Manual - CL1000 (3) 1 PDF

User Manual
Laser Ablation System
CL 1000
Version: 03/2009
Clean-Lasersysteme GmbH
Dornkaulstraße 6
D-52134 Herzogenrath
Tel.: +49 2407 9097-0
Fax: +49 2407 9097-111
E-Mail: [email protected]
Internet: http://www.cleanlaser.de
Table of Contents
1___ GENERAL OPERATING INSTRUCTIONS 1.1
1.1 HOW TO OPERATE LASER SYSTEMS 1.1
1.1.1 ANGLE OF INCIDENCE LASER TO W ORK PIECE 1.1
1.1.2 ANGLE OF INCIDENCE LASER WITH 2D OPTIC (STAMP SERIES) 1.3
1.1.3 MECHANICAL FORCES ON CABLE PACKAGE AND BENDING RADIUS OF FIBER OPTICS 1.5
1.1.4 PROTECTION GLASS 1.6
1.1.5 SUCTION SYSTEM 1.7
1.1.6 INFLAMMABLE MATERIALS 1.7
2___ GENERAL OPERATING INSTRUCTIONS 2.1

2.1 HOW TO OPERATE LASER SYSTEMS 2.1
2.1.1 ANGLE OF INCIDENCE LASER TO W ORK PIECE 2.1
2.1.2 ANGLE OF INCIDENCE LASER WITH 2D OPTIC (STAMP SERIES) 2.3
2.1.3 MECHANICAL FORCES ON CABLE PACKAGE AND BENDING RADIUS OF FIBER OPTICS 2.5
2.1.4 PROTECTION GLASS 2.6
2.1.5 SUCTION SYSTEM 2.7
2.1.6 INFLAMMABLE MATERIALS 2.7
3___ SPECIAL SAFETY INFORMATION 3.1

3.1 POTENTIAL DANGERS FOR THE CL 1000 LASER CLEANING SYSTEMS 3.1
2.1.1 DANGER TO EYES AND SKIN 3.1
3.1.2 FIRE HAZARDS 3.3
3.1.3 DANGERS CAUSED BY HIGH-VOLTAGE 3.3
3.2 DANGER DURING LASER OPERATION 3.4
3.3 WARNING SIGNS & LABELS 3.5
3.3.1 SIGN POSTING LASER CLASS 4 PRODUCTS 3.5
3.3.2 WARNING OF INVISIBLE LASER RADIATION 3.5
3.4 LASER DEVICE LABELING 3.6
3.5 OPERATION, REPAIR & MAINTENANCE 3.9
3.6 MANUFACTURER’S LIABILITY 3.9
4___ DESIGN & FUNCTION 4.1

4.1 GENERAL INFORMATION 4.1
4.2 BASE UNIT 4.2
4.2.1 LASER RESONATOR 4.4
4.2.2 FIBER OPTIC COUPLING SYSTEM 4.5
4.2.3 COOLING SYSTEM 4.5
4.2.4 CENTRAL CONTROL UNIT 4.7
4.2.5 HF UNIT 4.8
4.2.6 POWER SUPPLY MODULE 4.8
4.2.7 OPTIONS/ACCESSORIES 4.8
5___ START-UP & OPERATION 5.1

5.1 START-UP 5.1
5.1.1 START-UP & STOP CONTROLS 5.2
5.1.2 SWITCHING OFF THE LASER SYSTEM 5.4
5.1.3 USER INTERFACE MENU & FUNCTIONS 5.4
5.1.4 USER INTERFACE MENU STRUCTURE 5.5
5.1.5 USER MENU OPERATION 5.7
I
5.2 MENUS – SUB-MENUS WITH DESCRIPTIONS 5.11
5.2.1 OVERVIEW 5.11
5.2.2 MENU: OPTIC 5.13
5.2.3 MENU: OPERATING TIME 5.13
5.2.4 MENU: ERROR STATE 5.13
5.2.5 MENU: SERVICE CODE 5.14
5.2.6 MENU: RESONATOR 5.14
5.2.7 MENU: POWER SUPPLY 5.15
5.2.8 MENU: COOLER 5.15
6 ___ MAINTENANCE & SERVICE 6.1

6.1 CARE INSTRUCTIONS 6.1
6.2 SCHEDULED MAINTENANCE & SERVICE REQUIREMENTS 6.1
6.3 MAINTENANCE TASK INSTRUCTIONS 6.3
6.3.1 CHANGING THE COOLING SYSTEM PARTICLE FILTER 6.3
6.3.2 FILLING COOLING SYSTEM W ATER 6.4
6.3.3 REPLACING THE MOISTURE ABSORBING PACK INSIDE THE RESONATOR 6.5
6.3.4 CLEANING & CHANGING THE PROTECTIVE GLASS LOCATED ON THE END EFFECTOR 6.8
6.3.5 LASER APERTURE PROTECTIVE GLASS CLEANING INSTRUCTIONS 6.8
6.3.6 LASER APERTURE PROTECTIVE GLASS REPLACEMENT INSTRUCTIONS 6.9
7 ___ TRANSPORT, STORAGE, START UP AND SETTING-UP OPERATION 7.1

7.1 TRANSPORT AND STORAGE 7.1
7.2 START UP 7.1
7.3 SETTING-UP OPERATION 7.1
7.3.1 GENERAL 7.1
7.3.2 CONNECTING THE LASER SYSTEM 7.2
II
General Operating Instructions How to Operate Laser Systems
1 General Operating Instructions
1.1 How to Operate Laser Systems
Laser systems are tools to provide a precise treatment of surfaces. Our

systems are designed for industrial use, so they are able to work even
under rough environmental conditions.
Follow the hints and recommendations listed below to ensure a

failure-free usage.
1.1.1 Angle of Incidence Laser to Work Piece
The laser beam must not hit the work piece surface at a right angle. With
highly reflective, such as copper or aluminum as well as polished metal
surfaces in general, the optical wave guide might be damaged quickly.
Especially using the CL 20 the risk of quick damage is very high, due to
high intensities with at the same time small fiber diameter while the optical
isolator can only be purchased optionally. Using high performance lasers,
e.g. CL 500 and CL 1000, the fiber end might be thermally destroyed in
case of back reflection for several minutes.
Usually, short-term 0° positions, e.g. when passing through the centre area
for a short term, are uncritical, especially when using a mid power system
or a low power system with optical isolator (optical isolation for CL 50 and
CL 20 available as option). Similarly, matt or rough materials and plastics
generally are less reflective; therefore the risk of damage is clearly less.
Nevertheless, especially when it comes to automated treatment, you have
to make sure that the machining angle will not be too small. The
recommended angle of incidence is 15° ±10°.
A light beam will be reflected when it hits metallic ground. The angle of the
beam that hits the metal will be the reverse angle of the reflection.
In short: Angle of incidence (α) equals emergent angle (α„) (see picture
below)
Reflexion Laser
α' α
Picture 1.1: Angle of incidence equals emergent angle
If the angle of incidence is small the risk of back reflection which damages
the optic or laser unit is very high. This risk increases with an even shorter
focal distance.
Version: 07/2009 1.1

How to Operate Laser Systems
Picture 1.2: Influence of the angle of incidence (3°) and short focal distance: Damage to the optic
Focal Distance f [mm] Minimum Angle to Perpendicular
< = 80 > 10°
< = 100 > 8°
< = 120 > 7°
< = 150 > 5°
< = 250 > 3°
> 250 > 2°
Table 1.1: Minimum angle to perpendicular valid for reflecting parts
If you have any questions please don‟t hesitate to contact our Service
Hotline
+49/2407/9097-0 (Telephone) or +49/2407/9097-111 (FAX)
Mon.-Fri. 8.00 to 17.00 o‟clock (CET)
1.2
1.1.2 Angle of Incidence Laser with 2D Optic (Stamp Series)
To adjust the angle of incidence with a 1D machining optic the optic can be
tilted in order to realize a slightly penetrative or slowly moving treatment.
With a 2D optic the optical head will not be tilted, because tilting would lead
to a shifting of the whole treatment area; thus a treatment would be
impossible.
Due to the objective‟s physical buildup the beam will be emitted vertically
only in the centre of the treatment area. Despite using a F-Theta objective
the beams will be diffracted in increasing angles the closer the beams get
to the edges. The angle is smaller than 20°. The laser treatment takes
advantage of this angle insofar as a treatment at the edge of the scan area
can take place without critical back reflection.
Thus, when using a 2D objective (Stamp Series), make sure not to treat the
direct centre of the scan field but preferably the edges.
Picture 1.3: Treatment areas placed correctly
Version: 07/2009 1.3

Picture 1.4: Treatment areas placed incorrectly – Risk of back reflection
A reliable appointment of the critical field, which has to be avoided,

depends on the optic used as well as the material treated. The systems CL
150, CL 300, CL 500, and CL 1000 are less critical as to back reflection
than the systems CL 20, Backpack, and CL 50. With the latter a back
refection will lead to a turn-off of the laser radiation for approximately one
second without generating an external error message.
With highly reflective, such as copper or aluminum as well as polished
metal surfaces in general, the optical wave guide might be damaged
quickly. Especially using the CL 20 the risk of quick damage is very high,
due to high intensities with at the same time small fiber diameter while the
optical isolator can only be purchased optionally. Using high performance
lasers, e.g. CL 500 and CL 1000, the fiber end might be thermally
destroyed in case of back reflection for several minutes.
Hotline
+49/2407/9097-0 (Telephone) or +49/2407/9097-111 (FAX)
1.4
1.1.3 Mechanical Forces on Cable Package and Bending Radius of

Fiber Optics
Fiber optics are sensitive devices which transport light nearly free of losses.
To provide this the fiber is protected against mechanical forces by different
wrappings. The fiber will be bundled with other supply and signal cables to
become part of a cable package.
Always make sure that:
Always keep a minimum bending radius.
Never expose the fiber and / or cable package to any kind of

mechanical forces (tension, pressure, torsion, bending).
If the minimum bending radius is not kept the risk of damage to the fiber is
enormously high. A damaged fiber has to be exchanged by authorized
personnel.
The following minimum bending radii must be kept for the following
systems:
System Minimum Bending Radius
CL 20, Backpack, CL 50 80 mm
CL 150, CL 300; CL 500 250 mm
CL 1000 320 mm
Table 1.2: Minimum bending radius for optical fibers
The user is responsible for keeping the correct bending radii.
Even if the cable package is protected mechanical forces to the package

and fiber have to be reduced to a minimum. Especially no heavy weights
should impact the package, e.g. roll over the fiber / cable package with
means of transportation, parking of heavy gods etc.
Torsion and twisting of the package are strictly to be avoided. These forces
will damage the fiber rapidly.
Forces of tension and pressure have also to be avoided. The maximum

tractive force must be less than 10kg. For applications with very long cable
packages mounted vertically cleanLASER provide specially prepared cable
packages. These packages are customized for the individual system.
Version: 07/2009 1.5

Picture 1.5: Examples for cable package with OSA 70
If the optic of an application is robot-guided cable package components of

Leoni, Kabelschlepp or Igus are recommended. We are gladly willing to
assist you in design.
Hotline
+49/2407/9097-0 (Telephone) and +49/2407/9097-111 (FAX)
1.1.4 Protection Glass
The protection glass is an optical element which is in direct contact to the

process environment. It will be polluted by normal surrounding air and also
extremely with dust and gas emitted by the laser process. A fouled
protection glass will absorb laser radiation. This radiation will drop away
from the actual laser process and thus a reliable process can not be
guaranteed anymore. Hence, we recommend a control of the protection
glass regularly. The exact intervals vary from process to process. A
recommended value for cleaning the protection glass varies from once per
shift up to once per month.
For automated applications with OSA 70 or OSH80 a sensor-based

protection glass control can be offered.
To remove the dirt from the protection glass a manual cleaning of the glass
is sufficient. In case of scratches or fusion penetration of dirt the glass must
be exchanged. For further information please see chapter “Maintenance” of
the user manual.
Hotline
1.6
1.1.5 Suction System
While the laser treats the work piece, dust and gases will emerge (particle
stream). These streams contain the ablated material. Normally the material
does not change its chemical configuration. Nevertheless, in order to
protect employees and machines (also the laser optic) we explicitly
recommend the use of a suction system mounted closely to the process
area. Not using a suction system might lead to damage to the optic due to
dirt embedded in the particle stream. Machining optics with integrated
suction channel need to be connected to a suction system, because the
suction channel serves as cooling device for internal components.
To achieve best suction effect most of your machining optics have an

integrated suction channel. The ablated material can pass through this
channel up to the connected suction system. High vacuum systems have to
be used to guarantee a suction effect.
The suction system should clean the air through different types of filters
and the exhausted air should be lead – if possible – outdoors.
For automated processes we recommend suction monitoring by means of

the system control.
1.1.6 Inflammable Materials
Laser processes are thermal processes. It is forbidden to use the laser in

hazardous areas and / or explosive zones. While working with inflammable
materials special safety instructions have to be fulfilled. Please inform
yourself before using the laser unit and follow the instructions given.
It is not allowed to store easily inflammable materials close to the laser

process.
Version: 07/2009 1.7

2 General Operating Instructions
2.1 How to Operate Laser Systems
Laser systems are tools to provide a precise treatment of surfaces. Our

systems are designed for industrial use, so they are able to work even
under rough environmental conditions.
Follow the hints and recommendations listed below to ensure a

failure-free usage.
2.1.1 Angle of Incidence Laser to Work Piece
The laser beam must not hit the work piece surface at a right angle. With
highly reflective, such as copper or aluminum as well as polished metal
surfaces in general, the optical wave guide might be damaged quickly.
Especially using the CL 20 the risk of quick damage is very high, due to
high intensities with at the same time small fiber diameter while the optical
isolator can only be purchased optionally. Using high performance lasers,
e.g. CL 500 and CL 1000, the fiber end might be thermally destroyed in
case of back reflection for several minutes.
Nevertheless, especially when it comes to automated treatment, you have
to make sure that the machining angle will not be too small. The
recommended angle of incidence is 15° ±10°.
A light beam will be reflected when it hits metallic ground. The angle of the
beam that hits the metal will be the reverse angle of the reflection.
In short: Angle of incidence (α) equals emergent angle (α„) (see picture
below)
Reflexion Laser
α' α
Picture 2.1: Angle of incidence equals emergent angle
If the angle of incidence is small the risk of back reflection which damages
the optic or laser unit is very high. This risk increases with an even shorter
focal distance.
Version: 07/2009 2.1

Picture 2.2: Influence of the angle of incidence (3°) and short focal distance: Damage to the optic
Focal Distance f [mm] Minimum Angle to Perpendicular
< = 80 > 10°
< = 100 > 8°
< = 120 > 7°
< = 150 > 5°
< = 250 > 3°
> 250 > 2°
Table 2.1: Minimum angle to perpendicular valid for reflecting parts
Hotline
+49/2407/9097-0 (Telephone) or +49/2407/9097-111 (FAX)
2.2 Version: 03/2008

2.1.2 Angle of Incidence Laser with 2D Optic (Stamp Series)
To adjust the angle of incidence with a 1D machining optic the optic can be
tilted in order to realize a slightly penetrative or slowly moving treatment.
With a 2D optic the optical head will not be tilted, because tilting would lead
to a shifting of the whole treatment area; thus a treatment would be
impossible.
Due to the objective‟s physical buildup the beam will be emitted vertically
only in the centre of the treatment area. Despite using a F-Theta objective
the beams will be diffracted in increasing angles the closer the beams get
to the edges. The angle is smaller than 20°. The laser treatment takes
advantage of this angle insofar as a treatment at the edge of the scan area
can take place without critical back reflection.
Thus, when using a 2D objective (Stamp Series), make sure not to treat the
direct centre of the scan field but preferably the edges.
Picture 2.3: Treatment areas placed correctly
Version: 07/2009 2.3

Picture 2.4: Treatment areas placed incorrectly – Risk of back reflection
A reliable appointment of the critical field, which has to be avoided,

depends on the optic used as well as the material treated. The systems CL
150, CL 300, CL 500, and CL 1000 are less critical as to back reflection
than the systems CL 20, Backpack, and CL 50. With the latter a back
refection will lead to a turn-off of the laser radiation for approximately one
second without generating an external error message.
With highly reflective, such as copper or aluminum as well as polished
metal surfaces in general, the optical wave guide might be damaged
quickly. Especially using the CL 20 the risk of quick damage is very high,
due to high intensities with at the same time small fiber diameter while the
optical isolator can only be purchased optionally. Using high performance
lasers, e.g. CL 500 and CL 1000, the fiber end might be thermally
destroyed in case of back reflection for several minutes.
Hotline
+49/2407/9097-0 (Telephone) or +49/2407/9097-111 (FAX)
2.4 Version: 03/2008

2.1.3 Mechanical Forces on Cable Package and Bending Radius of

Fiber Optics
Fiber optics are sensitive devices which transport light nearly free of losses.
To provide this the fiber is protected against mechanical forces by different
wrappings. The fiber will be bundled with other supply and signal cables to
become part of a cable package.
Always make sure that:
Always keep a minimum bending radius.
Never expose the fiber and / or cable package to any kind of

mechanical forces (tension, pressure, torsion, bending).
If the minimum bending radius is not kept the risk of damage to the fiber is
enormously high. A damaged fiber has to be exchanged by authorized
personnel.
The following minimum bending radii must be kept for the following
systems:
System Minimum Bending Radius
CL 20, Backpack, CL 50 80 mm
CL 150, CL 300; CL 500 250 mm
CL 1000 320 mm
Table 2.2: Minimum bending radius for optical fibers
The user is responsible for keeping the correct bending radii.
Even if the cable package is protected mechanical forces to the package

and fiber have to be reduced to a minimum. Especially no heavy weights
should impact the package, e.g. roll over the fiber / cable package with
means of transportation, parking of heavy gods etc.
Torsion and twisting of the package are strictly to be avoided. These forces
will damage the fiber rapidly.
Forces of tension and pressure have also to be avoided. The maximum

tractive force must be less than 10kg. For applications with very long cable
packages mounted vertically cleanLASER provide specially prepared cable
packages. These packages are customized for the individual system.
Version: 07/2009 2.5

Picture 2.5: Examples for cable package with OSA 70
If the optic of an application is robot-guided cable package components of

Leoni, Kabelschlepp or Igus are recommended. We are gladly willing to
assist you in design.
Hotline
2.1.4 Protection Glass
The protection glass is an optical element which is in direct contact to the

process environment. It will be polluted by normal surrounding air and also
extremely with dust and gas emitted by the laser process. A fouled
protection glass will absorb laser radiation. This radiation will drop away
from the actual laser process and thus a reliable process can not be
guaranteed anymore. Hence, we recommend a control of the protection
glass regularly. The exact intervals vary from process to process. A
recommended value for cleaning the protection glass varies from once per
shift up to once per month.
For automated applications with OSA 70 or OSH80 a sensor-based

protection glass control can be offered.
To remove the dirt from the protection glass a manual cleaning of the glass
is sufficient. In case of scratches or fusion penetration of dirt the glass must
be exchanged. For further information please see chapter “Maintenance” of
the user manual.
Hotline
2.6 Version: 03/2008

2.1.5 Suction System
While the laser treats the work piece, dust and gases will emerge (particle
stream). These streams contain the ablated material. Normally the material
does not change its chemical configuration. Nevertheless, in order to
protect employees and machines (also the laser optic) we explicitly
recommend the use of a suction system mounted closely to the process
area. Not using a suction system might lead to damage to the optic due to
dirt embedded in the particle stream. Machining optics with integrated
suction channel need to be connected to a suction system, because the
suction channel serves as cooling device for internal components.
To achieve best suction effect most of your machining optics have an

integrated suction channel. The ablated material can pass through this
channel up to the connected suction system. High vacuum systems have to
be used to guarantee a suction effect.
The suction system should clean the air through different types of filters
and the exhausted air should be lead – if possible – outdoors.
For automated processes we recommend suction monitoring by means of

the system control.
2.1.6 Inflammable Materials
Laser processes are thermal processes. It is forbidden to use the laser in

hazardous areas and / or explosive zones. While working with inflammable
materials special safety instructions have to be fulfilled. Please inform
yourself before using the laser unit and follow the instructions given.
It is not allowed to store easily inflammable materials close to the laser

process.
Version: 07/2009 2.7

Special Safety Information CL 1000
3 Special Safety Information
Please be aware of the following:
Despite our best efforts we can not guarantee that the labels, their
wordings and the rules and regulations stated in this user manual
are sufficient to operate the laser device in a legally acceptable
manner in any other country than the Federal Republic of
Germany. We therefore strongly advise that local regulations be
checked and alterations be made to the labelling and/or handling
requirements where necessary before any form of laser operation
commences. Please be aware of the fact that any failure to comply
with local regulations may result in your being penalized.
In the United States, refer to the American National Standard for the Safe
Use of Laser, ANSI Z136.1, most current version, as the OSHA recognized
standard for industrial laser safety.
3.1 Potential Dangers for the CL 1000 Laser Cleaning Systems
The laser cleaning systems models CL 1000 are laser class 4 products and
may therefore only be operated by authorized personnel trained in the use of
Working with such lasers. While the laser is in use all persons present must wear
class 4 laser appropriate laser safety goggles (see section 1.1.1.1)!
radiation
These lasers emit dangerous invisible radiation! For this reason the
area surrounding the laser work station as well as persons residing in
that area must be protected from visible and invisible laser radiation!
The following potential dangers are inherent when working with class 4
lasers:
2.1.1 Danger to eyes and skin
The laser cleaning systems CL 1000 contain an Nd:YAG-solid state laser

(Neodymium doped Yttrium Aluminum Garnet) which emits dangerous class
4 laser radiation! The optical radiant power emitted is extremely high. This
radiation, close to the infrared range, has a wave length of 1064 nm and is
invisible.
Sources of danger are:
The direct laser beam

The mirrored/reflected laser beam
Diffusely scattered laser radiation
Version: English 03/2009 3.1

The fact that this kind of laser radiation traverses transparent

materials (glass, Plexiglas etc.) nearly unhindered
This invisible laser radiation is especially dangerous to the eyes as the high
level of radiation causes localized heat build-up and burns on the retina thus
damaging it. The damage caused ranges from an unnoticeable decrease in
vision to total loss of sight. The laser device’s radiation can still be
dangerous to eyes over a long distance, in the case of the CL 1000
systems, 51 meters (or 170 feet) or more without being noticeable
(Worst case: un-scanned beam, 10s exposure time). This is called the
Nominal Hazard Zone or NHZ. The precise NHZ resulting from direct or
indirect laser radiation depends on several factors including the type of optic
used and the settings that create the beam parameters. Ensure that the
minimum following protection and safety measures are adhered to within the
laser NHZ area at all times:
Laser areas in which laser beams are accessible must be closed off
with restricted access and have appropriate sign posted!
Safe-guard laser area against unauthorized entry!
Never allow children to enter the nominal hazard zone!
All persons residing in the NHZ must wear the appropriate laser
safety goggles.
Never look into the laser outlet directly or aim the laser at a person
– even if the laser is switched off!
3.1.1.1 Personal safety equipment

Appropriate laser safety glasses/goggles safeguard against direct laser
beams as well as mirrored or diffusely scattered radiation. Nevertheless,
even when wearing laser protection goggles - never look directly into the
laser outlet – even if the laser is switched off as the intense laser radiation
may not be averted due to a device malfunction, a fault in the safety glasses
or because the beam intensity may damage or destroy the protection filter.
When using laser safety goggles and windows, always inspect prior to laser
operation to ensure that they are not faulty or damaged and are suitable for
Laser safety the wavelength range of the laser.
glasses
For the CL 1000 lasers, use laser eye protection and/or shielding rated
for: the wattage of the laser (CL1000=1000 watts), laser source Nd:YAG
with a wavelength of 1064nm and an optical density (O.D.) of 6 or
higher.
Confusing laser safety goggles is dangerous as the protection afforded

by the filters only exists within a small wave length band and up to a defined
performance limit. For this reason laser safety goggles for a CO 2-laser
(wavelength of 10,6 µm) do not offer the required protection against the
radiation emitted by a Nd:YAG-laser (wavelength of 1064nm).
Compared to the eyes, the skin can withstand much higher radiation levels
without being damaged. Nevertheless, depending on the radiation‟s duration
and its intensity, tissue can be damaged or destroyed. Where necessary
wear protective clothing!
3.2 Version: English 03/2009

The laser ablation systems CL 1000 do not usually require the use of any
special protective gear clothing than laser safety glasses/goggles.
Nevertheless, avoid laser radiation exposure to skin!
Should you suspect or experience injury due to laser radiation:
Switch the laser off immediately

Secure laser against accidental re-starts
Inform you supervisor and the Safety Officer immediately
See a doctor and seek medical attention immediately.
3.1.2 Fire Hazards
The high power output of a class 4 laser is capable of heating, igniting or

vaporizing many materials. Flammable materials such as paper, wood, non-
fire retardant fabrics are some examples of things that can be ignited by
direct or reflected laser radiation.
Special precautions are required with respect to highly flammable materials,

liquids of gases. Containers of flammable or explosive solvents, chemicals or
pressurized gasses must either be removed from the area in which the laser
radiation is readily accessible or screened off using appropriate measures.
Laser radiation hitting these kinds of containers by coincidence can easily
cause fires very quickly.
Whenever working with laser radiation, always take precautions to protect

against fires and explosions prior to commencing.
3.1.3 Dangers Caused by High-Voltage
This laser appliance has been constructed in accordance generally accepted

technical standards based on the European Guidelines governing this
technology (e.g. EC Machinery Directive), the EN (European Standards), the
DIN-Standards and the VDE Testing and Certification Institute.
Any work on the electrical components of this equipment may only be

preformed by appropriately trained specialized personnel who are aware of
the dangers arising from invisible laser radiation.
The operation of the CL 1000 laser systems involve the use of life-
threatening high voltages, particularly when working on parts supplying
DANGER power to the laser resonator extreme care must be exercised. The life-
HIGH
VOLTAGE threatening high voltages existing in this area necessitate special precautions
as certain components may retain high voltage charges for a time even after
the power has been switched off.
Always switch off the power supply and remove the power cord plug
from the power source before performing any maintenance or repair
work!

Should the power supply be necessary for special maintenance or

repair work, such work may only be carried out by qualified personnel
trained in electronics who are aware of the dangers arising from laser
radiation and life-threatening high voltages.
When conducting any work on electrical components use extreme caution

and follow these 5 safety rules:
Disconnect the equipment from the power source

Secure against accidental re-start
Check that the device is isolated from the power supply
Ground and short-circuit the device
Cover and/or fence off neighboring live parts
3.2 Danger during Laser Operation
This laser device has been designed with a number of features to safeguard
against dangers resulting from laser radiation and high voltages. Should the
laser be damaged or become defective, uncontrolled and unintended laser
radiation can be emitted.
In the event the laser device, its safety features or accessories become
damaged or defective in any way:
Switch the laser off immediately

Secure the laser against unintentional re-starts
Repair/replace damaged parts through qualified personnel
Use only parts specifically authorized by the manufacturer
Check all laser system functions after completing repairs
Check the safety features and the accessories to ensure that they are
functioning correctly
During treatment with laser radiation, materials can release vapors and/or
particles referred to as Laser Generated Airborne Contaminants (or LGAC);
these may be toxic or hazardous. For example, when working on plastics,
coated or oil-covered surfaces, harmful fumes or particles may be released
into the air.
Use appropriate control measures to avoid health hazards and protect the
environment from LGAC including fumes, vapors and particles resulting from
laser surface treatments. Capture and extracted LGAC using suitable means
such as fume extraction equipment fitted with appropriate filters such as
HEPA and carbon filters.
If in doubt:
Conduct appropriate tests to ascertain the type and amount of
vapors/particles generated using a qualified testing lab

Wear respiratory protection as determined appropriate by those

responsible for hazard analysis and industrial hygiene
3.3 Warning Signs & Labels
3.3.1 Sign posting Laser Class 4 products
Laser Class 4 devices are identified with DANGER signs indicating the laser
radiation„s in watts, maximum output values, the pulse duration and the
emitting wavelength. These sign use white and black letters with DANGER
on a red background.
Areas of laser operation must be appropriately and clearly posted with

warning signs to quickly convey a visual hazard alert message to:
Warn of the presents of a laser hazard in the area
Indicate that specific polices are in effect for laser hazard controls
Indicate the severity of the hazard (i.e. laser class, Nominal Hazard
Zone)
Instruct as to appropriate actions to take to avoid hazards (i.e. Laser
Safety eyewear requirements)
3.3.2 Warning of invisible laser radiation
Laser system models CL 1000 emit invisible laser radiation at a wavelength

of 1064 nm. Signage for laser radiation emitted that is not within the visible
range of 400 nm to 700 nm must read “Invisible Laser Radiation”. Should the
emitted radiation contain wavelengths ranging from 400 nm to 700 nm as
well as other wavelengths, the label must read: “Visible and/or Invisible Laser
Radiation”.
Warning Sign Examples
Example 1: Danger, Class 4 Laser Operating with alert regarding invisible laser radiation and to avoid eye
or skin exposure to direct or scattered radiation

LASER
OPERATING
WEAR
LASER EYE
PROTECTION
CLASS 4 LASER PRODUCT
Examples 2: Danger, Class 4 Laser Operating with alert to Wear Laser Eye Protection
3.4 Laser Device Labeling
Laser devices must be labeled with signs to indicate hazards which are
durable, readable and clearly in sight during laser operation, service and
maintenance work.
Important Note
Should a classified laser device’s performance data or its intended

mode of functioning be modified in such a fashion as to influence its
classification, the person or organization performing the modification
will be deemed the manufacturer and will assume all responsibilities
pertaining to the manufacturer. These responsibilities include but are
not limited to obtaining a new laser classification, ensuring that all
necessary new labels are applied and new safety regulations are issued
where necessary.
The following labels are affixed to the equipment at certain locations as

shown in the illustration below.
Label #1
Danger regarding laser exposure hazard at RED visual indicator light on top

of laser when laser is on. When RED light is illuminated continuously (and
not blinking) laser is active and in standby mode without laser emission at
optic. Blinking RED light indicates active laser emission at optic.
AVOID EXPOSURE -
INVISIBLE LASER
RADIATION IS EMITTED
FROM THIS APERTURE
BEFORE
OPENING
DISCONNECT
MAINS!
Label #2
Danger warning for Class 4 Laser Product
SERVICE COVER MAY BE OPENED

ER - INVISIBLE LASER
BY TRAINED EXPERT STAFF ONLY.
IATION W HEN OPEN.
DANGER - INVISIBLE LASER
EYE OR SKIN EXPOSURE
TO DIRECT OR RADIATION WHEN OPEN. AVOID
EYE OR SKIN EXPOSURE TO DIRECT
TTERED RADIATION.
OR SCATTERED RADIATION.
Label #3
Danger warning on service cover at resonator
Danger
Invisible laser radiation if cover is
opened and security interlocks are
bridged, avoid eye and skin exposure
to direct or scattered radiation.
Label #4
Danger warning on component covers under which laser exposure can occur
if security interlocks are bridged at resonator.

Label #5
Danger warning labels on service panels under which high voltage hazard
exists. Disconnect unit from power supply before opening these panels.
AVOID EXPOSURE -
INVISIBLE LASER
RADIATION IS EMITTED
FROM THIS APERTURE
Label #6
Danger warning label at laser aperture.(example picture, real optic could look
diffrent)
Authorized Laser Operators
This laser equipment is designed for use by trained and authorized operators
only. Each operator must be instructed on all safety measures and
mechanisms as well as the proper use of the equipment. It is important to
ensure that all operators have understood the safety and use instructions
before being allowed to work with this equipment. Safety and operation
refresher training sessions (at least once a year) must be conducted for
equipment operators on a regular basis.
The laser operator is responsible for ensuring that all persons residing in the
laser work area are aware of the intention to utilize the laser prior to its being
switched on. The laser may only be operated when all safety procedures
have been followed, especially the use of personal safety equipment by all
personnel in the laser work area. (See section 3.1.1.1).

3.5 Operation, Repair & Maintenance
When working with or on the laser device:
The instructions laid out in the user manual must be adhered to closely
Ensure that laser radiation is never intentionally or accidently directed at
humans or animals
It must be ensured that every person operating, maintaining or repairing
the laser device understands and follows the instructions in the user
manual and the safety procedures/regulations for the laser device.
3.6 Manufacturer’s Liability
For information on the manufacturers‟ limits of liability, see Clean-

Lasersysteme GmbH‟s General Terms and Conditions of Business at this
web address (http://www.cleanlaser.de/Profil/AGB/agb.html).

Design & Function CL 1000
4 Design & Function
4.1 General Information
The CL 1000 series laser systems consist of a base unit and an optical unit
called the end effector or “optic”. These units are connected by an optical
fiber cable (LWL) and electrical control cable located within a steel jacketed
protective hose (see Picture 3.1)
End effector information is contained in a separate user manual.
Picture 4.1: Laser cleaning system type CL 1000
1 Manually guided end effectors (optional dual system shown)

2 Protective hose containing optical fiber and electrical control cable
3 Central control user interface panel with display
4 Service doors for base unit cooling and electrical systems

4.2 Base unit
The laser base unit consists of two primary sub-systems:
1. The laser system (also referred to as “the laser”) transforms electrical

energy into laser energy. This part consists of numerous optical and
electrical components such as the power supply unit, the laser
resonator and the fiber optic coupling system.
2. The cooling system (also referred to as “the cooler” or “chiller”)
maintains critical components at the optimal temperature while
removing excess heat resulting from the energy used to create the
laser beam.
The base unit contains controls, supply and operating elements within a
lockable heavy duty metal housing for safety and protection for from
environmental exposure. The following chart describes the main
components it contains and their functions:
Component Function Note

Produces the laser Highly sensitive optical
Laser Resonator
radiation needed for the element
see Chap. 4.2.1
cleaning process.
Focuses the laser Highly sensitive optical
radiation created in the element. Avoid
Optical Fiber
resonator into the mechanical stress! The
Coupling System
attached fiber optic (LWL) optic(s) for fiber coupling
see Chap. 4.2.2
are also located in the
laser unit
Provides constant thermal The cooling system must
conditions for the laser function correctly in order
Cooler Unit unit & peripheral parts of to maintain the entire
see Chap. 4.2.3 the system system‟s operations.
Manufacturer‟s settings
may not be altered!
Controls & monitors the Micro-controller based
Central Control
functions of the laser unit for operating control,
Unit
system & peripheral system communication,
see Chap. 4.2.4
components user interface
Provides high-frequency Included in the central
supply for internal q- control unit
HF Unit switches, central
see Chap. 4.2.5 Sensitive electronics!
controller & end effectors Alterations may damage
the entire system!
Power Supply Supplies the laser source Sensitive electronics!
Module in the resonator with Alterations may damage
see Chap. 4.2.5 controlled electrical the entire system!

current
Table 4.1: Base unit components
The sensitive laser resonator, the fiber optic coupling system and the
system controls are located in the base units‟ upper section service area.
These components are under a lockable service hood which can be
accessed from the back of the base unit.
Locations of the above described components are illustrated in Picture 3.3
CAUTION - Keep the resonator service hood closed and locked at all
times to prevent harmful dirt or moisture from entering. Avoid
mechanically and/or thermally stressing of the resonator and the fiber
optic coupling system! Only specially trained personnel are
authorized to access this service area.

1 2
3 4
5 6
Picture 4.2: Schematic design of CL 1000 Laser system base unit
1 Resonator service hood (keep closed & locked)

2 Laser resonator
3 Fiber optic protective hose & power cord hanger with end effector
4 User interface control panel & display
5 Control unit, HF-unit & laser power supply module compartment
6 Cooling system compartment
4.2.1 Laser Resonator
The resonator is a high precision electro-mechanical device that transforms

electrical energy into laser energy. A laser diode module is the heart of the
resonator. The diode module contains the lasing medium, a Nd:YAG
crystal, which is used to produce an intense and invisible laser beam.
Typically the diode module has a service life of 12,000 hours. The laser
diode module may only be serviced by specially trained personnel
authorized by the manufacturer.
When the laser is turned on, invisible laser radiation is emitted inside the
resonator. The emission of laser radiation is controlled by an electro-
magnetic optical circuit breaker. This circuit breaker – also called a shutter
– is controlled by the laser operator via the radiation initiator (trigger). The
shutter also provides a safety function. When the laser operator releases
the trigger at the end effector the shutter immediately stops laser
emissions.

Picture 4.3: Schematic design of CL 1000 Resonator
The resonator consists of an aluminum housing divided into separate

covered and sealed compartments. These compartments are specially
sealed to protect highly sensitive internal components from dust, moisture
and physical contact. Opening and incorrectly closing sealed chambers can
damage seals and lead to serious resonator damage.
DANGER – To avoid serious injury and equipment damage, only specially

trained service personnel, authorized by the manufacturer, may open
resonator compartments and only when the laser is de-energized and not in
operation.
Unauthorized opening any part of the resonator housing voids all

warrantees.
Optical-electronic components within the resonator have been pre-set to

optimum by the manufacturer. Under normal conditions, the resonator is
virtually maintenance-free.
4.2.2 Fiber Optic Coupling System
The fiber optic coupling system located inside the laser unit focuses the
laser light emerging from the laser resonator and directs it into the fiber
optic. The fiber optic coupling system of the CL 1000 is located inside the
resonator. The fiber optic coupling has been precisely adjusted by the
manufacturer.
4.2.3 Cooling System
The integrated cooling system utilizes a high-performance compressor

design. It consists of an interior closed cooling circuit filled with a special
de-ionized water solution containing a laser additive. The “chiller” functions
by way of an air interchange system by expelling excess heat through the
louvers in the laser base unit access panels. A fan draws fresh airflow
through the front access panel louvers of the base. Exhaust air is
channeled out of the louvers on the rear side. To ensure adequate air
exchange and cooling, the laser system must be operated in a well

ventilate area, with fresh temperate air and have a 2m minimum distance of
open space on each side of the base unit.
Picture4.4: Cooling system, front
Picture4.5: Cooling system, back
The cooling system reservoir must be filled to the proper level with laser
coolant before the unit is started for the first time. This coolant is drained
and replaced as part of the recommended maintenance schedule.
(See Chapter 6 Maintenance & Service).
CAUTION - To prevent serious equipment damage, use only clean DI

water with the correct mix ratio of special laser coolant additive
available from the manufacture.
The cooling system contains a particle filter that is changed at

recommended maintenance schedule. (See Chapter 6 Maintenance &
Service)

4.2.4 Central Control Unit
This unit consists of 3 main parts:
Internal controller unit

User interface control and display
HF-unit
The controller unit is located in the base unit. It consists of power supplies,
I/O-Ports, communication interfaces and a micro-controller. This system
controls all operations of the laser. It monitors communication between
devices, processes fault-management and operates the display.
The user interface control and display is located on the top left front of the
base unit. It provides information on all laser system conditions and buttons
to modify certain laser settings.
(See Chapter 5 Start-Up & Operation)
Read and understand the

user manual completely
before starting the laser
Picture 4.6: Central control unit user interface and display, buttons, key switch and emergency stop
The user interface panel includes a key switch used for normal start/stop of
the system and the emergency stop button.

A red indicator lamp above the user interface is provided to give a visual
indication and warning of the lasers‟ operating and beam emission status. A
blinking LED at the “LASER EMISSION ACTIVE” location on the control
panel also indicates the laser is emitting laser radiation. (See Picture 4.7)
Lamp Status Meaning

Lamp off: Laser unit is switched-off or inactive
Lamp continuously on: Laser is powered up and in standby mode
Lamp blinking: Laser is emitting laser radiation
Laser radiation emits

when red lamp
blinking!
Picture 4.7: Central control unit user interface and display with laser warning lamp
4.2.5 HF Unit
The HF-unit provides the high frequency for the q-switch and several
electronic devises. It is located in the controller unit. All adjustments and
setting within the HF unit are factory preset and must not be tampered with
or changed. (See Chapter 4.2.4)
4.2.6 Power Supply Module
The power supply module provides energy and controls the current to the
laser diodes. It is located in the base unit behind the front left side service
panel. (See Picture 4.2)
4.2.7 Options/Accessories
4.2.7.1 Interlock connections & external interface
Communication sockets are located left from the user interfaces.
Consult with the manufacture for information on the use of these features.

DANGER - To prevent serious injuries and equipment damage, only

manufacturer trained personnel are permitted to access or enable
these optional features.
1 2 3
4 5 6
Picture 4.8: Optional communication sockets
See attached chapters for pinning of interlock socket.
1 NC
2 NC
3 NC
4 NC
5 Externer I/O-Port
6 Interlocks

Start-up & Operation CL 1000
5 Start-Up & Operation
DANGER – To avoid serious injury, before laser start-up verify that all
safety protocols are fulfilled including proper equipment installation.
5.1 Start-up
The control panel contains switches needed to operate the laser as well as a
digital display that shows both operating settings and system status. It
consists of the display, status lamps, beam switch buttons, menu navigation
buttons, on/off key switch and emergency stop.
Picture 5.1: Touch panel for CLQ- Control and Control panel - user interfaces
The CLQ-Control can be used to operate the system. The software and its
usage is described separately.
This chapter describes the usage of the control panel.
1 6 7
3
2 5
Picture 5.2: Control panel - user interface, Menu navigation buttons, key switch and emergency-stop button
1 Display
2 Menu navigation buttons

3 Status lamps
4 Beam switch buttons
5 Option/ESC (escape) – button
6 On/Off key switch
7 EMERGENCY STOP (for emergency shutdown ONLY)
5.1.1 Start-Up & Stop Controls
Key Switch
The laser is turned on and off using a key switch at the user control panel.
Emergency Stop
The emergency stop button adjacent to the key switch is a safety control used
for laser shutdown in emergency situations.
IN CASE OF EMERGENCY WHILE OPERATING THE LASER - PUSH IN

THE RED EMERGENCY STOP BUTTON TO IMMEDIATELY TURN OFF
THE SYSTEM.
CAUTION – To prevent system damage, only use the emergency stop button
when conditions arise that require immediate laser shutdown for safety
reasons.
Note: When the laser has been shutdown using the emergency stop button,
the keys switch must be turned to “off” and the emergency stop button must
be disengaged, by pulling it out until it clicks, before the laser will restart.
Start-up Procedure

Control Action Note

1 EMERGENCY Make sure the E- The laser will not operate
STOP Stop button is with the E-Stop engaged
pulled out before (pushed-in).
operating the key
switch.
2 Key Switch Turn key clockwise Digital display lights-up,

to the “ON” position startup / initialization
routines run.
Under normal conditions
(no water heat-up
necessary) the laser will
be ready for use within 10
seconds
Table 5.1: Starting the CL 1000
After turning the laser on and the unit completes its start-up diagnostic
routines, the red warning lamp atop the laser will light-up and stay on
continuous to indicate the laser system is “ready for emission”. When laser
emission begins (the end effector is “triggered”) this warning lamp will start
blinking and will continue to do so until the end effector trigger is released.
This lamp is a safety feature and visual alert for personnel approaching so
they will be aware the laser is on and emitting Class 4 laser emissions.
An LED on the user panel at the “LASER EMISSION ACTIVE” location also
lights-up to indicate the status of the laser; steady on for standby or blinking
for active laser emissions.
Red Lamp on
laser in standby mode
Red Lamp blinking

laser emitting radiation
Laser radiation emits
when red lamp
blinking!
Picture 5.3: Laser indicator warning lamp and LED for laser status
Red Lamp “ON” continuously = laser in standby mode
Red Lamp “Blinking” = laser emitting radiation

5.1.2 Switching Off the Laser System
To shutdown the laser system, turn the key switch in a counter clockwise
direction as described in the following table
Control Action Note

Key Switch Insert key and turn It takes a moment for
counter-clockwise to the unit to power off
the “OFF” position while the system
completes its internal
shutdown routine.
Sometimes the cooling
system will continue to
operate briefly.
Table 5.2: Switching off the CL 1000
5.1.3 User Interface Menu & Functions
After Starting up the system, the Main Menu (first menu) will be displayed.
1 3
2
5
Picture 5.4: Overview graphic user interface
No. Item Description

Shows system settings and operating
1 Display
conditions
Menu navigation The buttons can be used to navigate to the
2
buttons menu of the laser system.
Shows if laser is active (ready) or if laser
3 Status lamps radiation emits
Shows also if an error occurs
Beam switch buttons Use to switch from optic 1 to optic 2.

4 nd
(Active when 2 optic LED lights to show which optic is active

is installed) The beam switch is an optional feature on

systems with 2 end effectors installed
Option / ESC
5 To leave the menu press ESC
(Escape)
Table 5.3: Description of CL 1000 user interface
5.1.4 User Interface Menu Structure
The user interface features easy to adjust controls for changing operating
functions and parameters along with a display of important system
information. From the main menu, sub-menus are accessed to adjust settings
and monitor systems.
The laser system can is operated by the User Menu. A special Service Menu
is used by the manufacturer to modify critical settings in the system. To avoid
system malfunctions due to improper setting changes, a Service Code must
be entered to access the Service Menu.

The User Menu contains 9 sub-menus or status displays:
3. Main Menu
4. Optic #2 State
5. Optic #1 State
6. Operating Time
7. Error State
8. Service Code
9. Resonator State
10. Power Supply State
11. Cooler State
Each menu has its own display screen. Picture 5.5 shows an example of the
Main Menu display.
1
5
2
6
3
7
4
Picture 5.5: Main Menu display
No. Displays
1 Main Menu is displayed at start-up
2 “PSet” - Power setting value in “watts”
3 “Puls” – Pulse frequency setting value in kHz
Operating status - “Warm-up”, “Idle”, “Ready” or “Run”. Also
4
shows “No Error” and location/type of “Error”
5 “POut” - Power output value in “watts”
6 “TChi” Current chiller water temperature (deg. C)
7 Reads either “No Error” or “Error”
Sub-menus are described in Section 5.2.

5.1.5 User Menu Operation
Main Menu
At system start-up, the Main Menu displays the operating settings for laser
power and pulse frequency, actual chiller temperature, the laser output power
and system status including errors messages.
In most cases, the Main Menu is the only menu in which the user can change
settings. There are two important user adjustable laser settings: laser
power and pulse frequency. The intensity of a laser beam is determined by
the laser power (watts) and pulse frequency (number of pulses per second or
kHz). The settings for each of these functions will significantly influence
the laser process.
CAUTION – To avoid damage to sensitive parts, these setting should be

carefully adjusted and set to safe and optimal values based on the results of
prior testing for each application. Until you are familiar with these
adjustments, consult with the manufacturer before changing laser power and
pulse frequency settings in the User Menu.
Laser Power
“PSet”, #2 above is the “Power Setting”: This is the laser power setting
measured in watts.
As a safety feature to ensure that no laser radiation will be emitted

unintentionally when the shutter is opened, the laser output power setting
[PSet] is reset to “0” each time the laser is turned on. After the unit is
powered on and before the laser can be used, the operator is required
to select a suitable laser output power setting for the application.
Laser power can be adjusted up and down within the minimum / maximum
wattage range for a particular laser system.
Laser System Min. Laser power [W] Max. laser power [W]
CL 1000 500 1000
Table 5.4: Minimum and maximum power output in watts
More watts equal higher laser power, more energy per laser pulse and faster
production rates compared to a lower wattage laser system.
“POut”, #5 above: displays the laser power output as measured in watts by

an internal laser power analyzer before the beam is coupled into the fiber
optic. The value displayed should be close to the adjusted value of “PSet”.
Due to measurement variations, a small difference between the “PSet” and
“POut” values is possible.
Pulse Frequency
“Puls”, #3 above: Is the laser beam pulse frequency measured in kHz
Pulse frequency can be adjusted at the end effector or at the control panel
up and down within the minimum / maximum range for a particular laser
system.

The pulse frequency adjustment range varies based on the laser system and
type of end effector used.
Min. pulse frequency Max. pulse frequency

Laser System
[kHz] [kHz]
CL 1000 24 40
Table 5.5: Minimum and maximum pulse frequency adjustment range
As the pulse frequency is lowered, the intensity of each laser pulse increases
and the beam becomes more aggressive. When the pulse frequency is
raised, the intensity of each pulse is decreased. In short, there is more energy
in a “slow/long” pulse versus a “fast/short” pulse. The pulse frequency setting
influences process speed. Generally, a low pulse frequency will result in a
lower process speed than that which is possible from a high pulse frequency.
Since the pulse frequency significantly affects the level of laser intensity, this
is a very important setting used to optimize laser material processing
The illustration below depicts the relationship of pulse frequency settings to

process outcome.
Removal of heavy material

High Intensity More affect on substrate
Low process speed
High Pulse Frequency
Optimal cleaning/de-coating results

Optimal Intensity No damage to substrate
Desired process speed
Low Pulse Frequency
Removal of light material

Low Intensity No affect on substrate
High process speed
Picture 5.6: Pulse frequency relationship to application factors
“TChi”, #6 above represents “Temperature Chiller”. The value shown is the

current temperature of the water, measured in deg. C, used to cool the laser
module. After laser start-up and during normal operation, this temperature
reading should be between 23.5 to 25.5 °C.
Operating Status and “No Error”/ Error Messages, #4 and #7 above

There are 6 different operation modes that can be displayed: “Idle” – “Ready”
– “Run” – “Warm-up” and “No Error” or “Error”. Idle means the system is
ready, but there is no laser power. Ready means the laser diode module is
supplied with current and the laser could emit radiation immediately. Run
means the laser is actively emitting laser radiation. Warm-up is displayed
when the laser is first turned on in cool weather while the laser cooling liquid
is being warmed by an internal heater to reach the correct operating
temperature. During normal laser start-up and operation, “No Error” is
displayed. When internal sensors detect a condition that prevents normal

system operation, an “Error” message is displayed along with the location of

the problem detected.
If an Error message appears at start-up, wait a few minuets for the system to
automatically clear the issue, such as in the case of “Warm-up”. After waiting,
if the error message remains, press the OPTION ESC button. If this does not
clear the error, refer to Sub-Menu section involved in the following pages of
the user manual and follow the instructions there.
User Settings
To set or adjust the settings for laser power and/or pulse frequency (when not
adjusted at the end effector), the display must be changed from the display-
mode (default) to the edit-mode.
Enter the edit-mode by pressing the SELECT ENTER button. A blinking

cursor will appear at the first row of the menu. Press the UP PREV. button or
DOWN NEXT button to move the cursor to the menu function to be changed.
When the cursor is at the desired function, press the SELECT ENTER
button. The cursor will jump to the last digit of the selected function.
To increase a setting, press the UP PREV. button. The selected digit can be
increased to as high as “9”.
To decrease a setting, press the DOWN NEXT button. The selected digit can
be decreased down to as low as “0”.
To move to the next digit, press the SELECT ENTER button. Increase or
decrease this digit as described above using the UP PREV. button to
increase or DOWN NEXT button to decrease the value. Repeat these steps
until the desired setting is obtained. Next press the OPTION ESC button to
exit that function and save the new setting. To change the next menu item
repeat the procedure as described above.
Repeated pressing of OPTION ESC button will skip directly to Main Menu.
An illustration on the next page depicts the above steps

Menu Navigation
The diagram below illustrates the above steps used to change certain
function settings.
Picture 5.7: Steps for changing setting of a menu item (Diagram)

5.2 Menus – Sub-Menus with Descriptions
The following menus are accessed by pressing the OPTION ESC button.
5.2.1 Overview
Menu Picture Description
Item: Main Menu (discussed above)

Information:
Laser output power setting [PSet]
Setting of Laser Laser power output [POut]
Output Power Pulse frequency [Puls]
Chiller temperature [TChi]
Operation mode (Idle – Ready – Run –
Warm up)
Error code
Adjustable setting:
Laser output power setting [PSet]
Laser pulse frequency [Puls]
Description at: Chapter 5.2.1
Item: Optic #2 State (dual optic systems)
Information:
Laser power output [POut]
Pulse frequency [Puls]
Fiber temperature [TF2]
Error code
Adjustable setting: None
Item: Optic #1 State
Information:
Pulse frequency [Puls]
Fiber temperature [TF2]
Error code

Item: Operating Time (in hours)

Information:
System available / key switch on [On]
[Rdy] Time laser is on, ready, idle
[Run] Time laser is running/beam on
[Actv] Changes Rdy to Run
Item: Error State
Information:
System – sub-system that sent an error
message to the control unit
Emerg.Stp - the emergency stop is
active/engaged
Interlock – A safety interlock circuit is
open
Item: Service Code
Used to enter service code (for trained
service technicians only)
Item: Resonator State

Information:
Resonator temperature [Tre]
Error code
Item: Power Supply State
Information:
Output current [Ia]
Output voltage [Ua]
Error code

Item: Cooler (Chiller) State

Information:
Chiller temperature [TChi]
Error code
Table 5.6: Overview of User Interface Menus
5.2.2 Menu: Optic
This Menu indicates the status and selected parameters for optics #1 and
optics #2. Optics #1 and Optics #2 menu look the same (see Table 5.5).
[POut#] is the internally measured laser output power. [TF#] is the

temperature in °C of the fiber optic cable. The temperature must be below
70°C. The pulse frequency setting is displayed as [Puls#].
For laser systems equipped with the optional beam switch, values at the
optics (end effector) menu will only be displayed correctly when the
corresponding optic is activated (e.g. temperature).
To exit this menu and return to the Main Menu press OPTION ESC
5.2.3 Menu: Operating Time
In this menu no item / value can be changed. This is a read only menu.
In this menu various times in hours are displayed that are useful for
scheduled maintenance or to get an overview how the laser has been used.
Actv Numbers of activations (Change from Ready mode to Run mode)

On System operating time (power on)
Rdy Ready – Diode module has current and is ready to emit laser radiation
Run Laser radiation is emitted
5.2.4 Menu: Error State
System Part of the system that sent error signal to control unit
Emerg.Stp The emergency stop is engaged

Interlock A safety interlock circuit is open
If a system error occurs call the manufacturer for support. If the error is at the
E-Stop of safety interlock, check the indicated issue and correct.
In case of questions call the manufacturer
5.2.5 Menu: Service Code
This menu is only for use by trained service personnel.
5.2.6 Menu: Resonator
Laser power output [POut] describes the power of the laser beam inside the
resonator. This is also the power that is displayed at [POut] on the main
menu.
Resonator temperature [Tre] is the temperature inside the resonator. The

temperature should be between 18°C and 35°C.
If an error code occurs the following topics can be shown:
Error Meaning Solution/Action

Humid 80 The Humidity in the pump Change the desiccant at the
chamber is above 80 % resonator
Humid 60 The Humidity in the pump Change desiccant at the
chamber is above 60 % resonator
Qswitch1 Over temperature of Call manufacturer
Q-switch 1
Qswitch2 Over temperature of Call manufacturer
Q-switch 2
Water1 Water leakage in Q-switch Call manufacturer
chamber 1
Water2 Water leakage in Q-switch Call manufacturer
camber 1
Water3 Water leakage at pump Call manufacturer
module

Shutter Difference between actual Call manufacturer
& reference control value

TempMax The temperature inside the Check ambient temperature

resonator is too high increase ventilation
TempMin The temperature inside the Check ambient temperature
resonator is too low Move unit to warm area
For help and information regarding error messages please contact the
manufacturer
5.2.7 Menu: Power Supply
Output current [Ia] describes the output current. The current is proportional to
the laser power. The Maximum level of the power is limited by factory
settings.
Output voltage [Ua]

Overtemp Over temperature in the Change to Idle mode. Check
power supply coolant hoses for leaks
Current Over current Check for short circuit
Call manufacturer
Voltage Over voltage Check electrical connection
Call manufacturer
Softfault Internal communication error Call manufacturer
SumFault More than one error occur Call manufacturer
manufacturer
5.2.8 Menu: Cooler
The temperature settings for the chiller control are displayed.

Typ. Value
TN- 5 °C
Tmin 20 °C
TWr- 26 °C
TWr+ 30.5 °C
Tmax 32 °C
TN+ 38 °C
These are factory preset values -no changes by the user are necessary.
Over temperature
Overtemp Shut down laser system
Water temp. above Tn+
Poor water flow in laser Check water coolant level &

Flow Main
cooling circuit filter condition
Poor water flow in the

Flow Aux
auxiliary cooling circuit
Fill to above min. level with

Level Water level in tank is too low
laser coolant liquid
Error in the cooling control

ErControl
unit
Water will be heated – wait

Min.Temp Water temperature is too low
for internal heater to work
Check ambient temperature

Max.Temp Water temperature is too high Provide fresh air for cooling
unit
manufacturer

Maintenance & Service CL 1000
6 Maintenance & Service
DANGER – To aviod serious injury and/or death from electrical shock,

or laser radiation exposure, always make sure the laser is turned off
and that the power cord is disconnected from the mains power source
before opening service panels and performing any maintenace work.
6.1 Care Instructions
Follow these instructions to ensure reliable operation:
Avoid equipment exposure to excessive dust as well as thermal and

mechanical stress
Avoid exposure to impact, knocks and vibrations as these conditions can
reduce performance or destroy components entirely
When transporting the system, carefully pack and maintaining the unit in an
upright position
Do not expose the unit to temperatures below 4°C while transporting or in
storage. Contact the manufacture for instructions regarding protection
from damage due to low temperatures.
Keep the equipment clean using only a soft cloth dampened with water. Do
not under any circumstance spray with water or other liquids.
Avoid exposure to extreme changes in humidity and /or temperature. Allow
time to acclimate to normal conditions before operating. Residual
condensation on optical elements can lead to heavy damage and major
repairs.
CAUTION - For safety and to keep this equipment in good operating
condition as well as maintain warranty coverage, the owner must
follow all scheduled maintenance and service requirements. This
requirement particularly applies to the yearly maintenance services
provided by manufacturer authorized service personnel.
Please contact the manufacturer for information regarding yearly

service plans and any maintenance questions.
6.2 Scheduled Maintenance & Service Requirements
This equipment is designed to operate with reliable performance with a

minimum amount of scheduled maintenance. Maintenance actions and
schedules are influenced by such factors as the hours operation, typical
applications, the environment in which the equipment is used and to the
extent that the user manual instructions are followed.
Specific maintenance and service activities are included here that must be
completed at regular intervals, or in some cases, on an as needed basis.

Keep tack of and document all maintenance activities. Use the “Operating
Time” sub-menu to ensure important hour related service items are
completed at the proper intervals. See Section 5 of the user manual for
information on accessing the Operating Time menu.
Picture 6.1: Control Panel User Interface (left) Operating Time Sub-Menu Display (right)
Owner Maintenance Items Frequency

Every At least 1 X As
No. Activity Daily 3500
per Year Necessary
Hours
Change 5 µm particle filter for main

1 X X X
cooling water and refill water*
2 Change cooling water* X X X
Inspect laser system & peripheral
3 X X
components for damage
Depends on application.
Check/clean the end effector
4 May be needed frequently & after short
aperture lens protective glass
period of laser operation!
Change the end effector aperture
5 X
lens protective glass
*Fill / Refill with proper mixture of DI water & Special Laser Additive Only
Table 6.1: Owner Maintenance Schedule - other maintenance actions may be needed based on
operating conditions
Manufacturer Authorized Service

Frequency
Technician Work*
Every 3500 At least Once A When

No. Activity
Hours Year Necessary
Inspection & check-up of the entire

12 X X X
system
13 Performance-data check X X X
typ.
14 Exchange of Laser-Diode Module 12000hrs.

Precautionary maintenance
15 measures according the X X X
inspection protocol
Table 6.2: Authorized Service Technician Maintenance Schedule – other services may be needed
based on operating conditions
6.3 Maintenance Task Instructions
6.3.1 Changing the cooling system particle filter
Picture 6.2: Particle filter location
DANGER – To aviod serious injury and death from electrical shock,

always make sure the laser is turned off and that the power cord is
disconnected from the mains power source before opening service
panels and performing any maintenace work.
Using the access panel key, open the right front service panel to
access the chiller bay.
Picture 6.3: Remove the particle filter

Locate the filter (Picture 6.3). Place a towel under the filter to soak-up any
water that drips when the filter is removed. Turn the lower particle filter
housing (clear section) clockwise to remove.
Remove old particle filter element and replace with a new filter element.
Install the lower filter housing with the new filter carefully turning it in a
clockwise direction. Do not to over-tighten – firm hand-tighten only.
Make sure the filter housing gasket is seated properly. Replace the gasket
if damaged.
Prior to closing the service panel, re-starting the laser and check the water
cooling system to ensure that there are no leaks. If any leaks are
discovered, TURN OFF THE LASER IMMEDIATELY AND
DISCONNECT THE POWER CORD FROM THE MAINS POWER
SUPPLY. Correct any leaks found and test again.
6.3.2 Filling Cooling System Water
The cooling system contains a closed circuit with a water reservoir that
normally does not require refilling after initial system set-up. Nevertheless
after transporting, filter exchanges or leakage, the system may require
additional coolant water. Following the transport of the unit, filter exchanges
or if the system experiences a leak, the coolant water reservoir level must
be checked to ensure that the level is safely above the minimum required.
Picture 6.4: Coolant Water Reservoir – Water Level Indicator (left) fill location (right)
The coolant water reservoir is located inside the rear service panel opposite
the chiller bay. A water level indicator, mounted to the face of the reservoir,
will show the water level when the level is above the bottom of the
indicator. If no water is visible, or if the level is less than 90% up to the
black maximum fill line, additional coolant water must be added. Never let
the coolant level approach or fall below the red minimum level fill line on the
indicator.
Coolant water is added at the fill location shown in Picture 5.4. Add coolant
by unscrewing the fill, inset a funnel and carefully pour in the amount of
coolant needed to reach the proper level.
If it‟s necessary to drain the system, use the hose or drain valve fitting
shown in Picture 5.5. Drain the coolant into a bucket or container. The
amount of coolant drained will be about 10 liters or 2.6 gallons. Take care
that the level of the drain hose is lower than the bottom of the reservoir so

all coolant will drain. Open the filler cap for venting while draining the
system.
Picture 6.5: Reservoir drain – hose design (left) valve with fitting (right) – designs may vary.
CAUTION – To avoid damage to internal components, only use the

recommended solution to fill the cooling system. The solution is a
mixture of clean distilled water with a special additive provided by the
manufacturer. DO NOT use any other liquids or plain tap water in the
cooling system. Be sure to rinse clean the filler funnel before use after
use with clean water.
6.3.3 Replacing the moisture absorbing pack inside the resonator
If the control panel displays the warning “Humid 60” more than once, this
indicates the moisture absorbing pack in the resonator needs replacement.
Changing the moisture absorbing pack requires opening the sealed

resonator. Therefore, to prevent harmful dirt or moisture from entering the
unsealed resonator, complete this task as quickly as possible and only in a
very clean area.
The locations of the absorbing packs are shown in Picture 6.6 Section
of resonator where moisture absorbing pack is located Picture 6.6
2
3
Picture 6.6 Section of resonator where moisture absorbing pack is located
1 Label for recording maintenance work
2 Sealed cover with 6 screws

3 Pick up help (tapped hole)
Instructions for moisture absorbing pack replacement
Note: Be careful not to damage the cover seal during this process.
Note: The pictures show a similar resonator. The procedure is the

same!
No. Description No. Description

Remove the 6 recessed screws on the To unseal the cover, screw in one of the
sealed cover as shown screws removed from the cover into the
threaded hole near the upper right
corner of cover as shown
1 2
Once the seal is broken, remove the Remove the old moisture absorbing pack
cover by lifting it with the inserted from the recessed chamber & discard it
screw.
3 4
Carefully install the new moisture Replace the sealed cover & install the 6
absorbing pack inside the chamber screws previously removed
5 taking care to ensure no parts of the 6 Fill-in a new maintenance label noting
pack overlap & that it is fully inside the the date of service.
chamber.

Table 6.3: Replacing the moisture absorbing pack at the resonator

6.3.4 Cleaning & changing the protective glass located on the end
effector
To protect the lasers‟ high precision focusing lens at the beam aperture, an
optical quartz protection window (referred to as “protective glass”) treated
with a special anti-reflective coating is installed over the aperture lens. The
protective glass must be treated with care to prevent scratches that will
harm the lasers‟ performance.
Since end effector designs vary, review the end effector user manual for
specific instructions on cleaning and changing the aperture lens protective
glass.
Carefully follow the cleaning instructions below to maximize the service life
of the of the aperture protection glass.
6.3.5 Laser aperture protective glass cleaning instructions
Step Action Note

Close shutter and make sure that Power down the system!
1 shutter cannot be opened during
cleaning
2 Remove nozzle for better access Only on optics with nozzle
Pre-clean lens/window by using a Do not use high-pressure
3
soft dry compressed airflow compressed air or oily air
Put a few drops of ethanol (water Do not use other cleaning
4 free!) on fresh optical cleaning solutions, towels or papers
paper
Clean optics by wiping over with Do not press down while wiping
damp optical paper (see step 3), to avoid scratching the
5 repeat cleaning process if protective glass coating
necessary until there are no
spots remaining on the surface
Final cleaning step – gently pull a This method removes residual
sheet of ethanol damped optical streaks. Remember - Check
cleaning paper (see step 3) over the protective glass frequently
6 the protective glass surface and clean as needed
without any pressure, just by
using the force of the liquids‟
surface tension.
Table 6.4: Cleaning of aperture lens protective glass

6.3.6 Laser aperture protective glass replacement instructions
DANGER – To aviod serious injury from acciendtal laser radiation

exposure, before changing the protective glass, always follow these
precautions:
Turn off the laser to ensure that no laser radiation can be emitted
while servicing the protective glass
Never look straight into the laser aperture – even if you think the laser
is off…it may not be!
Always wear laser safety goggles/glasses when cleaning and
changing the aperture glass or lens
To change a damaged protective glass, follow these instructions:
Clean the protective glass and the surrounding area as describe above.
Avoid any contact with fingers or scratching tools on the surface of the new
protective glass.
Be careful not to damage the seal around the protective glass as this
prevents dust, dirt and moisture from entering inside the end effector.
When installing the protective glass, check for proper sealing and fit
into the aperture lens housing.
Refer to the end effector user manual for more information.
Contact the manufacturer for help with any maintenance questions


Transport, Storage, Start up and Setting-up Operation CL 1000
7 Transport, Storage, Start up and Setting-up Operation
7.1 Transport and Storage
While transport and/or storage please take care of the following items:
The ambient temperature must be between 5°C and 40°C.

If you can‟t guarantee this (e. g. while transport) take care that the
cooling water is drained from the system (for details see Chapter
Maintenance) Do not use any add ons while transport!
The humidity should be < 90% and non condensing.
If you discover condensate then the system mustn’t be switch on!
The system must stand on plane and solid ground
The System may be craned or lifted in horizontal position only. Fork
lifter has to be set between Rollers. Shock impact has to be avoided!
Keep away dust and dirt from the system
Before the system will be started again check the pressure of absorbers
and if necessary set the right pressure. Check also the cooling water level
and if necessary refill cooling water. Follow instructions of Chapter 7.3
Setting-up Operation
Transports by airplane or in Winter time are a risk to damage the cooling

system (see ambient temperature). Before transporting the system drain
the water out of the cooling system (for details see Chapter Maintenance.)
7.2 Start up
The initial start up of a Clean laser ablation system has to accomplish by an

employee of Clean-Lasersysteme GmbH or a well qualified, laser trained
assistant that is authorized by Clean-Lasersysteme GmbH.
Start up after a longer term of storage has to be accomplish by a well

qualified, laser trained assistant that is familiar with the laser system.
For further details see Chapter 7.3 Setting-up Operation
7.3 Setting-up Operation
7.3.1 General
While assembling or operating a Clean laser system the following items

have to be followed:
7.1 Version: 03/2009

The ambient temperature must be within the appliance limitations

The laser system must stand on a plane, solid ground
The wheels of the appliance must be locked
The cooling system can exchange its warmed air by ventilation. The
fins of the air inlet and air outlet must not be covered (minimum
distance to any objects > 2m).
In closed rooms a sufficient ventilation must be ensured
All control elements, particularly emergency stops, must be accessible
with out handicap
The operation area must be labeled with safety signs which are
durable, readable and clearly in sight
Check if in main and help cooling circuits contain enough water
All supply lines (inlet or outlet) must be laid and labeled correctly
Please check all this items. If there is any deviation please correct it.
7.3.2 Connecting the laser system
The laser system is completely self-sufficient. For operating the system

only mains supply is necessary. If the system is provided with a water to
water cooling system you also have to provide access to external cooling
water (for specifications please see Chapter 7.3.2.1). Air to water cooling
systems usually exhaust the heat to the surrounding area. In this case an
external water supply is not necessary.
The laser system needs the following electrical supply assumptions:
CEE 3x400 V (+/- 10V), AC / 16A

N, PE;
50Hz or 60 Hz
For non European use the system is supplied with a special transformer
that is agreed in the contract. Connecting wires are also provided.
Version: 03/2009 7.2

Picture 7.1: Mains plug for power supply European version (picture similar left Workstation, right mobile
system)
Before connecting the system to the mains make sure that
The ground wire (PE) is connected in proper form

All connectors and plugs of the laser system and the mains are working
in a faultless condition and not defect
The mains supply‟s‟ clockwise 3-phase system is properly connected.
All potentials have to fit
Take care that the neutral wire is connected
The public power supply can ensure that the necessary electrical power
for the system is available
Never disconnect the working laser system by unplugging the mains

power connector but for emergency reasons! The abrupt switch-off of
the cooling system may cause major overheating damages to the
resonator and the whole system!
7.3.2.1 Water to water cooling system (optional)

Regarding the quality of the external cooling water the following
specifications should be observed:
Max. ambient temperature 38°C

Max. external water temperature * 10°C up to 17°C
Max. pressure inlet 4,5 bar
Difference pressure at cooling water inlet 2,0 – 3,0 bar
and outlet
Others Non corrosive, PH neutral
drinking water quality,
7.3 Version: 03/2009

Particles <100µm, applicable

for copper alloys
* special options for up to 28°C water temperature available
Version: 03/2009 7.4

Manual - CL1000 (3) 1 PDF

Uploaded by

Copyright:

Available Formats

Manual - CL1000 (3) 1 PDF

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Manual - CL1000 (3) 1 PDF

Uploaded by

Copyright:

Available Formats

User Manual

Laser Ablation System

2___ GENERAL OPERATING INSTRUCTIONS 2.1

3___ SPECIAL SAFETY INFORMATION 3.1

4___ DESIGN & FUNCTION 4.1

5___ START-UP & OPERATION 5.1

6 ___ MAINTENANCE & SERVICE 6.1

7 ___ TRANSPORT, STORAGE, START UP AND SETTING-UP OPERATION 7.1

1 General Operating Instructions

1.1 How to Operate Laser Systems

Laser systems are tools to provide a precise treatment of surfaces. Our

Follow the hints and recommendations listed below to ensure a

1.1.1 Angle of Incidence Laser to Work Piece

Picture 1.1: Angle of incidence equals emergent angle

Version: 07/2009 1.1

Focal Distance f [mm] Minimum Angle to Perpendicular

< = 80 > 10°

< = 100 > 8°

< = 120 > 7°

< = 150 > 5°

< = 250 > 3°

> 250 > 2°

Table 1.1: Minimum angle to perpendicular valid for reflecting parts

+49/2407/9097-0 (Telephone) or +49/2407/9097-111 (FAX)

Mon.-Fri. 8.00 to 17.00 o‟clock (CET)

1.1.2 Angle of Incidence Laser with 2D Optic (Stamp Series)

Picture 1.3: Treatment areas placed correctly

Version: 07/2009 1.3

Picture 1.4: Treatment areas placed incorrectly – Risk of back reflection

A reliable appointment of the critical field, which has to be avoided,

+49/2407/9097-0 (Telephone) or +49/2407/9097-111 (FAX)

Mon.-Fri. 8.00 to 17.00 o‟clock (CET)

1.1.3 Mechanical Forces on Cable Package and Bending Radius of

Always make sure that:

Always keep a minimum bending radius.

Never expose the fiber and / or cable package to any kind of

System Minimum Bending Radius

CL 150, CL 300; CL 500 250 mm

Table 1.2: Minimum bending radius for optical fibers

The user is responsible for keeping the correct bending radii.

Even if the cable package is protected mechanical forces to the package

Forces of tension and pressure have also to be avoided. The maximum

Version: 07/2009 1.5

Picture 1.5: Examples for cable package with OSA 70

If the optic of an application is robot-guided cable package components of

+49/2407/9097-0 (Telephone) and +49/2407/9097-111 (FAX)

Mon.-Fri. 8.00 to 17.00 o‟clock (CET)

1.1.4 Protection Glass

The protection glass is an optical element which is in direct contact to the

For automated applications with OSA 70 or OSH80 a sensor-based

+49/2407/9097-0 (Telephone) and +49/2407/9097-111 (FAX)

Mon.-Fri. 8.00 to 17.00 o‟clock (CET)

1.1.5 Suction System

To achieve best suction effect most of your machining optics have an

For automated processes we recommend suction monitoring by means of

1.1.6 Inflammable Materials

Laser processes are thermal processes. It is forbidden to use the laser in

It is not allowed to store easily inflammable materials close to the laser

Version: 07/2009 1.7