How to Change the LD Module in an LMV1000 with ProLase XP As the LD Module in an LMV1000 starts to age, there will come a time when the available output power will not be sufficient enough to mark your materials. Once this point is reached, the LD Module will need to be replaced. Miyachi Unitek offers two different LD Modules, a new unit (L-05269-003) and a refurbished unit (L-05269-004). The refurbishment process works by factory refurbishing your particular LD module. The downside to refurbishing your LD module is that your Marker will be down for approximately 4 weeks. If your process cannot accommodate a 4 week down-time, then a new LD Module should be purchased. The response of each LD Module differs from unit to unit and must be calibrated to your particular LMV1000 Laser Marker. Two parameters must be set before using the new LD module, the wavelength and the LD Current Response. The output wavelength of the LD module has a direct correlation to the transfer efficiency of the Laser Marker and its cooling temperature. In order to achieve maximum performance, the cooling temperature must be set according to the output wavelength response of the LD Module. The LD Module fundamentally works by applying a DC current through each of the Laser Diode Arrays within the LD module. The usable output power is proportional to the applied current. If the maximum designed output power of the LD Module is exceeded, the usable lifetime of the LD module will be significantly reduced. This procedure outlines how to change and calibrate the LD module for your particular LMV1000 Marker System using ProLase XP software. Required Items: • • • • LD Module (new or refurbished) Graphite Sheet, optional (P/N 090-047) POD Interface Unit Phillips Screwdriver (cover screws) • • • • 4mm Hex Driver (handle screws) 3mm Hex Driver (LD Module) 8mm open-ended wrench Optical Fiber Dust Caps (P/N 247-012) Basic Steps: Before starting work, please read this entire procedure first. You must have a complete understanding of what is required before starting work. If you do not want to perform this procedure, the Laser Marker may be sent back to Miyachi Unitek for refurbishment. Contact Miyachi Unitek for more details. The LD Module replacement can be summarized as outlined in the steps below. For further details on each step, refer to the remainder of this document. 1. 2. 3. 4. Replace the LD Module (steps 1 – 22). Set the wavelength response (steps 24 – 27). Determine and set the LD Current response (steps 28 – 39). Set the maximum LD current value for 10W output (steps 40 – 49). Rev. 08-05-11 Page 1 of 9 Replace the LD Module: DANGER Before replacing the LD (Laser Diode) Module, turn off the power to the equipment (Marker and PC) and wait for at least five minutes before starting work. If you start the work with the power turned on, electric shock, fire, or personal injury (burns, blindness, etc.) may occur. 1. Remove the four 4mm hex screws securing the transport handles on the top of the Control Unit. 2. Remove the six 3mm Phillips Head screws on both sides of the Control Unit. 3. Slide the top cover backwards approximately ½”, then lift the cover upward to remove. 4. Remove the LD module insulating cover, by lifting it vertically. 5. Insert the short circuit jumper between the RED and BLACK terminals as shown on the right. 6. On the right side of the Control Unit, unplug the connector labeled CN5 on the thermal switch harness. 7. Remove the LD Power Supply, Peltier Power Supply and Interlock Connectors. Rev. 08-05-11 Page 2 of 9 8. Hold the LD - I/O connector and pull it out horizontally. 9. Loosen the four Phillips-head screws on the optical fiber fixture on the rear of the Control Unit to allow the optical fiber to be removed. 10. Turn the fastening nut of the optical fiber CCW (counter-clockwise) with an 8mm wrench. Slowly pull out the optical fiber. Immediately place a dustproof cap (247-012) on the fiber to prevent dust from collecting on the fiber end face. 11. Remove the four, 3mm hex screws that fasten the LD Module to the Control Unit. Remove the old LD Module. Leave the 090-047 graphite sheet (placed between the heat sink and the LD module) inside the Control Unit. If the graphite sheet is cracked or creased, replace it. The graphite sheet is used to transfer heat from the LD module to the Peltier Cooling device and must be free of voids. 12. Install the new LD Module into the Control Unit on to the graphite sheet. Fasten the LD module with the four hex screws removed in the previous step. Record the wavelength value hand-written on the top of the new LD Module. Wavelength ______________ (nm) 13. Remove the dust cap from the new LD module and place it on the old LD module. 14. Remove the protective cap from the optical fiber and slowly insert it horizontally into the new LD module. 15. Secure the optical fiber onto the LD module by turning the fastening nut CW (clockwise). Tighten snugly, but do not overtighten. Rev. 08-05-11 Page 3 of 9 16. Insert the LD – I/O connector so that the RED marks align. 17. Connect the LD Power Supply, Peltier Power Supply, thermal switch and relay connectors. 18. Move the short-circuit jumper on the new LD module to both RED terminals as shown on the right. 19. Replace the LD insulating cover. 20. Install the top cover back onto the Control Unit. And slide the top cover forward to secure it. 21. Replace the screws and handles removed in steps 1 & 2 to secure the cover. 22. Remove the POD loop-back connector from the back of the LMV1000 control unit (as required) and replace this loop-back connector with the POD. 23. Verify that all Marker, ProLase I/F Box and PC connections are securely fastened and then turn on the PC. Allow the ProLase XP program to start before continuing with the next step. 24. Turn on the Power to the LMV1000 Marker. If an Option Error occurs on the POD, ignore it by selecting the lower left corner of the screen with your finger. The error is successfully ignored when the Operate Screen appears. 25. From the Operate Screen, select MNTAIN to access the Maintenance Screen. Rev. 08-05-11 Page 4 of 9 Set the Wavelength Response: 26. From the Maintenance Screen, press and hold the Reset button (for several seconds) until the LD wave length setup Screen appears. 27. Update each of the fields in the LD wave length setup screen by selecting the appropriate field and entering the numerical value using the POD keypad. Enter the data according to the table below. Once all data is entered, select OK. Verify the LD Intergral hours in the Maintenance screen is reset back to zero (note: key switch must be in the off position in order to reset the hours). LD wave length Wavelength value recorded in step 12. Calibration: Enter the Calibration values that are written on the green datasheet that is sent with the LD module. LD current limit: Enter the LD current required to get 10W of output power. This LD current value is written on the green datasheet that is sent with the LD module. Prepare for LD Current Response: 28. From the Maintenance Screen, select the Password button to access the Maintenance (Management) Screen. 29. From the Maintenance (Management) Screen, touch the upper left corner + F2 function key simultaneously to access the Maintenance (Monitor) screen. 30. Note the location of the LD current field. The measurements indicated in this area will be used throughout the rest of this procedure. Rev. 08-05-11 Page 5 of 9 LD Current Response (determine the DAC voltage / LD current relationship) DANGER From this point on, Laser protective goggles with an optical density of at least 7+ (at 1064nm) must be worn for the remainder of this procedure. All unauthorized personnel should be removed from the area before continuing. If replacing an LD module in a LMV1000G(E) Green Laser marker, additional protection at a wavelength of 532 nanometers is also required. 31. Place a piece of anodized aluminum (or similar) under the f-theta output lens. 32. In ProLase XP, open the Calibration, I/O Control, Laser Control configuration tab from the pull-down Menu: Marking > Config > Calibrate 33. Select the Power button in the Calibration Tables field. When the ProLase warning window appears, choose OK. 34. Record the currently entered DAC Voltage and Laser Power table values for reference. 35. Set both the DAC Voltage values and Laser Power values exactly as defined in the table below: DAC Voltage Laser Power 0.500 4.8 1.000 9.6 1.500 14.4 2.000 19.2 2.500 24 3.000 28.8 3.500 33.6 4.000 38.4 4.500 43.2 5.000 48 (ref point # 1) (ref point # 2) To simplify this procedure, two discrete reference points will be used to calculate the LD Current response, 9.6A (1.000 v) and 28.8A (3.000 v). Rev. 08-05-11 Page 6 of 9 36. Create a simple line (or similar figure) in ProLase XP. Set the Laser Output Power for this figure to 28.8A. Mark the image and note the LD current reading on the POD. Repeat the same marking process with the Laser Output Power set to 9.6A. Mark the image and note the LD current reading on the POD. Record the results in the table below: DAC Voltage Theoretical LD Current 3.000V 28.8A 1.000V 9.6A Actual LD Current (POD) 37. Determine the slope (m) of the LD response equation from the formula below: Note: This equation only works at the two discrete points defined above. 38. Calculate the LD Current for each DAC voltage setting from the formula below and enter each calculated value in the table below: DAC voltage m (slope) Theoretical LD Current 0.500V 4.8A 1.000V 9.6A 1.500V 14.4A 2.000V 19.2A 2.500V 3.000V Value from step 37 LD Current (calculated) enter from step 36 above 24A 28.8A 3.500V 33.6A 4.000V 38.4A 4.500V 43.2A 5.000V 48A enter from step 36 above 39. Copy the values from the table above into the ProLase XP Laser Power table (as shown in step 35) for each DAC voltage setting. Rev. 08-05-11 Page 7 of 9 LD Current Response (limit the output current) WARNING Failure to limit the LD current to 10W of maximum output power will significantly reduce the lifetime of LD module. 40. Refer to the green datasheet that was sent with the LD module and determine the LD current necessary to get 10W of output power. LD Current (@ 10W output) = _________________ 41. Calculate the discrete DAC voltage required to achieve the maximum LD current (@10W) from the equation below: 42. Determine where the LD current limit (@10W) falls within the Laser Power table. Select the ; Edit DAC Voltages value field then select the DAC voltage value you want to change. 43. Once the DAC voltage value button is selected, the Calibration Value Edit Dialog window will appear. Enter the calculated DAC voltage value in the appropriate field, followed by OK. 44. To limit the LD current from exceeding the maximum value (of 10W), enter very high power (current) values (10,000 and higher) for the remaining DAC voltage values above the current limit. In the example shown on the right, a DAC voltage of 3.3V (32A) will result in 10W of output power. Typical POUT vs. DAC Voltage response: Rev. 08-05-11 Page 8 of 9 45. In order to prevent entering the same information each time ProLase XP starts, save the configuration values as the default values. Marking > Config > Save As Navigate to the ProLase XP Root Directory, and save as default.cfg. If prompted to over-write the existing file, choose Yes or OK. 46. Once the Laser Power table is complete, turn the keyswitch OFF. 47. Once the Ready LED stops blinking, you can turn the Main power switch to the OFF position. 48. Close ProLase XP, then shutdown the computer. 49. Remove the POD and replace it with the POD loop-back connector. If you need a POD to complete this procedure, contact Miyachi Unitek. A POD will be sent to you on a consignment PO (purchase order). Once the POD is returned, you will be given full credit for the POD purchase price. If the POD is damaged, you will be charged a fee in order to bring the POD back to working order. Contact Miyachi Unitek for an RMA number before returning the POD unit. Carefully package the POD and send it back to: Miyachi Unitek Corporation Attn: Laser Field Service 1820 South Myrtle Ave. Monrovia, CA 91016 RMA # _________________ Parts List (for reference): Part Description LD Module (new) LD Module (refurbished) Optical Fiber Dust Cap Graphite Sheet POD Touchscreen Unit 3mm Hex Driver 4mm Hex Driver MUC P/N L-05269-003 L-05269-004 247-012 090-047 270-302 770-036 770-037 End of Procedure Rev. 08-05-11 Page 9 of 9