During Failed State
4 - 15
4 - 16
Operation
CHAPTER FIVE: OPERATION
Introduction This chapter provides startup, power adjustment, and shutdown

procedures for the DIAMOND E-150 OEM laser system, as well as
data plots showing typical laser performance at different control
parameters.
Startup This procedure assumes that the laser has been installed in accor-
dance with the procedures in Chapter Three, Utility Requirements
Procedure and System Installation.
Ensure all personnel in the area are wearing laser safety

eyewear appropriate for the wavelengths and power levels
produced.
Refer to Chapter Six, Maintenance and Troubleshooting, to resolve

any faults or problems encountered during startup.
Before proceeding, ensure all safety practices are in effect

including those in Chapter Two of this manual, and that the
laser is directed in a safe manner so that the output beam will
not strike an unintended target.
1. Place a suitable power sensor or a beam stop in front of the

laser to block the output beam.
2. Turn on the laser system cooling water. To avoid over-pressur-
ization of the cooling system, open the drain valve before
opening the supply valve. Check the system interlock to ensure
the water flow switch is closed.
Failure to perform the next step could result in the beam exiting
the laser when power is applied.
5-1
3. Ensure the laser functions in Table 5-1 are observed.
Table 5-1. Laser Turn-on Functions
FUNCTION COMMENT
DC power supply Off
Off. Table 4-2 lists pinouts for the RF amplifier. The RF amplifier is disabled when pin 3 is
Modulation enable
not connected to return.
200 µs
Pulse width A 200 µs pulse width in combination with a 6,000 µs pulse period is recommended for initial
turn-on. This combination should result in 15 to 30 watts output power.
6,000 µs
Pulse period A 6,000 µs pulse period in combination with a 200 µs pulse width is recommended for initial
turn-on. This combination should result in 15 to 30 watts output power.
4. Turn on the facility circuit breaker and facility On/Off switch

if installed.
5. Turn on (enable) the DC power supply. The following should
occur:
• The +48V indicator on the DC power supplies turn on.
• The simmer circuit in the laser head starts.
6. Enable the RF amplifier by connecting the ENABLE function
to RETURN. From initial cold system wait for a period of 20
seconds after applying DC before applying modulation
command. If the laser has been off for a long period of time
(hours) this period should be greater than 2 minutes.
7. Turn on the modulation signal and adjust for the desired
output. Refer to the paragraph below entitled,
“Adjusting the E-150 Output”, for additional information.
Adjusting the The DIAMOND E-150 can operate using various pulse formats
which allows full user control of the output depending on the appli-
E-150 Output cation. Parameters that can be controlled by the operator that affect
the output include:
• Pulse period: 10 µs minimum
(or pulse frequency: 100 kHz maximum)
• Pulse width: 2 to 1,000 µs
5-2
Operation
Varying one or both of these parameters impacts the following

output characteristics:
• Average output power
• Peak pulse power (pulse energy)
• Duty cycle (range: 0 to 70%)
The total number of possible input parameter variations and the
resulting output is quite large. The following discussion provide
graphs and examples of many of the possibilities:
A graphical definition of the pulse width is shown in Figure 5-1.
During the time interval of the pulse width, the RF power is directed
to the laser head. In the DIAMOND E-150 laser system, the RF
frequency is 81 MHz. The pulse width is the time that the RF is
turned on and the pulse period is the time between the leading edges
of these repetitive pulses. Another way to describe the pulse period
is the pulse frequency which is just the inverse of the pulse period.
A pulse period of 1,000 µs corresponds to an operating frequency of
1 kHz.
PULSE WIDTH
81 MHz
PULSE PERIOD
PULSE WIDTH
DUTY CYCLE = X 100%
PULSE PERIOD
Figure 5-1. Typical Pulse/Modulation
In order to have an efficient laser, all the power that is developed by

the RF amplifier must be delivered to the laser tube. In practice, over
95% of the power that is developed by the RF amplifier is delivered
to the laser tube and the remaining power is reflected back toward
the RF power supply. The waveforms of the forward RF voltage
directed to the tube and then reflected are shown in Figure 5-2.
These parameters are important in the function of the DIAMOND
E-150 laser system and they have several related warning functions
discussed in Chapter Four.
5-3
3
RF VOLTAGE
0
0 1000 2000 3000 4000 5000 6000
TIME (µs)
A. FORWARD RF
3
RF VOLTAGE
PULSE WIDTH = 300 µs

2 PULSE PERIOD = 1000 µs
0
0 1000 2000 3000 4000 5000 6000
TIME (µs)
B. REFLECTED RF
Figure 5-2. Laser Tube Forward and Reflected Voltage Waveforms
5-4
Operation
In order to adjust the laser power, two different alternatives are

possible and these are shown in Figure 5-3. The center illustration
shows the starting condition with a 100 µs pulse width, a pulse
period of 1,000 µs and a typical output of about 40W. One method
to increase the laser power is to increase the pulse width and leave
the pulse period the same. This is illustrated in the top trace in
Figure 5-3. Under these conditions the pulse width has been
increased to 200 µs and the output power has increased to about
80 W. The other method to increase the laser power, is to decrease
the pulse period while leaving the pulse width the same. The lower
trace of Figure 5-3 shows the reduced pulse period of 500 µs and the
same pulse width of 100 µs. The output power would increase to
about 80W.
Figure 5-4 shows the output power at different pulse periods
(frequencies) and pulse widths for the E-150. Each curve in these
plots represents different pulse periods or operating frequency.
Changing the pulse width has the effect of moving along one of the
lines labeled with a pulse period. Changing the pulse period has the
effect of moving vertically on this chart.
There are a large number of pulse widths and pulse periods that can
deliver the same average output power. The correct pulse parameters
depend on the specific application. Often the effective speed of the
beam on the sample will determine the desired pulse period. As the
speed increases, then the pulse period will need to be decreased.
Often there are other factors such as edge finish which will be
important in selecting both the pulse parameters and the average
operating power for a specific process. As the pulse width is varied,
there are also effects on the peak power available from the laser. The
range of the peak power is illustrated in Figure 5-6. Generally, the
peak power increases as the duty cycle decreases.
The form of the instantaneous output power is shown on
Figure 5-5a. Each laser pulse has a 90 µs rise time to full power and
on the trailing edge a similar 90 µs decay time from full power to no
laser output. For laser pulses of several hundred microseconds dura-
tion, there is little impact on the laser performance due to this rise
and fall time. But for pulses of about 100 µs and less, the actual laser
output is more triangular in shape than square as shown in
Figure 5-5b. The advantage of this characteristic is at the short pulse
periods, the peak processing power decreases due the rise and fall
time. This leads to more process control for many applications. As
the pulse period is reduced for these triangular shaped peaks, the
bases of the triangles merge into each other. This has the effect of
being a quasi CW performance for these short pulse widths. This
effect has been observed for pulse period of 100 µs and a pulse width
of about 50 µs.
5-5
3
RF POWER (kW)
POWER: 80 WATTS
2 PULSE WIDTH: 200 µs
PULSE PERIOD: 1000 µs
0
0 1000 2000 3000 80 WATTS CAN BE ACHIEVED BY
TIME (µs) INCREASING THE PULSE WIDTH WHILE
LEAVING THE PULSE PERIOD AT 1000 µs.
4
3
RF POWER (kW)
STARTING POWER: 40 WATTS

0
0 1000 2000 3000
TIME (µs) 80 WATTS CAN BE ACHIEVED BY
DECREASING THE PULSE PERIOD WHILE
LEAVING THE PULSE WIDTH AT 100 µs.
4
3
RF POWER (kW)
POWER: 80 WATTS
0
0 1000 2000 3000
TIME (µs)
Figure 5-3. Example of Changing Laser Power
5-6
Operation
Figure 5-4. Typical DIAMOND E-150 Laser Output Power Plots
5-7
160
INSTANTANEOUS OUTPUT POWER

90 µs RISE TIME AND FALL TIME
120
80
40
0
0 1000 2000
TIME (µs)
A. Pulse Width: 200 µs, Pulse Period: 500 µs
120
INSTANTANEOUS OUTPUT POWER
90
60
30
0
0 1000 2000
TIME (µs)
B. Pulse Width: 50 µs, Pulse Period: 500 µs
Figure 5-5. Instantaneous Laser Output Power Showing Rise and Fall Times
The high effective processing power of the DIAMOND E-150 laser

results from its square-wave pulse performance. The primary vari-
ables of the effective processing power are the pulse width and the
duty cycle. Figure 5-6 shows the range of the peak power during a
pulse for various pulse widths. The pulse power is the average power
during a single pulse. Increasing the duty cycle has the effect of
moving vertically down on this graph.
5-8
Operation
Typical E-150 Peak Powers at 10%, 35% and 70% Duty Cycles
Values shown are typical values obtained from a typical DIAMOND E-150 laser with less
than 500 hours of operation. They are not intended to reflect performance for each indi-
vidual laser.
Figure 5-6. Effective Processing Power vs. Pulse Width
5-9
The typical power stability curves at different duty cycles is shown

in Figure 5-7. Note that power measurements were taken over a 5
minute period, ignoring the first 10 seconds..
Figure 5-7. Typical Power Stability at Different Duty Cycles
5 - 10
Operation
The typical near-field beam profile at 70% duty cycle is shown in

Figure 5-8.
Figure 5-8. Typical Near-field Beam Profile at 70% Duty Cycle
5 - 11
The typical beam divergence at 70% duty cycle is shown in

Figure 5-9.
Figure 5-9. Typical Beam Divergence at 70% Duty Cycle
5 - 12
Operation
Shutdown
Procedure
Failure to perform the next step could result in the beam exiting
the laser when power is applied during turn-on.
1. Set the laser system functions as indicated in Table 5-2. This

step is all that is required for temporary shutdown when oper-
ating in a normal environment. If the humidity is high or for
full system shutdown, complete the following steps.
2. Turn off the facility circuit breaker and facility on/off switch if
installed.
3. Wait approximately 30 seconds for the system to cool down,
then turn off the laser system cooling water.
Table 5-2. Control Unit Settings for Laser Shutdown
CONTROL UNIT SWITCH INDICATION

Output beam Position a beam block or suitable power meter to block the output beam.
Modulation Off.
DC power supply Off (the +48Vindicator turns off.)
5 - 13
5 - 14
Maintenance and Troubleshooting
CHAPTER SIX: MAINTENANCE AND

TROUBLESHOOTING
Introduction This chapter contains preventive maintenance procedures, trouble-

shooting, and corrective actions. The electrical interface that these
are based on include the mandatory functions and the recommended
warning functions. Without these functions available in some form,
troubleshooting the laser system is extremely difficult.
This chapter includes troubleshooting procedures for the DC power
supply option provided by Coherent.
To perform the procedures in this chapter, there is potential

access to laser output power. Follow the below listed safety
guidelines:
Safety Guidelines for Troubleshooting

• Perform the shutdown procedure before performing functions
that will lead to laser output.
• Ensure the laser beam is directed at a power absorber or into a
power meter.
Preventive Monthly inspection of water and electrical connections will assist in

keeping the laser system in good operating condition.
Maintenance
Water System Inspect water hoses, fittings, and connections for signs of wear, cuts,
Inspection nicks, corrosion, or leaks. Water connections are located on the laser
head. In addition, inspect laser system connections to facility water
supply and drain lines. Repair water leaks and replace worn hoses
immediately.
Optics Inspection Since the optical train is sealed, periodic inspection and cleaning of
and Cleaning optical components is not required. Periodic maintenance of the
beam delivery optics will be required.
6-1
Purge Gas Filter Regular maintenance of the purge gas filter panel is required to
Panel (option) ensure maintaining the required quality of the purge gas entering
both the laser head and the beam delivery optics.
On a weekly basis:
• Inspect filters and gas lines for any sign of leaks or damaged
purge tubing. Repair leaks and replace any damaged purge
tubing.
• The coalescing filters will collect both liquid oil and water and
will automatically discharge this liquid when it reaches a
specific level. Push the float at the bottom of each filter bowl
to make sure that it moves freely.
Every twelve months (or when filter media changes color):

• Replace filter cartridges inside the filter housings. Replace
more frequently if required. When changing filters, always
place the coalescing pre-filter closest to the air compressor as
shown in Figure B-2. To change a filter, turn off the laser and
turn off the purge gas. Remove the filter bowl and clean out
bowl. Replace the filter element and replace the bowl. Perform
the same steps for the coalescing filter.
• Replace the air dryer by removing the fittings and dismounting
it from the panel. Replace with like filter. Note the air flow
direction. Fitting connections should be sealed with Teflon
tape.
6-2
Electrical
Inspection
Do not remove the DC power supply cover or covers on the laser

at any time. These units contain no user serviceable components.
Perform the shutdown procedures prior to performing the elec-

trical inspection. Disconnect the DC power supply line cord
from facility power.
• Inspect electrical connections to ensure good contact.

• Also check that wiring and insulation are in good condition,
free of cuts, nicks, and excessive wear. Look for discoloration
on the wire insulation, a sign that excessive heat is building up
in the wire. In addition, inspect the wiring to your connector
and the facility AC hook-up for signs of overheating.
• Inspect electrical connections inside the laser head.
• Ensure the DC connections at both the DC power supply and
at the RF amplifier are securely connected.
6-3
Troubleshooting Charts 1 through 4 provide troubleshooting flow charts with supple-

mental information referenced to the numbered paragraphs that are
also part of the chart.
When troubleshooting the DIAMOND E-150 laser system, ensure
that the laser output beam will be safely contained.
One practical method to determine power is by using a Coherent
LabMax meter with a thermal detector head capable of absorbing at
least 1,000 watts. There are a variety of manufacturers who can
provide power meters. A 100 µs pulse width and 1,000 µs pulse
period will provide approximately 50 watts of power.
Table 6-1. System Faults and Warning Indications
FAULT INDICATION EXPLANATION/REMEDY

If this condition persists during continuous operation, RF power from
The DIGITAL FORWARD signal (pins 9 the RF amplifier to the laser tube is lower than a factory set level indi-
and 22) at the RF amplifier DB25 cating a potential problem with the RF amplifier. This signal should
connector is active (not changing state). be checked 100 ms after starting the modulation signal.
If the problem persists and laser power is low, replace the laser.
If this condition persists during continuous operation, reflected RF

The DIGITAL REFLECTED signal power from the laser tube to the RF amplifier is greater than a factory
(pins 8 and 21) at the RF amplifier DB25 set level indicating a potential problem with the tube. This signal
connector is active. should be checked 100 ms after starting the modulation signal.
The VSWR LIMIT indicates that the ratio of the reflected RF voltage
to the forward RF voltage has exceeded a preset limit. This typically
The VSWR LIMIT (pins 11 and 24) at the indicates a problem with the tube. In some transient starting situa-
RF amplifier DB25 connector is active. tions, the VSWR LIMIT warning will be activated. Check the status
of this signal about 100 ms after starting the modulation signal.
The duty cycle is limited to 70% and the pulse width must be
The DUTY CYCLE LIMIT (pins 10
<1,000 µs. Exceeding 70% duty cycle or a pulse width in excess of
and 23) at the RF amplifier DB25
1,000 µs will cause this function to become active. Increase the modu-
connector is active.
lation pulse period or reduce pulse width to correct this problem.
The cooling water temperature has exceeded the maximum tempera-

The OVER TEMPERATURE (pins 4 ture of 60°C (140°F). At this point the laser modulation is inhibited
and 17) at the RF amplifier DB25 and there is no laser output. Check the water flow rate and decrease
connector is active. the inlet water cooling temperature. The inlet water temperature
should not exceed a maximum of 35°C (95°F).
6-4
This page intentionally left blank.
6-5
Chart 1. Laser Does Not Start (No Output Beam)
Start
Check input voltage

Is 48 VDC at the
to DC supply and
input terminals on
enabling of DC
laser head? NO supply.
YES
Is water flow switch Is water flow rate Correct water flow

indicating proper flow OK? rate to meet
rate? NO (1) NO conditions listed in
(1) Table 1-1.
YES
YES
Replace water flow

switch.
Is RF amplifier Enable the RF

ENABLED? amplifier.
NO
(2)
YES
Is MODULATION Apply modulation

applied to the RF signal.
amplifier? NO
(3)
YES
Any warning Contact Product

signals active? Support.
(4) NO
YES
Refer to Table 6-1.
6-6
Chart 1. Laser Does Not Start (No Output Beam) (Continued)
The numbered paragraphs below are keyed to, and supplement the flowchart for this
chart.
Failure to use the water flow switch to inhibit laser operation when water flow is
below minimum requirement can result in catastrophic damage to the laser and
could result in voiding the warranty.
[1] There are two common methods of determining water flow rate. The simplest and most accurate method
is to install an in-line flow meter in the return line. The alternate method which is described below uses a
calibrated water bucket at the point water enters the drain or returns to closed loop cooling.
If water flow rate is below or only slightly above (+10%) specification, increase the water flow. If water
flow fluctuates, investigate water uses which are connected to your water source. For example, a device
on the same water line may cause a sudden drop in supply water flow.
If the laser system is connected to a closed-loop cooling system, the water flow rate test may not give a
valid result. If the drain back-pressure of the closed-loop system is too high, the water flow rate through
the laser system will not be as high as your measurement indicates. In this case, increase the input pressure
of water going to the laser system or increase diameter of cooling water hoses.
An alternate method for determining if a closed-loop cooling system is causing the problem is to connect
the laser system to a facility water supply to determine if this corrects the problem
[2] Use the ANALOG FORWARD signal as a monitor of the RF amplifier performance. The output is approx-
imately +3V at 10% duty cycle (or +2.4V at 70% duty cycle) when the RF amplifier is turned on and
should have the same duration as the modulation pulse width. To enable the RF amplifier, the ENABLE
function at pin 3 should be connected to the RETURN at pin 14.
[3] Use the ANALOG FORWARD signal as a monitor of the RF amplifiers performance. The output is
approximately +3V when the RF amplifier is turned on and should have the same duration as the modula-
tion pulse width. Ensure that the MODULATION signal to the amplifier is present and that the signal at
ANALOG FORWARD has the same pulse width and pulse period as the MODULATION signal.
[4] Warning signals monitored at the RF amplifier DB25 connector are listed below:
• Digital forward
• Digital reflected
• VSWR limit
• Duty cycle
• Over temperature
6-7
Chart 2. Low Output Power
Start
Verify the output Is DUTY Is VSWR LIMIT Is DIGITAL Is DIGITAL

power. Does output CYCLE LIMIT signal active? REFLECTED FORWARD
compare with NO signal active? NO NO signal active? NO signal active?
performance charts?
(1) (2) (3) (4) (5)
YES YES YES YES YES
Adjust modulation Replace laser Replace laser Replace laser

End pulse width or pulse using the using the using the
period so that the duty procedures in procedures in procedures in
cycle is less than 70% this chapter. this chapter. this chapter.
or pulse width is less
than 1000 µs.
Check DC power Replace DC power

supply for +48 V. supply using the
NO procedures located in
Is output OK? this chapter.
(6)
YES
Verify output beam

Contact Product
mode. Is beam shaping unit
Support.
NO damaged. NO
Mode OK?
(7)
YES YES
Contact Product
Support. Replace laser using the
procedures located in
this chapter.
6-8
Chart 2. Low Output Power (Continued)
chart.
[1] The following must be considered when evaluating system output:

• An accurate power meter capable of handling the output power must be used. The power meter should
be verified using a known good source or be calibrated on a periodic basis.
• Note that output power may degrade with tube age. For example, a tube with 4,000 operating hours
may not have the same output power as the same tube with 300 hours.
[2] The DUTY CYCLE LIMIT indicates that the selected duty cycle exceeds 70% or the selected pulse width
is greater than 1,000 µs. Correct the problem by reducing the pulse width or increasing the pulse period.
[3] The VSWR LIMIT indicates that the ratio of the reflected RF voltage to the forward RF voltage has
exceeded a preset limit. In some transient starting situations, the VSWR LIMIT warning will be activated.
Check the status of this signal about 100 ms after starting the modulation signal. If the warning signal
persists during stable operation and laser power is low, replace the laser using the procedures in this
chapter.
[4] When the DIGITAL REFLECTED signal at the RF amplifier DB25 connector is active during continuous
operation, reflected RF power from the laser tube to the RF amplifier is greater than a factory set level
indicating a potential problem with the tube. This signal should be checked 100 ms after starting the modu-
lation signal.
[5] When the DIGITAL FORWARD signal at the RF amplifier DB25 connector is active during continuous
operation, RF power from the RF amplifier to the laser head is lower than a factory set level indicating a
potential problem with the RF amplifier. This signal should be checked 100 ms after starting the modula-
tion signal.
[6] Measure the output of the DC power supply across the lugs on the RF amplifier. Refer to Figure 3-3 for
the location of the lugs. If the LED on one of the DC power supplies is not lit, that power supply is not
producing full power. Replace the DC power supply to achieve full power operation.
[7] Check mode quality as follows:

• Turn off modulation to the laser.
• A low output power setting (200 µs pulse width, 6,000 µs pulse period) of 15 to 20 watts is recom-
mended.
• Position a mode card approximately 3 meters in front of the output beam. A thermal image plate can
also be used to inspect mode.
• Apply a single modulation pulse to the laser. The output beam will mark the mode card. Inspect the
card for asymmetric mode.
If there are rings or partial rings surrounding the central beam, the laser beam is misaligned to the
optical system and might require re-alignment. Re-alignment is a factory procedure which requires
the system to be returned to Coherent.
6-9
Chart 3. Unstable Output Power
Start
A
Is DUTY Is any other Are input

CYCLE LIMIT warning parameters Adjust
signal active? NO function NO within the NO parameters.
active? range shown in
(1) (2) Figure 5-5?
YES YES YES
Replace laser Is modulation Replace

using the source free of modulation
procedures in noise, spikes, NO source.
this chapter. and other
instabilities?
YES
Adjust modulation
pulse width or pulse Output power A
period so that the duty NO stable? NO
cycle is less than 70%
or pulse width is less
than 1000 µs. YES
Check DC power Replace DC power
supply output voltage supply using the
DUTY CYCLE LIMIT
with laser on. NO procedures located in
signal active?
this chapter.
End Is output voltage stable
YES
to ± 0.5 V.
(3)
Replace laser
using the YES
procedures in
this chapter.
Is the inlet cooling Correct the condition
water temperature causing the cooling
between 10°C and NO water temperature
35°C and stable within fluctuations.
±2°C?
(4)
YES
Replace laser
using the
procedures in
this chapter.
6 - 10
Chart 3. Unstable Output Power (Continued)
chart.
[1] The DUTY CYCLE LIMIT signal can be monitored at pins 10 (+) and 23 (–) at the RF amplifier DB25
connector. When this signal is active, the modulation selected is >70% or the pulse width exceeds
1,000 µs. Reduce the duty cycle to <70% to or reduce the pulse width to <1,000 µs to eliminate this
problem. Reduce the duty cycle by lowering the pulse width or pulse period settings, or by lowering a
combination of both settings.
[2] The VSWR LIMIT indicates that the ratio of the reflected RF voltage to the forward RF voltage has
exceeded a preset limit. This typically indicates a problem with the tube. In some transient starting situa-
tions, the VSWR LIMIT warning will be activated. Check the status of this signal about 100 ms after
starting the modulation signal. If the warning signal persists during continuous operation, and the laser
power is low or unstable, return the laser to Coherent using the procedures in this chapter.
When the DIGITAL FORWARD signal at the RF amplifier DB25 connector is active during continuous
operation, RF power from the RF amplifier to the laser head is lower than a factory set level indicating a
potential problem with the RF amplifier. This signal should be checked 100 ms after starting the modula-
tion signal. If the warning signal persists during continuous operation, and the laser power is low or
unstable, return the laser to Coherent using the procedures in this chapter.
When the DIGITAL REFLECTED signal at the RF amplifier DB25 connector is active during continuous
operation, reflected RF power from the laser tube to the RF amplifier is greater than a factory set level
indicating a potential problem with the tube. This signal should be checked 100 ms after starting the modu-
lation signal. If the warning signal persists during continuous operation, and the laser power is low or
unstable, return the laser to Coherent using the procedures in this chapter.
[3] Measure the output of the DC power supply across the terminals labeled +48 VDC and 48 VDC RETURN
on the laser head. Refer to Figure 4-4 for the location of the lugs. Operate laser over a range of duty cycles
from 10% to 69%.
[4] There are two common methods of determining water temperature. A simple, economical, and most accu-
rate method is a multi meter temperature accessory attached to a water hose fitting. The alternate method
which is described below consists of touching the inlet water hose.
Check inlet water temperature by touching the cooling water inlet hose attached to the laser head. If the
hose is warm to the touch, inlet water may be too hot for the system to turn on, or the system may shut
down after a short operating period. Request that facilities personnel correct this problem. Refer to the
specifications for correct inlet water temperature.
6 - 11
Chart 4. Degraded Mode Quality
Start
Verify mode Are input

quality. Any warning parameters Correct input
NO functions NO within the NO parameters.
Mode good? active? range shown in
(1) Figure 5-5?
YES YES YES
Replace laser Replace laser

End using the using the
procedures in procedures in
this chapter. this chapter.
6 - 12
Chart 4. Degraded Mode Quality (Continued)
chart.
[1] Check mode quality as follows:

• Turn off modulation to the laser.
• A low output power setting (200 µs pulse width, 6,000 µs pulse period) of 15 to 20 watts is recom-
mended.
• Position a mode card approximately 3 meters or more in front of the output beam. A thermal image
plate can also be used to inspect mode.
• Apply a single modulation pulse to the laser. The output beam will mark the mode card.
If there are rings or partial rings surrounding the central beam, the laser beam is misaligned to the
optical system and might require re-alignment.
[2] The location of the beam shaper is factory set to ensure the laser output is pointing in a specific direction.
No adjustment is required.
Note: Ensure that the laser is switched OFF while any adjustment to the lens position
is made.
6 - 13
Replacement [ ] Call your local representative or Coherent service for an

RMA number to purchase or obtain a replacement laser.
Procedure
[ ] Complete the failure description form.
[ ] Shut down laser in accordance with instructions given in
Chapter Five.
[ ] Ensure all water and electrical inputs are shut down.
[ ] Disconnect the control line (25 pin cable)
[ ] Disconnect the 48 VDC power cables.
[ ] Disconnect the purge tube.
[ ] Install the beam shaper output dust cap.
[ ] Disconnect the water lines and if available, blow out the
water input lines with low pressure compressed air. This
ensures that the internal water lines will not freeze during
shipping. Plug the water ports.
[ ] Return the laser and package in the original shipping box. It
is important for Coherent to receive the laser without any
additional damage caused by shipping or mishandling.
Drain all liquid from the laser before storage or shipment. If

exposed to temperatures at or below freezing, water left in the
laser may freeze and rupture internal components causing
permanent damage. Freeze damage is not covered under the
warranty.
6 - 14
Parts List
APPENDIX A: PARTS LIST
The following parts can be ordered by contacting Coherent

Customer Service at 1-800-367-7890 (within USA) or
1-408-764-4557 (outside USA) or your local Coherent representa-
tive.
Table A-1. Parts List
DESCRIPTION PART NUMBER

DIAMOND E-150 Laser w/Beam Shaper Assembly 1167003
Alternative Foot support 0171-249-00

– Does not support beam shaping assembly (one of each is necessary) 0171-250-00
Purge gas filter panel assembly (option) 1166836
Contact CT Components -
Replacement filter elements (for optional purge gas filter panel assembly)
see Accessories section
1/4 inch OD Teflon tubing (specify length required) 2521-0210
A-1
A-2
Accessories
APPENDIX B: ACCESSORIES
Power Meters Coherent offers a variety of instruments for laser test and measure-
ment. For additional detailed information, including product selec-
and Sensors tion guides, please visit our web site at www.Coherent.com.
Coherent’s For the most common diagnostics, Coherent recommends the

Recommendation LabMaxII™-TO power meter with a LM-1000 thermal sensor to
measure the DIAMOND E-150 laser output. This combination of
power meter and thermal sensor is ideal for the medium power
Diamond E-Series products.
The power meter is a versatile, easy to use digital meter designed for
field service and production applications. The thermal sensor is
water-cooled*, surface absorbing for powers up to 1,000 watts
covering a broad spectrum of wavelengths from 0.19 µm to 11 µm.
* Water-cooling is customer supplied.
LabMaxII™-TO Power Meter LM-1000 Thermal Sensor

Part Number 1104619 Part Number 1098409
Figure B-1. Power Meter and Thermal Sensor
B-1
Purge Gas Filter A pre-assembled purge gas filter panel assembly is available for
those needing to filter compressed air. This panel is available from
Panel Assembly Coherent or directly from CT Components, (860) 633-0277.
Coherent P/N 1166836
CT Components P/N 600218COH
Replacement filters are available from CT Components or directly
from Parker (Filtration Division). For size and mounting hole loca-
tions refer to Figure B-2 below.
Figure B-2. Purge Gas Filter Panel Assembly
B-2
Warranty
APPENDIX C: WARRANTY
DIAMOND E-150 Coherent, Inc. warrants to the original purchaser that the
DIAMOND E-150 laser conforms to the specifications published by
Laser Warranty Coherent and is free from defects in materials and workmanship.
For specific warranty terms and conditions for your DIAMOND
E-150 laser system, refer to your sales contract.
DIAMOND E-150 laser systems are warranted for parts and labor
for a period of twenty-four (24) months. Warranty begins from the
date of shipment.
DIAMOND E-150 laser and accessories do not include installation
in the purchase price.
Conditions of For warranty service requiring the return of any product to Coherent,
the product must be returned to a service facility designated by
Warranty Coherent. The Buyer is responsible for all shipping charges, taxes
and duties.
Parts replaced under warranty shall become the property of Coherent
and must be returned to Coherent, Inc., Santa Clara, or to a facility
designated by Coherent. All laser systems must be carefully packed
in a suitable shipping container(s). Coherent does not assume
responsibility for components broken in shipment due to improper
packaging or handling. The Buyer will be obligated to issue a
purchase order for the value of the replaced parts and Coherent will
issue credit when the parts are received.
Responsibilities Damage to the DIAMOND E-150 laser caused by failure of Buyer's

utilities or the Buyer's failure to maintain an appropriate operating
of the Buyer environment, is solely the responsibility of the Buyer and is specifi-
cally excluded from any warranty.
The Buyer is responsible for prompt notification to Coherent of any
claims made under warranty. In no event will Coherent be respon-
sible for warranty claims later than seven (7) days after the expira-
tion of the warranty.
C-1
Limitations of The foregoing warranty shall not apply to defects resulting from:
Warranty 1. Components or accessories with separate warranties manufac-
tured by companies other than Coherent.
2. Improper or inadequate maintenance by Buyer.
3. Buyer-supplied interfacing.
4. Operation outside the environmental specifications of the
product.
5. Improper site preparation and maintenance.
6. Unauthorized modification or misuse.
Coherent assumes no responsibility for customer-supplied material.
The obligations of Coherent are limited to repairing or replacing,
without charge, equipment that proves to be defective during the
warranty period. Replacement systems may contain reconditioned
parts. Repaired or replaced parts are warranted for the duration of
the original warranty period only. This warranty does not cover
damage due to misuse, negligence or accidents, or damage due to
installations, repairs or adjustments not specifically authorized in
writing by Coherent.
C-2
Glossary
GLOSSARY
% Percent
1/e2 Beam diameter parameter = 0.13534
°C Degrees Celsius
°F Degrees Fahrenheit
µm Micrometers = 10-6 meters
µrad Microradians = 10-6 radians
µsec Microseconds = 10-6 seconds
Ω Ohm
Ø Phase
AC Alternating Current
Amp Amperes
BNC A type of connector
CaCO3 Calcium carbonate

CDRH Center for Devices and Radiological Health (U.S. Government)
CFR Code of Federal Regulation
cm Centimeters = 10-2 meters
CO2 Carbon dioxide
DC Direct Current
DVM Digital voltmeter
FPT Female pipe thread
gpm U.S. Gallons per minute
hex Hexagon
Hz Hertz or cycles per second (frequency)
ID Inside Diameter
IR Infra-red
kg Kilograms = 103 grams

kHz Kilohertz = 103 hertz
kPa Kilopascals = 103 pascals
kV Kilovolts = 103 volts
kW Kilowatts = 103 watts
LED Light Emitting Diode

lpm Liters per minute
mA Milliamperes = 10-3 Amperes

mg Milligrams = 10-3 grams
MHz Megahertz = 106 Hz
mJ Millijoules = 10-3 Joules
mm Millimeters = 10-3 meters
mrad Milliradians = 10-3 radians (angle)
Glossary - 1
ms Milliseconds = 10-3 seconds

mW Milliwatts = 10-3 watts (power)
N2 Nitrogen
nm Nanometers = 10-9 meters (wavelength)
NPT Standard pipe tapered thread (American National
Standards Institute, B2-1-1968)
OD Optical Density, or Outside Diameter
PE Protective Earth, or
Polyethylene
psi Pounds per square inch
RF Radio frequency
RMS Root mean square (effective value of a sinusoidal wave)
STD Standard
TTL Transistor-to-Transistor Logic
V Volts
VAC Volts Alternating Current
VDC Volts Direct Current
VSWR Voltage, Standing Wave Ratio
W Watts
Glossary - 2
Index
INDEX
A I
Accessories B-1 Input circuit 4-4
Ambient (room) temperature 3-3, 3-4 Input signals 4-2
Ambient temperature 1-3 Requirements 4-1
Installation 3-5
C Equipment required 3-6
Compliance to standards relevant to CE mark 2-6
Mounting hardware locations 3-7
Connections
Preparing the facility for 3-5
DC power 3-13
Receiving inspection 3-5
Electrical cables 3-5
Unpacking 3-6
Water lines 3-5, 3-10
Interface for test function 4-9
Control interfaces 4-1
Interference
Cooling water 3-1
Potential of the system 2-5
Flow rate 1-3
Simple measures to correct 2-6
Temperature 1-3
Interlock safety 2-5
D L
DB25 connector pinouts 4-3
Laser head 1-4
DC power connections 3-13
Diagram 1-5
Drive circuit for RF amplifier 4-2
Dimensions 3-7
Dust cap 3-9
Electrical requirements 1-3
E DC input voltage 1-3
Effective processing power vs. pulse width 5-9 Maximum DC current 1-3
Electrical Peak current 1-3
Inspection 6-3 Indicators and connectors 3-12, 3-13
Requirements 3-1 Mounting hardware details 3-8
Safety 2-4 Tube 1-4
Laser head 2-4 Resonator structure 1-5
Emission, radiated compliance 2-5 Laser output power
Environmental 1-3 E-150 5-7
Ambient temperature 1-3 Laser safety (see Safety) 2-1
Operating altitude 1-3 Laser system 1-1
Relative humidity 1-3 Mounting 3-6
Tube gas consumption 1-3 Laser tube forward 5-4
Equipment required for installation 3-6 Line drivers 4-5
Example of changing laser power 5-6 M
External delivery system 3-9
Main power disconnect 3-1
F Maintenance 6-1
Fault indication 6-4 Preventive 6-1
System 2-5
G Maximum 1-3
Guaranteed performance Monitoring circuit example 4-7
Average output power 1-2 Mounting
M2 - transverse mode quality 1-2 Laser system 3-6
System warranty time 1-2
Tube shelf life 1-2 O
Operation 5-1
H Optical safety 2-1
Humidity 3-3, 3-4 Optics inspection and cleaning 6-1
Index - 1
Optics purge (gas) 3-4 Maintenance 2-5

Output
Adjusting 5-2
T
Circuit of RF amplifier 4-6 Temperature
Signal description 4-7 Ambient 1-3
Signal recommendation 4-4 Cooling water 1-3
Signal waveforms 4-10 Test function operation 4-9
Signals 4-2 Troubleshooting 6-1, 6-4
Output aperture dust cap 3-9 Degraded mode quality 6-12
Laser does not start (no output beam) 6-6
P Low output power 6-8
Processing power vs. pulse width 5-9 Unstable output power 6-10
Pulse width vs. effective processing power 5-9 Typical drive circuit 4-5
Purge gas filter panel assembly B-2 Typical laser output power
Purge gas quality 3-9 E-150 5-7
Purge specification 1-3 Typical monitoring circuit 4-8
Purpose of this manual 1-1 Typical performance
Average power range 1-2
R Beam diameter 1-2
Radiated emission compliance 2-5
Beam divergence 1-2
Recommended minimum inlet cooling water
Beam ellipticity 1-2
temperature 3-3, 3-4
Beam polarization 1-2
Reflected voltage waveforms 5-4
Beam waist diameter 1-2
Replacement procedure 6-14
Divergence asymmetry 1-2
Requirements
Modulation pulse width range 1-2
Cooling water 1-3
Optical pulse rise and fall time 1-2
Electrical
Output power stability 1-2
DC power supply option 3-1
Peak effective power 1-2
Laser head 1-3, 3-1
Pulse energy range 1-2
Input signals 4-1
Pulse frequency 1-2
Safety 2-4
Pulse period (minimum) 1-2
Utility 1-2, 3-1
Wavelength 1-2
RF amplifier
Typical pulse/modulation 5-3
Control connector interface 4-1
Features 1-6 U
U.S. export control laws compliance -vii
S Unpacking the laser system 3-6
Safety Utility requirements 1-2, 3-1
Electrical 2-4
Laser head 2-4 W
Guidelines for troubleshooting 6-1 Warning indications 6-4
Interlocks 2-5 Warranty C-1
Optical 2-1 Conditions of C-1
Requirements 2-4 Limitations of C-2
Selecting the correct cooling water temperature 3-2 Responsibilities of the buyer C-1
Shutdown procedure 5-13 Water 1-3
Simmer circuit 1-6 Cooling 3-1
Simplified system block diagram 1-4 Cooling water flow rate 1-3
Specifications 1-2 Cooling water hardness 1-3
Startup Cooling water temperature 1-3
Laser turn-on functions 5-2 Hardness 1-3
Procedure 5-1 Heat load 1-3
System Inlet pressure 1-3
Faults 6-4 Line connections 3-10
Installation (see Installation) 3-1 Particulate size 1-3
Interference potential of 2-5 pH 1-3
Index - 2
Index
Pressure drop 1-3

System inspection 6-1
Temperature stability 1-3
Wavelength 1-2
Weight
Laser head and RF Amplifier 1-2
Index - 3
Index - 4
DIAMOND™ E-150 OEM Manual
© Coherent, Inc., 08/2010 (RoHS), Printed in the U.S.A.
Coherent Part Number: 1168329, Rev. AC

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OEM Manual

DIAMOND™ E-150 Laser

5100 Patrick Henry Drive

Coherent, the Coherent Logo, DIAMOND, ModeMaster and LabMax are

Outside the USA:

Coherent provides telephone and web technical assistance as a service to

Chapter One: Description and Specifications................................................ 1-1

Chapter Two: Laser Safety ....................................................................................... 2-1

Chapter Three: Utility Requirements and

Attaching External Delivery System to Beam Shaping Unit..................................... 3-9

Chapter Four: Control Interface ........................................................................... 4-1

Chapter Five: Operation ............................................................................................. 5-1

Chapter Six: Maintenance and Troubleshooting ........................................ 6-1

Appendix A: Parts List................................................................................................ A-1

Appendix C: Warranty ................................................................................................C-1

Glossary ..................................................................................................................... Glossary-1

Index ................................................................................................................................. Index-1

2-1. Nominal Ocular Hazard Distance (NOHD)..................................................................... 2-2

4-1. Input Circuit of RF Amplifier .......................................................................................... 4-4

5-1. Typical Pulse/Modulation................................................................................................ 5-3

B-1. Power Meter and Thermal Sensor ...................................................................................B-1

3-1. Recommended Minimum Inlet Cooling Water Temperature

4-1. Summary of RF Amplifier Control and Indicator Signals............................................... 4-2

5-1. Laser Turn-on Functions.................................................................................................. 5-2

6-1. System Faults and Warning Indications .......................................................................... 6-4

A-1. Parts List ......................................................................................................................... A-1

Caution — use of controls or adjustments or performance of

This symbol is intended to alert the operator to the presence of

This symbol is intended to alert the operator to the presence of

This symbol is intended to alert the operator to the danger of

This symbol identifies DIRECT CURRENT electrical potential.

CHAPTER ONE: DESCRIPTION AND SPECIFICATIONS

Introduction The DIAMOND E-150 laser is an RF excited, sealed-tube industrial

Purpose of This manual is designed to assist the original equipment manufac-

Table 1-1. DIAMOND E-150 Specifications and Utility Requirements

M2 – Transverse mode quality (2) ≤1.2

System warranty time 2 year

Tube shelf life >1 year

Peak effective power 375 watts

Average power range (3) 20 to 150 watts

Pulse energy range 5 to 315 mJ

Pulse period (minimum) 10 µs (equivalent to a

Pulse Frequency Single shot to 100 kHz

Output power stability (4) <± 7%

Beam diameter at 60 cm (5)(6) 4.6 mm ± 1 mm

Beam waist diameter (1/e2) (2) 2.2 mm ± 0.6 mm

Beam divergence (full angle) 6.6 mrad - typical

Beam waist asymmetry (2) <1.3:1

Beam ellipticity at 60 cm (5)(6) 1.3 (Wy/Wx)

Divergence asymmetry (5)(6) 1.2 (Wy/Wx)

Beam polarization (parallel to base plate) Linear >100:1

Modulation pulse width range 2 to 1,000 µs

Optical pulse fall time (7) 35 to 65 µs

Wavelength 10.2 to 10.8 µm

Laser head assembly weight 36 lbs. (16.3 kg)

The above specifications subject to change without notice.

Table 1-1. DIAMOND E-150 Specifications and Utility Requirements (Continued)

DC input voltage(8) 48 VDC ± 1%

Maximum DC current 55 Amps

Peak current 100 Amps