FIELD SERVICE BULLETIN

Bulletin No. SVC-FSB-0009

Release Date 2/9/2016

Contact [email protected]

Product
Laser Modules

Category
INFORMATION: This service bulletin is for informational purposes only. It is intended for use by
Northrop Grumman Cutting Edge Optronics (NG CEO) employees and is distributed to non-NG
CEO employees as a courtesy. NG CEO assumes no liability for any inaccuracy in the content of
this document or for any damage caused by the information or advice provided. Please contact a
NG CEO factory support representative for further assistance.

Laser Module Coolant Recommendations

Laser diodes are usually the most expensive component in a solid-state laser system. The most
frequent cause for failure in NG CEO laser modules is customer damage. The most frequently
observed types of customer damage are (in order):
 Operating a laser module without coolant
 Using contaminated coolant
 Condensation on the diode (Operated chiller at less than dew point temperature)
To prevent damage to the laser diodes, NG CEO requires that the following guidelines be
followed when designing the cooling water system for a laser module.

General Chiller Information

1. NG CEO equipment requires a chiller which can provide at least 60 psi (4.14 bar) water
pressure. If your chiller can achieve the required minimum flow rate through the laser
module with a lower water pressure (typically 30-50 psi [2.07-3.45 bar]), it is acceptable.
The flow rate must be at or above the minimum flow rate listed in the table below.
Laser Module type Minimum Flow Rate
(gallons per minute, liters per minute)
All RB, RBA, RBAT 1.0 gpm or 3.8 lpm

RD 1.5 gpm or 5.7 lpm

REA 2.0 gpm or 7.6 lpm

RGA 2.5 gpm or 9.5 lpm

2. Chillers used with NG CEO laser modules must have a heat capacity greater than the total
power consumption of the unit(s) being cooled. Power consumed by the laser module is the
power input into the laser module minus the optical power extracted from the module.

© 2016 Cutting Edge Optronics, Inc. 1 SVC-FSB-0009B Coolant Recommendations

 FIELD SERVICE BULLETIN
Bulletin No. SVC-FSB-0009

Release Date 2/9/2016

Contact [email protected]

3. All NG CEO laser modules should be used with a flow interlock installed on the water output
side of the module. If the chiller water is not flowing, or if the water drops below the
minimum flow rate, the interlock should interrupt power to the diodes.
4. NG CEO laser modules should always begin life with the chiller set at the temperature
recommended on the final test report (usually 20-30 C). As the laser module ages, it will be
necessary to run the chiller at a cooler temperature to compensate for reduced efficiency and
wavelength shift. Also, as the diodes degrade, more drive current may be required to
produce the required output power.
5. NG CEO does not endorse one chiller manufacturer over another. However, when NG CEO
provides a module complete with chiller, we generally offer a Polyscience model with the
laser. The following table lists the Polyscience chillers offered with NG CEO module types.
The chiller is selected based on the expected end of life heat load for the laser module, with a
slight allowance for heat load of a Q-switch capable of handling the module’s laser output.

EOL 60 HZ Electrical Outlet 50 HZ Electrical Outlet

NG CEO Module1
Load (W) Capacity Model # Capacity Model #
RBATX0-1C2 5762 850 6262T31CE10B 700 6252T41CE30E

RBATX4-1C2 7682 1400 6362T31CE20C 1280 6352T41CE30E

RBATX5-1C2 9602 1400 6362T31CE20C 1280 6352T41CE30E

REAXX06-1C2 19202 2300 6762T41CE30D 2200 6752T41CE30E

REAXX06-1C4 33003 5200 6862T66CE70D 4371 6852T66CE70E

REAXX08-1C2 25602 2900 6162T41CE30D 4316 6852T66CE70E

REAXX08-1C4 44003 5200 6862T66CE70D 4316 6852T66CE70E

REAXX10-1C4 52253 5200 6862T66CE70D Contact NG CEO

REAXX12-1C4 66003 Contact NG CEO Contact NG CEO

1
The X in the model number refers to digits which specify the rod diameter in mm, and does not affect the heat load.
2
End of Life heat load (EOL) at 32A.
3
End Of Life heat load (EOL) at 50A

Please contact NG CEO for PowerPulse™ QCW pumped laser module chiller requirements

© 2016 Cutting Edge Optronics, Inc. 2 SVC-FSB-0009B Coolant Recommendations

 FIELD SERVICE BULLETIN
Bulletin No. SVC-FSB-0009

Release Date 2/9/2016

Contact [email protected]

Filtration

NOTE: The chiller must run continuously to prevent biological growth or corrosion. If
the chiller is to be shut down for more than 1 week, the coolant loop should be
drained, flushed with 3% hydrogen peroxide solution and purged with oil-free, dry
filtered air or (N2).

1. Chillers used with NG CEO laser modules should always have a water filter installed on the
input line to the laser module. The filter should be capable of removing particles 5 µm or
larger. The filter should be changed at a minimum of every one month. If the filter becomes
noticeably dirty (most have an inspection port for viewing) it should be changed
immediately.
2. Every time the filter is changed, the coolant should be completely drained and replaced. NG
CEO recommends cleaning the chiller with 3% Hydrogen Peroxide.
3. Select a filter that is appropriate for its intended use. Improper filters can become a source of
contamination causing reduced flow through the diode array heat exchangers and potential
damage to the diode arrays.

Possible Coolants
NG CEO recommends that an algaecide and a corrosion inhibitor be used with NG CEO laser
modules.

Distilled Water with Optishield Plus

NG CEO recommends a mix of one part Optishield Plus for every 9 parts water. Optishield Plus
is a combined algaecide and anti-corrosive which will help protect the laser module. Optishield
Plus can be ordered from Opti-Temp at www.optitemp.com

Ethylene Glycol and Optishield Plus in Distilled Water

NG CEO recommends a solution of 30% lab grade (99% pure) ethylene glycol, 10% Optishield
Plus, and 60% distilled water by volume. See SVC-FSB-0005 for more information.

The ethylene glycol mixture does not have heat transfer capability as good as the distilled water
and Optishield mixture. The chiller will need to be operated at a lower temperature to properly
cool the diodes. Verify that the temperature is not in the range that will cause condensation
inside the laser. The customer will also need to dispose of the used ethylene glycol in accordance
with applicable environmental laws and regulations.

De-Ionized Water (Not Recommended)

© 2016 Cutting Edge Optronics, Inc. 3 SVC-FSB-0009B Coolant Recommendations

 FIELD SERVICE BULLETIN
Bulletin No. SVC-FSB-0009

Release Date 2/9/2016

Contact [email protected]

NG CEO laser diodes have exposed bare copper inside the coolant loop. For this reason, NG
CEO does not recommend using DI water. It attacks the copper in the diode heat exchangers. If
DI water is used as the coolant, it is very important to maintain the water resistivity between 300
- 700 K ohm-cm, and to keep the water slightly basic (i.e. keep the water between 7.0 – 8.0 pH).

Cleaning the Cooling Fluid System

NG CEO recommends using 3% Hydrogen Peroxide to clean the cooling fluid system. The
cleaning process steps are drain the expired cooling fluid, replace the filter, refill with distilled
water and circulate for 5 minutes, drain and refill with 3% Hydrogen Peroxide and circulate for
40 minutes, drain and refill with distilled water and circulate for 5 minutes, replace the filter,
drain and refill with cooling fluid, run for 30 minutes with the reservoir cap loose, top off and
tighten the reservoir cap. See SVC-FSB-0001 for more information.

Maintenance Frequency
The cooling system should be drained, cleaned and refilled at an interval of every 1 month. Also
replace the cooling fluid 5 micron filter. Dispose of old chiller coolant in accordance with
applicable environmental laws and regulations. It is crucial that the cooling fluid filter be
inspected at least once a week for any signs of contamination such as color change or residue.
The laser also needs to be monitored for signs of contamination such as power loss or increased
current to reach the rollover point during optimization.

Calculating Air Condensation Temperature

The air condensation temperature (or dew point) is the highest surface temperature that allows
water to form from the ambient water vapor. The dew point is dependent on the surrounding air
temperature and relative humidity. If a surface (such as a laser diode) is cooled at or below the
condensation temperature, water may collect on that surface. Water on the diode arrays causes
catastrophic damage to the arrays, requiring them to be replaced. Condensed water on the laser
module end plates can cause damage to the rod ends and surrounding equipment.

A formula for calculating dew point is given below, along with a calculated table. All
temperatures are given in Celsius.

Condensation Temperature

237.7   (T , RH ) 17.27  T  RH 
Td   (T , RH )   ln  
17.27   (T , RH ) where 237.7  T  100 

T is the ambient air temperature in degrees Celsius (0 < T < 60)

RH is the relative humidity in percent (1% < RH < 100%)

© 2016 Cutting Edge Optronics, Inc. 4 SVC-FSB-0009B Coolant Recommendations

 FIELD SERVICE BULLETIN
Bulletin No. SVC-FSB-0009

Release Date 2/9/2016

Contact [email protected]

Td is the air condensation temperature

Table of Air Condensation Temperature at Given Ambient Air Temperature (Celsius) and Relative Humidity (percent)

Relative Humidity

1% 10% 20% 30% 40% 50% 60% 70% 80% 90% 100%

10 -43.9 -20.2 -11.9 -6.8 -3.0 0.1 2.6 4.8 6.7 8.4 10.0

12 -42.6 -18.7 -10.3 -5.0 -1.2 1.9 4.5 6.7 8.7 10.4 12.0

14 -41.4 -17.1 -8.6 -3.3 0.6 3.7 6.4 8.6 10.6 12.4 14.0

16 -40.2 -15.6 -7.0 -1.6 2.4 5.6 8.2 10.5 12.5 14.4 16.0

18 -39.0 -14.1 -5.3 0.2 4.2 7.4 10.1 12.4 14.5 16.3 18.0

20 -37.8 -12.5 -3.6 1.9 6.0 9.3 12.0 14.4 16.4 18.3 20.0
Air Temperature oC

22 -36.6 -11.0 -2.0 3.6 7.8 11.1 13.9 16.3 18.4 20.3 22.0

24 -35.4 -9.5 -0.4 5.3 9.6 12.9 15.7 18.2 20.3 22.3 24.0

26 -34.2 -8.0 1.3 7.1 11.3 14.8 17.6 20.1 22.3 24.2 26.0

28 -33.0 -6.5 2.9 8.8 13.1 16.6 19.5 22.0 24.2 26.2 28.0

30 -31.8 -4.9 4.6 10.5 14.9 18.4 21.4 23.9 26.2 28.2 30.0

32 -30.6 -3.4 6.2 12.2 16.7 20.3 23.2 25.8 28.1 30.1 32.0

34 -29.5 -1.9 7.8 13.9 18.5 22.1 25.1 27.7 30.0 32.1 34.0

36 -28.3 -0.4 9.5 15.7 20.2 23.9 27.0 29.6 32.0 34.1 36.0

38 -27.1 1.1 11.1 17.4 22.0 25.7 28.9 31.6 33.9 36.1 38.0

40 -26.0 2.6 12.7 19.1 23.8 27.6 30.7 33.5 35.9 38.0 40.0

For example, suppose your chiller is running at 22 °C and the ambient air temperature near the
laser is 28 °C (82 °F). Referring to calculated table above and the graph on the following page,
find the intersection of the 28 °C air temperature and the curve for the 22 °C diode temperature.
At a relative humidity of 70 percent or greater, condensation will form on the laser diodes.

Operating the chiller at a temperature equal to or lower than the dew point temperature (Td), will
cause condensation to form on the diode arrays.

© 2016 Cutting Edge Optronics, Inc. 5 SVC-FSB-0009B Coolant Recommendations

 FIELD SERVICE BULLETIN
Bulletin No. SVC-FSB-0009

Release Date 2/9/2016

Contact [email protected]

If required to operate a laser module in conditions near to the condensation temperature, take
precautions to keep the laser module dry. The laser module should be operated inside an area that
is purged with nitrogen (N2) or encased in a sealed enclosure with a desiccant.

© 2016 Cutting Edge Optronics, Inc. 6 SVC-FSB-0009B Coolant Recommendations