1

Operating Manual
Ytterbium Laser System
YLS-10000-S2
S/N 11076750

IPG Laser GmbH

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IPG Laser GmbH

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Terminology
# Item Explanation Synonym

The complete system including Laser Fiber laser, Laser

1 Laser
source, integrated optics and fibers system, device

2 Laser Module Generates Laser radiation λ=1070 nm Module

Power Supply ON,

Signal Main Power Supply is switched
3 Laser ON “Start” (push button
on
at Laser front side)

4 Internal Optics Optical parts inside Combiner Module

Optical device for coupling fibers. Can

5 Integrated Optic be installed inside Laser cabinet or in
external cabinet.

Integrated Optic for connecting 1, 2, 4

5.1 Beam Switch or 6 Process fibers, Contains mirrors to
switch between Optical paths

Output of Beam Switch for connecting

5.2 Optical path Light path
a Process fiber

Integrated Optic for connecting one Fiber Coupler,

5.3 Beam Coupler
Process fiber Fiber/Fiber-Coupler

Guides Laser radiation from source to Glass fiber cable,

6 Fiber Cable
process optics Fiber optic cable

6.1 Feeding Fiber Fiber spliced to the Laser source

6.2 Process Fiber Exchangeable fiber cable which guides

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the laser radiation from Integrated

optics to the Processing optics

Optical path (Light path) related Safety

7 Cabinet Door Cell door
door

Unit for collimating and focusing the

8 Processing Optic
laser beam

9 Shutter The Fiber Laser contains no Shutter.

10 Absorber The Fiber Laser has no Absorber.

IPG Laser GmbH

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IPG Laser GmbH

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PLEASE TAKE TIME TO READ AND UNDERSTAND THIS OPERATING

MANUAL AND FAMILIARIZE YOURSELF WITH INFORMATION WE HAVE
COMPILED FOR YOU BEFORE YOU START USING THE PRODUCT. THIS
USER’S GUIDE SHOULD STAY WITH THE PRODUCT TO PROVIDE YOU AND
ALL FUTURE USERS AND OWNERS OF THE PRODUCT WITH IMPORTANT
OPERATING, SAFETY AND OTHER INFORMATION

INFORMATION CONTAINED IN THIS DOCUMENT IS SUBJECT TO CHANGE

WITHOUT NOTICE. IPG LASER GMBH (IPG) BELIEVES THAT THE
INFORMATION PROVIDED IS ACCURATE AND RELIABLE, HOWEVER IPG
MAKES NO WARRANTY OF ANY KIND AS TO THE INFORMATION
CONTAINED IN THIS DOCUMENT, INCLUDING WITHOUT LIMITATION THE
IMPLIED WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A
PARTICULAR PURPOSE. FURTHER, IPG DOES NOT ASSUME
RESPONSIBILITY FOR USE OF THE INFORMATION CONTAINED IN THIS
DOCUMENT OR FOR ANY INFRINGEMENT OF PATENTS OR OTHER RIGHTS
OF THIRD PARTIES THAT MAY RESULT FROM ITS USE. IPG SHALL NOT BE
LIABLE FOR ERRORS CONTAINED IN THESE DOCUMENTS OR FOR
INCIDENTAL OR CONSEQUENTIAL DAMAGES IN CONNECTION WITH THE
FURNISHING, PERFORMANCE OR USE OF THIS MATERIAL.

IPG GRANTS NO LICENSE, DIRECTLY OR INDIRECTLY UNDER ANY

PATENT OR OTHER INTELLECTUAL PROPERTY RIGHTS FROM USE OF
THE INFORMATION PROVIDED HEREIN.

IPG Laser GmbH

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Table of Content
1 General Information...................................................................................... 9
1.1 Contact ......................................................................................................... 9
1.2 About IPG Photonics .................................................................................. 13
1.3 Patent right ................................................................................................. 14
1.4 Copyright .................................................................................................... 14
1.5 Original equipment manufacturer ............................................................... 15
1.6 Scope of this Operating Manual ................................................................. 16
1.7 Device identification ................................................................................... 16
1.8 Industry Standard Compliance ................................................................... 17
1.9 Warranty ..................................................................................................... 18
1.10 Software agreement ................................................................................... 20
1.11 Declaration of Conformity ........................................................................... 28
1.12 Important Safety Advices ........................................................................... 29
2 Safety and Accident prevention .................................................................. 30
2.1 Safety Conventions in this Manual ............................................................. 30
2.2 Fundamental Safety References ................................................................ 32
2.3 General Safety references for lasers .......................................................... 35
2.4 Special Safety references .......................................................................... 37
2.5 Safety labels and location at the device ..................................................... 39
3 Device description ...................................................................................... 41
3.1 Functional principle .................................................................................... 41
3.2 Interlock and E-stop system ....................................................................... 43
3.3 Operational modes ..................................................................................... 47
3.4 Operational Controls .................................................................................. 48
3.5 Interfaces description ................................................................................. 49
4 LaserNet software ...................................................................................... 74
4.1 Settings and minimum system requirements .............................................. 74
4.2 Software installation ................................................................................... 75
4.3 Establish a connection to the laser ............................................................. 77
4.4 General Information.................................................................................... 78
4.5 Starting LaserNet software ......................................................................... 79
4.6 Main Menu of LaserNet software................................................................ 80
4.7 LaserNet Screen ........................................................................................ 93
4.8 LaserNet Property Pages ........................................................................... 95
4.9 LaserNet Program Editor .......................................................................... 121
5 Installation and Start up ............................................................................ 126
5.1 Installation requirements .......................................................................... 126
5.2 Setting up ................................................................................................. 127
5.3 Fiber Handling .......................................................................................... 136
5.4 Cleaning of fiber connector ...................................................................... 141
5.5 Optics alignment....................................................................................... 145
5.6 Connection between robot controller and laser ........................................ 150
5.7 First start up ............................................................................................. 153
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5.8 Demounting .............................................................................................. 155

5.9 Disposal ................................................................................................... 156
6 Operation ................................................................................................. 157
6.1 Switching ON / OFF the Power Supply .................................................... 157
6.2 Manual mode............................................................................................ 159
6.3 Manual mode using Laser programs ........................................................ 160
6.4 External modulation mode ........................................................................ 161
6.5 Analogue control mode ............................................................................ 163
6.6 QCW mode............................................................................................... 165
6.7 Hardwiring ................................................................................................ 167
6.8 Fieldbus .................................................................................................... 169
6.9 Multi Port Interface ................................................................................... 170
6.10 Service Mode ........................................................................................... 178
7 Fault clearance ......................................................................................... 179
7.1 Status messages ...................................................................................... 180
7.2 Warning messages................................................................................... 181
7.3 Alarm messages....................................................................................... 185
7.4 Beam Switch ............................................................................................ 209
8 Maintenance ............................................................................................. 214
8.1 Water system ........................................................................................... 214
8.2 Laser parameters ..................................................................................... 217
8.3 Optical components.................................................................................. 218
8.4 Service to be done by IPG ....................................................................... 219
8.5 In event of damage................................................................................... 220
9 Appendix A – Accessories ........................................................................ 221
10 Appendix B – Specifications ..................................................................... 223
10.1 Optical characteristics .............................................................................. 223
10.2 General characteristics ............................................................................. 224
10.3 Outside Dimensions of the device ............................................................ 225
10.4 Beam Switch specifications ...................................................................... 225
Internal 2-ways Beam Switch ........................................................................... 225
10.5 Conditioner ............................................................................................... 226
11 Appendix C ............................................................................................... 227

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1 General Information

1 General Information
1.1 Contact
USA
IPG Photonics
Corporation
Oxford, MA 01540, USA
50 Old Webster Road
Phone (877) 980-1550
Phone (508) 373-1100 Main
Fax (508) 373-1103

Sales

Phone (508) 373-1126 Sales Main

Materials Processing
Phone (508) 373-1144
Sales
Phone (508) 373-1173 Telecom Sales
Scientific & Special
Phone (508) 373-1169
Sales
E-Mail [email protected]
Customer Support
Phone (508) 373-1157
E-Mail [email protected]

Germany

IPG Laser GmbH

Siemensstr. 7
57299 Burbach
Phone +49 2736 44 20 100
Fax +49 2736 44 20 160

Sales

Phone +49 2736 44 20 342

E-Mail [email protected]
Customer Support
Phone +49 2736 44 20 451
E-Mail [email protected]

IPG Laser GmbH

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1 General Information

Italy

IPG Fibertech S.r.l.

Via Kennedy 21
20023 Cerro Maggiore
Italy
Phone +39 0331 170 6900
Fax +39 0331 170 6919
E-Mail [email protected]

United Kingdom

IPG Photonics (UK) Ltd.

22 Buckingham Gate
London SW1E 6LB, UK
Phone +44 207 828 9929
Fax +44 207 834 1521
E-Mail [email protected]

India

IPG Photonics Pvt. Ltd.

Tirumala Tech Park,
No.27, 1st cross, 2nd
Phase Doddanekundi
Industrial Area,
Bangalore 560 048 India
Phone +91 80 2852 4861
Phone +91 80 2852 4862
Fax +91 80 5116 3282
E-Mail [email protected]

Russia

IRE – Polus Co.

Vvedenskogo Sq.1
Fryazino, Moscow
1411190 Russia
Phone +7 095 526 9083
Fax +7 095 702 9573
E-Mail [email protected]
URL http://www.ntoire-polus.ru

IPG Laser GmbH

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1 General Information

Japan
IPG Photonics
Japan Limited
Technical Center,
Yokohama Business Park,
134 Godo-cho, Hodogaya-
ku, Yokohama-shi
Kanagawa 240-0005
Japan
Phone +81-45-350-5430
Fax +81-45-338-1704
E-Mail [email protected]
URL http://www.ipgphotonics.co.jp

China

IPG (Beijing) Fiber Laser

Technology Co., Ltd.
F28, 2 Jingyuan North St.
BDA
Beijing, China 100176
Phone +86-10-6787-3377 ext.1020
Fax +86-10-6787-9294
+86-138 1177 3621 (24 hours
Hotline
available)
E-Mail [email protected]

South Korea

IPG Photonics (Korea)

Ltd
Daega Bld. 3rd Floor, 641-
11 Bongmyung-Dong
Yuseong-Gu, Daejon,
Korea
Phone +82 42 825 6354
Fax +82 42 825 6352
E-Mail [email protected]
URL http://www.ipgk.kr

IPG Laser GmbH

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1 General Information

Singapore
IPG Photonics
Corporation
205 Henderson Road,
#02-01
Singapore 1594596
Phone +65-62722663
Fax +65-63773116
E-Mail [email protected]

IPG Laser GmbH

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1 General Information

1.2 About IPG Photonics

IPG delivers fiber laser in all domains of laser material processing, medical
engineering and scientific institutes and universities. IPG is the accepted market
leader in this modern fiber laser technology. IPG-Photonics contains subsidiaries
in many European, Asiatic and American developed counties. Main production site
for these lasers is Burbach in Germany with a vertical range of manufacture of
90%. This guarantees you as user a high grade of competence and reliability.
High output power, excellent beam quality, high stability and mobility are
outstanding predicates of the fiber laser. The superiority of the fiber laser is
efficiency, flexibility, modularity, thermal and mechanical robustness that comes
along with a simple constructive assembly. Further important characteristics for
the industrial use are low running costs.
Economic feasibility studies show, that it is possible to realize faster, better and
more cost-effective industrial applications with high power fiber laser. IPG has the
production capacity for a production in high piece numbers. More information you
can find under www.ipgphotonics.com.

Picture 1-1 : IPG Photonics Subsidiaries world wide

IPG Laser GmbH

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1.3 Patent right

This product is covered by the U.S. Pat. Nos. 5,422,897 and 5,774,484 and any
foreign counterparts thereof, and other patents pending (U.S. Patent Appl. No.
11/973,437)

1.4 Copyright

Copyright 2003-12 IPG Laser GmbH. All rights reserved. You may not reproduce,
transmit, store in a retrieval system or adapt this publication, in any form or by any
means, without the prior written permission of IPG, except as allowed under
applicable copyright laws.

We have identified words that we consider as trademarks. Neither the presence

nor absence of trademark identifications affects the legal status of any trademarks.

IPG Laser GmbH

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1.5 Original equipment manufacturer

IPG Laser GmbH

Siemensstraße 7
D-57299 Burbach
Germany

Visitor Adress

Carl-Benz-Str. 27
D-57299 Burbach, Germany

Commercial Register:
HR B 4466
Tax No.: 342/5828/1911
VAT No.: DE167880868

Managing Directors:
Dr. Valentin P. Gapontsev, CEO
Dr. Eugene A. Shcherbakov
Igor Samartsev

IPG Laser GmbH

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1 General Information

1.6 Scope of this Operating Manual

This Operating Manual is bound for Laser type YLS-10000-S2 with Serial Number
11076750.

This manual contains basic instructions that must be observed during initial
operation of the device, as well as during regular operation and maintenance. This
manual must therefore be read by the installer and the operating personnel in
charge prior to initial operation. It must also be permanently available at the
location where the device is being used.
All safety instructions including the instructions mentioned in other sections of this
manual must be observed. Non-observance of the safety instructions may cause
injuries, destroy the environment or damage the device.

1.7 Device identification

This manual belongs to:

Laser Model YLS-10000-S2

Serial Number 11076750

Year of
2012
production

Current revision OPERATINGMANUAL_englisch_BeamSwitch_1.5.1.doc

1
Picture 1-2 :Device idendification

1
Example, can differ
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1.8 Industry Standard Compliance

EMC-Directive: 2004/108/EC
Low voltage directive: 2006/95/EC

EMC Test:

Emission:

EN 55011: 2009 +A1:2010

Immunity:

EN 61000-3-12:2005 Emission harmonic currents

EN 61000-3-3:2008 Emission flicker
EN 61000-6-2:2005 Immunity for industrial environments
EN 61000-4-2:2009 ESD
EN 61000-4-4:2004 + A1:2010 Burst
EN 61000-4-6:2009 Conducted immunity

Laser Safety:

EN 60825-1:2008

Safety of Machinery – Electrical Equipment of Machines

EN 60204-1: 2006 + A1 2009

Emergency Shutdown:

EN ISO 13849-1:2008 Cat. III: switching off time less than 1 sec
EN ISO 13849-2:2008

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1.9 Warranty
1.9.1 General Warranty

All products are warranted by IPG against defects in materials and workmanship
for the period of time as set forth on the applicable purchase order or in the
specifications starting with the date of shipment. IPG also warrants that this
product will meet applicable specifications under normal use.

IPG shall, at its option, repair or replace any product that proves, in the reasonable
opinion of IPG, to be defective in materials or workmanship during the warranty
period. All products repaired or replaced under warranty are only warranted for the
remaining un-expired period of time in the original warranty for the particular
defective product. IPG reserves the right to issue a credit note for any defective
products that have proved defective through normal usage.

1.9.2 Warranty Limitations

This warranty excludes products, parts (including fiber connectors) or equipment

which have been tampered with, opened, disassembled, opened, or modified by
persons other than IPG personnel, misused, neglected, or damaged by accident,
used in applications which exceeds their specifications or ratings, used outside of
environmental specifications for the product, used with buyer software or
interfacing, improperly installed, maintained or otherwise abused or used other
than in accordance with the information and precautions contained in this User’s
Manual. It is the customer’s responsibility to understand and obey operating
instructions in this User’s Guide and specifications prior to operation—failure to do
so may result in voiding this warranty. Accessories and fiber connectors are not
covered by this warranty.

Buyer must claim under the warranty in writing no later than 31 days after the
claimed defect is discovered. This warranty does not extend to any third party,
including without limitation Buyer's end-users or customers, and does not apply to
any parts, equipment or other products not manufactured by IPG.

1.9.3 Driver Software

Any driver software provided now or in the future is provided solely under non-
exclusive license from IPG Laser. By using the software, you agree to the terms
herein. Trade secret laws, United States copyright laws and international treaty
provisions protect the driver software. IPG Laser reserves all ownership rights.
The owner of the device may only use the driver software only with the product(s)
identified by IPG Laser, and may make duplicate copies of the software solely for
archival backup purposes. Any alterations of the driver software will void the
warranty on the equipment provided by IPG Laser.

The driver software is provided “as is” with no warranties whatsoever, whether
express or implied, including the warranties of fitness for a particular purpose. IPG

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1 General Information

Laser does not warrant that the functions contained in the software will meet the
user’s requirements or that the operation of the equipment or driver software will
be uninterrupted or error free. Not all driver software has gone through IPG
Laser’s normal quality control or product purposes, but is provided to users as an
accommodation to respond to their requests. End-user support is not implied or
provided, and you are assumed to have working knowledge of a particular
development language. IPG Laser may make changes to the driver software and
has no obligation to distribute newer versions.

EXCEPT FOR THE LIMITED WARRANTIES EXPRESSLY SET FORTH ABOVE,

IPG SPECIFICALLY DISCLAIMS ANY AND ALL OTHER WARRANTIES TO
BUYER, INCLUDING WITHOUT LIMITATION, ANY AND ALL IMPLIED
WARRANTIES, SUCH AS FREEDOM FROM INFRINGEMENT,
MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE

1.9.4 Exclusive Remedies

THE REMEDIES PROVIDED HEREIN ARE BUYER’S SOLE AND EXCLUSIVE

REMEDIES. IN NO EVENT SHALL IPG BE LIABLE FOR DIRECT, INDIRECT,
SPECIAL, INCIDENTAL, CONSEQUENTIAL, EXEMPLARY OR PUNITIVE
DAMAGES (EVEN IF ADVISED OF THE POSSIBILITY OF SUCH DAMAGES)
ARISING FROM OR RELATING TO THE PRODUCT (INCLUDING, LOSS OF
PROFITS) WHETHER BASED ON CONTRACT, TORT OR ANY OTHER LEGAL
THEORY. IPG'S MAXIMUM LIABILITY WILL NOT EXCEED, IN THE
AGGREGATE, THE TOTAL AMOUNT PAID FOR THE PRODUCT BY BUYER.

1.9.5 Service and Repair

IMPORTANT ADVICE:
Never send any product back to IPG without a Return Merchandise
Authorization (RMA). Please request a RMA Clearance Form at IPG
([email protected] or +49 2736 4420 451). Any
device send to IPG without a RMA number will be send back to the
customer. The customer will be charged for the cost of repairing
the product if the product is not under warranty or if the repair is
not covered under the warranty.
Any damage noted upon receipt of the device must be documented
for appropriate claim against the carrier.

IPG Laser GmbH

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1.9.6 Changes

We reserve the right to make changes in design or constructions of any of our

products at any time without incurring any obligation to make changes or install the
same on units previously purchase.

1.10 Software agreement

Software agreements
Software License Agreement for LaserNet™
IPG Laser GmbH
Single Use License

PLEASE READ THIS SOFTWARE LICENSE AGREEMENT (”LICENSE”)

CAREFULLY BEFORE USING THE SOFTWARE OR THE EQUIPMENT. BY
CLICKING ON THE "ACCEPT" BUTTON, USING THIS SOFTWARE, OR USING
THE EQUIPMENT THAT CONTAINS THIS SOFTWARE, YOU ARE
CONSENTING TO BE BOUND BY THIS AGREEMENT. IF YOU DO NOT AGREE
TO ALL OF THE TERMS OF THIS AGREEMENT, CLICK THE "DO NOT
ACCEPT" BUTTON AND THE INSTALLATION PROCESS WILL NOT CONTINUE,
RETURN THE PRODUCT TO THE MANUFACTURER.

1. General.

The software, documentation and any fonts accompanying this License whether
on disk, in read only memory, on any other media or in any other form (collectively
the “IPG Software”) are licensed, not sold, to you by IPG Laser GmbH and its
affiliates (“IPG”) for use only under the terms of this License, and IPG reserves all
rights not expressly granted to you. The rights granted herein are limited to IPG’s
and its licensors’ intellectual property rights in the IPG Software and do not include
any other patents or intellectual property rights. You own the media on which the
IPG Software is recorded but IPG and/or IPG’s licensor(s) retain ownership of the
IPG Software itself. The terms of this License will govern any software upgrades
provided by IPG that replace and/or supplement the original IPG Software product,
unless such upgrade is accompanied by a separate license in which case the
terms of that license will govern.

2. Permitted License Uses and Restrictions

A. This License allows you to install and use one copy of the IPG Software on a
single computer at a time. This License does not allow the IPG Software to exist
on more than one computer at a time, and you may not make the IPG Software
available over a network where it could be used by multiple computers at the same
time. You may make one copy of the IPG Software in machine-readable form for
backup purposes only; provided that the backup copy must include all copyright or
other proprietary notices contained on the original.

B. Except as and only to the extent permitted in this License and by applicable
law, you may not copy, decompile, reverse engineer, disassemble, modify, or
create derivative works of the IPG Software or any part thereof. THE IPG
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SOFTWARE IS NOT INTENDED FOR USE IN THE OPERATION OF NUCLEAR

FACILITIES, AIRCRAFT NAVIGATION OR COMMUNICATION SYSTEMS, AIR
TRAFFIC CONTROL SYSTEMS, OR OTHER EQUIPMENT IN WHICH THE
MALFUNTION OF THE IPG SOFTWARE WOULD RESULT IN THE
FORESEEABLE RISK OF INJURY OR DEATH TO THE OPERATOR OF THE
EQUIPMENT OR SYSTEM OR TO OTHERS.

3. Transfer.

You may not rent, lease, lend, redistribute or sublicense the IPG Software. You
may, however, make a one-time permanent transfer of all of your license rights to
the IPG Software (in its original form as provided by IPG) to another party,
provided that: (a) the transfer must include all of the IPG Software, including all its
component parts, original media, printed materials and this License; (b) you do not
retain any copies of the IPG Software, full or partial, including copies stored on a
computer or other storage device; and (c) the party receiving the IPG Software
reads and agrees to accept the terms and conditions of this License.

4. Termination

This License is effective until terminated. Your rights under this License will
terminate automatically without notice from IPG if you fail to comply with any
term(s) of this License. Upon the termination of this License, you shall cease all
use of the IPG Software and destroy all copies, full or partial, of the IPG Software.

5. Limited Warranty on Media

IPG warrants the media on which the IPG Software is recorded and delivered by
IPG to be free from defects in materials and workmanship under normal use for a
period of ninety (90) days from the date of original purchase. Your exclusive
remedy under this Section shall be, at IPG’s option, replacement of the IPG
Software which is returned to IPG or an IPG authorized representative. THIS
LIMITED WARRANTY AND ANY IMPLIED WARRANTIES ON THE MEDIA
INCLUDING, BUT NOT LIMITED TO, THE IMPLIED WARRANTIES OF
MERCHANTABILITY, OF SATISFACTORY QUALITY, AND OF FITNESS FOR A
PARTICULAR PURPOSE, ARE LIMITED IN DURATION TO NINETY (90) DAYS
FROM THE DATE OF ORIGINAL PURCHASE.

6. Disclaimer of Warranties

YOU EXPRESSLY ACKNOWLEDGE AND AGREE THAT USE OF THE IPG

SOFTWARE IS AT YOUR SOLE RISK AND THAT THE ENTIRE RISK AS TO
SATISFACTORY QUALITY, PERFORMANCE, ACCURACY AND EFFORT IS
WITH YOU. EXCEPT FOR THE LIMITED WARRANTY ON MEDIA SET FORTH
ABOVE AND TO THE MAXIMUM EXTENT PERMITTED BY APPLICABLE LAW,
THE IPG SOFTWARE IS PROVIDED “AS IS”, WITH ALL FAULTS AND
WITHOUT WARRANTY OF ANY KIND TO THE FULLEST EXTENT PERMITTED
BY APPLICABLE LAW, IPG AND ITS SUPPLIERS FURTHER DISCLAIM ALL
WARRANTIES, EXPRESS OR IMPLIED, INCLUDING, WITHOUT LIMITATION,
IMPLIED WARRANTIES OF TITLE, NON- INFRINGEMENT, ACCURACY,
IPG Laser GmbH
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MERCHANTABILITY, AND FITNESS FOR A PARTICULAR PURPOSE, AND

ANY WARRANTIES THAT MAY ARISE FROM COURSE OF DEALING, COURSE
OF PERFORMANCE, OR TRADE PRACTICE. THE ENTIRE RISK ARISING OUT
OF THE USE OR PERFORMANCE OF THE IPG SOFTWARE OR RELATED
MATERIALS REMAINS WITH YOU. APPLICABLE LAW MAY NOT ALLOW THE
EXCLUSION OF IMPLIED WARRANTIES, SO THE ABOVE EXCLUSIONS MAY
NOT APPLY TO YOU. IPG MAY MAKE CHANGES TO THE IPG SOFTWARE
AND HAS NO OBLIGATION TO DISTRIBUTE NEWER VERSIONS.

7. Limitation of Liability

NEITHER IPG NOR ANY OF ITS SUPPLIERS SHALL BE RESPONSIBLE OR

LIABLE FOR ANY INDIRECT, INCIDENTAL, CONSEQUENTIAL, SPECIAL,
EXEMPLARY, PUNITIVE OR OTHER DAMAGES (INCLUDING, WITHOUT
LIMITATION, DAMAGES FOR LOSS OF BUSINESS, LOSS OF DATA OR LOST
PROFITS), UNDER ANY CONTRACT, NEGLIGENCE, STRICT LIABILITY OR
OTHER THEORY ARISING OUT OF OR RELATING IN ANY WAY TO THE IPG
SOFTWARE EVEN IF IPG OR ITS SUPPLIERS HAVE BEEN ADVISED OF THE
POSSIBILITY OF SUCH DAMAGES. YOUR SOLE REMEDY FOR
DISSATISFACTION WITH THE IPG SOFTWARE IS TO STOP USING THE IPG
SOFTWARE. THE SOLE AND EXCLUSIVE MAXIMUM LIABILITY TO IPG FOR
ALL DAMAGES, LOSSES AND CAUSES OF ACTION, WHETHER IN
CONTRACT, TORT (INCLUDING, WITHOUT LIMITATION, NEGLIGENCE) OR
OTHERWISE, SHALL BE THE TOTAL AMOUNT PAID BY YOU, IF ANY, FOR
USE OF THE IPG SOFTWARE. THESE LIMITATIONS MAY NOT APPLY TO
YOU UNDER THE LAWS OF CERTAIN JURISDICTIONS.
The foregoing limitations will apply even if the above stated remedy fails of its
essential purpose.

8. Export Law Assurances

You acknowledge that IPG Software is subject to European Union export

jurisdiction. You agree to comply with all applicable international and national laws
that apply to the IPG Software, as well as end-user, end-use and destination
restrictions issued by applicable governments.

9. Controlling Law and Severability.

This License will be governed by and construed in accordance with the laws of
Germany, as applied to agreements entered into and to be performed entirely
within Germany between German residents. This License shall not be governed by
the United Nations Convention on Contracts for the International Sale of Goods,
the application of which is expressly excluded. If for any reason a court of
competent jurisdiction finds any provision, or portion thereof, to be unenforceable,
the remainder of this License shall continue in full force and effect.

10. Complete Agreement; Governing Language.

IPG Laser GmbH

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This License constitutes the entire agreement between the parties with respect to
the use of the IPG Software licensed hereunder and supersedes all prior or
contemporaneous understandings regarding such subject matter. No amendment
to or modification of this License will be binding unless in writing and signed by
IPG. Any translation of this License is done for local requirements and in the event
of a dispute between the English and any non-English versions, the English
version of this License shall govern.

MICROSOFT CORPORATION EMBEDDED SOFTWARE

END USER LICENSE AGREEMENT

You have acquired a device ("EQUIPMENT") that includes software licensed by

IPG Photonics Corporation or its affiliates (collectively, “IPG”) from an affiliate of
Microsoft Corporation ("MS"). Those installed software products of MS origin, as
well as associated media, printed materials, and "online" or electronic
documentation ("SOFTWARE") are protected by international intellectual property
laws and treaties. IPG, MS and its suppliers (including Microsoft Corporation) own
the title, copyright, and other intellectual property rights in the SOFTWARE. The
SOFTWARE is licensed, not sold. All rights reserved.

IF YOU DO NOT AGREE TO THIS END USER LICENSE AGREEMENT ("EULA"),

DO NOT USE THE EQUIPMENT OR COPY THE SOFTWARE. INSTEAD,
PROMPTLY CONTACT IPG FOR INSTRUCTIONS ON RETURN OF THE
UNUSED EQUIPMENT(S) FOR A REFUND. ANY USE OF THE SOFTWARE,
INCLUDING BUT NOT LIMITED TO USE OF THE EQUIPMENT, WILL
CONSTITUTE YOUR AGREEMENT TO THIS EULA (OR RATIFICATION OF ANY
PREVIOUS CONSENT).

This EULA is valid and grants the end-user rights ONLY if the SOFTWARE is
genuine and a genuine Certificate of Authenticity for the SOFTWARE is included.
For more information on identifying whether your software is genuine, please see
http://www.microsoft.com/piracy/howtotell.

GRANT OF SOFTWARE LICENSE. This EULA grants you the following license:

You may use the SOFTWARE only on the EQUIPMENT.

Restricted Functionality. You are licensed to use the SOFTWARE to provide only
the limited functionality (specific tasks or processes) for which the EQUIPMENT
has been designed and marketed by IPG. This license specifically prohibits any
other use of the software programs or functions, or inclusion of additional software
programs or functions that do not directly support the limited functionality on the
EQUIPMENT. Notwithstanding the foregoing, you may install or enable on an
EQUIPMENT, systems utilities, resource management or similar software solely
for the purpose of administration, performance enhancement and/or preventive
maintenance of the EQUIPMENT.

If you use the EQUIPMENT to access or utilize the services or functionality of

Microsoft Windows Server products (such as Microsoft Windows Server 2003), or
use the EQUIPMENT to permit workstation or computing devices to access or
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utilize the services or functionality of Microsoft Windows Server products, you may
be required to obtain a Client Access License for the EQUIPMENT and/or each
such workstation or computing device. Please refer to the end user license
agreement for your Microsoft Windows Server product for additional information.

NOT FAULT TOLERANT. THE SOFTWARE IS NOT FAULT TOLERANT. IPG

HAS INDEPENDENTLY DETERMINED HOW TO USE THE SOFTWARE IN THE
EQUIPMENT, AND MS HAS RELIED UPON IPG TO CONDUCT SUFFICIENT
TESTING TO DETERMINE THAT THE SOFTWARE IS SUITABLE FOR SUCH
USE.

NO WARRANTIES FOR THE SOFTWARE. THE SOFTWARE is provided "AS IS"

and with all faults. THE ENTIRE RISK AS TO SATISFACTORY QUALITY,
PERFORMANCE, ACCURACY, AND EFFORT (INCLUDING LACK OF
NEGLIGENCE) IS WITH YOU. ALSO, THERE IS NO WARRANTY AGAINST
INTERFERENCE WITH YOUR ENJOYMENT OF THE SOFTWARE OR AGAINST
INFRINGEMENT. IF YOU HAVE RECEIVED ANY WARRANTIES REGARDING
THE EQUIPMENT OR THE SOFTWARE, THOSE WARRANTIES DO NOT
ORIGINATE FROM, AND ARE NOT BINDING ON, MS.

No Liability for Certain Damages. EXCEPT AS PROHIBITED BY LAW, MS SHALL

HAVE NO LIABILITY FOR ANY INDIRECT, SPECIAL, CONSEQUENTIAL OR
INCIDENTAL DAMAGES ARISING FROM OR IN CONNECTION WITH THE USE
OR PERFORMANCE OF THE SOFTWARE. THIS LIMITATION SHALL APPLY
EVEN IF ANY REMEDY FAILS OF ITS ESSENTIAL PURPOSE. IN NO EVENT
SHALL MS BE LIABLE FOR ANY AMOUNT IN EXCESS OF U.S. TWO
HUNDRED FIFTY DOLLARS (U.S. $250.00).

Restricted Uses. The SOFTWARE is not designed or intended for use or resale in
hazardous environments requiring fail-safe performance, such as in the operation
of nuclear facilities, aircraft navigation or communication systems, air traffic control,
or other devices or systems in which a malfunction of the SOFTWARE would
result in foreseeable risk of injury or death to the operator of the equipment or
system, or to others.

Limitations on Reverse Engineering, Decompilation, and Disassembly. You may

not reverse engineer, decompile, or disassemble the SOFTWARE, except and
only to the extent that such activity is expressly permitted by applicable law
notwithstanding this limitation.

SOFTWARE as a Component of the Equipment-Transfer. This license may not be

shared, transferred to or used concurrently on different computers. The
SOFTWARE is licensed with the EQUIPMENT as a single integrated product and
may only be used with the EQUIPMENT. If the SOFTWARE is not accompanied
by EQUIPMENT, you may not use the SOFTWARE. You may permanently
transfer all of your rights under this EULA only as part of a permanent sale or
transfer of the EQUIPMENT, provided you retain no copies of the SOFTWARE. If
the SOFTWARE is an upgrade, any transfer must also include all prior versions of
the SOFTWARE. This transfer must also include the Certificate of Authenticity
label. The transfer may not he an indirect transfer, such as a consignment. Prior to
IPG Laser GmbH
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the transfer, the end user receiving the SOFTWARE must agree to all the EULA
terms.

Consent to Use of Data. You agree that MS, Microsoft Corporation and their
affiliates may collect and use technical information gathered in any manner as part
of product support services related to the SOFTWARE. MS, Microsoft Corporation
and their affiliates may use this information solely to improve their products or to
provide customized services or technologies to you. MS, Microsoft Corporation
and their affiliates may disclose this information to others, but not in a form that
personally identifies you.

Internet Gaming/Update Features. If the SOFTWARE provides, and you choose to

utilize, the Internet gaming or update features within the SOFTWARE, it is
necessary to use certain computer system, hardware, and software information to
implement the features. By using these features, you explicitly authorize MS,
Microsoft Corporation and/or their designated agent to use this information solely
to improve their products or to provide customized services or technologies to you.
MS or Microsoft Corporation may disclose this information to others, but not in a
form that personally identifies you.

Internet Based Services Components. The SOFTWARE may contain components

that enable and facilitate the use of certain Internet-based services. You
acknowledge and agree that MS, Microsoft Corporation or their affiliates may
automatically check the version of the SOFTWARE and/or its components that you
are utilizing and may provide upgrades or supplements to the SOFTWARE that
may be automatically downloaded to your EQUIPMENT. Microsoft Corporation or
their affiliates do not use these features to collect any information that will be used
to identify you or contact you. For more information about these features, please
see the privacy statement at
http://go.microsoft.com/fwlink/?LinkId=25243.

Links to Third Party Sites. You may link to third party sites through the use of the
SOFTWARE. The third party sites are not under the control of MS or Microsoft
Corporation, and MS or Microsoft are not responsible for the contents of any third
party sites, any links contained in third party sites, or any changes or updates to
third party sites. MS or Microsoft Corporation is not responsible for web casting or
any other form of transmission received from any third party sites. MS or Microsoft
Corporation are providing these links to third party sites to you only as a
convenience, and the inclusion of any link does not imply an endorsement by MS
or Microsoft Corporation of the third party site.

Notice Regarding Security. To help protect against breaches of security and

malicious software, periodically back up your data and system information, use
security features such as firewalls, and install and use security updates.

No Rental/Commercial Hosting. You may not rent, lease, lend or provide

commercial hosting services with the SOFTWARE to others.

Separation of Components. The SOFTWARE is licensed as a single product. Its

component parts may not be separated for use on more than one computer.
IPG Laser GmbH
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1 General Information

Additional Software/Services. This EULA applies to updates, supplements, add-on

components, product support services, or Internet-based services components
("Supplemental Components"), of the SOFTWARE that you may obtain from IPG,
MS, Microsoft Corporation or their subsidiaries after the date you obtain your initial
copy of the SOFTWARE, unless you accept updated terms or another agreement
governs. If other terms are not provided along with such Supplemental
Components and the Supplemental Components are provided to you by MS,
Microsoft Corporation or their subsidiaries then you will be licensed by such entity
under the same terms and conditions of this EULA, except that (i) MS, Microsoft
Corporation or their subsidiaries providing the Supplemental Components will be
the licensor with respect to such Supplemental Components in lieu of the
"COMPANY" for the purposes of the EULA, and (ii) TO THE MAXIMUM EXTENT
PERMITTED BY APPUCABLE LAW, THE SUPPLEMENTAL COMPONENTS
AND ANY (IF ANY) SUPPORT SERVICES RELATED TO THE SUPPLEMENTAL
COMPONENTS ARE PROVIDED AS IS AND WITH ALL FAULTS. ALL OTHER
DISCLAIMERS, LIMITATION OF DAMAGES, AND SPECIAL PROVISIONS
PROVIDED BELOW AND/OR OTHERWISE WITH THE SOFTWARE SHALL
APPLY TO SUCH SUPPLEMENTAL COMPONENTS. MS, Microsoft Corporation
or their subsidiaries reserve the right to discontinue any Internet-based services
provided to you or made available to you through the use of the SOFTWARE.

Recovery Media. If SOFTWARE is provided by IPG on separate media and

labeled "Recovery Media" you may use the Recovery Media solely to restore or
reinstall the SOFTWARE originally installed on the EQUIPMENT.

Backup Copy. You may make one (1) backup copy of the SOFTWARE. You may
use this backup copy solely for your archival purposes and to reinstall the
SOFTWARE on the EQUIPMENT. Except as expressly provided in this EULA or
by local law, you may not otherwise make copies of the SOFTWARE, including the
printed materials accompanying the SOFTWARE. You may not loan, rent, lend or
otherwise transfer the backup copy to another user.

End User Proof of License. If you acquired the SOFTWARE on EQUIPMENT, or

on a compact disc or other media, a genuine Microsoft "Proof of
License"/Certificate of Authenticity label with a genuine copy of the SOFTWARE
identifies a licensed copy of the SOFTWARE. To be valid, the label must be
affixed to the EQUIPMENT, or appear on IPG’s software packaging. If you receive
the label separately other than from IPG, it is invalid. You should keep the label on
the EQUIPMENT or packaging to prove that you are licensed to use the
SOFTWARE.

Product Support. Product support for the SOFTWARE is not provided by MS,
Microsoft Corporation, or their affiliates or subsidiaries. For product support,
please refer to IPG support number provided in the documentation for the
EQUIPMENT. Should you have any questions concerning this EULA, or if you
desire to contact IPG for any other reason, please refer to the address provided in
the documentation for the EQUIPMENT.

IPG Laser GmbH

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1 General Information

Termination. Without prejudice to any other rights, IPG may terminate this EULA if
you fail to comply with the terms and conditions of this EULA. In such event, you
must destroy all copies of the SOFTWARE and all of its component parts.

EXPORT RESTRICTIONS. You acknowledge that SOFTWARE is subject to U.S.

and European Union export jurisdiction. You agree to comply with all applicable
international and national laws that apply to the SOFTWARE, including the U.S.
Export Administration Regulations, as well as end-user, end-use and destination
restrictions issued by U.S. and other governments. For additional information see
http://www.microsoft.comexporting/

IPG Laser GmbH

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1 General Information

1.11 Declaration of Conformity

IPG Laser GmbH

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1 General Information

1.12 Important Safety Advices

The IPG Fiber Laser Model YLS-10000-S2, including Feeding fiber and Process
fiber(s) respectively, are Laser Class 1 product. All laser system fiber exits are
Laser Class 4 products as designated by IEC EN 60825-1. The laser is specifically
developed for the integration into other equipments or machines. It is the
responsibility of the user to make sure that the fiber output or the optical
processing head shall have a protective housing to ensure Class 1 according to
IEC 60825:2001-08. The laser cabinet and the Feeding fiber / Process fiber(s) are
Laser Class 1. When connecting an optical head the laser class is changed to
class 4.
This laser emits a maximum average power of 10000 Watts of invisible laser
radiation in the optical band near 1070nm ±10 nm.

DANGER TO LIFE
Do never defeat the interlock system! Avoid eye or skin exposure
to direct or scattered radiation emitted from the optical output.
DANGER Do not open the front and rear doors of the laser case, if laser
emission is ON.
Do not open the device. There are no user serviceable parts,
equipment or assemblies in this product. All service and
maintenance shall be performed by qualified IPG personnel.

IPG Laser GmbH

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2 Safety and Accident prevention

2 Safety and Accident prevention

2.1 Safety Conventions in this Manual
We use various words and symbols that are designed to call your attention to
hazards or important information. These include:

DANGER:
Refers to a personal potential hazard. It requires a procedure that, if
not correctly executed, may result in serious bodily harm or in
DANGER death to you and/or others Do not proceed beyond the warning
sign until you completely understand and meet the required
conditions.

WARNING:
Refers to a potential personal hazard. It requires a procedure that, if
not correctly executed, may result in bodily harm to you and/or
others. Do not proceed beyond the WARNING sign until you
completely understand and meet the required conditions.
WARNING

CAUTION:
Refers to a potential product hazard. It requires a procedure that, if
not correctly obeyed, may result in damage or destruction to the
CAUTION product or components. Do not proceed beyond the CAUTION sign
until you completely understand and meet the required conditions.

IMPORTANT ADVICE:
Refers to any information regarding the operation of the product.
Please do not overlook this information.

DANGEROUS LASER RADIATION

This symbol indicates laser radiation. We place this symbol on
products which have a laser output

ELECTRICITY
This symbol indicates high voltage. Danger to life!

IPG Laser GmbH

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2 Safety and Accident prevention

LASER SAFETY GOGGLES

This symbol indicates that all personnel near by the laser must
wear laser safety goggles!

IPG Laser GmbH

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2 Safety and Accident prevention

2.2 Fundamental Safety References

2.2.1 Intended use
The laser is designed for R&D and industrial usage.
The laser may only be used for material processing, in particular for welding and
cutting applications of metals and its alloys.
To the intended use also belongs:

► To obey the instructions and advices given in this manual

► To obey the maintenance instructions

RISKS OF DAMAGE
Risks of damage to the device caused by unadjusted processing
parameters
CAUTION ► The back reflected light can be too much if the parameters are
not chosen correctly.
► Too much back reflected light can affect the laser in a negative
way.
► For the operation conditions for processing of copper and its
alloys you shall consult with IPG Photonics.

2.2.2 Non-Permissible operation methods

The operational safety of the delivered device is guaranteed only if the device is
properly used as intended. The limit values included in the laser specifications
must not be exceeded.
It is only allowed to operate the laser with the matching chiller.
The use of optics (Fibers, Beam Coupler, Beam Switch, process fibers, material
processing head) which are not authorised by IPG Photonics or one of its
subsidiaries respectively, will not be covered by warranty.

DANGER TO LIFE
► This product must be used only in normal conditions.
► If this instrument is used in a manner not specified in this
WARNING document, the protection provided by the instrument may be
impaired.

IPG Laser GmbH

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2 Safety and Accident prevention

2.2.3 Obligation of the operator

It is the operators obligation that personnel working with the device

► is briefed in fundamental regulations of safe performance of work, accident

prevention and operation of the device
► have read, understood and confirmed by signature reading chapter 2 Safety
and Accident prevention in this user manual
► is briefed in laser safety regulations according to legal requirements

2.2.4 Obligation of the personnel

All personnel working with the device is obligated to

► Have received briefing in fundamental regulations of safe performance of

work, accident prevention and operation of the device
► have read, understood and confirmed by signature reading chapter 2 Safety
and Accident prevention in this user manual
► is briefed in laser safety regulations according to legal requirements

before start working with the device.

2.2.5 Personnel qualification and training

Operating, maintenance, inspection and installation personnel must be properly
qualified for their work. Scope of responsibility and supervision of personnel must
be defined and periodically reviewed by the facilities’ management.

2.2.6 Safe performance of work

The safety instructions mentioned in these operating instructions, including the

existing national regulations on accident prevention as well as any specific plant
safety instructions must be observed.
Protective guards that have been installed to prevent contact with moving parts
may not be removed when the device is being operated. Danger from the use of
electrical power must be excluded. (For detailed information, refer to the VDE
regulations and the regulations of the local power supply companies.)
The device shall only be used

► for the intended use described in this user manual

► in faultless condition.

IPG Laser GmbH

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2 Safety and Accident prevention

2.2.7 Protective equipment

The protective equipment (adequate laser safety goggles for accordant power and
wave length) must be provided by the operator (only necessary in case of
maintenance – Service mode active).

2.2.8 Arbitrary modification and production of spare parts

The device may be converted or modified only when an agreement has been
reached with the manufacturer. Original spare parts and accessories accepted by
the manufacturer are authorised as such for safety. The use of any other parts
may cancel the manufacturer's liability for subsequent damages.

2.2.9 Safety precautions during normal operation

Operating the device is allowed only when all safety installations are in function.
The device must be checked for visible damages and for damages of the safety
installations once a week.

2.2.10 Safety instructions on maintenance, inspection, and

installation work
As a basic rule, none of the cleaning or maintenance tasks may be performed until
the device has come to a complete stop. The shutdown procedure described in the
operating instructions must be observed. As soon as this work has been
completed, all the safety devices and protective equipment must be mounted or
installed according to their proper function.

IPG Laser GmbH

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2 Safety and Accident prevention

2.3 General Safety references for lasers

2.3.1 Laser Classification
The IPG Fiber Laser Model YLS-10000-S2, including Feeding fiber and Process
fiber(s) respectively, are Laser Class 1 product. All laser system fiber exits are
Laser Class 4 products as designated by IEC EN 60825-1. The laser is specifically
developed for the integration into other equipments or machines. It is the
responsibility of the user to make sure that the fiber output or the optical
processing head shall have a protective housing to ensure Class 1 according to
IEC 60825:2001-08. The laser cabinet and the Feeding fiber / Process fiber(s) are
Laser Class 1. When connecting an optical head the laser class is changed to
class 4.

This laser emits a maximum average power of 10000 Watts of invisible laser
radiation in the optical band near 1070nm ±10 nm.

The human eye is exceptionally jeopardised to this infrared (invisible) laser

radiation due to the focusing effect of the pupils at the retina. Heating or even
burning effects will occur at the retina which will cause degradation or even loss of
eye-sight.

This level of light power is extremely dangerous. Despite radiation being invisible,
the scattered beam may cause irreversible damage to the cornea. Laser safety
eye wear is not provided with this instrument, but must be worn at all times while
the laser is in operation.

The device has integrated Guide lasers classified as class 2M laser under IEC EN
60825.
The Guide lasers are based on diodes with a wavelength of 635 nm and/or 658
nm and an output power less than 1mW. Do not stare into the beam directly or
view directly with an optical instrument.

DANGER TO LIFE
Danger to life or bodily harm by laser radiation
► The generated laser light has a wave length of 1070nm and is
WARNING invisible for the human eyes.
► Do never install output fiber connector if the main disconnect
switch of the laser is on
► Always follow the safety instructions given in this manual
► Always wear the personal protective equipment

IPG Laser GmbH

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2 Safety and Accident prevention

2.3.2 Laser safety representative

The operator has to obey the state and local rules and regulations of the accident
prevention and insurance association (Germany: BGV B2).

The company operating the laser must have a Laser Safety Representative.

2.3.3 Laser safety goggles

Laser safety eyewear is wavelength specific.

The following information is needed to select the appropriate laser safety eyewear:
► Wavelength(s)
► Mode of operation (continuous wave or pulsed)
► Maximum exposure duration (assume worst case scenario)
► Maximum irradiance (W/cm2) or radiant exposure (J/cm2)
► Maximum permissible exposure (MPE)
► Optical density (OD)

IPG Laser GmbH

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2 Safety and Accident prevention

2.4 Special Safety references

2.4.1 Danger by means of laser radiation

Laser radiation hazard by

► Direct laser light

► Reflected laser light
► Scattered laser light
The part of the human body that is most sensitive to laser light and can most
easily be damaged by lasers is the human eye.
A mandatory laser safety goggle provides protection against direct laser light,
reflected laser light and scattered laser light. Anyway, never look directly into the
beam. The high intensity can destroy the protective filter.

During maintenance work at the laser of class IV, all personnel must wear
appropriate laser safety goggles. The laser safety goggles must match with the
wavelength and the maximum output power of the laser.
Only qualified personnel is authorised to defeat the interlocks for maintenance
work.

Exposure of the skin to high power laser beams can cause burns.

FIRE HAZARD
The high output power of the class IV laser can emblaze different
kind of materials. The operator has to take actions for fire
CAUTION prevention.

2.4.2 Danger by means of Electricity

Ascertain before using the device that the electrical connections are in perfect
condition. To any damages and alarm messages must be paid attentions.

Make sure the instrument is properly grounded through a protective conductor of

the AC power cable. Any interruption of the protective ground conductor from the
earth terminal can result in personal injury.

2.4.3 Advice for operating the laser

Do not open the front and rear doors of the laser case if laser emission is ON. It
can present serious personal danger.

For the operation conditions for processing of copper and its alloys you shall
consult with IPG Photonics.

IPG Laser GmbH

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2 Safety and Accident prevention

NEVER look directly into output connector when laser is ON and make sure that
the appropriate laser safety glasses are worn at all times while operating the
product

Do not install output fiber connector when laser electrical power in ON.

IPG Laser GmbH

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2 Safety and Accident prevention

2.5 Safety labels and location at the device

The figures below show the labels and their placement at the device.

Table 2-1Laser safety labels

Label Description
Power and Wavelength label2

► At all doors and apertures

where interlocks are installed
► All exit apertures for laser
radiation
Certification label

► At all doors and apertures

where interlocks are installed
► All exit apertures for laser
radiation
Certification label

► Front side of the laser

Certification label

► Front side of the laser

► All exit apertures for laser
radiation

Laser radiation

► At all doors and apertures

where interlocks are installed
► All exit apertures for laser
radiation

2
Example, may differ for each laser
IPG Laser GmbH
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2 Safety and Accident prevention

Electricity

► Electrical cabinet door

► All parts which present a
potential hazard due to high
voltage

IPG Laser GmbH

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3 Device description

3 Device description
3.1 Functional principle

The laser power is generated in the Laser modules. Each Laser Module can be
considered as a discrete laser. Depending on the module type the output power
can reach 400W to 1200W. Depending on the nominal power of the laser a
quantity of the laser modules is configured.
To generate the laser radiation inside the modules a DC voltage of
60VDC…75VDC (depending on the module type) is needed.
The power of the single modules is combined into a single fiber (Feeding fiber)
inside the Beam Combiner. Optional a Beam Switch or a Beam Coupler can be
used to achieve different fiber diameters and fiber lengths.

IPG Laser GmbH

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3 Device description

Picture 3-1: Basic setup of IPG Multimode fiber laser

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3 Device description

3.2 Interlock and E-stop system

The safety system (Interlock and E-Stop system) of the laser consist of two safety
relays

► Interlock system, relay MSR127TP (K6) automatic reset

► E-Stop system, relay MSR127RP (K7) manual reset

and power contactors K1, K2 to apply 400VAC to the main power supply.

Picture 3-2: Interlock and E-Stop Safety relay

Picture 3-3: Interlock and E-Stop circuit schematic

IPG Laser GmbH

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3 Device description

3.2.1 Interlock Safety relay

Interlock safety relay is configured to operate with automatic reset: If all interlock
circuits are closed, this relay automatically turns ON and yellow Interlock button –
LED on the Laser front side will switch off. By pushing the Interlock button at any
time the operator can check that LED and 24VDC are OK.

Picture 3-4: Interlock Safety Relay - automatic reset

The Interlock circuits connected to the input of the Interlock Safety Relay are as
follow:

► Optical interlock of Feeding fiber from the laser (to the optical switch unit or
processing head, respectively)
► Leak detection (Sensors on the floor inside the laser cabinet).
► Front and rear doors of the laser cabinet and doors of optical switch cabinet
► External interlock (E-Stop input: pins C2-C3 and C1-C4 of XP2 Safety
Interface Connector)

IPG Laser GmbH

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► Temperature sensors attached to the absorber at the Beam Switch (if

installed)
Statuses of the optical interlock, leak detect, front and rear doors of the laser are
additionally monitored and displayed by the LaserNet.

External safety contacts or external E-Stop Push-Button can be connected to E-

Stop input of the.

3.2.2 E-Stop Safety relay

Outputs (safety contacts) of the interlock safety relay are connected to the input of
the second E-Stop safety relay. The E-Stop safety relay is configured to operate
with monitored manual reset: when all input circuits of the relay are closed, reset is
required to turn this relay ON. Illuminated Start push button on the Laser performs
reset function of the E-Stop safety relay. When relay is ON, green LED will light on
the Start push-button. Additionally following circuits are connected in series to the
input of E-Stop safety relay:

Picture 3-5: E-Stop Safety Relay - manual reset

► E-Stop push button on the laser

► E-Stop push button on the optical switch unit
► E-Stop from internal logic (additional relay driven by the micro controller)

In addition to the Start push-button, E-Stop Safety relay can also be reset by the
software command (Laser ON software button in the LaserNet window) and by the
external potential-free contacts connected between pins C5 and C6 of XP2 Safety
interface connector. E-Stop safety relay turns ON power contactors K1 and K2,
thus connecting main power supply of the laser to 400VAC line. The status signal
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3 Device description

of contactors can be monitored between pins B7 and B8 of XP2 Safety interface

connector. These pins can be used to control, for example, an external safety
warning lamp.

In order to facilitate connection of all E-Stop buttons of the system (including robot
controller) in one loop, additional contact blocks on the internal E-Stop push-
buttons are connected to pins B4-B5; B3-B6 of XP2 Safety interface connector to
provide E-Stop output for the customer’s use.

Picture 3-6: Outputs for E-Stop button monitoring

Picture 3-7 shows the connection principle for manual reset of the safety circuit.
External contacts or external Push-Button can be connected. Function of this
input is the same as the function of “Start” Push-Button on the laser.

Picture 3-7: Inputs for manual reset E-Stop safety relay

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3 Device description

3.3 Operational modes

The laser can be operated in two different operation modes, which are chosen by
the key switch:

► TEST → control by LaserNet

► ROBOT → control by external device
For maintenance purposes (alignment of integrated optics) in TEST -Mode the

► SERVICE MODE
should be used.

LOSS OF THE INTERNAL CONFIGURATION

► A change of the operational modes can cause problems when
starting up the internal controller if the procedure described
CAUTION below is not followed.
► During the switching between the operational modes (TEST to
ROBOT or vice versa) the switch has to remain in OFF
position for at least 5 seconds.

IMPORTANT ADVICE:
► After switching the laser controller ON (switching to TEST or
ROBOT mode) it can take up to two minutes to finish the start
up procedure due to the time required for booting the internal
computer.

3.3.1 Test mode

► Manual Mode (Control by LaserNet software)

► External modulation mode
► Analogue control mode
► QCW mode
► Service mode (For Maintenance, activated by internal key switch)

3.3.2 Robot mode

► Analogue control mode

► Hardwiring controlled mode
► Fieldbus controlled mode
► QCW controlled mode
A detailed description of the operational modes is given in chapter 6 Operation.
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3 Device description

3.4 Operational Controls

# Name Description Location

Key Switch “Test / Off / To switch between operational

S1 Laser Front side
Robot” modes

Lit up yellow if Interlock circuit

S2 “Interlock” button Laser Front side
is opened

Push to switch of Power

S3 “E-Stop” Push button supply and Emission in case of Laser Front side
Emergency

Push to switch on Power

Supply
S4 “Start” Push button Laser Front side
Lit up green if Power supply is
on

To bypass the door interlock Inside Laser cabinet,

“Service Mode” key
S5 for alignment of Integrated Front side or Rear
switch
optic side

“Service Mode active” Lit up red if Service mode is

S6 Laser Front side
button activated

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3.5 Interfaces description

3.5.1 XP1 – Hardwiring interface
The XP1 – Hardwiring interface is used for communication between Laser and
customers PLC3.

Type of connector Remark

Han®-D, 64-pin female part on the cabinet side

IMPORTANT ADVICE:
► All inputs / outputs are potential free.
► High level is active for all inputs / outputs.
► Below is the preliminary assignment of the signals. Further
changes are possible after negotiation with the customer.

CAUTION:
► Only shielded cables must be used for connections of
interfaces.
CAUTION

Table 3-1: Hardwiring interface pin layout

XP1 – Hardwiring Interface
Type: Standard
INPUTS
Pin
Name Description
number
HIGH ACTIVE
With this signal one of several external controllers
(robots) can request laser power. If only one robot
is connected to the laser, this bit always must be
A1 Laser Request
set during the control process. Without this bit all
other input bits are ignored. As a conformation
that laser is connected now to this particular
controller (robot), B7 will be set high.
HIGH ACTIVE
With this input the laser programs can be started
A2 Program start
and stopped. A program gets started if input is
active and stopped if the input is cleared or the

3
Programmable Logic Controller
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program ends. Program starts only once. Program

number is defined by bits A8-A14. If the program
number is 0000000 and bit A6 is high, than laser
power is controlled by Analog input. If the program
number is 0000000 and A6 is low, laser power
value can be set by Ethernet program if A3 is
high. B1 must be high before start of the program.
After start of the program conformation “Program
active” (B9) will be set high. B9 will be cleared
after the end of the program and B10 (End of the
program) will be set high. B10 will be cleared after
A2 (Program start) is cleared (handshake; - not
valid if program number is 0000000).
HIGH ACTIVE
Internal Control Some control functions from Ethernet program are
A3
Enabled enabled with this bit.

HIGH ACTIVE
This input is used to reset all messages of the laser
system and output bits: “Laser Error”, “Program is
A4 Reset errors
interrupted” and “Warning”. Input should be active at
least for 1ms.

HIGH ACTIVE
A5 Guide laser ON
With this bit guide laser can be switched ON.
HIGH ACTIVE
Analogue
A6 Analogue control input can be activated by this bit if
control ON
program number is 0000000.
HIGH ACTIVE
Active program can be immediately stopped by
A7 Program STOP this bit. If this happens before the end of the
program, B11 and B13 will be set, B9 will be
cleared and B10 will not be set.
A8
HIGH ACTIVE
A9
A8 – LSB
A10
Program A14- MSB
A11
number Any program number change is ignored until next
A12
low-to-high transition of A2.
A13
A14
HIGH ACTIVE
Synchronization
A15 This input can be used in the laser program (wait
input
for high or wait for low).
A16 GND Common pin for all inputs (0V)
HIGH ACTIVE
This input is used to switch ON and OFF the
Laser (main power supply). If the laser can not be
C1 Laser ON
switched ON (E-stop loop is open), B13 will be
set. To switch ON the laser C1 should be cleared
and set high again. As a conformation, B8 is set
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high when the laser is ON.

C2 spare input
HIGH ACTIVE
C3 C3 – LSB
C6 – MSB
Beam Switch optical way in binary code
C4 Beam Switch The number 0000 (0-decimal) - all Beam Switch
Channel mirrors are in Home position.
C5 number4 The number 0001 (1-decimal) - the Beam Switch
mirror of the channel 1 is in work position.
The number 0010 (2-decimal) - the Beam Switch
C6 mirror of the channel 2 is in work position.

HIGH ACTIVE
With this bit the QCW mode is switched on. The
C7 QCW mode
power supply voltage will be adjusted. During this
time (~3 sec) the Laser Ready signal is set LOW
C8
C9 Spare inputs
C10
Outputs
HIGH ACTIVE
If this bit is high, Laser program can be started by
“Program Start” bit A2. Laser is not Ready if:
► Chiller Failure,
► Front Door opened,
B1 Laser Ready ► Rear Door opened,
► Out of the Temperature Range for the
Water of the External Optics, Out of the
Temperature Range for the Water of the
Laser.

HIGH ACTIVE
B2 Emission ON
Laser emits radiation.
HIGH ACTIVE
Internal control
B3 Some control functions from Ethernet program are
enabled
enabled.
HIGH ACTIVE
One of the following abnormal situations is
detected inside the Laser.
B4 Laser Error ► E-Stop / button / external
► Laser Overheat (Module overheat t≥35°C)
► Laser Module disconnected

4
Only available if Beam Switch is installed
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► Laser Module failure

► Laser Fiber Interlock
► Coupler Failure
► Critical Error
► Water in Laser
► Power supply Failure
► Low Water Flow Laser
► Low Water Flow Fiber Connector
► Unexpected Pump Current
► Unexpected Ground Leakage
► High Back Reflection
► Scattered light
► FFBD
► Internal Failure of the Beam Switch
Emission (and Power Supply) is switched off
Guide Laser is HIGH ACTIVE
B5
ON Guide laser is switched ON.
Analogue HIGH ACTIVE
B6
Control is ON Laser power is controlled by analog input.
HIGH ACTIVE
B7 Laser assigned This is the answer of the laser to bit A1. If this bit
is low, all input information is ignored.
HIGH ACTIVE
B8 Laser is ON
Conformation that laser is switched ON.
HIGH ACTIVE
B9 Program active
Laser is executing the laser program
HIGH ACTIVE
B10 End of program Laser program was completely executed. B10 will
be cleared after A2 is cleared.
HIGH ACTIVE
Program
B11 Program has been interrupted. Reset (A4) is
interrupted
required to clear B11.
HIGH ACTIVE
Synchronization
B12 Can be used in the Laser Program (set high or set
output
low).
HIGH ACTIVE
The Warning output is activated if
► the reserve module is activated
B13 Warning output ► if the power supply is not switched on after
the signal to switch on was received
► one module temperature >32°C
B14 Spare output

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B15 B15: + 24VDC

B16: 0VDC Potential free voltage, provided by
B16
the customer to drive outputs.
D1 – LSB
D1 D4 – MSB

D1 – D4 – Beam Switch optical way in binary code

D2 confirmation.
Beam Switch
The number 0000 - all Beam Switch mirrors are in
channel
home position.
number5
D3 The number 0001- the Beam Switch mirrors of the
Channel 1 is in work position.
The number 0010- the Beam Switch mirror of the
D4 Channel 2 is in work position.

HIGH ACTIVE
► The DI cooling water conductivity is ≥ 15
µS
► the water temperature of the tap circuit ≥
D5 Chiller warning TTh1 - 2°C or ≤ TTh2 + 2°C
► The water temperature of the DI circuit ≥
TTh3 - 2° C or ≤ TTh4 + 2°C.

HIGH ACTIVE
► Conductivity is ≥ 25 µS
► the water temperature of the tap circuit ≥
TTh1°C or ≤ TTh2°C
D6 Chiller error
► the water temperature of the DI circuit ≥
TTh3°C or ≤ TTh4°C
► CHILLER FAULT.

HIGH ACTIVE
D7 QCW mode
The QCW mode is active.
D8 Spare output

5
Only available if a Beam Switch is installed
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3.5.2 XP2 – Safety interface

INTEGRATION OF THE E-STOP CIRCUIT :
► Two-channel External emergency stop (Interlock) input is
designed in accordance with EN ISO 13849-1 Cat.3 norms.
► Both channels should be used for E-Stop.

IMPORTANT ADVICE:
Only shielded cables must be used for connections of interfaces.

Type of connector Remark

Han®-D, 25-pin female part on the cabinet side

Table 3-2: Safety interface pin layout

XP2 – Safety Interface

Pin
Name Description
number
INPUT
Potential free input, if +24 V is applied between
A1 Emission ON
A1/A2, then the Laser Emission will be ON. If 0 V –
Laser Emission will be OFF.
A2 Emission ON
The input is active, if Hardwiring interface is not used.
C1 E-Stop IN
Two channel external E-Stop input C1-C4 channel 1,
C2 E-Stop IN
C2-C3 channel 2. Only potential free contacts can be
C3 E-Stop IN
connected between pins C1-C4, C2-C3.
C4 E-Stop IN
C5 SC reset Safety Circuit Reset Input. Only potential free
C6 SC reset contacts can be connected between pins C5 and C6
OUTPUT
A3 Emission ON Potential free output, A3 and A5 closed as the
A5 Emission ON emission is activated.
B3 E-Stop
Two channel potential free output. B3-B6 channel 1,
B4 E-Stop
B4-B5 channel 2. When internal E-Stop push-button
B5 E-Stop
is activated, channel 1 and 2 are opened.
B6 E-Stop
B7 SC6 status Potential free output. B7 and B8 closed = Safety
B8 SC status Circuit is ON.

6
Safety circuit
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3.5.3 XP3 – Chiller control interface7 (Riedel Chiller)

Type of connector Remark

Han®-D, 15-pin female part on the cabinet side

Table 3-3: Chiller interface pin layout

XP3 – Chiller Interface

Pin
Name Description
number
A1 GND Common pin for all inputs (0V)
If no Chiller error is presented, Chiller ready signal
A2 Chiller ready
will be active
Chiller error appears in case of
► Water deficiency TAB water circuit
A4 Chiller error ► Water deficiency DI water circuit
► Accumulative fault8

B1 Temp_DI Temperature DI water circuit

B2 Temp_TAB Temperature TAB water circuit

B3 Cond_DI Conductivity DI water circuit

B5
C1 Remote Start
Switch on Chiller by switching on Laser
C2 Chiller

7
Only available if external chiller is delivered
8
Please refer to the chiller manual for detailed information
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3.5.4 LSR-XPC Chiller Control Interface for IPG Chiller

Type of connector Remark

Sub-D 15 pin female part on the cabinet side

The communication takes place via CAN-Bus communication.

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3.5.5 XP4 – Analogue control interface

The Analogue control interface is used for control and modulation of the pump
laser diode current.

Type of connector Remark

Han® 7 D, 15 Pin female part on the cabinet side

Table 3-4: Analogue interface pin layout

XP4 – Analogue Interface

Pin
Name Description
number
INPUT
External Analogue Voltage to set output power
1 AIN_POS Input 0…+10VDC
0V - 10 V corresponds to 0 % - 100% pump current
2 A_GND Static Accuracy +/- 2 %
Response Time ≤ 100 µs
OUTPUT

3 AOUT_POS Analogue control monitor

Output 0…+8VDV
4 A_GND 0V – 8 VDC corresponds to 0 % - 100% pump current

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3.5.6 XP5 – Ethernet

The Ethernet interface is used for communication with an external PC for
monitoring purposes.
The connection between control computer and laser is made by a standard 100
MBit Ethernet connection. If the computer is directly connected a crossed cable is
to be used. If a hub controls the communication between several lasers and the
control computer straight cables are needed. For a switch it does not matter.

Type of connector Remark

Harting RJ45 Data 3A Panel Feed

female part on the cabinet side
Through

Table 3-5: XP5 Ethernet interface

XP5 - Ethernet Interface

Pin
Name Description
number
Communication rate: 100Mbit

For further information please refer to chapter 4.6.3 Settings / IP Configuration

page 83.

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3.5.7 XP 9 / 10 / 11 / 12 - Cabinet doors – Light path related Safety

interface9

Type of connector Remark

Han® 10A (if 2-ways Beam Switch) female part on the cabinet side
®
Harting Staf 20 (if 4-ways Beam
female part on the cabinet side
Switch)

Table 3-6: switch safety interface channel 1 pin layout

XP 9 - Beam Switch Safety interface channel 1 (Cabinet door 1)

Pin
Name Description
number
A1
A2 Two channel Only potential free contacts can be connected
A3 cabinet door input between pins A1/A2; A3/A4.
A4
A5 Potential free outputs. A5-A6 are closed if mirror
Mirror OFF
A6 is in Home position
A7 Potential free outputs. A7-A8 are closed if mirror
Mirror ON
A8 is in Work position

Table 3-7: switch safety interface channel 2 pin layout

XP 10 - Beam Switch Safety interface channel 2 (Cabinet door 2)

Pin number Name Description

A9
A2 Two channel Only potential free contacts can be connected
A10 cabinet door input between pins A9/A2; A10/A4.
A4
A5 Potential free outputs. A5-A6 are closed if mirror
Mirror OFF
A6 is in Home position
A7 Potential free outputs. A7-A8 are closed if mirror
Mirror ON
A8 is in Work position

9
Only available if Beam Switch is installed
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Table 3-8: switch safety interface channel 3 pin layout

XP 11 - Beam Switch Safety interface channel 3 (Cabinet door 3)

Pin number Name Description

A11
A2 Two channel Only potential free contacts can be connected
A12 cabinet door input between pins A11/A2; A12/A4.
A4
A5 Potential free outputs. A5-A6 are closed if mirror
Mirror OFF
A6 is in Home position
A7 Potential free outputs. A7-A8 are closed if mirror
Mirror ON
A8 is in Work position

Table 3-9: Beam Switch safety interface channel 4 pin layout

XP 12 - Beam Switch Safety interface channel 4 (Cabinet door 4)

Pin number Name Description

A13
A2 Two channel Only potential free contacts can be connected
A14 cabinet door input between pins A13/A2; A14/A4.
A4
A5 Potential free outputs. A5-A6 are closed if mirror
Mirror OFF
A6 is in Home position
A7 Potential free outputs. A7-A8 are closed if mirror
Mirror ON
A8 is in Work position

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3.5.8 Field bus protocol, 4 word

Inputs
Byte Word Name Description
1 Every one of bits of this field is interpreted as
1 Control a separate managing signal to the laser. (little-
2 endian byte order)
3 Power of the laser in watts (up to 65kW).
2 Power
4 (little-endian byte order)
For the laser with beam switch this field sets
5 Optical Ch.
the optical channel.
3
This field sets the number of the laser
6 Program No.
program.
7 This field sets the ramping time in ms.
Ramping
4 Direction of the ramping time sets in the
8 time
control field.(little-endian byte order)
Outputs
Byte Word Name Description
1 Main status bits of the laser (little-endian byte
1 Status
2 order)
3 Output power of the laser in Watts (little
2 Power
4 endian byte order)
Optical Current optical channel (Beam switch channel,
5
channel light path)
3
Program
6 Current program number.
number
7 Reserved
4
8 Reserved

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Input word “Control”

Bit Name Description
Activates control via Profibus (without this
0 Laser request
signal all other bits will be ignored).
1 Laser ON Switch on the main power supply.
2 Reset errors Switch on the main power supply.
3 Guide laser ON Switch on the guide laser.
Start the laser program (number of the
4 Program start
program must be set in the byte 6).
5 Program stop Stop of the running laser program.
Set the optical channel (number of the optical
6 Set optical channel
channel must be set in the byte 5).
Switch on analog control for set output power
7 Analog control ON
of laser.
8 Reserved
Set the ramping time for up as a value in
9 Set ramp up
bytes number 7-8.
Set the ramping time for down as a value in
10 Set ramp down
bytes number 7-8.
Can be used in laser programs for
11 Synchronization input
synchronization
12 Reserved
13 Reserved
14 Reserved
15 Reserved
Output word “Status”
Bit Name Description
Control of laser from Profibus (confirmation
0 Laser assigned
of control bit 0).
1 Laser is ON The main power supply of laser is on.
2 Laser error Laser has error(s).
3 Guide laser is ON The guide laser is on.
4 Program active Laser program is running.
5 End of program Laser program is ended.
6 Program is interrupted Laser program was interrupted.
7 Analog control is ON Analog control in the laser is ON.
8 Laser warning Laser has warning(s).
9 Laser is ready Laser is ready for emission.
10 Emission is ON Emission is ON.
Synchronization Can be used in laser programs for
11
output synchronization
12 Chiller warning Chiller has warning(s)
Chiller was overheat or has signal "Chiller
13 Chiller error
fail"
14 Reserved
15 Reserved
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3.5.9 Fieldbus protocol, 8 Word

Inputs
Byte Word Name Description
Everyone bit of this field is interpreted as a
separate managing signal to the laser. Little-
or big-endian bytes order, configured by
1 LaserNet.
Example: value 143 (0x008F,
0000000010001111B)
Little-endian (Intel bytes order):
byte #(N) - low part byte (LSB): 143 (0x8F,
1 Control
10001111B)
byte #(N+1) - high part byte (MSB): 0 (0x0,
00000000B)
2 Big-endian (Motorola bytes order):
byte #(N) - high part byte (MSB): 0 (0x0,
00000000B)
byte #(N+1) - low part byte (LSB): 143
(0x8F, 10001111B)
Power of the laser in watts (up to 65kW). 1 Bit
3 = 1 Watt.
Decimal coded.
2 Power Example: value 255 (0x00FF,
0000000011111111B) = 255 Watt.
4 Little- or big-endian bytes order, configured by
LaserNet.
For the laser with beam switch this field
defines the optical channel. The beam switch
mirror will be set automatically to the beam
position by the laser at request moment (also
after failure reset) and dropped to the home
position after request signal reset (or if one of
signals Laser Error, Channel Error, Chiller
5 Optical Ch.
Error, Slot Error is appear).
Decimal coded.
Examples:
3 value 0 (0x00, 00000000B) = Channel 0
(home position - all mirrors are dropped);
value 1 (0x01, 00000001B) = Channel 1;
value 3 (0x03, 00000011B) = Channel 3;
This field sets the number of the laser
program. This value can be set simultaneously
with the control signal "Program start".
6 Program No. Decimal coded (0 .. 50)
Examples:
value 1 (0x01, 00000001B) = Program #1;
value 5 (0x05, 00000101B) = Program #5;
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7 The ramping rise time value which can be

used for the laser program #0 and set power
through fieldbus interface (bytes #3-4).
Ramping rise 1 Bit = 1 ms. Decimal coded.
4
8 time Example: value 255 (0x00FF,
0000000011111111B) = 255 ms
Little- or big-endian bytes order, configured by
LaserNet.
The number of requested laser. This number
is compared to the installed laser number at
request moment. If this number is different the
laser will set the signal "Slot Error" (output
Laser
9 Status2 word, bit #7).
Number
5 Decimal coded.
Examples:
value 1 (0x01, 00000001B) = Laser Number 1;
value 3 (0x03, 00000011B) = Laser Number 3;
10 Reserved
Additional word #1 which can be used in laser
11
programs for set value of power or time.
For the laser program #0 this value can be
Additional
used for set the ramping fall time.
word 1 /
6 Decimal coded.
Ramping fall
12 Example: value 255 (0x00FF,
time
0000000011111111B) = 255 Watt.
Little- or big-endian bytes order, configured by
LaserNet.
Additional word #2 which can be used in laser
13
programs for set value of power or time.
Decimal coded.
Additional
7 Example: value 255 (0x00FF,
word 2
14 0000000011111111B) = 255 Watt.
Little- or big-endian bytes order, configured by
LaserNet.
Additional word #3 can be used in laser
15
programs for set value of power or time.
Decimal coded.
Additional
8 Example: value 255 (0x00FF,
word 3
16 0000000011111111B) = 255 Watt.
Little- or big-endian bytes order, configured by
LaserNet.
Outputs
Byte Word Name Description
1 Main status bits of the laser.
Same coding as input control word.
1 Status
2 Little- or big-endian byte order, configured by
LaserNet.
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3 Device description

3 Measured (real) output power of the laser in

watts.
Decimal coded.
Output
2 Example: value 255 (0x00FF,
4 Power
0000000011111111B) = 255 Watt.
Little- or big-endian bytes order, configured by
LaserNet.
The current optical channel.
Decimal coded.
Optical
5 Examples:
channel
value 1 (0x01, 00000001B) = Channel 1;
value 3 (0x03, 00000011B) = Channel 3;
3
The current program number.
Decimal coded.
Program
6 Examples:
number
value 1 (0x01, 00000001B) = Program #1;
value 5 (0x05, 00000101B) = Program #5;
7
4 Status 2
8
The number of the laser which hardware
installed in the laser (or through LaserNet for
lasers without hardware for coding).
Laser
9 Decimal coded.
5 Number
Examples:
value 1 (0x01, 00000001B) = Laser Number 1;
value 3 (0x03, 00000011B) = Laser Number 3;
10 Reserved
11 Reserved
6
12 Reserved
13 Reserved
7
14 Reserved
15 Reserved
8
16 Reserved

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3 Device description

Input word: Control

10
Bit Name Description
Activates control via fieldbus (without this signal all
other bits, except control bit #3 "Guide Laser ON",
will be ignored). High (1) is active. With this signal
one of several external controllers (robots) can
request laser power. This function is only valid if
several I/O cards are installed. If only one robot is
0 Laser request connected to the laser, this bit always must be set YES
during the control process. Without this bit all other
input bits (except control bit #3 "Guide Laser ON")
are ignored. As a confirmation that laser is
connected now to this particular controller (robot),
status bit #0 "Laser is assigned" in the status word
will be set high (1).
Switch on the main power supply. High (1) is active.
This bit is used to switch ON and OFF the Laser
(main power supply). If the Laser can not be
switched ON (E-stop loop is open), the status bit
1 Laser ON NO
#11 "Warning" will be set. To switch ON the Laser
the bit #2 “Reset” should be set high. As a
conformation, the status bit #1 "Laser is ON" is set
high when the Laser is ON.
Reset not fatal errors in the laser. High is active.
This control bit is used to reset all not fatal
messages of the laser system and status bits: #2
“Laser Error”, #6 “Program is interrupted”, #11
2 Reset errors NO
“Warning” and Status2 bit #7 ”Slot Error”. If the input
bit #1 "Laser ON" is in the active state (High), the
power supply will be switched on. This bit should be
active at least for 5 ms.
Switch on the guide laser. High (1) is active. Guide
lasers can be switched ON without the command
"Laser Request" and response "Laser is Assigned".
In all optical channels (competent for the current
Guide laser
3 fieldbus slot) where mirrors in home position (down) YES
ON
guide lasers are switched on. In the channel where
the mirror in the work position the channel guide
laser is switched off and the main guide laser of the
laser is switched on.
Start the laser program (before the number of the
program must be set in the byte 6). High (1) is
active. With this bit the Laser programs can be
4 Program start started and stopped. A program gets started if bit is NO
active and stopped if the bit is cleared or the
program ends. Program starts only once. Program
number is defined by the byte 6. If the program

10
Show of actual state and response to inputs without assignment
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3 Device description

number is 0 and the control bit #7 "Analog control

ON" is high (1), than laser power is controlled by
hardware Analog input. If the program number is 0
and the control bit #7 "Analog control ON" is low (0),
laser power value can be set fieldbus interface word
#2 (bytes #3 and #4). The status bit #9 "Laser
Ready" must be High (1) before start of the
program. After start of the program conformation
status bit #4 “Program active” will be set High (1).
This bit will be cleared after the end of the program
and the status bit #5 "End of the program" will be
set high. Status bit #5 will be cleared after control bit
#4 "Program start" is cleared (handshake; - not valid
if program number is 0).
For start of the program again slope of this bit is
necessary.
Stop of the running laser program. High (1) is active.
The active program can be immediately stopped by
this bit. If this happens before the end of the
5 Program stop program, the status bit #6 "Program is interrupted" NO
will be set, the status bit #4 “Program active” will be
cleared and the status bit #5 "End of the program"
will not be set.
6 Reserved - -
Switch on analog control for set output power of
Analog control
7 laser. High (1) is active. Analog control input can be NO
ON
activated by this bit if program number is 0.
Control by
external Enable some functions of control in the program
8 NO
software LaserNet.
enable
Set the ramping time for up as a value in bytes #7-8.
Set ramp up This is ramping time will be valid only under laser
9 NO
(rise time) program #0 and at set of the power through fieldbus
or LaserNet.
Set the ramping time for down as a value in bytes
Set ramp down #11-12. This is ramping time will be valid only under
10 NO
(fall time) laser program #0 and at set of the power through
fieldbus or LaserNet.
Synchronizatio This input can be used in the Laser Program (wait
11 NO
n input for high or wait for low).
12 Reserved - -
13 Reserved - -
14 Reserved - -
The system has error (not because of the laser).
After reception of this signal the laser will drop a
15 External Error NO
mirror to the home position and will set the status
signal "Slot Error".
Output word: Status1
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3 Device description

Bit Name Description

Control of laser from fieldbus (confirmation of
Laser is control bit 0). High (1) is active. If this bit is low (0),
0 0
assigned all inputs, except "Laser request" and "Guide Laser
ON", are ignored.
The main power supply of laser is on. High (1) is
1 Laser is ON YES
active.
Laser system has error(s). High (1) is active.
Abnormal situation is detected inside or outside the
2 System error Laser. This signal the combined value of following YES
signals: "Laser error", "Chiller error", "Channel
error", "Safety open", “Slot Error” no "Interlock".
Guide laser is
3 The channel guide laser is on. High (1) is active. YES
ON
Program
4 Laser program is running. High (1) is active 0
active
Laser program was completely executed. High (1) is
End of
5 active. This bit will be cleared after control bit #4 0
program
"Program start" is cleared.
Laser program has been interrupted. High (1) is
Program is
6 active. “Reset” (control bit #2) is required to clear 0
interrupted
this bit.
Analog control
7 Analog control in the laser is on. High (1) is active 0
is ON
Laser system has warning(s). High (1) is active.
System
8 This signal the combined value of following signals: YES
warning
"Laser warning", "Chiller warning".
Laser is ready for emission. High (1) is active. If this
bit is high, Laser program can be started by control
bit #4 “Program Start”. Laser is not Ready when:
Chiller Failure, Front Door opened, Rear Door
9 Laser is ready opened, Top Cover opened, Out of the Temperature 0
Range for the Water of the Laser, Out of the
Temperature Range for the DI Water of the Optics,
Main power supply is OFF, the mirror of the optical
channel not in the work position.
Emission is Emission is on. High (1) is active. Laser emits
10 0
ON radiation.
Synchronizatio Can be used in the Laser Program (set high or set
11 0
n output low).

12 "Robot" mode The hard key in the "Robot" position. High (1) is YES
active.
Internal Safety Circuit of Laser is closed. High (1) is
13 Interlock YES
active.
14 Laser alive Fieldbus controller is working YES
Control by
Some functions of control in the program LaserNet
15 external YES
are enabled.
software is
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3 Device description

enabled
Output word: Status2
Bit Name Description
Laser has error(s). High (1) is active. Abnormal
situation is detected inside the Laser: Module
Overheat (t >= 35C), Module Unconnected, Module
Failure, Laser Fiber Interlock, Beam Switch Failure,
High FFBD light, High scattered light, Water in
0 Laser error Laser, Water in Beam Switch, Low water flow in YES
process fiber connectors, Low water flow in feeding
fiber connector, Power Supply Failure, Low Water
Flow Laser, Unexpected Pump Current, Unexpected
Ground Leakage, High Back Reflection.
Operation is stopped.
Laser has warning(s). High (1) is active. The status
is detected in the Laser system: failed operation of
1 Laser warning the bit Laser ON, Warning Lamp Failure, Module YES
Warning Overheat (t >= 33C).
Operation is possible.
Water in the chiller too hot. High (1) is active. It is DI
water conductivity is >= 25 µS, the water
2 Chiller error YES
temperature of the tap circuit >= T1 or <= T2, the
water temperature of the DI circuit >= T3 or <= T4.
Water in the chiller too warm. High (1) is active. It is
DI water conductivity is >= 15 µS, the water
3 Chiller warning temperature of the tap circuit >= T1 - 2C or <= T2 + YES
2C, the water temperature of the DI circuit >= T3 -
2C or <= T4 + 2C.
Safety circle for the specified channel is open. High
4 Safety open YES
(1) is active.
The specified optical channel has error. High (1) is
5 Channel Error YES
active.
Laser has been assigned by other interface or
6 Laser is busy YES
controller. High (1) is active.
Invalid laser number (input byte #9) or invalid
7 Slot Error channel number (input byte #5) was set or the input 0
signal "External Error" is Active. High (1) is active.
Cabinet door The cabinet door in one of allowed channels is
8 YES
open open. High (1) is open.
9 Reserved - -
10 Reserved - -
11 Reserved - -
12 Reserved - -
13 Reserved - -
14 Reserved - -
15 Reserved - -

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3 Device description

3.5.10 Multi PLC Interface (MPI) / Coding Cable

The MPI in combination with the Coding cable provides an approved and save
method to operate a large number of lasers in a complex cross-linked production
line.

Dip switches and Coding cable

The optical channel coding and laser number coding is done using dip-switches.
The dip-switches are installed on the IG297 board next to the Beam Switch
channels. For each optical channel an IG297 board is designated.

Picture 3-8: Dip switch boxes and Coding cables

For each process fiber or optical channel respectively a coding number between 1
and 255 can be chosen. For the laser a coding number between 1 and 31can be
chosen.

Picture 3-9: Dip switches

Example: In the picture above the optical channel is coded with value 68 (SW 5
and SW12). The laser is coded with value 1 (SW 7). The parity check bit SW 2
was set to value 1 because the parity check results an odd number (SW 5, SW 7,
SW 12).

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3 Device description

DANGER TO LIFE
Death or heavy bodily injury by faulty settings of the dip switches
► The dip-switch settings and the coding respectively must be
WARNING done only by well skilled personal.
► False or incorrect settings can lead to bodily injury.
► Before operating the device make sure the settings are
correct.

DISTURBANCE OF THE LASER OPERATION

Disturbance of the laser operation due to faulty settings of the dip
switches
► The dip-switch settings and the coding respectively must be
done only by well skilled personal.
► False or incorrect settings can cause problems in the laser
operation.

Table 3-10: Dip switch lay out

IG_297 Dip switches
Destination Dip switch no. Bit no. Value
11
Parity check 2 - -
3 0 1
4 1 2
5 2 4
Optical channel 6 3 8
number 8 4 16
10 5 32
12 6 64
14 7 128
7 0 1
9 1 2
Laser number 11 2 4
13 3 8
15 4 16

11
Parity check bit
If the parity check results an even number, the parity check bit must be 0
If the parity check results an odd number, the parity check bit must be 1
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3 Device description

IMPORTANT ADVICE:
For each optical channel the status of the mirror position is
assigned by the coding cable. Also the status of the Cabinet doors
(A), (B) is verified via the coding cable.

IMPORTANT ADVICE:
The coding cable must be taken from the laser to the working cell.
The query of the coding and check-up with the controller must be
realized by the customer to ensure a maximum of safety.

Table 3-11: Coding cable pin layout

Coding Cable pin layout
Pin
Name Description
number
A1
A2 Only potential free contacts can be
Cabinet doors (A) and (B) connected to pins A1- A2 and A3 -
A3 A4
A4
A5 Potential free output
Mirror ON
A6 A5 - A6 closed if mirror is “ON”.
A7 Potential free output
Mirror OFF
A8 A7 – A8 closed if mirror is “OFF”.
B2 +24V DC Input
B3 Parity bit
B4 Optical channel number bit 0
B5 Optical channel number bit 1
B6 Optical channel number bit 2
B7 Optical channel number bit 3 Potential free outputs.
B8 Optical channel number bit 4 24VDC at B2 must be provided by
the customer to receive a HIGH
C1 Optical channel number bit 5 signal when status is active.
C2 Optical channel number bit 6
C3 Optical channel number bit 7
C4 Laser number bit 0
C5 Laser number bit 1
C6 Laser number bit 2
C7 Laser number bit 3

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3 Device description

C8 Laser number bit 4

IMPORTANT ADVICE:
The coding cable must become secured against interchange. Lock
the coding cable with the delivered clamps to the process fiber
cable. The free cable length inside the Beam Switch must match
only with the appropriate IG297 board.

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4 LaserNet software

4 LaserNet software
4.1 Settings and minimum system requirements

The LaserNet program is supplied with the laser and allows to monitor current
state/statuses and to operate the laser. The program can control up to 100
different lasers chained through the Fast Ethernet 100 Mbit/sec (Standard IEEE
802.3).

Computer requirements for operation of LaserNet:

► Pentium III/IV 1GHz or compatible (recommended - Pentium IV 2 GHz);

► RAM 256MB (recommended 512MB);
► Screen resolution 1024х768 (XGA) 256 colours (recommended - True
Colour);
► Free space on the hard disc drive (HDD) – 20 MB;
► Ethernet 100Mbit;
► CD-ROM;
► Modem (optional) or VPN connection
► Operating system Windows 2000 / XP / VISTA / 7

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4 LaserNet software

4.2 Software installation

To install the LaserNet program on your computer insert the delivered CD in the
CD ROM drive and execute the LaserNetSetup.exe (folder Setup).
Follow the Installation Wizard.

The Setup Wizard will start up.

Press Next.

Select the Installation Folder and

press Next.

Enter a name for the Start Menu

Folder and confirm with Next.

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4 LaserNet software

Select / Deselect the options. We

recommend to keep the default
settings.

Finish the Installation with pushing

the button Install.

Keep the selection Launch LaserNet

to start LaserNet when press Finish.

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4 LaserNet software

4.3 Establish a connection to the laser

To establish a connection between laser and PC both must be connected to the

same local network.

Connect a Network cable between the XP5 Interface of the laser and the Network
adapter of your local PC. Use a cross-over cable for the Laser - PC connection.
(Current PC’s can also handle straight through cables)

Default IP address laser

IP address 192.168.100.1

Subnet mask 255.255.255.0

At your local PC go to Local Area Connection Properties and set the Internet Protocol
(TCP/IP) Properties as follows:

The IP address of the

laser and the local PC
have to be equal in the
first nine digits and have
to differ in the last three
digits.

After the connection

between laser and PC was
established, the IP
address of the laser can
be changed. Therefore
please refer to chapter
4.6.3 Settings / IP
Configuration on page 83.

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4 LaserNet software

4.4 General Information

In the LaserNet program three different coloured LED-style indicators are

generally used to reflect statuses of the laser.

A lightning LED indicates an active signal.

The red LEDs represent alarm signals which generally disable the laser emission.
The yellow LEDs represent warning signals that do not influence the laser
emission.
The green LEDs indicators are generally used to display status information.

Green LED in “OFF” state

Green LED in “ON” state

Yellow LED in “OFF” state

Yellow LED in “ON” state

Red LED in “OFF” state

Red LED in “ON” state

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4 LaserNet software

4.5 Starting LaserNet software

Before starting the LaserNet program ensure that both the laser and the computer
are connected to the same LAN. (If a single laser is used, a cross-over cable
connection can be employed)
Start the program LaserNet.exe and the following window will appear12:

Picture 4-1: LaserNet, No net connection

Choose menu Settings / IP Configuration. The window below will appear. Click on
Add to add a laser. Change the State to Enabled (click on actual state to alter).
Click on OK.

After the connection between laser and program has been established the window
will change:

12
The number of parameters and indicators can vary due to different laser models and options
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4 LaserNet software

4.6 Main Menu of LaserNet software

The table below gives an overview of the LaserNet main menu and its submenus.
A detailed description is given beneath the manual.

Menu Structure

File

└►Monitor file…input window

└►Exit

Settings

└► IP Configuration…input window

└► Laser ► Change of Access ► Choose access level

└► Laser ► Reset Critical Errors…Input window

└► Laser ► Fieldbus Settings… Input window

└► Laser ► Advanced Settings…Input window

└► Laser ► Configuration update…Browser window, choose *.hplp-file

└► Enable Controls

└►Change password…Input window

└►LaserNet Settings ► Control…Input window

└►LaserNet Settings ► Events…Input window

└► Language…Choose language

View

└►Toolbar

└►Status bar
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4 LaserNet software

Tools

└►Program Editor…to launch Laser Program Editor

└►Access Levels…Information window

└► Profibus Debug Window

Help

└► LaserNet Help…Information window

└► About LaserNet…Information window

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4 LaserNet software

4.6.1 File / Monitor File…

LaserNet Software offers the possibility to write a monitor file. With the help of a
monitor file the operator can follow all signal and statuses displayed in LaserNet
Status, Control and Alarm page.
To activate the monitor file go the LaserNet File / Monitor File...

Picture 4-2: Path to Monitor file…

Picture 4-3: LaserNet, Monitor File window

Select the time period and the signals that should be monitored. To record the
Monitor file click on “enable to record in the monitor file.”

IMPORTANT ADVICE:
The Enable to record in the monitor file should be deactivated after
the investigation. If it is not deactivated data will be continuously
created and stored to the monitor file.

The monitor file is stored in the Laser folder on the computer. The file format is .txt.

4.6.2 File / Exit

Push to close the LaserNet software program.

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4 LaserNet software

4.6.3 Settings / IP Configuration

Picture 4-4: LaserNet, IP Configuration

The Laser name is used as identification when controlling multiple lasers from one
computer. These names are visible in the left plane of the LaserNet software.
The IP address is used by the computer to establish connection to the Laser. If the
real IP of the laser differs there will be no connection.
The State indicates if the connection to the laser will be Enabled or Disabled.

By pushing IP Properties (a laser with active connection must be selected) the

following dialog window will open:

Picture 4-5: LaserNet, IP Properties

In this pop-up window the IP of the laser can be altered.

IMPORTANT ADVICE:
The IP address of the Laser and the IP of the computer (TCP/IP
settings) must be equal in the 1st nine digits.

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4 LaserNet software

4.6.4 Settings / Laser / Change of Access

In LaserNet there are 4 different user levels defined. The levels are monitor,
operator, engineer and Supervisor. The actual selected operator is marked with an
arrow.

Picture 4-6: LaserNet, Change of Access

If the user level is changed a password is requested. The change of the user level
can only be done if the correct password is typed in.
The different user rights can be checked in the folder Tools / Access levels
described beneath this chapter.

4.6.5 Settings / Laser / Reset Critical Errors

In this menu a Critical Error of the laser can be reset. The alarm message Critical
Error is activated together with the alarm Coupler failure. This alarm will remain
active until the reset code is provided.

Picture 4-7: LaserNet, Reset Critical Errors

To receive a reset code, please call IPG Laser. The following information is
needed by IPG:

► What was the process / parameters during the failure happened?

► Is the Guide Laser visible after the fiber connector?
► Download the Log files and send it to [email protected]
► What is the Laser serial number?
► What is the Code No?

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4 LaserNet software

4.6.6 Settings / Laser / Fieldbus Settings

Picture 4-8: Fielbus Settings window

For each slave module (slot) the following settings needs to be done:

► Address
This is the slave address for the slave module. If more than one slave module is
installed, the slave modules must have unequal slave addresses. The address can
be changed here.

► Byte Order
Defines the byte order (Big-endian or Little-endian) for the communication
protocol. For each module the byte order can be defined separately.

► Allowed optical channels

The access to these optical channels by the accordant slave module is defined by
selecting or deselecting the check boxes. Only selected optical channels can be
accessed by this slave module. An optical channel can be allocated to different
slave modules.

► Number of optical channels

No input can be made in these fields. This part is just for monitoring purposes. The
coding of the channels needs to be done inside the Beam Switch cabinet
respectively. The description how the coding is done you can find below.

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4 LaserNet software

Example: The physical optical channel no.1 is coded as no.42. So the master must
request the channel no. 42.

► Laser number
No input can be made in these fields. This part is just for monitoring purposes. The
coding of the laser number needs to be done inside the laser cabinet or the Beam
Switch cabinet (IG297) respectively. The description how the coding is done you
can find below.
The laser number must be the same for each slave module in a laser.

Example: The physical laser number 1 is coded as no.6. So the master must
request the laser no. 6.

► Check-up

If this option is selected the Laser number will be verified. If this option is not
selected, the requested Laser number does not matter.

► Update Config file

To update or change the Fieldbus settings of the slave module a *.dbm file can be
loaded. The file you will receive on request at IPG Laser GmbH.

CHANGE OF THE SETTINGS REQUIRES RESTART OF THE LASER

CONTROLLER
► Each change of the Fieldbus settings requires a restart of the
laser controller system.
► To perform a restart of the laser system, turn the key switch to
OFF position. Wait for 10 seconds and turn the key switch to
“Robot” position.
► Before restart of the system verify that the change of settings
was successful

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4 LaserNet software

4.6.7 Settings / Laser / Advanced settings

► Automatic Switching OFF

An Automatic Switching OFF can be defined here. The emission will stop after the
defined time in seconds, whether a program is active or not.
Zero (0) seconds defines the Automatic Switching OFF function is not active.
Additionally it can be selected if the power supply should switch OFF or not.

► Feeding Fiber Output

If the Laser has the Feeding Fiber Option it can be chosen between feeding fiber
is connected to an external optics such as beam switch or beam coupler or directly
to a processing optics.

4.6.8 Settings / Laser / Configuration update

A browser window will be opened to upload a *.hplp file to update firmware and/or
configuration of the laser.

4.6.9 Settings / Enable Controls

LaserNet control can be protected by a general password. The definition of this

password is done under Settings/Change Password. If LaserNet is password
protected the user has to go to Settings/Enable control and type in the password
to enable controls.

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4 LaserNet software

4.6.10 Settings / Change Password

Picture 4-9: LaserNet, Change Password

This dialog window is used to define a computer specific password for LaserNet
independent of all user levels. The LaserNet controls will be blocked until the
password is typed in Settings / Enable control.

If you don’t remember your password, you can delete it using the Registry editor in
your local PC. You will find the file user in the following path:

HKEY Current User

Software
IPG Laser GmbH
LaserNet
Settings

Delete the file user and restart your LaserNet software.

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4.6.11 Settings / LaserNet Settings / Control…

Table 4-1: Settings of control

Menu Description
All controls in LaserNet control window are blocked
Control disable
when active.
Emission On cannot be activated in LaserNet
Emission disable
control window when this function is active.
Reset always enable Reset button in LaserNet always active
“Ctrl” for Reset and User has to push "Ctrl"-key to unblock Reset and
Emission Emission On button in LaserNet
When running more than one laser from one
Warning at switching
computer user is asked for confirmation during
lasers
switching from one laser to the other.

4.6.12 Settings / LaserNet Settings / Events…

Choose the maximum number of events stored in the Events4.dat file to limit the
file size.

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4.6.13 Settings / Language

At the moment the following languages are implemented to LaserNet: English,

German, Russian, French, Spanish, Italian, Chinese, Korean, and Japanese.

4.6.14 View / Toolbar

Shows / hides the toolbar.

4.6.15 View / Status bar

Shows / hides the Status bar.

4.6.16 Tools / Program Editor

A detailed description how to use the Program Editor is given in chapter 4.9
LaserNet Program Editor, page 121.

4.6.17 Tools / Access levels

Picture 4-10: LaserNet, Access levels

In Access levels a review of the access rights is given. The rights can’t be altered.
The passwords entered are laser specific. The passwords are defined in the dialog
window when pushing the Passwords button:

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Picture 4-11: LaserNet, Access levels, Passwords

By pushing the Change button of the desired Access level another dialog window
will open:

Picture 4-12: LaserNet, Change Password

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4.6.18 Tools / Profibus Debug Window

Picture 4-13: Profibus Debug mode

If Debug mode button is checked you can set any bits for fieldbus outputs (at this
case laser has not reaction for fieldbus inputs).
If Debug mode button is unchecked, all information in this window are just for
monitoring.
(Minimum Firmware requirement (LaserNet property page Log files): LaserNet
Version 2.82.9, PC104 Version 3.91)

4.6.19 Help / LaserNet Help

To launch the LaserNet offline help (if installed).

4.6.20 Help

Picture 4-14: About LaserNet

The dialog window provides information about the currently used LaserNet
software version.

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4.7 LaserNet Screen

Picture 4-15: LaserNet, Screen

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Table 4-2: Overview of LaserNet desktop

Item Name Description
Up to 256 lasers can be monitored by one
computer. The lasers names must be unique. If
1 Laser selection
an Ethernet connection is established, the red
cross vanishes.
2 Submenus Access to submenus.
3 Connection status Shows the status of the currently selected laser
Power /
Shows the current output power and mean
4 Temperature
temperature of the modules.
Indication
Laser ON Power supply ON / OFF
Laser Laser ready / not ready for
Ready emission
Chiller is ready / not ready, Chiller
Chiller
ready signal is precondition for
ready
5 Laser status13 Laser ready signal
Guide
Guide laser is ON / OFF
laser14
Laser error Laser has Error / NO Error
Emission
Emission is ON / OFF
ON
6 Properties pages (Selection of) Property status page

13
For detailed information see also chapter 7 Fault clearance
14
Guide laser will only be displayed, if no chiller is configured
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4.8 LaserNet Property Pages15

4.8.1 Status page

Picture 4-16: LaserNet, Status page

Table 4-3: Survey of LaserNet Status signals

Status
Description of the status and its effects
indicator
Indicates the status of the Main Power Supply.
The Power Supply transforms the 400VAC input voltage to
65…75VDC output voltage for the supply of the laser modules.
This signal corresponds to the signal Laser ON.

Main Power Without this signal the laser emission is not possible.
supply ON
The main power supply will not switch ON if

► Interlock circuit is open

► E-Stop (button) is active

15
Type and content will vary with type of laser
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Indicates that control by LaserNet is disabled. Basically this is the

case when operating in Robot Mode.
Internal Control In this case all controls apart from "Reset" are blocked in the
disabled LaserNet property page control.
The control can be enabled by setting the appropriate signal
(internal control enable) by the PLC.
Indicates that there is potential emission. Therefore the main
power supply must be switched on and the signal Laser Ready
Emission enable must be present. Activation of the signal "Emission On" will lead
to activation of "Emission enable." The selected laser output
power can be 0.
Indicates that the emission ON / OFF signal is externally
controlled.
External control can be enabled by pressing buttons External
control ON/OFF or Analogue control ON/OFF on the property
page Control. Once the external control is enabled, the laser
emission can be started (stopped) on applying (removing) +5…24
External control
V DC to the pins A1 [positive] and A2 [negative/ground] of the
safety interface XP2. In this case, the output power (or pump
current) has to be set on the property page Control and Emission
ON button should be pressed.
See also the description of Analogue control below and chapter
6.4 External modulation mode, page 161.
Indicates that the laser is in Analogue control mode.
This mode can be activated / deactivated by using the button
Analogue Control ON/OFF on the property page Control.
If the laser is in the Test mode the External control will turn ON
automatically once the Analogue control is switched ON.
Switching emission ON/OFF operates in the way described above
for the “External control”. The output power can be directly set by
Analogue
applying an analogue voltage to the pins 1 [positive] and 2
Control
[negative, ground] of the analogue control interface XP4. 0V DC
corresponds to 0% power and 10V DC to 100% output power.
If the laser is in the mode “Robot”, the Analogue control mode can
be enabled / disabled by applying/removing the analogue signal
through the hardwiring interface XP1. In the “Robot” control mode,
the output power (0 to 100%) is proportional to the 0 to +10 V DC
signal applied via the analogue interface XP4.
Guide laser Indicates that the lasers integrated Guide laser is switched ON.
Hardwiring Indicates that XP1 Hardwiring interface is enabled (key switch
active must be in Robot position
Indicates that the chiller is ready. If Chiller ready status goes off,
the emission will stop and signal Laser ready will be removed.
Chiller ready
For further analysis please refer to the LaserNet Chiller property
page.
Rear door open Indicates that a door at the back side of the laser is open. If this

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signal is active the main power supply can not be switched ON /

will be switched OFF in case it is already ON. Therefore emission
is not possible when this signal is active. Exception: Service Mode
is active.
Indicates that a door at the front side of the laser is open. If this
signal is active the main power supply can not be switched ON /
Front door open will be switched OFF in case it is already ON. Therefore emission
is not possible when this signal is active. Exception: Service Mode
is active.
Beam Switch:
Indicates the status of the Beam Switch. The active signal is
Laser
precondition for Laser Ready signal.
Permission
The signal is activated as soon as a optical channel (mirror) is
Beam Switch:
requested and no error is active in this channel.
Laser Enable
Indicates that the laser is potentially ready to be switched on
(Power supply can be switched on) and no alarm signal is in state
Laser “Standby”
HIGH.
This signal is independently from the mirror position.

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4.8.2 Alarms page

Picture 4-17 : LaserNet property page Alarms

Type and quantity of the alarm messages depends on the laser type and
configuration.

For detailed description and further information please refer to chapter 7.3 Fault
clearance / Alarm messages.
In the table below a brief summary is given.

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Table 4-4: Survey of Alarm signals

Status Laser17 Laser Laser18
Cause Remedy Reset
indicator16 ON ready error
Appears together with another alarm
E-Stop Safety loops are open. message, except if one of the laser doors is Automatic NO NO NO
open.
Release push button at front side of the
E-Stop button E-stop push button is pressed Automatic NO NO NO
laser.
XP2 safety circuit (C1-C4, C2-
Close XP2 safety circuit (C1-C4, C2-C3).
C3) has become interrupted,
E-Stop external Appears after a Laser fiber interlock was Automatic NO NO NO
feeding fiber not plugged or
reset by plugging the feeding fiber
damaged respectively.
Check the laser water flow.
One of the laser modules has
Check the piping and the filters.
Laser overheat reached a temperature >35°C Automatic YES NO YES
The module is enabled again as soon as
and was disabled.
the temperature is <32°C
The safety loop of the feeding
fiber is interrupted. In Lasers Plug the feeding fiber to an optical head.
Laser fiber with an Optoskand FFC also Check the interlock contacts inside the
Manual NO NO YES
interlock the survey of the process fiber optical head.
is included in this alarm Replacement of feeding fiber.
message.
Check optical head (protective glass) for
Internal sensor has detected
High back contamination.
to high level of light coming Manual YES NO YES
reflection Check parameters, focus position, power,
back from the work piece
and angle of the application.

16
The kind and number of alarm messages depend on the type and the configuration of the laser
17
In standard configuration
18
In standard configuration
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Call for Service.

If a reserve module is installed, the laser will
Laser module One of the laser modules is
continue emitting. If no reserve module is Manual YES YES NO
failure damaged / disabled.
installed, emission is stopped. After reset
the error the laser emits with less power.
The integrated (or external)
Check the accordant LaserNet chiller
Chiller failure chiller has detected Automatic YES NO YES
property page for further information.
malfunction.
Temperature of tap water or
DI water is out of range or Check the accordant LaserNet chiller
Chiller error Automatic YES NO YES
conductivity is too high. Also property page for further information.
active in case of chiller failure.
Internal sensor has detected
Combiner Check visibility of the Guide laser.
a problem inside combiner Manual NO NO YES
failure Call for Service.
module.
Occurs only together with
Critical error Combiner failure or Splice box Refer to chapter 1.1 to “Reset Critical Error” manual NO NO YES
failure.
The temperature in the Check if the van is rotating.
Electronic
Electronics cabinet exceeded Check the setting of the temperature Automatic YES YES NO
overheat
its limit (>50°C) sensor.
Initialization Configuration failure or wrong
Check DIP switches. Automatic YES NO YES
error MPI settings were detected.
Low water flow TAB water flow to cool the
Check performance of the chiller. Manual YES NO YES
laser laser is below the limit
DI water flow to cool the
Low water flow
feeding fiber connector is Check performance of the chiller. Automatic YES NO NO
fiber connector
below the limit
One of the water leakage Open the laser cabinet doors and check for
Water in laser Manual NO NO YES
sensors has detected water. a leaking of a water connection.

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Water inside A sensor inside the Beam

Switch off chiller. Call for Service. Automatic NO NO YES
Beam Switch Switch has detected water.
Laser The average temperature
Check the chiller TAB water temperature
temperature is of all modules is below Automatic YES NO YES
settings. Set to 21°C.
too low 18°C.
Some malfunction was Refer to the according LaserNet page and
Power supply
detected by the Main Power chapter 7.3 Alarm messages for further Manual NO NO YES
failure
Supply. information.
AC power Phase loss or too low supply
Check if external power supply voltage Manual NO NO YES
interruption voltage (400VAC line)
Always connect both circuits of the Beam
Beam Switch
Beam Switch error is Switch safety to the cabinet door. Don’t
permission Manual NO NO YES
detected. open the cabinet door while the accordant
malfunction
mirror is in working position.
Appears if the power supply
applies the pump current to
Unexpected Remove the fuse of the responsible
one or all the laser modules Manual NO NO YES
pump current module. Call IPG for Service.
while no emission ON signal
is present.
Indicates a pump current
leakage in the circuit
Unexpected between the negative Remove the fuse of the responsible
Manual NO NO YES
ground leakage terminal of the power supply module. Call IPG for Service.
and the protective earth (PE)
terminal.
A sensor inside the Check visibility of the Guide laser.
Splice box
intermediate Splice box has Call for Service. Refer to chapter 1.1 to Manual NO NO YES
failure
detected a problem. “Reset Critical Error”
Average power
In QCW(+) lasers only Check modulation input Manual YES NO NO
too high

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4.8.3 Warnings

Type and quantity of the warning messages depends on the laser type and
configuration.

The warning messages will not interrupt the laser emission.

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Status Laser Laser Laser

Cause Remedy Reset
indicator ON ready error
Indication One of the stack light is Check the stack lights for proper
Automatic YES YES NO
lamps failure damaged or dismounted installation.
One of the active laser
Reserved modules detected an
Call IPG for Service. Automatic YES YES NO
module is ON internal failure and was
switched of.
One parameter
Warning chiller (temperature, pressure) is Check chiller settings. Automatic YES YES NO
close to the limit.
At least one of the
Module modules has reached a Check the water flow of the chiller.
Automatic YES YES NO
overheat temperature higher then Check the piping of the module.
32°C.
The communication
Laser module between at least one Check the connection at the front side of
Automatic YES YES NO
disconnected module and the micro the modules.
controller is lost.
Indicates an error in one of The discharge circuit is built up
Discharge the two internal discharge redundant. Inform your provider about
Automatic YES YES NO
circuit is defect circuits of the power the defect. Exchange of the damaged
supply. device is required.
Laser The average temperature
Check the chiller TAB water
temperature of all modules is below Automatic YES YES NO
temperature settings. Set to 21°C.
too low 19°C.
Reduced active Amount of active modules Check for module failures (LaserNet
Automatic YES YES NO
modules is insufficient modules page)

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4.8.4 Control page

Control pane Description

Laser button allows switching the main power supply of
the laser ON or OFF. The state of the power supply is
shown on the face of the button.

Emission button allows switching the laser emission ON

and OFF. The current state of emission (ON in red or
OFF in blue) is displayed on the button. Pressing the
Emission button showing OFF state will cause transition
to ON and will switch the laser emission on; pressing the
ON state emission button will cause transition ON to OFF
state and will stop laser emission. If the laser is in
External control mode, pressing the emission button will
not start the emission but will only set the laser to a ready
state when emission is allowed at any moment; the
emission can be turned on by applying the external
emission ON command via XP2 connector. If the laser is
not in External control mode, pressing the emission will
start the emission instantaneously. In both modes of
operation, pressing the emission button (once it is in ON
state) will stop the emission.

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Guide lasers control buttons switch the installed guide

laser ON or OFF. Once the guide laser is ON, the
corresponding button will change its shape and green
LED indicator will light.

Channel 0: Guide laser installed inside laser

Channel 1…4: Guide lasers installed inside Beam switch
channels 1..4

Beam switch pane controls allow altering the positions of

the beam switch mirror(s) to allow power sharing
between installed output channels. With the slide bar in
“home” position all mirrors are down and optical channels
are inactive and the beam power is dissipated by the
beam dump. Other positions of the slide bar move the
mirror of the corresponding channel in “work” position
enabling a particular power share output. If the green
indicator LED corresponding to the beam path
configuration set with the slide does not lit, this
corresponds to failure of the beam switch. Refer to the
beam switch properties page. In no circumstances two
different mirrors can be in “work” position at the same
time; presence of more than one lit green LEDs indicates
failure in the beam switch.
External control button allows switching the external
control mode ON or OFF. The state is shown on the face
of the button. To turn laser emission on in the external
control mode, the button emission has to be pressed first
(ON state) and then the emission on signal has to be
applied via the XP2.
Analog control button allows switching the Analog control
mode ON or OFF. The currently selected mode is shown
on the face of the button. In the Analog control mode the
laser output power can be controlled with an analog
voltage signal applied via the XP4 interface. 0V DC
corresponds to 0% output power and +10V DC will set
output emission power to 100%.
Selection of the Analog control mode automatically
enables the External control mode. To switch the
emission on, set Analog control ON, Emission ON, apply
the analog voltage (0 to +10V DC) to the XP4 interface;
apply External ON signal voltage (5 to +24V DC).

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Ramping time pane has two fields for power ramping

setting. The first allows setting a desired rise the second
fall time. Set the time value in milli-seconds into the blank
field and press Enter on the keyboard or click Set button
next to the input field. The currently set values are shown
above the input fields.

Laser program pane contains controls and statuses of

the Laser Program (LP). The input field allows entering
and selecting the LP number between 1 and 50. The
Run-Stop button and three different indicators of the LP
state operate as follows. If the laser is in “Ready” state,
execution of a desired program will start after the LP
number has been set and the button RUN pressed.
Once the program is being executed, the Run button
name and function will change to stop and back to RUN
after the program has been completed. If Stop is pressed
during execution of the program, the program will stop
instantaneously. The green indicator “Program active”
will remain lit from start to the end of the program. If the
program has completed without errors, the indicator “End
of program” will lit and will remain on until the following
program starts or the “Reset” button is pressed. If the
program is interrupted due to some reason, the indicator
“Program is interrupted” will light and will remain on until
“reset” button is pressed. The reason for interruption of
the program will display in the “Events” window.

Power (W) / Current (%) slide bar allows setting the output power of the laser as
absolute value in Watts or as relative value pump current in percents of the
maximum value. Either power or current mode can be selected by clicking the
corresponding check box above the slide bar. An indicator line below the slide bar
and the scale shows the actual power or current value. A box with numerical value
input on the right of the slide bar allows setting a specific value of the power or
current. The selected value should be confirmed by pressing “Enter” on the
computer’s keyboard. The pump current value can be chosen between 0 and
100 % and output power between 0 and 10000 W.
The laser starts emission after the pump current exceeds approximately 7%.

Alternatively in dependence of the laser configuration the slide bar can show
Power (W) / Power (%).

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4.8.5 Events page

This window provides information about events recorded by the laser system. All
entries have the following format: Event – Start time – End time.
The submenu (click on right mouse button) provides following options:
► To sort the events by date
► To save the events as *txt - file
► To delete the events list
The quantity of events stored on hard disk can be limited under Settings /
LaserNet settings / Events.
The update events list (file Events4.dat) is written to the hard disk of your local PC
each time LaserNet software is closed.

The symbols on the left side act as filters.

Represents information about the laser system and external optics.

Gives information about warnings.
Constitutes laser alarms.
Denotes information concerning the laser.
Represents information about the chiller.
Gives information concerning the Beam Switch or Beam Coupler.

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4.8.6 Log files page

LaserNet Software creates Log files which delivers important information about the
laser, the modules and the operation statuses.
The Log files are only readable by IPG Laser Service personnel. Costumers have
only the possibility to download these Log files on the Hard Disk of their computer.

The Log files can be downloaded at the LaserNet Log files page. An active
network connection to the laser is necessary.

First select the date of interest:

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Next the desired files must be selected either by manual (mark files by click left
mouse button) or by automatic (right mouse click, Select all files) selection:

When the files are selected, press button LOAD to download the files to the
computers hard disk. The files will be stored in the following folder:

► C:\Program Files \ IPG Laser GmbH \ LaserNet 2.93.7\ Laser. This folder
location is only available if you have installed the LaserNet software on your
Hard Disk in the Program Files Folder.

► C:\Documents and Settings \ username \ Desktop or directly on the Desktop.

This folder location is only available if you have installed the LaserNet
software on your computer Desktop.

► If you do not find the created file, use the Searching Option from Windows
under Start/Search/For Files or Folder/All files and folders/ and search for
the date when the failure happened. Example 27.10.08

The last step would be to send the folder per mail to

[email protected] this operation you have the possibility to
compress the files with WinZip or similar program.
Each Log files day/folder should be send separately to IPG Service Group to avoid
server trouble. Many costumers are limited in the size of the attached files for the
mailing. Please have a look to your Net Work capacity before sending folders to
IPG.

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4.8.7 Beam Switch

Signals which require any action are lighting red. Green lighting signals showing
status messages.

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Signal Description (Signal active)

Mirror active Laser is sending signal to set mirror in Working position

Guide laser ON Guide laser is switched on for the accordant channel

Mirror OFF Mirror is in Home position

Mirror ON Mirror is in Working position

Signal to the laser that the channel is ready for

Laser permission
operation

Cabinet door (A) Laser cell door (A) is open

Cabinet door (B) Laser cell door (B) is open

Error Accumulative fault for accordant channel

Too high value of scattered light was detected near

Scattered light
mirror

Too high value of scattered light was detected near

FFBD
process fiber input

Low water flow: DI water flow at output connector side (processing head
process fiber output side) is below set limit

Low water flow: DI water flow at input connector side (beam switch side)
process fiber input is below set limit

Optical interlock Process fiber interlock circuit is open

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4.8.8 Power Supply - Type Analogue control

The Main Power Supply is providing the direct voltage for the laser modules. If the
direct voltage is not in the specified range the laser will not give the Laser ready
signal.

Table 4-5: Power supply status

Q1 Q2 Q3 Q4 Status Comments

0 0 0 0 Normal operation

0 0 0 1 Overheating

0 0 1 0 Output overvoltage These events relate to external

parameters or environment
Output overcurrent / (water flow, input voltage, etc.)
0 0 1 1
Short circuit

Input undervoltage /
0 1 0 0
Phase loss

Internal failure These messages relate to

1 0 0 0
(Code_X) internal errors and assume that
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the power supply should be

Internal failure
1 0 0 1 replaced.
(Code_Y)

Internal failure
1 1 1 1
(Code_Z)

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4.8.9 Power Supply - Type CAN-Bus control

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4.8.10 Chiller - Type Riedel PC 160 / PC 250 / PC 400

The following parameters are monitored as numerical values:

Parameter Description
Water for external optics Actual DI water temperature at chiller
Water for laser Actual TAB water temperature at chiller
Water conductivity Actual water conductivity in DI water circuit
Chiller status Chiller status (Hex code)

Parameter Signal Type Range19

Operating Range 25°C – 35°C
Water for external optics Warning ≤ 27°C or ≥ 33°C
Error ≤ 25°C or ≥ 35°C
Operating Range 18°C – 25°C
Water for laser Warning ≤ 20°C or ≥ 23°C
Error ≤ 18°C or ≥ 25°C
Operating Range < 15 µSv/cm
Water conductivity Warning ≥ 15 µSv/cm
Error ≥ 25 µSv/cm

19
Depending on the laser configuration settings
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4.8.11 Chiller - Type IPG

For further information check the chiller user interface and the chiller operational
manual.

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4.8.12 Hardwiring (BS, default)

This property page is only for monitoring purpose and can be used for diagnostic
purpose.

On the left side the Input signals sent are shown. These signals must be sent by the
customer.
On the right side the output signal provided by the laser are shown.

For a detailed signal description please refer to chapter 3.5.1 XP1 – Hardwiring
interface page 49.

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4.8.13 Options - QCW

The QCW mode can be switched ON/OFF by selecting the QCW mode in the
Options page of the LaserNet program. For QCW frequency selection the slider
wheel must be used.
For further information please go to chapter 6.6 QCW mode, page 165.

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4.8.14 Fieldbus

For a detailed description of the signals please refer to the corresponding chapter.

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4.8.15 Modules

The property page Modules shows the actual state of the modules:

Table 4-6: Module Indications

Status Description
No indication Module active
R Module in reserve state
D Module not active, damaged or no communication

By enabling the Selection of modules the manual module selection is activated. So it

is possible to work with single modules. The output power is scaled according the
nominal output power.

Example: If 2 of 5 modules are selected, the output power will be 2/5 of the
nominal output power.

It is recommended to use this option if less than 10% nominal output power is
needed.

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4.9 LaserNet Program Editor

IMPORTANT ADVICE:
Writing, editing and storing of LP is only possible in Supervisor
mode.
As soon as an external controller (PLC) has selected a program
number, the program can not be edited.
A running program can not be edited.

4.9.1 Creating Laser Programs

Picture 4-18: LaserNet, Program editor

The Program Editor allows writing, editing, storing and loading LaserPrograms
(LP).

Loading and editing of the LP is done by filling in the corresponding table in the
dialog window. For each line, a new command in the column “CMD” has to be
selected and its parameters edited in the column “Param 1” and “Param 2”. The
command or parameters can be selected by clicking mouse in the corresponding
field and by choosing or typing in the desired values.
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A new line can be added either by left mouse click over the first following empty
line (default command “STOP” appears automatically in the new line, but can be
changed to any other available command) or by inserting a new line in front of the
existing line by right click with the mouse over the existing line and choosing
option “Insert line” (the new line with the default command “Stop” will appear
above this line).
To erase the existing command line, right click on the line and select “Delete line”.
If the program consists of a single line, the line can not be deleted.

To save the LP into the laser, press “Write” button. A dialog for assigning the
program number will appear and a number between 1 and 50 can be assigned to
the program. A green number indicates an empty memory capacity. A red number
indicates a memory capacity which is already in use. If connection with the laser is
not established, a warning will appear.

To load a stored program press “Read”, select the program number to load
(between 1 and 50). After loading the current program number will be displayed in
the title of the table dialog window. If connection with the laser is not established, a
warning will appear.

The LP can be saved as a file on the computer by selecting “File\Save...” and

inputting the path and file names. The program file will be stored as a text file with
extension “.inp” and can be viewed or altered by a standard text editor. Loading a
program file stored on the computer can be done by selecting “File\Load...” and
choosing the desired file.

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4.9.2 Table of commands used by the LaserProgram (LP)

Command Paramete Parameter

Remarks
# Name r1 2
1 STOP - - No parameters
0 – max
0 – 65534 Parameter 1 – time in ms
2 SPT power
or FBUS Parameter 2 – power in W
or FBUS
0 – max Parameter 1 – ramping ratio in
0 – 65534
3 SPR power W/ms
or FBUS
or FBUS Parameter 2 – power in W
SI LOW Wait for low level on Sync. In.
SI HIGH Wait for high level on Sync. In.
Wait for transition from low to
SI LH
4 WAIT high level on Sync. In
Wait for transition from high to
SI HL
low level on Sync. In
0 – 65534
Time Delay in ms
or FBUS
Go to the specified line of LP if
Line 0 – 99 SI LOW
low level is detected on Sync. In
5 GOTO Go to the specified line of LP if
Line 0 – 99 SI HIGH
high level is detected on Sync. In
Line 0 – 99 0 - 32767 Go to specified line by counter
SO LOW Set Sync. In to low level
6 OUT
SO HIGH Set Sync. In to high level
ANALOG Switch over to analog interface
7 EXTPWR -
FBUS Switch over to fieldbus interface
Channel Select the optical channel (only
8 SETCHAN -
1…N for lasers with beam switch)

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4.9.3 Structure of the laser program (LP)

Each LaserProgram consists of a three-column table. The codes of commands are

specified in the first column, parameters of the commands in the second and third
columns. Total number of lines in each LP is limited by 100 (defined by internal
FLASH memory). The maximum number of LPs is limited by 50.

Description of commands available for the LaserProgram:

Stop
Switches the emission OFF, switches analogue control OFF, stops execution of
the LaserProgram and sets the status “End of the program” to high.

SPT - Set output power in a certain time

(Linear interpolation between two points) - sets output power (in Watts) as
specified by the second parameter of this command, in time duration (in ms) as
specified by the first parameter. The initial value of the power is taken from the
previous command if applicable, or set to 0 if previously unspecified. If the initial
power setting equals the new value, the command will only perform a specified
time delay. This command switches analogue control OFF if it was switched ON
before.
All parameters of this command can contain a fixed (constant) value or FBUS
value.
In case of FBUS:
A power value is taken from the power word in the fieldbus protocol (or from
LaserNet, if the laser works in the test mode, or the control bit “Control by external
software enable” in the fieldbus control word is in the high level (1));
a time value is taken from the ramping time word in the fieldbus protocol.

SPR - Set output power with ramping time

Acts similar to the previous command except for the first parameter where a
ramping ratio (in W/ms) should be specified instead.
All parameters of this command can contain a fixed (constant) value or FBUS
value.
In the case of FBUS:
A power value is taken from the power word in the fieldbus protocol (or from
LaserNet, if the laser works in the test mode or the control bit “Control by external
software enable” in the fieldbus control word is in the high level (1));
a ramping time value is taken from the ramping time word in the fieldbus protocol.

WAIT - Wait for event

Allows waiting for one of the following events:
· Transition high/low at Synchronization Input,
· Transition low/high at Synchronization Input,
· Low level at Synchronization Input,
· High level at Synchronization Input,
· Time (ms). The time can be a fixed (constant) or FBUS value.
In the case of FBUS a time value is taken from the ramping time word in the
fieldbus protocol.
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Enabling synchronization input or timer selection is done by specifying the first

parameter, a type of the event is specified by the second parameter.

GOTO - Go to another command line

This command performs “GOTO” the command line whose number specified by
the first parameter, and if the number specified by the second parameter (counter)
is not zero. After having gone to the specified line, the counter value (second
parameter) decreases by one. If the initial state of the counter is zero, the GOTO
command performs unconditionally. In addition to the GOTO with the counter,
GOTO IF can be used.
· Low level at Synchronization Input,
· High level at Synchronization Input.

GOTO specified line will be performed, if one of the specified conditions is

detected.

OUT - Set signal on “Synchronization Output”

Sets low or a high level at Synchronization Output. Number of “Synchronization
Outputs” (one in this version) is specified by the first parameter, the level (high or
low) by the second parameter.

EXTPWR – Switch over to external mode

After performing this command the value of the output power is read from an
external interface. The external interface is specified by the first parameter of the
command. Execution of this command can be stopped by commands 1, 2, 3 (and
7, but with the different external interface specified).
In the case of FBUS a power value is taken from the power word in the fieldbus
protocol (or from LaserNet, if the laser works in the test mode or the control bit
“Control by external software enable” in the fieldbus control word is in the high
level (1)).

Note: The current version of LaserProgram supports two types of external

interfaces, the External analogue control interface and the Fieldbus control
interface.

SETCHAN – Selection of the optical beam switch channel

The first parameter of this command sets the desired beam switch channel. This
command is only available for lasers with beam switch.

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5 Installation and Start up

5 Installation and Start up

5.1 Installation requirements
5.1.1 Preparative actions of the operator

► Adequate place of installation with stated air flow rate for the Chiller20
► Minimum clearance laser: 1.0 m
► Minimum clearance chiller: 1.5 m
► Supply cable inclusive CEE-connector for laser and chiller (see chapter
5.2.3 Electrical connections / Connected load page 130)
► Supply by means of transport forklift and lifting equipment
► Preparation of robot / robot control according to the demands
For starting up the system including a power measurement
► Water supply (forward/backward) for Primes power measurement device
(min. flow = 0.7 l/kW and 5.0 l/min respectively)
► 220 VAC power source outlet

5.1.2 Position
The laser must become brought in such a position that doors and side panels can
be reached for service (1 meter space to each side). The length of supply and
control lines must be arranged in a way that laser can be moved 1m. The supply
and control lines should be passed in order not to snap off. At laser installation in
the laser cabin the general health and safety regulation of the operator have to be
followed. The casters at the bottom side of the laser cabinet have to be fixed at the
place of final installation. A rugged installation has to be assured. Consider the
weights at higher places of installation.
If needed laser and chiller has to be equipped with appropriate intercepting tanks
against leaking water.

The laser is lockable and should be secured after work against unauthorized use.
The seal of the external cabinet secures power supply and laser modules against
environmental dust. The in the laser cabinet (power supply) produced waste heat
becomes derived trough installation of an internal heat exchanger. Thereby water
chilled lasers do not need an additional fan.

5.1.3 Accessories
Refer to Appendix A – Accessories, page 221.

20
Only for water-air chiller
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5 Installation and Start up

5.2 Setting up
5.2.1 Unpacking
The fiber laser becomes delivered in a package offering maximal safety. The
package becomes particulate delivered with a push detector which warns by
misuse. If the package shows any signs of an external damage or if push detector
became activated, check the device for damages and inform in written form the
carrier about the damage.

IMPORTANT ADVICE:
Upon receiving the laser check the packaging and parts for any
possible damage that may have occurred while in transit. If damage
is apparent contact the IPG representative immediately.

Picture 5-1: Tilt watch® indicator

Picture 5-2: Shock watch®, left – OK, right – NOK contact IPG representative

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Take the whole content out of the package and keep the package material and
inserts. You should be extremely cautious while taking the device off the
package. The optical cable must not become damaged or broken.

The documentation includes a packing list (see 5.1.3 Accessories). After receipt of
the laser check if all parts are there and inform IPG immediately for missing or
damaged part. In case of any supposed or apparent damage, do not try to install
or run the laser.

Keep the package for later transport or storage of the device.

5.2.2 Unloading
If the laser arrives on a pallet it can be moved by a fork lifter (Picture 5-3).
On the upside of the laser transport eyes are fixed. With lifting equipment the laser
can be lifted from the pallet. Take care of the barycentre and make sure the device
is not tipping.

Picture 5-3: Transport of a Fiber Laser by means of a fork lifter

If the laser arrives in a box and is not placed on a pallet it must be removed from
the box by a crane. Therefore the special mountings which are attached to the
laser must be used.

Picture 5-4: Removing a Fiber Laser by means of a crane

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5 Installation and Start up

CAUTION:
The maximum angle between the cords or the chains must be 40°
degree. Please select the length of the cords or chains according to
CAUTION this requirement.

The laser can be moved with casters. Transport without the euro-pallet is not
permitted. The Laser can be moved with fixable casters to the final place of
installation if the sub font is appropriate to it.
The laser has to be installed on a plane base. Against autonomous movement the
laser has to be secured through fixing the casters.

Picture 5-5: Fixable casters

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5 Installation and Start up

5.2.3 Electrical connections / Connected load

LETHAL HIGH VOLTAGE

Death or heavy bodily injury by heavy current
► Work on the main power supply line as other live ones
DANGER
parts/lines may be accomplished only by technical personnel
► Make sure the device is properly grounded through a
protective conductor of the AC power cable.
► Any interruption of the protective ground conductor from the
earth terminal can result in personal injury.

CAUTION OF DAMAGE TO THE DEVICE

Damage to the device by incorrect mains voltage/frequency
► Failure to use the correct voltage could cause damage to the
CAUTION device.
► Work on the main power supply line as other live ones
parts/lines may be accomplished only by technical personnel
► Before supplying the power to the instrument make sure that a
correct mains voltage of the AC power source is used.

DANGER OF FIRE
Death or heavy bodily injury by fire
► For continued protection against fire hazard replace the line
WARNING fuses only with the same types and ratings.
► The use of other fuses or materials is prohibited.
► Fuses may only replaced by technical personnel

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Table 5-1: Connected load

Max. Power
Full loaded Max. operation Starting current Consumption
Laser power Voltage / VAC Fuses / A
current / A current / A /A
/ kW

Type: YLS-compact

1.0 kW 400±10%, 3P+PE 32 / 20 19.6 / 11.6 7.5 8.0 4.0

1.2 kW 400±10%, 3P+PE 32 / 20 19.6 / 11.6 9.0 18.0 4.8
2.0 kW 400±10%, 3P+PE 32 / 20 19.6 / 11.6 15.0 18.0 8.0

Type: YLS

1.0 kW 400±10%, 3P+PE / 50 Hz 20 18

7.0 16.0 4.0
480±10%, 3P+PE / 60 Hz 20 15
2.0 kW 400±10%, 3P+PE / 50 Hz 20 18
15.0 16.0 8.0
480±10%, 3P+PE / 60 Hz 20 15
3.0 kW 400±10%, 3P+PE / 50 Hz 32 31
22.0 32.0 12.0
480±10%, 3P+PE / 60 Hz 30 27
4.0 kW 400±10%, 3P+PE / 50 Hz 32 31 29.021 / 45.022 /
32.0 / 80.0 / 80.0 16.0 / 22.0 / 27.5
480±10%, 3P+PE / 60 Hz 30 27 50.023
5.0 kW 400±10%, 3P+PE / 50 Hz 80 58 / 77 / 80
33.0 / 50.0 / 53.0 63.0 / 80.0 / 80.0 20.0 / 26.0 / 29.0
480±10%, 3P+PE / 60 Hz
6.0 kW 400±10%, 3P+PE / 50 Hz 80 80
63.0 160.0 36.3
480±10%, 3P+PE / 60 Hz

21
Without chiller
22
With integrated heat exchanger, tank heating switched on
23
With integrated water / water chiller, tank heating switched on
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5.2.4 Water connections, flow rates and additives

CAUTION OF DAMAGE TO THE DEVICE
Damage to the device by incorrect connection of the cooling
► Absence of adequate water cooling will result in damage to
CAUTION the laser and external optics.
► Work on the cooling circuit may be accomplished only by ÍPG
Service personnel or skilled technical personnel.
► The cooling water flow rates given in the table below must be
fulfilled.

YLS-10000-S2 laser is a water cooled model. Tap water is used for cooling the
laser, deionised water for external optics cooling.

Lasers type YLS with power up to 2.5 kW only have one cooling circuit for laser
and optics. DI water may be used only.
Lasers type YLS with power more than 2.5 kW have two cooling circuit. TAB water
(drinking water quality) should be used for laser cooling. DI water should be used
for optics cooling.

Cooling water flow rate

Table 5-2: water flow minimum requirements

Minimum Optimal
Laser laser Minimum Optimal
Laser
cooling cooling DI water DI water TAB Water DI Water
power ,
water water flow , flow , connection connection
kW
flow , flow , l/min l/min
l/min l/min

Type: YLS-compact

1.0 kW 5 10 0.5 1.0 - ¾’’; ½’’

1.2 kW 5 10 0.5 1.0 - ¾’’; ½’’
2.0 kW 10 15 0.5 1.0 - ¾’’; ½’’
2.5 kW 10 15 0.5 1.0 - ¾’’; ½’’

Type: YLS

1.0 kW 5 10 0.5 1.0 ¾’’ ½’’

2.0 kW 10 15 0.5 1.0 ¾’’ ½’’
3.0 kW 15 20 1.0 1.5 ¾’’ ½’’
4.0 kW 20 25 1.0 1.5 1’’ ½’’
5.0 kW 20 30 1.0 1.5 1’’ ½’’
6.0 kW 20 35 1.0 1.5 1’’ ½’’
8.0 kW 20 40 1.5 2.0 1’’ ½’’
10.0 kW 30 50 1.5 2.0 1’’ ½’’

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15.0 kW 30 60 1.5 2.0 1’’ ½’’

20.0kW 30 80 1.5 2.0 1 ½’’ ½’’

Lasers types YLS-compact only have one cooling circuit for laser and optics. DI
water should be used.

TAB water additives

If you heard about problems with bacterial polluted water or algae growth inside
cooling systems in your company, we recommend using the long term biocide
Nalco 77352 in the water circuit of the laser. Please follow the instructions given
by the manufacturer. The list of suppliers you will find on www.Nalco.com.

DI water additives

CAUTION OF DAMAGE TO THE FIBER CONNECTOR

Damage caused by none specified additives
► Not specified additives can cause serious damage to the fiber
CAUTION connector, integrated optics and external optics
► Inside optical circuit (DI water circuit) no water additives are
allowed.

COOLING WATER SPECIFICATION

► For further information and detailed specifications about water
quality et cetera please refer to the manufacturers Chiller
manual.

Connections of 6 mm pipes near the optical head

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Dew point temperature table

There is a risk of condensation damage when laser is placed in a high temperature

and humidity environment, while cooling water temperature is colder than the dew
point of the surrounding air. The cooling water temperature must always be above
the dew point temperature.

Table 5-3: Dew point temperature table (min. cooling water temp.)

Relative Humidity, %

Air
20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95
temp.

16°C 0 2 4 5 7 8 9 10 11 12 13 14 15

18°C 1 3 4 6 8 9 11 12 13 14 15 16 17 18

21°C 1 3 5 7 9 11 12 13 14 16 17 18 18 19 21

24°C 3 6 8 9 11 13 14 16 17 18 19 20 21 22 23

27°C 2 5 8 10 12 14 16 17 18 19 21 22 23 24 25 26

29°C 4 7 10 12 14 16 18 19 21 22 23 24 26 27 28 28

32°C 7 10 12 15 17 19 21 22 23 25 26 27 28 29 31 31

35°C 9 12 15 17 19 21 23 24 26 27 29 30 31 32 33 34

38°C 11 14 17 20 22 24 26 27 29 30 31 33 34 35 36 37

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5.2.5 Software installation

Please refer to chapter 4 LaserNet software.

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5 Installation and Start up

5.3 Fiber Handling

DANGER TO LIFE OR BODILY HARM

Danger by means of laser radiation
► If the fiber connector is not covered with the intended
WARNING protective cap and is placed on a electro conductive surface it
can lead to an shortcut of the fiber interlock circuit.
► If the fiber interlock circuit is closed laser emission might be
possible.
► As long as the fibers are not in use it must be covered by the
intended cap (see picture below).
► Only the original manufacturer protective caps are intended to
use.

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5.3.1 General fiber handling

In handling of the fiber, there is a risk of fiber breakage due to stresses on the fiber
itself.
The minimum bending radius specified is 0,1m, which is perfectly OK for short
distance bending. It is however not possible to bend the fiber over the whole
length, with that short bending radius. The problem does normally not occur during
operation, but during handling and coiling of the fiber.
We will therefore introduce a limitation o the bending during coiling according to
the figure below. The specification is not given as a bending radius, but as the
length of each turn.

Picture 5-6: IPG Process fiber with compensator

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5 Installation and Start up

5.3.2 Fiber packing

Please follow the instructions below for packing fibers.

(1) Disconnect the fiber from the optical head and the external optics (beam
switch or beam coupler).

(2) Place on each connector the protective caps.

(3) Coil carefully the fiber in a proper way.

(4) Take care to do not stress the fiber.

(5) Use plastic bags with desiccant bag to protect the connectors.

(6) Lay the fibers in the transportation box.

(7) Fix the fiber with cable straps.

Picture 5-7: Original IPG fiber box Picture 5-8: Original Optoskand fiber box

CAUTION OF DAMAGE TO FIBER CABLES

► To protect the connectors, please use the plastic bag with
desiccant bag.
CAUTION ► Do not send the fiber naked, please place the fiber in a carton
box or in the original package.

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5 Installation and Start up

5.3.3 Dynamic Compensator

Picture 5-9: IPG process fiber Dynamic Compensator

The Dynamic Compensator is installed to avoid and compensate stress inside the
fiber cable. Do not open the Dynamic Compensator or the fiber can get damaged.

CAUTION
► Do not open the compensator.
► If the dynamic compensator is removed or opened, the fiber
CAUTION input can be stressed or damaged.

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5 Installation and Start up

5.3.4 Laying fiber cables

Fiber cables are precision devices to guide laser light from the laser source to the
work place.
An utmost capacity on cleanness is needed.

CAUTION OF DAMAGE TO FIBER CABLES

► Avoid shocks and impacts on the connector.
► Avoid mechanical stress by all means as soiling, twisting,
CAUTION drilling and too strong bending.

Unroll the fiber cable without twisting. Do not pull the fiber laterally.

Place the fiber cable sorted inside an appropriate cable channel.

Clean the fiber connector end face (quartz block surface) as described in chapter
5.4 Cleaning of fiber connector.

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5 Installation and Start up

5.4 Cleaning of fiber connector

DANGER TO LIFE OR HEAVY BODILY HARM

Danger to bodily harm when using microscope and guide laser
► The Guide laser is of class 2M. When viewed through optical
WARNING instruments (microscope) it can lead to serious bodily harm.
► During cleaning the laser needs to be secured against restart.
(Remove key from key switch)
► Inform all relevant personnel about the cleaning process
► Only specially trained personnel should perform the cleaning

CAUTION OF DAMAGE TO FIBER CABLES

Caution of burning dust to quartz block end face
► Through dust and insufficient cleaning the fiber connectors
CAUTION can become contaminated.
► Mostly damages at quartz block end face are irreversible
► Damaged fiber cables are not covered by warranty
► Clean the fiber connectors only according to the instructions
in this manual.
► It is highly essential that a fiber connector is checked for dust
and dirt every time before it is connected with an optical head
or beam coupler.

IN ORDER TO PRVENT AGAINST CONTAMINATION

Please follow the instructions below to prevent any contamination
►

For cleaning a fiber connector you need the following materials:

► Kodak lens cleaning paper

► Optical cleaning sticks
► Isopropanol (water free!)
► Acetone (water free!)
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5 Installation and Start up

► Compressed air (oil free, water free!)

► Microscope, model IPG incl. light source

Picture 5-10: Cleaning needs

Picture 5-11: Microscope Type IPG

The following procedure has to be followed for cleaning fiber connectors:

(8) Put the microscope on a plane surface. To minimize the risk of

contamination after the cleaning process, place the microscope near the
optical head (Beam Switch or Beam Coupler).

(9) Spray some Isopropanol at the fiber connector and blow it away with
compressed air

(10) Fix the connector in the holder of the microscope

Picture 5-12: QBH Connector in microscope

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5 Installation and Start up

CAUTION: Internal deposit of dust and dirt in protective cap

In the cap internal deposit of dust and dirt can contaminate the
quartz block.
CAUTION Always place the cap face-down to prevent deposit of dust and dirt

Picture 5-13: Protective cap

(11) Switch on the microscope’s light source. Focus the microscope onto the
connector’s quartz block surface. Look at the surface at a slight angle to
improve the visibility.

(12) Check the surface carefully. If some contamination is visible on the

quartz block surface, cleaning is necessary:

a. Try to blow away the dust with compressed air from the side

b. Put a drop of Isopropanol onto a Kodak lens cleaning paper and

wipe the wet spot laterally over the surface until it is dry.

c. Put some Isopropanol on the cleaning bud and gently wipe over the
quartz block surface with circular moves, do not scratch.

Picture 5-14: Cleaning with stick

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5 Installation and Start up

CAUTION:
Danger of contamination of the quartz block due to dirty cleaning
paper or cleaning sticks.
CAUTION Touching the quartz block with dirty cleaning paper can
contaminate the laser and lead to serious damage to the laser or to
the fibers.
Never let the face of the cleaning paper you touched get into
contact with the surface of the quartz block.

d. Repeat the cleaning process a-c with acetone instead of Isopropanol.

The cleaning procedure can always be stopped if a good result has
already been achieved.

e. Make sure the surface is free of streaks. (Streaks will appear if the
Isopropanol or the Acetone is of poor quality.)

CAUTION:
Risk of damage at the fiber connectors
Misuse, inaccurate cleaning, use of not intended chemicals can
CAUTION lead to damage at the fiber connector. These damages are not
covered by the warranty
Activities at the fiber connectors are only to be executed according
to the manual. The allowed cleaning materials and procedure of
cleaning are explained in the according chapter.

(13) Install the cleaned connector into the optical head (Beam Switch or
Beam Coupler unit) and close the bayonet fixing.

CAUTION:
Always try to keep the connector upside down, when moving the
connector from microscope to the optics, to minimize the risk of
CAUTION contamination after the cleaning process.

(14) If the fiber is not to be connected instantly with a suitable optical

component recap it with the protective cap. Do not forget to clean the cap
before use.

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5 Installation and Start up

5.5 Optics alignment

5.5.1 Beam Switch alignment

DANGER:
The beam way of the laser must become absorbed in an adequate
device, e.g. a beam trap. Ensure that the beam way is determined
DANGER before starting adjustment.

CAUTION:
Serious danger of damage to Beam Switch, optical head, fibers and
Laser due to inaccurate alignment. The Beam Switch is a highly
CAUTION sensitive product.
Inaccurate alignment can result serious damages.
Every change or alignment of the Beam Switch is only permitted
after an instruction through qualified IPG personnel.
Tampering with the Beam Switch without training by IPG will void
the warranty.

IMPORTANT:
The Beam Switch can only be aligned if fiber cables are connected
to entrance and exit of the switch.

Picture 5-15 : IPG Beam switch

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5 Installation and Start up

Beam Switch water connections:

The Beam switch should be connected to a water cooling system before use. Only
deionised water should be used. The Beam Switch has water outlets MS-5H-6
compatible with tubes 4x6mm. The focusing units and the collimator unit have two
water outlets (one as input and other as output). It is not important which one of
them is input (output).

Beam Switch optical properties:

The Beam Switch has QBH adaptors for optical connection of feeding fiber and
process fiber. Feeding fiber is set into collimating unit. Process fiber is set into
focusing unit.
The optical magnification is 1.2x.

The beam can be adjusted only at the output side (focusing unit).

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5 Installation and Start up

Beam Switch preparations before alignment

(1) Insert a fiber with a cleaned quartz block surface (for cleaning instructions
refer to chapter 5.4 ) into the Beam Switch and close the bayonet fixing.

(2) Plug the other end of the fiber into an optical head, close the bayonet fixing.
Install the cooling water tubes both at the Beam Switch and the optical head.

(3) Connect the MCX/Banana plug cable to the Beam Switch MCX connector
and to the Multi meter respectively. Alternatively the FFBD indication in
LaserNet property page Beam Switch can be used.

Picture 5-16: MCX / Banana plug cable

(4) Install power meter to absorb and measure the output power. Use the
Guide laser to ensure the beam path is free and the beam matches the
entrance of the power meter.

(5) Insert the key into the key switch S5 and make a ¼ turn counter clockwise
to activate the Service Mode. In Service mode the Interlock circuit is
bypassed for Front door and Top cover. The interlock circuit will be closed
for a certain period of time preset by K16 and K17. If the key is turned it is
not possible to remove the key. (Please also refer to chapter 6.10 Service
Mode.)

Picture 5-17 : Key switch for activation of Service Mode

The Beam Switch is now ready for alignment.

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5 Installation and Start up

Beam Switch alignment procedure

DANGER:
Danger of life through Laser radiation
Radiation can lead to burns, blindness and death.
DANGER
Never look directly into the beam.
Laser radiation-safe eye protection has always to be worn when
laser is active.

IMPORTANT ADVICE:
Please read the entire adjustment instructions before attempting
any adjustments.

(6) Make sure that fibers and cables are attached to the Beam Switch and that
the beam becomes absorbed in an adequate absorber / power meter.

(7) Switch on the laser in Test mode. Start LaserNet software to control the
laser.

(8) Remove the four Phillips screws which are sealing the adjustment screws.

(9) Activate the Guide laser to check the pre-alignment. If the guide laser is
visible at the output the alignment can be started with low power. If the
guide laser is not visible do not switch on the laser power.

(10) If the guide laser is not visible the position of the focusing lens must be
adjusted using the alignment screws until the guide laser is clearly visible.

IMPORTANT ADVICE:
For the X-, Y-, XY- and F-screws there are no scales. That’s why you
always have to remember how many turns in which direction the
adjustment screws are twisted. If you do not obey this instruction it
is possible to misalign the lenses so strong that the beam is lost.
After that it is very difficult to find the beam again. We highly
recommend only make small movements.

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5 Installation and Start up

(11) After base adjustment of Beam Switch with the guide laser the fine
alignment with the fiber laser has to follow.

(12) Switch off guide laser and start the multi-meter. There should be a
voltage signal in the range of -10mV to 10mV DC. (This value may vary due
to different diodes). This signal has to be constant until the fiber laser starts
emission. Make a note of all measured values do that you can make
comparisons in the future.

(13) Start with a power of 10% (current) and one module active only. Move
the lens in all three directions until a local minimum of the indicated voltage
is reached. (This means that the voltage value increases no matter in which
direction the adjustment screw is turned). To check the quality of the optical
adjustment the FFBD signal at MCX connector should be controlled. The
signals minimum correspondents the optimal adjustment

(14) Increase the power by 10% steps to 100% and check power and
photodiode signal. The output power should equal the Indicated Power in
LaserNet software. The photodiode signal should show linear increase with
increase of current. If the loss of power is more than 5% and the photodiode
signal increases exponentially the alignment has to be rechecked.

(15) Repeat the previous steps (11) and (12) for normal laser setup (using
all modules)

(16) Install back the Phillips screws to seal the adjustment screws.

The Beam Coupler is now ready for use.

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5 Installation and Start up

5.6 Connection between robot controller and laser

5.6.1 Hardwiring

All optocoupled inputs of XP1 interface connector (Hardwiring) have common pin
(A16). Optocouplers have two infrared LEDs connected in inverse parallel, so that the
common pin (A16) can be either positive or negative (Picture 5-18, page 151).

PROCESS PROBLEMS CAUSED BY BOUNCING SIGNALS

Make sure that input signals are not bouncing. Bouncing can
be caused by electromechanical switches. Bouncing input
signals can lead to malfunctions in the signal process.

Description Input signal demands

Input current at nominal input voltage (24VDC) 5 mA

Maximum input voltage range ± 35VDC
Recommended input voltage range ± 30VDC
Low level input voltage - 3.5…+3.5VDC
High level input voltage - 30…-15VDC
+15…+30VDC

All optocoupled outputs have common supply voltage which has to be provided
externally by the customer. Each output returns the supplied voltage to the customer
if set to “high” and have high impedance if set to “low”. These are current outputs and
an external load between output terminals and negative supply terminal (B16) are
required for proper operation. Common pin for the inputs (A16) and common pin for
the outputs (B16) are not linked internally and can have different potential on the
customer side if required (Picture 5-18, page 151).

Description Output signal demands

Minimum output current (recommended) 3mA

Maximum output current 0.625A
Supply voltage range 11…45VDC

Smart Power High-Side-Switch in each output channel can also be used for driving
an inductive load, and has all necessary protection features required by industrial
applications.

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5 Installation and Start up

Picture 5-18: Functional schematic around XP1 interface connector

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5 Installation and Start up

5.6.2 Profibus

Type: Profibus
Type of connector: SubD, 9 pole
Interface type: CIF30-DPS / CIF104-DPS / -R
Slave address (default): 1
GSD file: GSD_7504.GSD
Slave settings: 8 Byte input – 0x27
8 Byte output – 0x17

5.6.3 DeviceNet

Type: DeviceNet
Type of connector:
Interface type: CIF104-DNS
Slave address: 1
EDS file: CO4DNS.EDS
Slave settings: BYTE ARRAY Input Data 10
BYTE ARRAY Output Data 10

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5 Installation and Start up

5.7 First start up

5.7.1 General switching on procedure

Please follow these instructions to switch on the laser to ensure proper operation.

(1) Turn the Main Disconnect switch of the laser to ON position.

(2) If an external chiller is used, turn the Main Disconnect switch to ON position.

(3) Ensure that all valves are open. If a water/water chiller is used ensure that
the external water supply is present.

(4) If optics in an external DFE24 is used, turn the Main Disconnect switch to
ON position.

(5) If an external chiller is used, turn the Operation switch at the chiller from 0
to 1.

(6) Turn the key switch at the front side of the laser to TEST or ROBOT
depending on the application.

24
Dust free enclosure
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5 Installation and Start up

5.7.2 General switching off procedure

After completion of the work switch of the laser following the procedure below:

(1) Switch off the laser emission.

(2) Switch off the main power supply.

If the laser is located in a place where there is a risk of frost, do

NOT follow this instruction any further.
Ensure that all valves of the system stay open. The tempered
CAUTION cooling water will prevent the system from frostiness caused
damages.
►

(3) Turn the key switch at the front side of the laser to OFF position.

(4) If an external chiller is used, turn the Operation switch at the chiller from 1
to 0.

(5) If optics in an external DFE is used, turn the Main Disconnect switch to OFF
position.

(6) If an external chiller is used, turn the Main Disconnect switch to OFF
position.

(7) Turn the Main Disconnect switch of the laser to OFF position.

Ensure that the laser system (including external chiller and external
DFE) is placed in a frost-free location.
If this can not be guaranteed, the complete water must be removed
CAUTION from the system (laser, external DFE and external chiller) if the
system is switched OFF for a long time and the heating can not
stay in operation.

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5 Installation and Start up

5.8 Demounting
5.8.1 Switching off the laser
(1) Switch off the laser by turning key switch to OFF position. Switch off chiller.

5.8.2 Removing water

(2) Remove the cooling water pipes from the laser and the chiller. Remove the
water from the pipes.

(3) Turn the key switch to TEST position to open the solenoid-operated valves.
Use a compressor to blow out all water from the laser water cooling circuits,
external optics like Beam switch and Beam coupler respectively. Remove
the water from the chiller by opening the draining valve.

(4) Switch off the laser by turning key switch to OFF position.

5.8.3 Uninstall electrical power

(5) Switch off Main disconnect switch. Remove power cable plug from the
socket. Remove power cable from the laser.

DANGER:
Only qualified personnel are permitted to uninstall electrical power
connections.
DANGER

ELECTRICITY
Danger to your life. High voltage!

5.8.4 Demounting optics

(6) Remove cooling water pipes from fiber connector, collimation and focusing
unit of processing head.

(7) Remove fiber connector from processing head.

Take care when unplugging fiber connector from processing head

not to damage quartz block surface.
Put the protective cap on the fiber connector.
CAUTION Close the processing head bayonet using the accordant protective
cap.

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5 Installation and Start up

(8) Remove all water from fiber connector. Do not use compressed air. Put the
connector inside plastics bag.

CAUTION
To protect the connectors, please use the plastic bag with
desiccant bag.
CAUTION Do not send the fiber naked, please place the fiber in a carton box
or in the original package or roll it on top of the laser. Avoid stress
and drilling to the fibers.
Please also refer to chapter 5.3 Fiber Handling, page 136.

5.8.5 Safe package for transport

(9) Secure the laser for transport.

5.9 Disposal

Please contact your supplier or IPG Laser for further information.

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6 Operation

6 Operation
6.1 Switching ON / OFF the Power Supply

To generate the laser radiation a direct current voltage (60VDC…75VDC

depending on laser module type) is needed. This voltage is provided by the main
power supply. Below different options to switch on the power supply are explained.

Definition
LASER ON = POWER SUPPLY ON = START
► The status LASER ON means the Main Power Supply of the
Laser is switched ON.
► Laser radiation is not yet emitted.

INCREASED GROUND LEAKAGE CURRENT

► EMI-Filter is installed at the input of main power supply of the
laser in order to fulfil CE-norms. Typical leakage current (steady-
state) at 400VAC is about 50 mA due to Y-Capacitors inside of the
EMI-Filter
► In case of using Earth-leakage detection device for power
connection, pulse leakage current during start-up of the Laser can
cause shutdown of such device.
► This well-known problem can be avoided using Earth-leakage
detection device with delay during start-up.

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6 Operation

6.1.1 “Start” Push button

Push the “Start” Push button to switch on the Power Supply manually. The push
button will lit up green if the Power Supply is switched on.

6.1.2 External Start via XP2 Interface

By closing the potential free inputs C5-C6 at XP2 Safety Interface (SC Reset) the
Power Supply will be switched on.
To switch on the Power Supply again after the Power Supply was shut down the
contacts must be opened first before closed again.

6.1.3 LaserNet Software

In TEST mode the Power Supply can be switched on by LaserNet software.

6.1.4 Hardwiring Interface

In ROBOT mode the Power Supply can be switched on by signal C1 (Laser ON)

6.1.5 Fieldbus Interface

In ROBOT mode the Power Supply can be switched on by the Word 1, Bit 1 (Laser
ON) controlled by the customers controller.

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6 Operation

It is very important that the laser is operated in the range of 10 to

100% of the lasers maximum current. Operating the laser in a
power range of less than 10 % is out of the specifications and is not
allowed by IPG. If a power less than 10% from the total power is
CAUTION
needed the single module mode should be activated (LaserNet
page Module). But also with manually selected amount of modules
the minimum power is 10%.
The only exception of this rule is when using ramp up / ramp down
option.

6.2 Manual mode

In Manual mode only an external computer and software LaserNet is needed to
drive the laser. The computer has to be connected to the laser via an Ethernet
cable to the Ethernet interface.

IMPORTANT ADVICE:
The push buttons in LaserNet always indicate the actual state.
Pushing the buttons will change the state.

Connect the Laser to an external computer. Put the laser’s key switch to “Test”
position. Start LaserNet program. Establishing the Net connection can take up to
two minutes. Laser parameters and states will be displayed in the multi window
screen.

At first switch ON the “Guide Laser” by pushing the appropriate button .

Verify the beam aiming position or proper termination by using the visible guide
laser. The Guide laser state will be active in the LaserNet.

Push the “Laser ON” button, the main power supply of the laser will switch on.
Signals “Laser ON” and “Laser ready” will be activated if all necessary conditions
are fulfilled. Steady lamps on top of the laser will be ON.

Set the required power or pump diodes current by using the slide control in the
LaserNet. Settings of the output power (in Watts) or pump diodes current (in
percent) will show in the LaserNet window.

Press “Emission” button. Laser will start emitting power; and emitted power will be
displayed. The flashing lamps on top of the laser will be ON.
Once Emission is ON, the output power level can be varied from 10% to 100%.
Switch the laser emission OFF by pressing “Emission ON” button.

Switch the main power supply of the laser OFF by pushing the button “Laser ON”.

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6 Operation

6.3 Manual mode using Laser programs

Connect the Laser to an external computer. Put the laser’s key switch to Test
mode position. Start LaserNet program. Establishing the Net connection can take
up to two minutes. Laser parameters and statuses will be displayed in the multi
window screen.

At first switch ON the Guide Laser by pushing the appropriate button .

Verify the beam aiming position or proper termination by using the visible guide
laser. The Guide laser status will be active in the LaserNet.

Push the Laser ON button, the main power supply of the laser will switch on.
Signals Laser ON and Laser ready will be activated if all necessary conditions are
fulfilled. Steady lamps on top of the laser will be ON.

Set the desired program number in the appropriate field .

Don’t push the button Emission.

To start a Laser program push the button RUN

, which will change to STOP
as long as the program is active. A
running program is indicated by the signal Program
active. When the program is finished the signal will be
LOW and the signal End of program will be HIGH.
An anomalous interruption of a running laser program
will be indicated by the signal Program is interrupted.
More detailed information can be achieved at the
LaserNet page Events.

IMPORTANT ADVICE:
A running Laser program can be stopped by pushing the button

After finishing the process switch the main power supply of the laser OFF by
pushing the button Laser ON.

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6 Operation

6.4 External modulation mode

For operation in External modulation mode, LaserNet software and an external

voltage signal of +4... 25V DC is required.

High level – emission ON, low level – emission OFF

The operation in External control mode is identical to the Manual mode except of
the external voltage signal.

The External control mode is only accessible in key switch TEST position.

Connect the Laser to an external computer. Put the key switch to Test. Start
LaserNet program. Establishing the Net connection can take up to two minutes.
Laser parameters and statuses will be displayed in the multi window screen.

Connect an external power supply (24VDC) with the XP2 Safety interface of the
laser. (Positive to pin A1, negative to pin A2). Ensure that the voltage signal is not
yet present.

Open the page Control in LaserNet software.

Switch ON the Guide Laser by pushing the appropriate button . Verify the
beam aiming position or proper termination by using the visible Guide laser. The
Guide laser status will be active in the LaserNet.

Push the button External Control OFF to enable the External control.
The button will change to ON state.

Push the Laser OFF button to switch the main power supply of the laser
ON. Signals Laser ON and Laser ready will be activated if all necessary
conditions are fulfilled. Steady lamps on top of the laser will be ON.

Set the desired laser power in LaserNet using the

slide bar in LaserNet Control page.

Push the Emission OFF button. The button will change to ON.
The flashing lamps on top of the laser will be ON. The emission
will not be enabled before the external voltage signal is set to
HIGH level.

Set the external voltage signal to HIGH level. The laser emission will be enabled
with the level of power selected before.

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6 Operation

CAUTION:
The External control input can also be used for external modulation
of the output of the laser. Connect a wave front electrical generator
CAUTION producing square positive voltage signal (0 to +4...25V amplitude)
to the modulation input. The laser output power can be modulated
with up to 5,000 Hz maximum frequency

The output power level can be varied from 10% to 100%.

To switch OFF the emission set the external voltage signal to LOW level.

After finishing the process switch the main power supply of the laser OFF by
pushing the button Laser ON.

IMPORTANT ADVICE:
It is not possible to use ramping times when the External control
signal is in use.

IMPORTANT ADVICE:
The following option must be enabled by the IPG Service Engineer
during the laser installation:
It is possible to set up the external voltage signal as an additional
switching ON condition to increase laser safety. Pushing the
External Control button is not necessary in this case.
With this additional condition switching ON the laser without an
external voltage signal is not possible in any operational mode.

The sample shows how to use the External control signal for switching on and off
the laser emission. The External control signal can be used for digital modulation
of the laser emission.

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6 Operation

6.5 Analogue control mode

Operation in Analog Control mode is available in TEST and ROBOT mode.

The operation in Analog control mode is similar to the External control mode but
the setting of the output power is done by XP4 and not by LaserNet.

For operation in this Analog control mode, an external modulation signal of +4...
25V DC and an analog signal are required. The analog signal is used for setting
the desired output power level; 0V DC correspond to the 0W output power, 10V
DC correspond to the nominal output power.

High level – emission ON, low level – emission OFF

Analog Control mode in TEST mode:

Connect the Laser to an external computer. Put the key switch to Test. Start
LaserNet program. Establishing the Net connection can take up to two minutes.
Laser parameters and statuses will be displayed in the multi window screen.

Connect an external power supply (24VDC) with the XP2 Safety interface of the
laser. (Positive to pin A1, negative to pin A2). Ensure that the voltage signal is not
yet present.

Open the page Control in LaserNet software.

Switch ON the Guide Laser by pushing the appropriate button . Verify the
beam aiming position or proper termination by using the visible Guide laser. The
Guide laser status will be active in the LaserNet.

Push the button Analog Control to enable the Analog

control. The button will change to ON state. The External
Control button will change to ON state automatically.

Push the Laser OFF button to switch the main power supply of the laser
ON. Signals Laser ON and Laser ready will be activated if all necessary
conditions are fulfilled. Steady lamps on top of the laser will be ON.

Set the desired laser power by the XP4 Analog control interface (Pin 1 positive,
Pin 2 GND). 0V DC corresponds to the 0W output power, 10V DC correspond to
the nominal output power.

Push the Emission OFF button. The button will change to ON.
The flashing lamps on top of the laser will be ON. The emission
will not be enabled before the external voltage signal is set to
HIGH level.

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6 Operation

Set the external voltage signal to HIGH level. The laser emission will be enabled
with the level of power selected by XP4 Analog control interface.

CAUTION:
The External control input can also be used for external modulation
of the output of the laser. Connect a wave front electrical generator
CAUTION producing square positive voltage signal (0 to +4...25V amplitude)
to the modulation input. The laser output power can be modulated
with up to 5,000 Hz maximum frequency

The output power level can be varied from 10% to 100%.

To switch OFF the emission set the external voltage signal to LOW level.

After finishing the process switch the main power supply of the laser OFF by
pushing the button Laser ON.

IMPORTANT ADVICE:
It is not possible to use ramping times when the External control
signal is in use.

IMPORTANT ADVICE:
The following option must be enabled by the IPG Service Engineer
during the laser installation:
It is possible to set up the external voltage signal as an additional
switching ON condition to increase laser safety. Pushing the
External Control button is not necessary in this case.
With this additional condition switching ON the laser without an
external voltage signal is not possible in any operational mode.

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6 Operation

6.6 QCW mode

The QCW mode can be used in TEST and ROBOT mode.

6.6.1 QCW mode in TEST mode

The QCW-mode can be switched ON/OFF by selecting the QCW mode in the
property page Options.

For QCW frequency selection the slider wheel must be used.

Duty cycle selection:

Using LaserNet

Select the Duty cycle by using the slider wheel on the

LaserNet property page Control.

Using Analogue and External Control

Push the button Analog Control to enable the Analog control.

The button will change to ON state. The External Control
button will change to ON state automatically.

Set the desired duty cycle by the XP4 Analog control interface (Pin 1 positive, Pin
2 GND). 0V DC corresponds to the 0% duty cycle and 10V to 50% duty cycle.

CAUTION:
0V – 1V is not allowed for static operation as the duty cycle is less
than 5%.
CAUTION

Push the Laser OFF button to switch the main power supply of the
laser ON. Signals Laser ON and Laser ready will be activated if all
necessary conditions are fulfilled. Steady lamps on top of the laser will
be ON.

Push the Emission OFF button. The button will change to ON.
The flashing lamps on top of the laser will be ON. The emission
will not be enabled before the external voltage signal is set to
HIGH level.

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6 Operation

Set the external voltage signal to HIGH level (XP2 Safety Interface A1 +24V, A2
0V).

6.6.2 QCW mode in ROBOT mode

Program number 0

To activate the QCW operation mode Hardwiring input C7 must be high.

Duty cycle selection:

Using LaserNet

The duty cycle can be selected using the slider wheel

on the LaserNet control page. Therefore Hardwiring
input signal A3 Internal control must be active.

Using Analogue Control

Set the desired duty cycle by the XP4 Analog control interface (Pin 1 positive, Pin
2 GND). 0V DC corresponds to the 0% duty cycle and 10V to 50% duty cycle.
Therefore Hardwiring input A6 must be high.

To activate Laser Emission Hardwiring input A2 must be high.

Program number 1-50

At first a Laser program must be written using the LaserNet program editor. The
program must be stored in the laser.

Sample program:

N CMD Param1 Param2

1 QCW 500 Hz ON

2 EXTPWR Analog

3 STOP

At the end of the laser program the QCW mode will be automatically disenabled.
This is independent of the status of Hardwiring input C7.

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6 Operation

6.7 Hardwiring

The laser has to be connected to the robot’s controller according to the Hardwiring
interface specification.

The XP1 Hardwiring interface is only active in key switch position ROBOT.

LaserNet software can be used for monitoring input and output signals.
Operational buttons are disabled.

IMPORTANT ADVICE:
To achieve a HIGH signal in the output pin rows B and D the supply
voltage +24VDC (B15), GND (B16) needs to be connected.

IMPORTANT ADVICE:
For laser with beam switch we highly recommend:
In case of interruption of a laser or robot program, set all signals
except Laser request to Low and remove the failure before
restarting the program.

IMPORTANT ADVICE:
For laser with beam switch we highly recommend:
After a laser or robot program has finished move the beam switch
mirrors back to home position before you open the laser cell doors
(LaserNet: Cabinet doors).
Opening the laser cell doors with mirrors in beam position will be
interpreted by the laser as a violation of safety. The laser will go to
Emergency OFF (E-STOP).

IMPORTANT ADVICE:
The Hand-shake principle must be applied for communication
between laser and controller. Set the input command HIGH and wait
for the appropriate answer.
The simultaneous setting of signals can cause problems in the
program flow.

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6 Operation

To start the laser emission in Hardwiring mode a LaserNet program must be

activated. In the following it will be distinguished between program number 0 and
program numbers 1…50.

Program number 0

If no program number is selected program number 0 is active. The laser will emit
radiation as long as the bit A2 - program start is HIGH. The output power level can
be selected either manually by LaserNet if B3 – Internal control is activated or by
Analog control if A6 – Analog control is activated.

Program number 1-50

At first a Laser program must be written using the LaserNet program editor
(Chapter 10 – LaserNet program description / IPG Laser program). The program
must be stored in the laser.

The controller selects the program number by setting the appropriate bits (A8, LSB
to A14, MSB) to HIGH state. The program will be started by setting bit A2 –
program start HIGH.
The bit A2 – program start must be HIGH at least as long as the program is
running. If the A2 – program start bit is set to LOW during a program is executing
the program will be interrupted and bit B11 – program interrupted is set to HIGH.
If the program is finished in regularly way the B9 – program active is set to LOW
and B10 – end of program is set to HIGH.

The following examples show the operation of the XP1 Hardwiring interface and
the interaction between Laser and Controller.

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6 Operation

6.8 Fieldbus

The laser has to be connected to the robot’s controller according to the Fieldbus
interface specification.

The Fieldbus interface is only active in key switch position ROBOT.

LaserNet software can be used for monitoring input and output signals.
Operational buttons are disabled.

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6 Operation

6.9 Multi Port Interface

The Multi Port Interface is installed on customer request. It provides a convenient
alternative to operate the laser. The MPI is designed for industrial use.

If the MPI is installed one or more PLC25 or robots can access the laser. Each PLC
communicates with the laser system by a separate interface connection.
The communication with the laser system is carried out by a Field bus system.
Depending on customer request this can be Profibus, DeviceNet or ProfiNet.

The MPI can only be operated in “Robot mode”. In this case the LaserNet software
can be used for monitoring purpose only. Turn the key switch to the “Robot”
position. Start the LaserNet software and wait until the connection between laser
and external PC is established.

Like using the Hardwiring interface laser programs no.0 and laser programs no.1-
50 are available for operating the laser.
Using laser programs the laser power can be selected either by LaserNet,
Analogue control interface or by Fieldbus interface (power word 2).

Chart 1: Laser request

By setting signal “Laser request” by PLC - Slot 1 the laser is requested. If the laser
is not in use by another participator, the laser will be assigned to PLC – Slot 1. The
signal “laser busy” will be sent to all the other participants.

25
Programmable logic controller
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6 Operation

Together with the “laser request” signal the laser number has to be sent. The
optical channel number can be sent, but doesn’t have to be sent with the “laser
request” signal. If no optical channel number is sent, the mirrors will remain in
“Home position”.

Without present signal “laser assigned” all other signals, except “Pilot laser on” are
ignored.

Chart 2: Selection of optical channel

To change the optical channel the correct optical channel number and the correct
laser number have to be chosen. Only the optical channels can be chosen, which
are enabled in the LaserNet software.

If all mirrors are in “Home position” the optical channel number will be no.0. If a
mirror is in working position the appropriate optical channel number is indicated.

Setting an optical channel number is only possible if the laser slot is assigned. If
the signal “laser request” is deactivated and a mirror is in “Working position”, the
mirror will move back to “Home position”.

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6 Operation

Chart 3: Channel error

If an invalid optical channel number is set, the signals “Channel error” and “System
error” are activated. After setting a valid optical channel number a reset of the
errors is necessary. The requested mirror will move to “Working position” as soon
as the reset is performed.

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6 Operation

Chart 4: Laser ON & Laser Ready

The signals “Laser no.1”, “Optical channel no.1” and “Laser ON” are sent before
the “Laser request” signal. The mirror for channel no.1 will be set as soon as the
“Laser request” and the “laser assigned” signal respectively, are presented. Also
the main power supply will switch on (“Laser ON”) as soon the laser is assigned.
Together with the “Laser ON” the “Laser ready” signal is activated (if all conditions
for the signal are fulfilled).

By deactivating the signal “Laser request” the mirror will go to “Home position”.
With it the “Laser ready” will disappear. The main power supply (“Laser ON”) will
remain.

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6 Operation

Chart 5: Laser programs No.1…50

A laser program (which needs to be programmed before) can be started by signal

“Program start”. Therefore the program number needs to be set first. Changing the
program number during a running program doesn’t influence the process. Always
the program number is valid, which was set before activating signal “Program
start”.

The output “Program active” will be high as long as the program is not yet finished.
When the program is finished the signal “Program active” will be deactivated and
the signal “End of program” will be activated.

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6 Operation

Chart 6: Laser program No.0

When working with laser program no. 0 the laser output power can be chosen
either by Profibus power word 2 or by XP4 Analogue Control interface.
The signal “Analogue Control ON” must remain as long as the power is set by
Analogue control interface.
To enable the emission the signal “Program start” needs to be set.

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6 Operation

Chart 7: Laser ON and System Error (Cabinet doors opened during process)

If the laser Cabinet doors are opened during the process (mirror in “Working
position”) the laser will stop the emission, switch off the main power supply and
move the mirror to “Home position”. The signals “System error” and “Channel
error” will be activated.
After closing the Cabinet doors a “Reset errors” is necessary. The main power
supply (“Laser ON”) will switch on automatically after the reset was performed.
Also the mirror of the requested optical channel will move to “Working position”
automatically.

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6 Operation

Chart 8: Laser ON and System Error (internal E-Stop and safety circuit opened)

If an internal error occurs, the e-stop push-button is activated or the safety circuit
is opened the main power supply will be switched off. Therefore also no emission
is possible anymore.
The signal “System error” will be activated. After closing the safety circuit or
releasing the e-stop push-button and reset the error it is possible to switch on the
power supply again.

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6 Operation

6.10 Service Mode

Insert the key into the key switch S5 and make a ¼ turn counter clockwise to
activate the Service Mode. In Service mode the Interlock circuit is bypassed for
Front door and Top cover. The interlock circuit will be closed for a certain period of
time (30 min) preset by K16 and K17. If the key is turned it is not possible to
remove the key.

Picture 6-1: Service Mode key switch S5

Picture 6-2 : Relays K16/K17 to define time for Service Mode active
With the upper adjustment screw one will select the time base, for example 60min.
With the screw below one will select the fraction of the time base, for example 0.5.
So the Service Mode will be active for 30 min. During this time the Service Mode
Active lamp will light.

Picture 6-3 : Service Mode lamp will light if Service mode is active

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7 Fault clearance

7 Fault clearance
As a basic rule, none of the cleaning or maintenance tasks may be performed until
the device has come to a complete stop. The shutdown procedure described in the
operating instructions must be observed. As soon as this work has been
completed, all the safety devices and protective equipment must be mounted or
installed according to their proper function.

WARNING:
Only trained personnel are allowed to perform trouble shooting
actions. For further support please contact IPG Service personnel.
WARNING

ELECTRICITY
Device is applied to high voltage. Do not start any actions before
device is disconnected from 400VAC power supply.
If the instructions are given below and/or during training are not
correctly followed, it may result in serious bodily harm or in death
to you and/or others

LASER SAFETY GOGGLES

If the laser is operated in Service Mode all personnel near by the
laser must wear laser safety goggles!

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7 Fault clearance

7.1 Status messages

Status message Laser Standby

Property page Status
Description

If no alarm is present and the power supply is switched off, the status message
Laser Standby is present.

It is not possible to switch on main power supply if the status Laser Standby is not
present.

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7 Fault clearance

7.2 Warning messages

7.2.1 Laser module disconnected

Warning message Laser module disconnected

Property page Alarms
Description

The warning message Laser module disconnected indicates a breakdown in the

communication between microcontroller and module. Regarding the configuration
of the laser it is possible that the signal Laser error is set to high.

Trouble shooting

Switch of the Power supply of the Laser and turn the key in Off position and open
the front door of the Laser.

Check all communication cables of the Laser modules. Check if all cables are
fixed. Switch the key of the Laser in Robot or Test.

Check if at all Laser Modules the green LEDs are active. A red LED indicates an
error in the Laser Module. The communication is interrupted, when no LED is
active.

Open the log file folder inside LaserNet and select the date when the failure
occurred. Right mouse click into light blue log files window. Select all files and
press load. The files are saved on the hard disc of the computer in a sub folder of
LaserNet corresponding to the name of the laser set in LaserNet. The log files are
saved to a folder corresponding to the date. Send the log files to IPG Laser GmbH.

7.2.2 Indication lamps failure

Warning message Indication lamps failure

Property page Alarms
Description

This warning message is present if one of the lamps on top of the laser is defect. It
will not affect the operation of the laser.

Trouble shooting

Check if the indication lamps are properly connected by rotating the lamp counter
clockwise to disconnect and remove the lamp. Afterwards put the lamp back and
turn clockwise to fix the lamp.

If the message is still present replace the indication lamp.

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7 Fault clearance

7.2.3 Module overheat

Warning message Module overheat

Property page Alarms
Description

If one module reaches a temperature of 32°C this warning message will be active.
The operation of the laser will not be immediately affected, but it could lead to a
Laser overheat if the temperature reaches 35°C.

Trouble shooting

Go to LaserNet property page Status and check the modules temperature. Check
the actual water flow is indicated on this page.

Check and compare the actual water flow with the required water flow. The
specified water flow is listed in the user manual.

Check the water levels of the chiller and refill water if necessary.

Check the quality of the air filter at water-air chillers. When the quality of the air
filter is very dirty and is necessary to exchange the air filter. A dirty air filter will
reduce the Air flow and reduce the cooling power of the Laser.

7.2.4 Chiller warning

Warning message Chiller warning

Property page Alarms
Failure description

Chiller warning is activated generally if any pressure or temperature sensor

measures a value closed to the limit of the specified range.

Trouble shooting

Check the LaserNet property page Chiller for further information.

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7 Fault clearance

7.2.5 Reserved Module ON

Alarm message Reserved module is ON

Property page Alarms
Failure description

This warning message indicates a failure of a laser module. The reserved module
is switched on. The laser operation is not affected by this message and it is
possible to continue to work with the laser.

Trouble shooting

Check the LaserNet property page Events for the day when the failure happened.
Go to LaserNet property page Log files and load the files of the corresponding
day. Send the files together with the Events4.dat to
[email protected]

7.2.6 Discharge circuit defect

Warning message Discharge circuit is defect

Property page Alarms
Failure description

For the discharging of the main power supply of the laser a special discharging
element is used. If a failure in one of the two circuits inside this element is
detected the warning message “Discharge circuit is defect” will be activated.

Trouble shooting

An exchange of the discharging element is required. Please inform your provider

of the laser system to clarify the next steps. Send the Log files together with the
Events4.dat to [email protected]

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7 Fault clearance

7.2.7 Laser temperature is too low

Warning message Laser temperature is too low

Property page Alarms
Failure description

The average temperature of all modules is below the specified value. It will not be
possible to start the emission due to Laser Ready signal is not active.

Trouble shooting

Check the temperature settings of the integrated or external chiller. For the chiller
default temperature settings check the attached Chiller Operational manual or
contact IPG Laser Service.
Check for warnings and alarms at the LaserNet property page Chiller.

7.2.8 Reduced active Modules

Warning message Reduced active Modules

Property page Alarms
Failure description

The amount of active modules is insufficient. Laser Ready will not be active.

Trouble shooting

Check the LaserNet property page Events for the day when the module failure
happened.
Go to LaserNet property page Log files and load the files of the corresponding
day. Send the files together with the Events4.dat to
[email protected]

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7 Fault clearance

7.3 Alarm messages

7.3.1 E-Stop

Alarm message E-Stop

Property page Alarms
Failure description

The alarm message shows that the internal or the external E-Stop circuit is
opened. This message is only shown together wit E-Stop button or External E-
Stop.

Trouble shooting

Please check the alarm messages E-Stop Button and E-Stop external.

7.3.2 E-Stop button

Alarm message E-Stop button

Property page Alarms
Failure description

This Alarm indicates that the E-Stop Button of the laser, the external Beam Switch
or Beam Coupler is pushed. If at least one E-Stop button is pushed laser operation
will be stopped, the power supply will be switched off.

Trouble shooting

Check status of the E-Stop buttons. If one of the buttons is pushed, release the E-
Stop button and check the alarm messages in LaserNet. If no further alarm is
present and the status message Laser standby is on, it is possible to switch on
power supply.

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7 Fault clearance

7.3.3 E-Stop external

Alarm message E-Stop external

Property page Alarms
Failure description

E-Stop external is present if at least on of the two channels external E-Stop circuit
is opened. Laser operation will be stopped, the power supply will be switched off
and the yellow interlock lamp on the front side of the laser will be on.

Trouble shooting

If E-Stop external is active the Interlock circuit is opened.

Check status of the two channel external E-Stop circuit. The external E-Stop circuit
is integrated in the XP2 safety interface. Channel 1 is XP2 safety interface C1 –
C4, Channel 2 is XP2 C2 – C3. If one of the channels was opened by any reason
it is necessary to open the second channel additionally and close both again.

Check the water leakage sensors. A water leakage inside of the Laser will first
activate the alarm Water in Laser. After the removal of the water leakage the alarm
message will disappear and the alarm Message E-Stop External is set high. It is
necessary to open both Channels at the XP2 interface to reset the alarm
message.

Check if the Feeding fiber is plugged to an optical head or an external optics

device such as beam switch or beam coupler. Check if the bayonet is closed
correctly.

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7 Fault clearance

7.3.4 Laser overheat

Alarm message Laser overheat

Property page Alarms
Failure description

Laser overheat will stop the Laser operation and Laser Emission in standard
configuration. The Signal Laser Ready becomes low, and the signal Laser Error
high.

This alarm is active if one of the laser modules reaches an operation temperature
of 35 °C. When the module temperature is below 32 °C the module is enabled
again and the warning message is switched off.

Trouble shooting

Check LaserNet property page Status. The maximum temperature, the related
module number and the actual water flow are indicated on this page. The water
flow threshold is listed in the Laser Manual.

Check if the water flow threshold is near the threshold. When it is near the
threshold check the water level of the chiller. Refill water if necessary.

Check if all valves are open and if there are any pressed or buckled tubes at the
water circuit.

If the Alarm appears again check status of refrigerant circuit of the chiller after 5
minutes of chiller operation. Inside the chiller this status can be monitored by
checking refrigerant window. The colour of the indicator should be green.

Picture 7-1: Refrigerant window

If there are air bubbles inside or the colour of the indicator is red inform your
provider of the laser system to clarify next steps.

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7 Fault clearance

7.3.5 Laser fiber interlock

Alarm message Laser fiber interlock

Property page Alarms
Failure description

This alarm will immediately switch of main power supply. The signal Laser Ready
will be set to low and the signal Laser Error will be high.

This alarm message indicates a possible damage of the feeding fiber of the laser.

If the Laser system contains a Fiber to Beam Coupler this message monitor
additionally the process fiber.

If the Laser systems contains a Beam Switch the process fiber are monitored
separately

Trouble shooting

Check if the Guide laser is visible at the output. If a Beam Switch is integrated in
the Laser system it is necessary to use the Guide laser No. 0. The mirror of the
according channel has to be in Working position. If the guide laser is not visible at
the output (optical head) it indicates, that there is a damages inside the fiber.

Check the temperature of the optical head near the fiber connector. At 70°C the
temperature switch inside the optical head will open automatically the interlock
circuit. If the temperature is too high it is necessary to check the DI-Water flow.
When the temperature of the optical head is cooled down it is possible to reset the
alarm. When the alarm appear several times, please contact IPG.

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7 Fault clearance

7.3.6 High back reflection

Alarm message High back reflection

Property page Alarms
Failure description

The alarm message switch off laser emission. The signal “Laser Ready” will be set
to low and the signal “Laser Error” will be active.

This alarm is caused by back reflected light from the work piece.

Trouble shooting

Check if the red guide laser beam is visible after the feeding fiber. If a Beam
Switch is integrated in the Laser system it is necessary to use the guide laser No.
0. The mirror of the Beam Switch channel where the guide laser beam is checked
must be in ON position. When the guide laser is very weak or not visible it
indicates, that there is a damages inside of the fiber.

There is no damage of the fiber, if the guide laser is visible after the Feeding fiber
or the process fiber.

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7.3.7 Laser module failure

Alarm message Laser module failure

Property page Alarms
Failure description

The alarm message Laser module failure indicates an internal failure of a laser
module.

The signal Laser Ready will be set to low and the signal Laser Error will be active.

The Laser can compensate the loss of power if a reserve module is installed.

If a Reserve module is installed, it will switch on immediately after the defect

module has been switched off. In this case the message Laser module failure will
not become active. The warning Reserve module is ON becomes active.

Trouble shooting

Check the status of the laser modules in LaserNet property page.

In case of alarm Unexpected Pump Current and/or Unexpected Ground leakage

open the fuse of the damaged laser module at the rear side of the laser. Laser
operation is now possible with accordant less power.

Open the Log files property page and select the date when the failure occurred.
Right mouse click into light blue log files window. Select all files and press load.
The files are saved on the hard disc of the computer in a sub folder of LaserNet
corresponding to the name of the laser set in LaserNet. The log files are saved to
a folder corresponding to the date. Send the log files to IPG.
See also chapter 4.8.6 Log files page for further help to download the log files.

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7 Fault clearance

7.3.8 Chiller failure

Alarm message Chiller failure

Property page Alarms
Failure description

This signal indicates an accumulative fault of the chiller.

Trouble shooting

If you are using an integrated IPG chiller (LHI) or heat exchanger (IHE) go to the
accordant LaserNet property page for further information. Use the attached chiller
manual for trouble shooting.

If you are using a RIEDEL chiller, do the following:

Check the water levels of the chiller and refill water if necessary.
Check the quality of the air filter at water-air chillers. If the filter is in a bad shape it
is necessary to exchange the air filter. A dirty air filter will reduce the air flow and
reduce the cooling power of the Laser.

Check the motor protection switch inside the chiller controller cabinet.

Motor protection switches

In case of High pressure failure, reset the pressure control by pushing the black
button.

Pressure control

Please also use the accordant Chiller User Manual for further information.

Only trained personnel are allowed to perform this action. For further support
please contact IPG Service personnel.

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7 Fault clearance

7.3.9 Combiner failure

Alarm message Combiner failure

Property page Alarms
Failure description

If the alarm message Combiner failure occurs the emission will be switched off.
Laser Ready will be set to low and Laser Error to high. The alarm message critical
error will be activated.

See also Critical Error.

Trouble shooting

Check if the Guide laser is visible at the output. If a Beam Switch is integrated in
the Laser system it is necessary to use the Guide laser No. 0. The mirror of the
according channel has to be in Working position. If the guide laser is not visible at
the output (optical head) it indicates, that there is an internal damage.

Open the Log files property page and select the date when the failure occurred.
Right mouse click into light blue log files window. Select all files and press load.
The files are saved on the hard disc of the computer in a sub folder of LaserNet
corresponding to the name of the laser set in LaserNet. The log files are saved to
a folder corresponding to the date. Send the log files to IPG.
See also chapter 4.8.6 Log files page for further help to download the log files.

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7 Fault clearance

7.3.10 Initialization Error

Alarm message Initialization Error

Property page Alarms
Failure description

The first possibility for an Initialization Error is an indication for an internal firmware
or configuration failure.

The second possibility for an Initialization Error is a failure in the Dip switch
settings (only if MPI is installed).

Trouble shooting

If the Laser is set up with a Multi Port Interface check if all boards (IG297) have
the same laser number. If the settings are incorrect please change to the correct
setting.

Open the Log files property page and select the date when the failure occurred.
Right mouse click into light blue log files window. Select all files and press load.
The files are saved on the hard disc of the computer in a sub folder of LaserNet
corresponding to the name of the laser set in LaserNet. The log files are saved to
a folder corresponding to the date. Send the log files to IPG.
See also chapter 4.8.6 Log files page for further help to download the log files.

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7.3.11 Electronics overheat

Alarm message Electronics overheat

Property page Alarms
Failure description

The Electronic overheat alarm signal will not influence the laser operation. The
alarm message Electronic overheat indicates a temperature higher than 50 °C
inside electronic cabinet of the laser.

Trouble shooting

Check the settings of the temperature sensor inside electronic cabinet of the laser.
If the setting of the temperature is different from 50 °C change to 50 °C.

Check if ventilator inside electronic cabinet is working.

Check status of alarm message again. If the alarm is still present please measure
the temperature inside of the electronic cabinet.

When the failure do not switch of, after the electronic cabinet cools down, please
inform IPG Laser GmbH.

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7.3.12 Low water flow: Laser

Alarm message Low water flow: Laser

Property page Alarms
Failure description

When the alarm message Low water flow: Laser is active laser operation is
stopped or not possible to start. The alarm message Laser error will be active.

Trouble shooting

Check and compare the actual water flow with the required water flow. The
specified water flow is listed in the user manual.

Check if all water valves are opened and if any tubes are pressed or bended.

Check if the signal Chiller ready is present in the LaserNet software on the
property page status. If the signal is not active check if the Alarm Chiller Failure is
active. The alarm message indicates a failure at the chiller side.

Check the water level of the water tanks. Refill water if necessary.

Check the water pressure of water in and water out at the chiller side.

For further information check the LaserNet property page Chiller.

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7.3.13 Low water flow: fiber connector

Alarm message Low water flow: fiber con

Property page Alarms
Failure description

The alarm message Low water flow fiber connector will switch off emission. Laser
Ready will be cleared and Laser Error will be activated.

The alarm message indicates a low water flow at the feeding fiber output.

Trouble shooting

Check the accordant flow switch. If the green LED OUT1 is on. If not the water
flow is below the threshold.

Flow switch with active OUT1

Check if all water valves are open and if any tubes are pressed or bended.
Check if the chiller is working properly.
Check the water level of the water tanks. Refill water when it is necessary.
Check the water pressure of water in and water out at the chiller side.

For further information check the LaserNet property page Chiller.

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7.3.14 Water in Laser

Alarm message Water in Laser

Property page Alarms
Failure description

In the case of a water leakage one of the two water leakage sensors inside the
laser cabinet will detect the water. These sensors are connected to the Interlock
Safety relay. The safety loop will be opened and switch of the main power supply.
The alarm message Water in Laser and Laser error will be activated.

Trouble shooting

Switch off the main switch of the Laser immediately.

Check for water inside the Laser. If there is water find out where it comes from. A
loose hose pipe could be the reason.

If there is no water leakage in the Laser cabinet, please check the leakage
sensors. One of the leakage sensors is inside the electronic cabinet. The second
one is inside the Laser cabinet. The yellow LED indicates a properly working and
not active water sensor. If the LED is off the sensor is detecting water or is
damaged.

leakage sensor

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7.3.15 Water in Beam Switch / Beam Coupler

Alarm message Water in Beam Switch / Fiber to Beam Coupler

Property page Alarms
Failure description

This alarm message will immediately switch off main power supply. The magnetic
valves inside the laser will be closed. Laser Error will be activated.

It is not possible to switch on main power supply as long as this alarm message is
present.

Trouble shooting

Try to reset the error. If it is not possible to reset the error check visually if water is
inside the unit. Open the cover only after consulting IPG Laser Service.
If an Optoskand process fiber is plugged, remove the fiber and check for leaking
parts.

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7.3.16 Laser temperature is too low

Alarm message Laser temperature is too low
Property page Alarms
Failure description

The average temperature of all modules is below 18°C (LaserNet indication). The
Laser Ready signal will be removed. Emission is not possible.

Trouble shooting

Check the chiller TAB water temperature settings. Set to 21°C. For further
information check the Chiller operational manual.

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7.3.17 Critical Error

Alarm message Critical Error

Property page Alarms
Failure description

This error usually appears in combination with Combiner failure.

A Combiner failure / Critical Error will immediately switch off the main power
supply. Laser Error will be activated.

Trouble shooting

It is not possible to reset a Critical error in the usual way by pushing Reset button
in LaserNet software.
To reset a Critical error please refer to chapter 4.6.5 Settings / Laser / Reset
Critical Errors page 84.

Open the Log files property page and select the date when the failure occurred.
Right mouse click into light blue log files window. Select all files and press load.
The files are saved on the hard disc of the computer in a sub folder of LaserNet
corresponding to the name of the laser set in LaserNet. The log files are saved to
a folder corresponding to the date. Send the log files to IPG.
See also chapter 4.8.6 Log files page for further help to download the log files.

IPG Laser GmbH

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7.3.18 AC power interruption

Alarm message AC power interruption

Property page Alarms
Failure description

If supply voltage for laser (400VAC) drops below some specified level, this alarm
will appear. The Main power supply will switch off. The laser stops emission.
“Laser Error” will be activated.

Trouble shooting

DANGER – HIGH VOLTAGE

Serious risk to your health

Please check if the specified input voltage (400VAC±10%) from

external supply is present. Check if all 3 phases are present.

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7.3.19 Power supply failure

Alarm message Power supply failure

Property page Alarms
Failure description

This Failure indicates an internal failure of the main power supply. Laser emission
will be switched off and the alarm Laser Error will high.

Trouble shooting

Go to the LaserNet property page Power supply and check the status of the power
supply.

Q1 Q2 Q3 Q4 Status Description
0 0 0 0 Proper Operation These events relate
external parameters or
0 0 0 1 Overheating environment (water flow,
0 0 1 0 Excessive input input voltage etc.)
voltage
0 0 1 1 Short circuit
0 1 0 0 No-load operation
0 1 0 1 Interlock open
0 1 1 0 Reserved
0 1 1 1 Reserved
1 0 0 0 Internal failure These messages relate
(Code_X) to internal errors and
1 0 0 1 Internal failure assume that the power
(Code_Y) supply should be
1 1 1 1 Internal failure replaced.
(Code_Z)

Open the Log files property page and select the date when the failure occurred.
Right mouse click into light blue log files window. Select all files and press load.
The files are saved on the hard disc of the computer in a sub folder of LaserNet
corresponding to the name of the laser set in LaserNet. The log files are saved to
a folder corresponding to the date. Send the log files to IPG.
See also chapter 4.8.6 Log files page for further help to download the log files.

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7.3.20 Chiller error

Alarm message Chiller error

Property page Alarms
Failure description

Chiller Error is a general failure message for the LaserNet property page Chiller.

Trouble shooting

Go to the Property page Chiller.

There you will find further information, depending on what type of chiller is installed
(Riedel PCxx.xx, LCI170.xx-x-x)

Check the water conductivity. If the value is over the threshold open the valve to
the DI-cartridge. If the valve is already open When the valve is already open it is
necessary to exchange the DI-cartridge.

Check the temperature for Laser and optic. If one of the values above or below the
threshold check the chiller.

Check the water levels of the chiller and refill water if necessary.

Check the quality of the air filter at water-air chillers. When the quality of the air
filter is very dirty and is necessary to exchange the air filter. A dirty air filter will
reduce the Air flow and reduce the cooling power of the Laser.

Reset Pressostat by pressing the black button. It is possible that the building form
the Chillers is different. The picture is only a sample.

Picture 7-2: Pressostat (Riedel)

Is it not possible to reset the error, please check for further information the chiller
manual. Additional support you can get from IPG Laser GmbH or from Riedel
Hotline.

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7.3.21 Unexpected pump current

Alarm message Unexpected pump current

Property page Alarms
Failure description

Unexpected pump current will immediately switch off main power supply. The
alarm message Laser Error will be activated. It is not possible to switch on main
power supply when this alarm message is present.

Trouble shooting

Check which Laser module is causing this failure by removing on after another
module fuse. Open the rear door of the laser cabinet and disconnect the fuse from
the first module. Then check the status of the alarm message when switching on
the main power supply. If the alarm message is still active remove the fuse of the
next module. Check again if the alarm is disappeared. Repeat this procedure until
the alarm message disappears. If the alarm message disappears the latest
disconnected laser module caused the failure.

The Laser can operate in this configuration with less power.

An installed reserve module will not switch on if a module creates an Unexpected

pump current.

Open the Log files property page and select the date when the failure occurred.
Right mouse click into light blue log files window. Select all files and press load.
The files are saved on the hard disc of the computer in a sub folder of LaserNet
corresponding to the name of the laser set in LaserNet. The log files are saved to
a folder corresponding to the date. Send the log files to IPG.
See also chapter 4.8.6 Log files page for further help to download the log files.

IPG Laser GmbH

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7.3.22 Unexpected ground leakage

Alarm message Unexpected ground leakage

Property page Alarms
Failure description

Unexpected ground leakage will immediately switch off main power supply. The
alarm message Laser Error will be activated. It is not possible to switch on main
power supply when this alarm message is present.

Trouble shooting

Check which Laser module is causing this failure by removing on after another
module fuse. Open the rear door of the laser cabinet and disconnect the fuse from
the first module. Then check the status of the alarm message when switching on
the main power supply. If the alarm message is still active remove the fuse of the
next module. Check again if the alarm is disappeared. Repeat this procedure until
the alarm message disappears. If the alarm message disappears the latest
disconnected laser module caused the failure.

The Laser can operate in this configuration with less power.

An installed reserve module will not switch on, if a module creates an Unexpected
Ground leakage.

Open the Log files property page and select the date when the failure occurred.
Right mouse click into light blue log files window. Select all files and press load.
The files are saved on the hard disc of the computer in a sub folder of LaserNet
corresponding to the name of the laser set in LaserNet. The log files are saved to
a folder corresponding to the date. Send the log files to IPG.
See also chapter 4.8.6 Log files page for further help to download the log files.

IPG Laser GmbH

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7 Fault clearance

7.3.23 High average power

Alarm message High average power

Property page Alarms
Failure description

This alarm is only available in QCW lasers.

The microcontroller is calculating the average power in the pulsed mode. If it
exceeds 55% of the maximum power in CW-mode, the alarm is activated and the
emission is stopped.

Trouble shooting

Check the external modulation frequency.

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7 Fault clearance

7.3.24 Beam Switch Permission malfunction

Alarm message Beam Switch permission malfunction

Property page Alarms
Failure description

The Beam Switch controller unit has detected an abnormal situation.

One of the Cabinet doors was opened during a running process (Laser ON).
The Cabinet door dual channels (A) and (B) are not opened simultaneously.

Trouble shooting

The Cabinet doors channels (A) and (B) must be opened simultaneously.

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7 Fault clearance

7.3.25 Splice Box failure

Alarm message Splice Box failure

Property page Alarms
Failure description

A sensor inside the intermediate splice box has detected an abnormal situation. If
the alarm message Splice box failure occurs the emission will be switched off.
Laser Ready will be set to low and Laser Error to high. The alarm message critical
error will be activated.

See also Critical Error.

Trouble shooting

Check if the Guide laser is visible at the output. If a Beam Switch is integrated in
the Laser system it is necessary to use the Guide laser No. 0. The mirror of the
according channel has to be in Working position. If the guide laser is not visible at
the output (optical head) it indicates, that there is an internal damage.

Open the Log files property page and select the date when the failure occurred.
Right mouse click into light blue log files window. Select all files and press load.
The files are saved on the hard disc of the computer in a sub folder of LaserNet
corresponding to the name of the laser set in LaserNet. The log files are saved to
a folder corresponding to the date. Send the log files to IPG.
See also chapter 4.8.6 Log files page for further help to download the log files.

IPG Laser GmbH

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7 Fault clearance

7.4 Beam Switch

7.4.1 Cabinet door (A), (B)

Alarm message Cabinet door (A), (B)

Property page Beam Switch
Failure description

Indicating the Cabinet door (dual channel) of the accordant optical channel (light
path) is opened.
As long as the Cabinet door is open it is not possible to switch the mirror in
working position.
If the mirror is in working position and the cabinet door will be opened the mirror
will go to Home position.
If the cabinet door will be opened during the mirror is in working position and the
Power Supply is ON (Laser ON), the mirror will go to Home position and the Laser
Power Supply and Emission will switch OFF. Additionally alarm Beam Switch
Permission malfunction will rise.

Trouble shooting

It is necessary to open and close both channels (A), (B) of the accordant cabinet
door and perform an active reset to reset the alarm message.

7.4.2 Error
Alarm message Error
Property page Beam Switch
Failure description

Alarm Error is an accumulative failure message of the Beam switch controller.

Error will be active in case of:
► Scattered Light
► FFBD
► Optical Interlock
► Low water flow: Process fiber input / output
► Signal Mirror active is present, but it is not possible to switch the mirror in
Working Position due to opened Cabinet door
► Internal failure

Trouble shooting

Check the alarm message which will rise at the same time.

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7.4.3 Scattered Light

LASER SAFETY GOGGLES

If the laser is operated in Service Mode all personnel near by the
laser must wear laser safety goggles!

IMPORTANT ADVICE:
Only special trained personnel are allowed to carry out the
maintenance work mentioned below.

Alarm message Scattered Light

Property page Beam Switch
Failure description

The signal of the Scatted light sensor is above the limit. Laser Ready signal will be
cleared, Emission will switch OFF, and Laser Error signal will be active.

The quality of the light in-coupling process into the process fiber is bad. Too much
energy is lost and there is a potential risk to damage the process fiber.

Trouble shooting

Check the quality of the Quartz block surface of the process fiber.
Check the quality of the in-coupling process using a power measurement device
and the Scattered light signal.
The output power of the laser should equal the internal measured power (Indicated
Power LaserNet). The scattered light signal will increase linear with the power.
See also chapter 5.5 Optics alignment.

IPG Laser GmbH

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7 Fault clearance

7.4.4 FFBD

LASER SAFETY GOGGLES

If the laser is operated in Service Mode all personnel near by the
laser must wear laser safety goggles!

IMPORTANT ADVICE:
Only special trained personnel are allowed to carry out the
maintenance work mentioned below.

Alarm message FFBD

Property page Beam Switch
Failure description

The signal of the FFBD sensor is above the limit. Laser Ready signal will be
cleared, Emission will switch OFF, and Laser Error signal will be active.
The quality of the light in-coupling process into the process fiber is bad. Too much
energy is lost and there is a potential risk to damage the process fiber.

Trouble shooting

Check the quality of the Quartz block surface of the process fiber.
Check the quality of the in-coupling process using a power measurement device
and the FFBD signal.
The output power of the laser should equal the internal measured power (Indicated
Power LaserNet). The scattered light signal will increase linear with the power.
See also chapter 5.5 Optics alignment.

IPG Laser GmbH

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7 Fault clearance

7.4.5 Low water flow: Process fiber output / input

Alarm message Low water flow: Process fiber output / input
Property page Beam Switch
Failure description

The cooling water flow for the fiber connector at the input or output side is below
the limit.
Laser Ready signal will be cleared.

Trouble shooting

Check if the chiller is in operation.

Check the flow rate indicated at the flow switch. See chapter 5.2.4, Table 5-2:
water flow minimum requirements.
Check if any valves are opened, any pipes are bended or blocked and if the pipes
are connected properly.

Check the settings of the flow switch.

Picture 7-3 : SMC Flow Switch

Check if the lamp OUT1 of the Flow switch is on. If the Lamp is off, the water flow
is less than the threshold.

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7 Fault clearance

7.4.6 Optical Interlock

Alarm message Optical Interlock
Property page Beam Switch
Failure description

The alarm message will immediately switch off laser emission. The signal Laser
Ready will be cleared, the Error signal will be high and the mirror will go to Home
Position. This alarm message indicates a possible damage of the process fiber of
the laser.

Trouble shooting

Switch on the red Guide laser and check if is visible at the output side of the
Process fiber.
If the Guide laser is not visible, the Process fiber is damaged and needs to be
replaced.
If the Guide laser is visible, check if the bayonet is closed properly at both sides
(input / output).
Check the temperature of the optical (processing) head. Most optics have internal
thermal switch which will open the Optical interlock circuit at 70°C.

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 214
8 Maintenance

8 Maintenance
As a basic rule, none of the cleaning or maintenance tasks may be performed until
the device has come to a complete stop. The shutdown procedure described in the
operating instructions must be observed. As soon as this work has been
completed, all the safety devices and protective equipment must be mounted or
installed according to their proper function.

IPG Laser recommends periodic maintenance by IPG Laser to ensure proper

operation of the system.

8.1 Water system

8.1.1 Water leakage
Checkpoint Water leakage
Method Visual inspection
Clearance Weekly
Expenditure of time < 5 min.
Tools Flashlight
Open the doors of the laser and the chiller cabinet and look
Description
for water leaks, leaky connections, damaged pipes…

8.1.2 Water level

Checkpoint Water level
Method Visible inspection
Clearance Weekly
Expenditure of time 5 – 15 min (incl. refilling)
Tools -
Check the water level of the TAB water and the DI water
reservoir using the accordant level indicators.

Description

Therefore open the rear door, right side of the laser (in case
of integrated chiller) or the rear door of the chiller. If
necessary refill TAB / DI water using the accordant filling
nipple. For the external optics cooling circuit only DI water
must be used!

IPG Laser GmbH

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 215
8 Maintenance

8.1.3 Water filter

Checkpoint Water filter

Method Visual inspection
Clearance Monthly check / annually exchange
Expenditure of time 20 min.
Tools Wrench, 19mm / 23 mm
Once per month the filter at the water input nipple should be
checked and cleaned if necessary to ensure optimum water
flow rate. Once per year the filter should be replaced.
The filter is placed at the water input nipple at the rear side of
the laser. Before removing the filter the chiller must be
switched of and all valves should be closed. If the filter is very
dirty the complete water should be changed.

Description

8.1.4 Cooling water quality

Checkpoint DI water quality / conductivity

Method Visual inspection
Clearance Monthly
Expenditure of time 30 min.
Tools -
Check the DI water conductivity using LaserNet property
page chiller. If the conductivity is higher than 15µS/cm a
Description warning will rise. Replace the DI cartridge. For further
information use the Chiller operational manual.
DI cartridge can be ordered at IPG Laser.

IPG Laser GmbH

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 216
8 Maintenance

8.1.5 Filter pad

Checkpoint Filter pad at external chiller

Method Visual inspection
Clearance Monthly
Expenditure of time 20 min.
Tools Screw driver
Depending on the air quality of the facility the filter pad needs
to be replaced more often. Only a clean filter pad will provide
optimum air flow and cleanness for the chiller. Filter pads can
be ordered at IPG Laser.

Description

IPG Laser GmbH

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 217
8 Maintenance

8.2 Laser parameters

LASER SAFETY GOGGLES

If the laser is operated in Service Mode all personnel near by the
laser must wear laser safety goggles!

IMPORTANT ADVICE:
Only special trained personnel are allowed to carry out the
maintenance work mentioned below.

8.2.1 Output power

Checkpoint Output power
Method Performance test
Clearance Annually
Expenditure of time 2 hours
Tools Power measurement device
To check the output power ask IPG laser for more detailed
Description
performance instructions.

8.2.2 Beam quality

Checkpoint Beam quality
Method Performance test
Clearance Annually
Expenditure of time 2 hours
Tools Beam quality measurement device
To check the beam quality ask IPG laser for more detailed
Description
performance instructions.

IPG Laser GmbH

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 218
8 Maintenance

8.3 Optical components

LASER SAFETY GOGGLES

If the laser is operated in Service Mode all personnel near by the
laser must wear laser safety goggles!

IMPORTANT ADVICE:
Only special trained personnel are allowed to carry out the
maintenance work mentioned below.

8.3.1 Process fibers / alignment

Checkpoint Process fibers / alignment
Method Visual inspection / Performance check
Clearance Annually
Expenditure of time 2 hours
Power measurement device
Tools Multimeter
MCX / Banana cable
The performance check of the process fibers generally
happens simultaneously by testing the laser parameters. An
Description
additional visual inspection can ensure a proper placing of the
fibers (Bending radius,…).

8.3.2 Beam switch / Beam coupler

Checkpoint Beam coupler / Beam switch
Method Visual inspection / Performance check
Clearance Annually
Expenditure of time 2 hours
Power measurement device
Tools Multimeter
MCX / Banana cable
The performance check of the Beam switch / Beam coupler
Description generally happens simultaneously by testing the laser
parameters.

IPG Laser GmbH

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 219
8 Maintenance

8.4 Service to be done by IPG

8.4.1 Laser Module exchange
Checkpoint Laser module
Method Performance test
Clearance In case of damage
Expenditure of time ~ 3 hours
Tools IPG Laser
Please inform your provider about the module failure.
For a preliminary analysis send the Log files and the Events
Description
file to Support.Europe@ipgphotonics or to your IPG Service
representative.

8.4.2 Feeding fiber exchange

Checkpoint Feeding fiber
Method Performance test
Clearance In case of damage
Expenditure of time ~ 3 hours
Tools IPG Laser
Please inform your provider about the feeding fiber failure.
For a preliminary analysis send the Log files and the Events
Description
file to Support.Europe@ipgphotonics or to your IPG Service
representative.

IPG Laser GmbH

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 220
8 Maintenance

8.5 In event of damage

8.5.1 Service Request
In case of damage use the attached form (Appendix C)

IPG Laser GmbH

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 221
Appendix

9 Appendix A – Accessories

Part Quantity Remark

Ytterbium Laser System

YLS-10000-S2 1
SN 11076750

Operating manual laser 1 This document

Operating manual chiller 1 -

Electrical Schematics 1 -

IPG Test results 1 Included in this manual

To switch between TEST / OFF /

Control key 2
ROBOT

Cabinet key 2 Per door, to open cabinet doors

Service mode key 2 To activate the Service mode

Chiller 1

Feeding fiber 1 HLC-8, 100µm, 5m

Quantity of Process fibers 1 -

Process fiber #1 - HLC-8, 400µm, 10m

Process fiber #2 - -

Process fiber #3 - -

Process fiber #4 - -

Set of tubes and hose clamps Length depends on process fiber

1
for water connections length

Adapters 13mm/6mm 2 Per process fiber

IPG Laser GmbH

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 222
Appendix

Ferrite ring filters26 3 -

Corrugated protective pipe 1m Per process fiber

IPG microscope only delivered on

Set of cleaning needs 1
demand

Set of interface connectors and Which connectors are delivered

1
pins depending on the device setup

Ethernet cable 1 Communication Laser - PC

Software on CD 1 LaserNet version 2.93.7

26
Quantity depending on power supply type
IPG Laser GmbH
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Appendix

10 Appendix B – Specifications
10.1 Optical characteristics

NN Characteristics Test conditions Symbol Min. Typ. Max Unit

1 Operation Mode CW, QCW

2 Polarization Random
Nominal Output
3 P nom 10.0 kW
Power
Output Power Tuning
4 10 105 %
Range
Emission Output power
5 1070 1080 nm
Wavelength 10 kW
Output power
6 Emission Linewidth 3 6 nm
10 kW
Switching ON/OFF Output power
7 80 100 µsec
Time 10 kW
Output Power Output power
8 5.0 kHz
Modulation Rate 10 kW
Over 8 hrs,
Output Power T water =const,
9 ± 1.0 ± 2.0 %
Instability Output power
10 kW
Internal 2-ways
10 Installed
Beam Switch
Beam Parameter
Feeding fiber core
Product* at entrance
11 diameter 100 um, BPP*(1/e2) 4.0 4.5 mm*mrad
to 2-ways Beam
length 5 m
Switch
HLC-8 Process
Beam Parameter
fiber core diameter
12 Product* at output of BPP*(1/e2) 14.0 16.0 mm*mrad
400 um, length 10
2-ways Beam Switch
m
HLC-8 Process fiber
13 10 m
length
Fiber Cable Bend
Radius :
14 R 100 mm
unstressed
200
stressed
* Measurement accuracy by means of Primes Focus Monitor ± 10 %

IPG Laser GmbH

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Appendix

10.2 General characteristics

Test
NN Parameters Min. Typ. Max Unit
conditions
Operation Voltage, three 400 /3P+PE or
1 VAC
phases 480/3P + PE

2 Frequency 50/60 Hz

Output power
3 Power Consumption 32 33.5 kW
10 kW

4 Maximum operation current 400 VAC 60 A

5 Starting current 83 A
Operating Ambient Air
6 Temperature Range with 10 50 °C
built-in conditioner
Laser cooling water
7 20 21 22 °C
Temperature Range
Laser cooling water Flow
8 50 75 l/min
Rate
Laser COLD START
9 20 °C
Temperature
Optics cooling DI water
10 27 30 33 °C
Temperature Range
Humidity:
11 T < 40 °C 95 %
with built-in conditioner

12 Storage Temperature Without water - 40 + 75 °C

Dimensions, W x D x H of
13 Laser Cabinet, see the 1480 x 806 x 1519 mm
picture below
14 Laser Weight 850 kg

IPG Laser GmbH

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Appendix

10.3 Outside Dimensions of the device

RIGHT SIDE FRONT LEFT SIDE BACK

TOP

10.4 Beam Switch specifications

Internal 2-ways Beam Switch

NN Option Key Parameters Conditions

Feeding fiber core diameter
BPP*(1/e2) ≤ 16.0 100 um, length 5 m
Internal 2-ways Beam switch,
1 mm*mrad HLC-8 Process fiber core
100 um x 400 um
diameter 400 um, length 10
m
HLC-8 Process fiber BPP*(1/e2) ≤ 16.0
2
400 um /10 m mm*mrad
* Measurement accuracy by means of Primes Focus Monitor ± 10 %

IPG Laser GmbH

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 226
Appendix

Beam Switch channel #1

Type of the connector: Han® 10 D, female part on the cabinet side:

Pin Name Description

number
A1
Two channel
A2 Only potential free contacts can be connected
Cabinet Door
A3 between pins A1/A2; A3/A4.
inputs
A4
A5 Potential free outputs. A5-A6 are closed, if the
Mirror OFF
A6 mirror is in home position
A7 Potential free outputs. A7-A8 are closed, if the
Mirror ON
A8 mirror is in up position

Beam Switch channel #2

Type of the connector: Han® 10 D, female part on the cabinet side:

Pin Name Description

number
A9
Two channel
A2 Only potential free contacts can be connected
Cabinet Door
A10 between pins A9/A2; A10/A4.
inputs
A4
A5 Potential free outputs. A5-A6 are closed, if the
Mirror OFF
A6 mirror is in home position
A7 Potential free outputs. A7-A8 are closed, if the
Mirror ON
A8 mirror is in up position

10.5 Conditioner
NN Option Key Parameters Related Parts
600 W cooling capacity.
Conditioner for laser cabinet Laser operation at high
1 810(H)x395(W)x135(D)
Model: Seifert KG-4270 400 temperature and humidity
Weight: 33 kg

IPG Laser GmbH

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Appendix

11 Appendix C
Form 12980 REV
IPG Laser GmbH SERVICE REQUEST FORM
04

Please mark applicable

Repair □ or Modification

□
DEVICE INFORMATION

Laser Type

Laser Serial Number

Total time of operation, days

Average time of operation
per day, hours
Date of Failure
Detailed failure description or
required modification
Method of operation before
failure
CUSTOMER INFORMATION

Company name

Address, Phone, Fax, E-Mail

Person in charge

Signature / Name

Thank you for providing complete information to ensure fast processing of your request.

TO BE FILLED BY IPG LASER

Person in charge at IPG / Dept.

IPG Authorization Signature / Date □ Return to IPG Laser □ Service at customer

RMA No. / Date of Issue RMA -

Service No. / Date of Issue SC -

Service No. / Date of Issue SCAFF -

IPG Laser GmbH

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Appendix

Notes
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IPG Laser GmbH

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Date 2012-11-20, Revision OPERATINGMANUAL_englisch_BeamSwitch_1.5.1.doc