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GSi JK125P, User Manual

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GSI Group - Laser Division 

JK300HP/JK300P/JK125P 

Issue 2.0 

Pre-installation and User Manual 

Part No: 1EA300E01 

Page 

1 of 172 

Introduction to GSI Group - Laser Division 

GSI Group - Laser Division is a worldwide technology company specialising in the 
development, production and support of lasers and laser-based systems.  The Company 
organisation includes manufacturing operations located in North America and Europe along 
with a network of support centres. 

GSI Group - Laser Division offers a complete range of lasers that cover applications in 
sectors including electronics, aerospace, automotive, advanced manufacturing, packaging 
and advanced research.   

GSI Group - Laser Division collaborates with customers to develop laser systems that 
increase productivity, solve manufacturing problems and meet the requirements of leading-
edge research. 

Petitioners Canadian Solar Inc. and Canadian Solar (USA) Inc. 

Ex. 1025, p. 1

Summary of Contents for JK125P

Page 1: ...installation and User Manual GSI Group Laser Division Cosford Lane Swift Valley Rugby Warwickshire CV21 1QN England Telephone 44 0 1788 570321 Fax 44 0 1788 579824 www gsig com Petitioners Canadian So...

Page 2: ...Group Laser Division JK300HP JK300P JK125P Pre installation and User Manual Issue 2 0 Page ii Part No 1EA300E01 Intentionally blank Petitioners Canadian Solar Inc and Canadian Solar USA Inc Ex 1025 p...

Page 3: ...ipment is inspected and the claim is settled 3 If the shipment has been made FCA Rugby Packed and shortages have occurred undertake the following actions 4 If the shipment delivered to you is not in a...

Page 4: ...Group Laser Division JK300HP JK300P JK125P Pre installation and User Manual Issue 2 0 Page iv Part No 1EA300E01 Intentionally blank Petitioners Canadian Solar Inc and Canadian Solar USA Inc Ex 1025 p...

Page 5: ...he above actions SAFETY WARNING It is of the utmost importance that the Safety Section of this manual is read and fully understood before any attempt is made to operate the equipment or undertake any...

Page 6: ...Group Laser Division JK300HP JK300P JK125P Pre installation and User Manual Issue 2 0 Page vi Part No 1EA300E01 Intentionally blank Petitioners Canadian Solar Inc and Canadian Solar USA Inc Ex 1025 p...

Page 7: ...rameters 17 1 11 1 Changing Parameters 17 1 11 2 Parameter Set Selection 19 1 12 Laser Outputs 19 1 13 Operating Guidelines 19 1 14 Processing Considerations 19 1 15 Fibre Optic Handling 20 1 15 1 Des...

Page 8: ...3 5 Electromagnetic Compatibility 44 3 6 Transportation 44 3 7 Electrical Connections 45 3 7 1 Connection Panel 45 3 7 2 PL601 Customer Interlocks 45 3 7 3 PL602 Workstation Interlocks 45 3 7 4 SK603...

Page 9: ...creen 66 6 8 1 Function 66 6 8 2 Entry Exit 67 6 8 3 Status Bar 67 6 9 SETUP screen 67 6 9 1 Function 67 6 9 2 Entry Exit 67 6 9 3 Status Bar 68 6 10 MODIFY SHAPE screens 68 6 10 1 Function 68 6 10 2...

Page 10: ...4 12 Alarm 2n12 Interlock Chain Input 12 Fault 79 7 4 13 Alarm 2n13 Interlock Chain Input 13 Fault 79 7 4 14 Alarm 2n14 Interlock Chain Input 14 Fault 80 7 4 15 Alarm 2n15 Interlock Chain Input 15 Fa...

Page 11: ...Fault 92 7 6 17 Alarm 4n17 Power Supply Input Voltage Loss 92 7 6 18 Alarm 4n18 Power Supply Contactor Out Fault 92 7 6 19 Alarm 4n19 Power Supply Shutdown During Operation 92 7 6 20 Alarm 4n20 Power...

Page 12: ...nitial Set up 101 8 3 Rear Mirror Tuning 102 8 4 Focus Head Setup 104 8 5 External Power Control EPC Set up 105 8 5 1 Set Up Procedure 105 9 User Maintenance 107 9 1 Introduction 107 9 2 User Maintena...

Page 13: ...ith Pulsed Lasers 159 10 2 1 Pulse energy 160 10 2 2 Peak Power 160 10 2 3 Pulse frequency and overlap 160 10 3 Welding in Continuous Wave Mode 161 10 4 Welding in Modulation Mode 161 10 5 Jigs and Fi...

Page 14: ...Group Laser Division JK300HP JK300P JK125P Pre installation and User Manual Issue 2 0 Page xiv Part No 1EA300E01 Intentionally blank Petitioners Canadian Solar Inc and Canadian Solar USA Inc Ex 1025 p...

Page 15: ...anufacturing operations located in North America and Europe along with a network of support centres GSI Group Laser Division offers a complete range of lasers that cover applications in sectors includ...

Page 16: ...oup Laser Division JK300HP JK300P JK125P Pre installation and User Manual Issue 2 0 Page 2 of 172 Part No 1EA300E01 Intentionally blank Petitioners Canadian Solar Inc and Canadian Solar USA Inc Ex 102...

Page 17: ...supplied with a Pre installation and User Manual The Manual provides information on Pre installation requirements Installation Procedures De Commissioning Procedures and user information The Pre inst...

Page 18: ...th Beam Quality Beam quality is defined using beam radius and half angle divergence and relates to 86 5 of enclosed power ISO 11146 Continuous Wave Laser operating and continuously emitting radiation...

Page 19: ...SD Least Significant Digit Machine Interface Facility that allows an external controlling device such as a PLC to control and monitor the Laser MSD Most Significant Digit Nd YAG Nd Neodymium Doping to...

Page 20: ...definition The Formula for calculating spot size is as follows Focussed Spot Diameter Fibre diameter x Focal length of Focus Lens Focal length of Recollimating Lens This assumes aberration free lenses...

Page 21: ...sig com lasers Or contact Customer Support at the manufacturing site in Rugby UK Tel 44 0 1788 532612 Fax 44 0 1788 553564 Email support laserdivision gsig com When contacting an office for support pl...

Page 22: ...the laser cabinet and is accessed from the front of the cabinet The Heat Management System combines two forms of cooling Water cooling This comprises two circuits 1 An internal cooling circuit removes...

Page 23: ...ure or disconnection occurs in the cable the FCMS will place the system into shutdown and generate an alarm on the Local or Remote Controller 1 7 2 Control System and Local Controller The JK300HP JK30...

Page 24: ...RH at 40 C 104 F These figures indicate the maximum humidity at the upper and typical temperature limits Refer to Figure 1 for humidity figures within the temperature range Electrical Supply Requirem...

Page 25: ...ute Pressure 6 bar 88 psi Cooling water flow rate is automatically regulated internally according to water inlet temperature and duty of the equipment This maintains the internal cooling water at the...

Page 26: ...th 60mm diameter output housing 200 mm 200 mm 200 mm Focal Length of Re collimating Lens when used with 40mm diameter output housing 100 mm 100 mm 100 mm Fibre Optic Cable Fibre Diameter 300 m 150 m 3...

Page 27: ...Temperature Relative Humidity Graph 0 5 10 15 20 25 30 35 40 45 50 5 10 15 20 Water Temperature Deg C Flow l min 0 1 2 3 4 Pressure Drop Bars Flow Pressure Drop Figure 2 External Water Parameters RH 1...

Page 28: ...ervention is then required to re establish the power supply See Section 2 7 5 for more information Remote interlock connection is via a 15 way D type plug male PL601 Refer to Section 3 7 1 9 2 Shutter...

Page 29: ...the same time this is called energy sharing The beam delivery options are Up to a maximum 4 way timeshare 3 way energy share Combinations of 2 way timeshare and 2 way energy share Individual Shutters...

Page 30: ...ter Open Acknowledge 50ms See note below TSC Time from Customer Command to Shutter Closed Acknowledge 50ms See note below Note Shutter movements do not occur during a pulse When laser pulse widths app...

Page 31: ...s for each set of parameters Operating limits are set by enabling the power and energy trips The limits are used to help ensure consistent quality of the parts processed by the Laser by preventing pro...

Page 32: ...ntroller is accepted by the Laser only when the PARAMETER STROBE input is active Reading of data is acknowledged by the PARAMETER ACKNOWLEDGE output from the Laser which remains active until the PARAM...

Page 33: ...f the Laser is operating under this condition the Laser must remain ON and the process must be controlled using the Shutter The time taken for the Laser output to increase from the Ready level to the...

Page 34: ...signed for use in factory environments care must be taken during installation and use to ensure optimum performance and acceptable lifetime Fibres optic cables are more fragile than electrical cables...

Page 35: ...sed as a supporting member for a group of more flexible cables pipes Fibre termination must not be subjected to forces caused by dropping impacting or collision by heavy objects Where the fibre input...

Page 36: ...adhered to The fibre cable should be held off the floor and routed along a path so that the fibre cable does not bend more than the minimum bend radius at any point along the fibre cable length throu...

Page 37: ...ents retinal injury This includes direct viewing of the laser beam with optics that could concentrate the laser output into the eye These lasers do present a dazzle hazard and appear uncomfortably bri...

Page 38: ...to skin Output Power less than 1mW Class II Laser Products are those emitting visible light for which the natural aversion response to bright light including the blink reflex prevents retinal injury T...

Page 39: ...beam power can be redirected The level of risk depends on the direction of the reflected beam relative to the personnel A Class 4 IV Laser beam can be reflected from non reflective surfaces Exposure c...

Page 40: ...rred by Safety Authorities and is recommended by GSI Group Laser Division for use with the JK300HP JK300P JK125P Series Laser If a Class 1 I enclosure is not employed and the Laser operates under Clas...

Page 41: ...advice on the safe electrical practices associated with the JK300HP JK300P JK125P Series Laser is given below All personnel working with the JK300HP JK300P JK125P Series Laser must be fully aware of t...

Page 42: ...equipment maintenance also increase the risk of Laser initiated fires Do not attempt to process reactive metals such as titanium and magnesium using oxygen as an assist gas Such materials must be pro...

Page 43: ...The exhaust appliance must be positioned as near as possible to the point of origin to prevent processing fumes contaminating the air of the workroom Care is needed in the choice of evacuation equipme...

Page 44: ...be used in oxygen lines Adhere strictly to Manufacturers Safety Recommendations and Procedures 2 5 4 Solvents Solvents are used for the maintenance of equipment Solvents are hazardous to health if ade...

Page 45: ...ct These materials have been assessed for their toxicity and fire potential Approved materials have an approved process method and recommended arrangements for fume containment and removal 2 6 2 Appro...

Page 46: ...fety Officer or an authorised GSI Group Laser Division engineer WARNING EXPOSURE OF THE HUMAN BODY TO LASER RADIATION IS EXTREMELY DANGEROUS Practices that may result in accidental bodily exposure e g...

Page 47: ...tted to the equipment in compliance with IEC regulations Before operating on any part of the Laser system the hazard level must be checked by examining the following labels Safety and Compliance label...

Page 48: ...d for in US and other DE 69308078 7 08 PRODUCT COMP LIES WITH FDA RADIATION CERTIFICA TION EN60825 1 2001 WAVELENGTH S 1064 6 35nm PRODUCT COMPLIES WITH IEC 60825 1 2000 VISIBL E AND INVISIBL E LASER...

Page 49: ...er Division JK300HP JK300P JK125P Issue 2 0 Pre installation and User Manual Part No 1EA300E01 Page 35 of 172 Figure 6 Safety Label Locations Petitioners Canadian Solar Inc and Canadian Solar USA Inc...

Page 50: ...orldwide IEC 60825 1 Europe EN 60825 1 North America FDA Regulation 21 CFR Chapter J 1040 10 When the terminals of the RIC are open circuit exposure to Laser radiation is prevented This is caused by e...

Page 51: ...nk within the Shutter interlock plug or by connecting a safety interlock switch to the Shutter interlock plug WARNINGS NO ONE MUST ENTER AN AREA WHERE EXPOSURE TO HARMFUL LEVELS OF RADIATION IS POSSIB...

Page 52: ...to provide adequate protection against specific Laser radiation must be used in all hazard areas where Class 3B or Class 4 Lasers are in use The eye protection goggles is designed to protect the weare...

Page 53: ...the JK300HP JK300P JK125P Series Laser is located within a room that contains no non related equipment or personnel This will enable the access controls and hazard precautions to be rigidly enforced...

Page 54: ...1EA300E01 3 2 General Arrangement 3 2 1 Dimensions and Weight Overall dimensions and footprint of the JK300HP JK300P JK125P Series Laser are shown in Figure 7 Refer to Section 1 8 for weight specific...

Page 55: ...um quantity of heat that has to be removed from the laser is 10kW Refer to Table 1 3 3 2 1 External Cooling Water The water shall be clean and free from solid and dissolved contaminants The water must...

Page 56: ...eeze additives have inherent corrosive properties and are nutrients for a wide range of bacterial contamination If anti freeze additives are used then the User must understand that the adding of anti...

Page 57: ...ator valve closes The magnitude of these pressure transients is dependent on the design of the facility water system and the total volume and flow rate of the water contained within the facility water...

Page 58: ...ommended that a Class 1 I enclosure be built around the laser workstation Refer to Section 2 Safety for laser hazards and safe operating information Laser Cabinet Recommendation GSI Group Laser Divisi...

Page 59: ...an be powered up Emergency Stop Outputs These are volt free outputs from the laser These outputs are from auxiliary contacts on the emergency stop pushbuttons in the laser Table 2 PL 601 Customer Inte...

Page 60: ...S 17 I CH 3 EXT SWITCH 2 0 Vdc YES 18 I CH 4 EXT SWITCH 24 Vdc YES 19 I CH 4 EXT SWITCH 2 0 Vdc YES 20 I CH 5 EXT SWITCH 2 0 Vdc NO 21 I CH 6 EXT SWITCH 24 Vdc NO 22 I CH 6 EXT SWITCH 2 0 Vdc NO 23 N...

Page 61: ...ivision JK300HP JK300P JK125P Issue 2 0 Pre installation and User Manual Part No 1EA300E01 Page 47 of 172 Figure 8 Location of M C Interface Panel Petitioners Canadian Solar Inc and Canadian Solar USA...

Page 62: ...Ext Power Feedback 23 GND GNDEXT_INT 11 10 Vdc EPC Ext Power Control 24 0 Vdc EPC Ext Power Control 12 25 13 3 7 4 1 Configuration The Machine Interface laser inputs and laser outputs may be configur...

Page 63: ...ernal Controller input must push current through the laser output To all I Ps I P SK603 x 24V 0V LASER CONTROLLER To all O Ps O P 24 SK603 x 0V 50mA MAX Figure 10 Sourcing Diagram 3 7 4 4 Machine Inte...

Page 64: ...d True Request Shutter open 9 REQUEST SHUTTER 2 False Shutter closed True Request Shutter open 3 7 4 6 Multishot Function The laser can operate in multishot mode which will open the shutter for a desi...

Page 65: ...ed as when the Laser is completely OFF READY is defined as when the lamp drivers are active up to simmer level ON is defined as when the lamp drivers are active above simmer level REMOTE READY STATUS...

Page 66: ...erface is opto isolated The Machine Interface must be powered by a 24Vdc power supply capable of delivering 200mA Power is provided by connecting to the PLC laser inputs Nominal load for each input is...

Page 67: ...ability of each output is 50mA Table 8 SK 605 Full Machine Interface I O Card 2 PIN I O FUNCTION PIN I O FUNCTION 1 O Selected Pulse 1 20 O Selected Pulse 2 2 O Selected Pulse 3 21 O Selected Pulse 4...

Page 68: ...Laser On SK603 17 I Select Multishot SK603 18 I Request Shutter 1 SK603 19 O Remote Ready Status SK603 22 O Shutter Status 1 Need to link out for Remote P C Box PL10 if not supplied with laser Plug F...

Page 69: ...pply meets specified requirements 6 Specified pipework available to allow connection to external water supply 7 Suitable gas supply with specified pipework available to allow connection 8 Suitable ext...

Page 70: ...ns 1 Ensure all relevant connections are made a PL601 Customer Interlocks b PL602 Workstation Interlocks c SK603 Basic machine M C Interface d SK604 Full M C Interface I O card 1 e SK605 Full M C Inte...

Page 71: ...in good working condition and inspection of site service connection Site location of laser system Pre installation check of laser system Mains power connection or inspection if carried out by customer...

Page 72: ...afety precautions are observed whilst handling the Fibre Optic cables 4 5 Installation Procedures The GSI Group Laser Division Installation Engineer will undertake the following procedures during the...

Page 73: ...IS EQUIPMENT 1 Check that the Laser Mains Isolator is OFF 2 Ensure power to supply cables is isolated at fuse board and locked out 3 Using cabinet door key open door to power distribution module 4 Rem...

Page 74: ...ter wipe up spillage using paper towels 5 4 Drain Internal Cooling System Drain Internal Water CAUTION Ensure water is fully drained from internal cooling system Ensure no residual water is left in pi...

Page 75: ...n 1 15 2 Remove fibre output end from focus head 3 At laser rail loosen hex screw in receiver collar 4 Remove fibre input end from the receiver 5 Feed fibre cable out of the laser cabinet 6 Remove fib...

Page 76: ...up Laser Division JK300HP JK300P JK125P Pre installation and User Manual Issue 2 0 Page 62 of 172 Part No 1EA300E01 Intentionally Blank Petitioners Canadian Solar Inc and Canadian Solar USA Inc Ex 102...

Page 77: ...ect the Standby Button the amber EMISSION lamp will flash several times The system will commence the start up sequence and the Standby Button will grey out to indicate that the system is in Ready Mode...

Page 78: ...hey are active Return Returns to the previous screen up the menu tree Rotate Moves between screens at the same level in the menu tree If two are available then screens alternate 1 2 1 2 etc If three a...

Page 79: ...backwards In all cases when the editing key is released the resultant value is transmitted via network message The value actually displayed is the result of polling the destination of the transmitted...

Page 80: ...accesses the Operate screen 6 7 4 Setup Active Key accesses the Setup screen 6 7 5 Alarm Warnings Active Key accesses the Alarm Warnings screen 6 7 6 System Active Key accesses the System Setup scree...

Page 81: ...prompt Multishot Fixed text Starts a Multishot sequence When pressed a confirmation prompt appears Pressing Yes starts the Multishot sequence which runs until the sequence is terminated Multishot Val...

Page 82: ...MODIFY SHAPE screens 6 10 1 Function For defining 2 sector shapes All new values have immediate effect 6 10 2 Entry Exit Entry to first screen from Setup screen Down arrow moves between first and seco...

Page 83: ...c En Trip Hi Value Shows current value Enables numeric editing of value 0 12 34 J see note below En Trip Lo Value Shows current value Enables numeric editing of value 0 12 34 J see note below Note Thi...

Page 84: ...value Shows current value Enables numeric editing of value 0 999999999 Coolant Flow value Shows current value from S W Not editable Flow Alarm value Shows current value Enables numeric editing of valu...

Page 85: ...Alarm or Warning number only On the Alarm display the Rst key will attempt to reset the Alarm The Clr key exits the Alarm display restoring the previous screen The Double Up arrow key is not availabl...

Page 86: ...up Laser Division JK300HP JK300P JK125P Pre installation and User Manual Issue 2 0 Page 72 of 172 Part No 1EA300E01 Intentionally blank Petitioners Canadian Solar Inc and Canadian Solar USA Inc Ex 102...

Page 87: ...been cleared This may or may not require manual intervention 7 2 Alarms For Generic Control System Lasers that allow alarm values to be read return values standardised across all lasers The return va...

Page 88: ...Laser Control Card stopped communicating on the laser control network Possible causes 1 Laser control card not fitted 2 Loose laser control network connections 3 Re programming Laser Control Card 4 Fa...

Page 89: ...g The safety relay engaged while the laser was off Possible causes 1 Faulty connections on safety relay 2 Faulty safety relay 3 Faulty interlock module 7 3 10 Alarm 1n10 Safety Relay Not Detected Mean...

Page 90: ...er Control Card Neuron device Possible causes 1 Laser Control Card DSP not programmed 2 Loose Laser Control Network connections 3 Faulty Laser Control Card 7 3 14 Alarm 1n14 Unexpected power down Mean...

Page 91: ...rlock Chain Input 4 Fault Meaning There is no voltage supply to this interlock input Possible causes 1 Interlock supply not turned on 2 Loose connection 3 Faulty interlock module 7 4 5 Alarm 2n05 Inte...

Page 92: ...ection 3 Faulty interlock module 7 4 7 Alarm 2n07 Interlock Chain Input 7 Fault Meaning There is no voltage supply to this interlock input Possible causes 1 Interlock supply not turned on 2 Loose conn...

Page 93: ...supply to this interlock input Possible causes 1 Interlock supply not turned on 2 Loose connection 3 Faulty interlock module 7 4 12 Alarm 2n12 Interlock Chain Input 12 Fault Meaning For JK laser produ...

Page 94: ...slot 1 of the control rack There is no voltage supply to this interlock input Possible causes 1 Interlock supply not turned on 2 Loose connection 3 Faulty interlock module 7 4 15 Alarm 2n15 Interlock...

Page 95: ...Card not programmed 8 Faulty shutter connected to channel 1 of the dual shutter card fitted in slot 3 of the control rack 9 Faulty shutter card fitted in slot 3 of the control rack There is no voltage...

Page 96: ...2 4 Shutter fault on the shutter fitted to channel 2 of the dual shutter card in slot 2 of the control rack 5 Dual shutter card fitted in slot 2 of the control rack is not programmed 6 Laser Control C...

Page 97: ...n 2 Loose connection 3 Faulty interlock module 7 4 20 Alarm 2n20 Interlock Chain Input 20 Fault Meaning There is no voltage supply to this interlock input Possible causes 1 Interlock supply not turned...

Page 98: ...Possible causes 1 Interlock supply not turned on 2 Loose connection 3 Faulty interlock module 7 4 26 Alarm 2n26 Interlock Chain Input 26 Fault Meaning There is no voltage supply to this interlock inp...

Page 99: ...onnection 3 Faulty interlock module 7 4 31 Alarm 2n31 Interlock Chain Input 31 Fault Meaning There is no voltage supply to this interlock input Possible causes 1 Interlock supply not turned on 2 Loose...

Page 100: ...w 2 Loose connections between detector and Cooler Module 3 Faulty level detector 4 Faulty Cooler Module 7 5 4 Alarm 3n04 Over Temperature Switch Meaning The temperature switch on the heat exchanger re...

Page 101: ...3n08 High temperature fault Meaning The coolant temperature has raised above a configurable threshold Possible causes 1 Incorrect cooler valve setting 2 Cooler valve stuck in the closed position 3 Fac...

Page 102: ...m 3n11 Low Coolant Flow Meaning The coolant flow level has fallen below a configurable threshold Possible causes 1 Loss of coolant in the system 2 Water leak 3 Flow threshold set too high 4 Incorrect...

Page 103: ...ol network Possible causes 1 Incorrect laser type specified 2 Power Supply not fitted 3 Loose laser control network connections 4 Re programming Power Supply 5 Faulty Power Supply 7 6 2 Alarm 4n02 Pow...

Page 104: ...ply Failed to initialise Meaning The Interlock Module timed out waiting for power supply n to response to an initialisation command and report that it had entered the initialised state during the lase...

Page 105: ...supply was on Possible causes 1 Broken lamp 2 Incorrect lamp type 3 Faulty power supply 7 6 12 Alarm 4n12 Power Supply Simmer Over Power Fault Meaning The power supply simmer circuit is on when it sho...

Page 106: ...6 17 Alarm 4n17 Power Supply Input Voltage Loss Meaning The power supply input voltage has fallen below operating limits while the laser was running Possible causes 1 Mains input power interrupt 2 Fa...

Page 107: ...Faulty power supply 7 7 Shutter Alarms Zone 5 7 7 1 Alarm 5n01 Shutter communication fault Meaning Shutter n stopped communicating with the laser control card Possible causes 1 Incorrect address sele...

Page 108: ...t Meaning The shutter failed to enter a safe state during normal operation Possible causes 1 Loose shutter connections 2 Loose Shutter card 3 Loose Laser Control Card 4 Faulty shutter 5 Faulty Shutter...

Page 109: ...more than one shutter shutter 3 would be referenced by Z 4 S 3 For systems having only one of a particular zone type S 1 N N is the actual warning number 7 10 System Level Warnings Zone 1 7 10 1 Warni...

Page 110: ...ad 7 10 8 Warning 1n08 High Output Trip Meaning The laser output exceeded the configured output threshold limit Laser performed the specified action Either continued or entered standby Reset when lase...

Page 111: ...emperature is above a configurable threshold Reset when coolant temperature falls below the configurable threshold 7 11 3 Warning 3n03 Low Flow Meaning The coolant flow is below a configurable thresho...

Page 112: ...ture Meaning The fibre temperature switch has overheated Requires laser alarm reset to clear 7 13 2 Warning 5n02 Shutter Temperature Meaning The shutter housing temperature switch has overheated Requi...

Page 113: ...8 Energy Share Configuration Fail Meaning The Energy share position s failed configuration Requires laser alarm reset to clear and retry 7 13 9 Warning 5n09 Datum Failure Meaning The encoder shutter f...

Page 114: ...p Laser Division JK300HP JK300P JK125P Pre installation and User Manual Issue 2 0 Page 100 of 172 Part No 1EA300E01 Intentionally blank Petitioners Canadian Solar Inc and Canadian Solar USA Inc Ex 102...

Page 115: ...onsists of tuning the Rear Mirror When this has been done the Laser will operate at maximum efficiency The setting up of External Power Control is described in Section 8 5 8 2 Initial Set up Power up...

Page 116: ...ter Use the parameters from Table 10 Table 11 Example Tuning Parameters Set Up Step Action Button 1 To set up for Height starting at 10 select HEIGHT 1 which will highlight the numbers to the right 2...

Page 117: ...r Mirror Figure 11 loosen the set screws item 3 located at the rear of the Rear Mirror housing located on the X Adjuster item 1 and Y Adjuster item 2 5 Adjust the X Adjuster item 1 to optimise for max...

Page 118: ...ely 5mm above the specified Focal Point of the Focus Head 4 Make sure that the Laser Status is READY Refer to Section 6 2 5 Set to desired operating parameters Refer to Section 8 3 for the Laser Param...

Page 119: ...Connect an external 24 Vdc supply to the M C Interface supply as shown below SK603 Pin 1 External 24 Vdc SK603 Pin 14 External 24 Vdc SK603 Pin 2 External 0 Vdc SK603 Pin 15 External 0 Vdc The maximu...

Page 120: ...laser Refer to Section 6 2 Note The EPC function can only be activated using the LaserviewTM SE software 2 In the settings tab External Power Control tick the enable box 3 Power Offset W will default...

Page 121: ...nting diode replacement and alignment Coverslide cleaning and replacement Focus lens cell replacement Bulb replacement Surge suppressor replacement Bendlock assembly The Coolant Replenishment Procedur...

Page 122: ...ion 9 6 1 Pump replacement Section 9 7 1 Arc lamp Replacement As necessary or when elapsed hours of Lamp reaches the configured limit Section 9 8 1 Fibre optic cable replacement and alignment Section...

Page 123: ...amaged Fibre Optic Assembly or component must be replaced immediately 4 Examine Laser beam path and ensure all housings and beam sealing tubes are in good condition fit correctly and are secure Check...

Page 124: ...el 1 can carry out this procedure 9 4 1 Materials Parts Required Part Number 10 litres of Analar Grade 3 Water 1D0M00801 Tools Equipment Spares Consumables Standard Tool Kit O Ring Kit Door Key Paper...

Page 125: ...ble assembly 7 Using the handle located on the Cooler assembly tray pull the tray out all the way 8 Identify the reservoir hose Position a container on the floor adjacent to the reservoir Hose 9 Conne...

Page 126: ...72 Part No 1EA300E01 9 4 3 Filling Procedure The Coolant level should be between the minimum line and the maximum line indicated on the reservoir If it is close to the minimum line Coolant should be a...

Page 127: ...ir Tank with Analar Grade 3 water until level reaches max line on reservoir Refer to the water specification in Section 3 3 2 2 9 Replace the yellow cap to the top of the reservoir tank 10 If necessar...

Page 128: ...dure Personnel authorised to Maintenance Level 1 can carry out this procedure Parts Required Part Number Paper Filter MP010995MS Tools Equipment Spares Consumables Standard Tool Kit O Ring Kit Filter...

Page 129: ...11 8 Remove and dispose of the Paper Filter The Paper Filter is non hazardous and can be disposed of through normal Industrial Waste routes 9 Empty the coolant from the Filter Body item 11 10 Inspect...

Page 130: ...Personnel authorised to Maintenance Level 1 can carry out this procedure Parts Required Part Number De ioniser Resin Refill MP010483MS Tools Equipment Spares Consumables Standard Tool Kit O Ring Kit D...

Page 131: ...n the Coolant if required 7 Using the filter wrench unscrew and remove the De ioniser body 8 Remove the De ioniser cartridge from the De ioniser body 9 Remove and retain the rubber gasket Inspect for...

Page 132: ...Materials Part Required Part Number Coolant Pump Assembly 50Hz 480002601 Coolant Pump Assembly 60Hz 480002701 10 litres of Analar Grade 3 Water 1D0M00801 Tools Equipment Consumables 13mm Ratchet Sock...

Page 133: ...ipes items 5 and 9 away from the Coolant Pump item 6 connectors 7 Using a spanner remove the pump outlet adaptor 8 Remove all 4 Bolts from the top of the electrical panel cover item 8 located at the t...

Page 134: ...HP JK300P JK125P Pre installation and User Manual Issue 2 0 Page 120 of 172 Part No 1EA300E01 9 7 3 Installation Procedure Figure 18 Coolant Pump Installation Petitioners Canadian Solar Inc and Canadi...

Page 135: ...x item 6 and the 4 bolts for the cover of the Electrical Panel box item 6 on top of the Coolant Pump item 6 6 Fit the Pump Outlet adaptor to the Coolant Pump outlet item 9 Use PTFE Tape or Loctite 533...

Page 136: ...p Laser Division JK300HP JK300P JK125P Pre installation and User Manual Issue 2 0 Page 122 of 172 Part No 1EA300E01 Intentionally blank Petitioners Canadian Solar Inc and Canadian Solar USA Inc Ex 102...

Page 137: ...uired Part Number Arc lamps x 2 or complete set for JK300HP and JK300P P55B6770B Arc lamp x 1 for JK125P 12280360A GSI Group Laser Division recommends that Arc lamps are changed as a complete set or i...

Page 138: ...ion JK300HP JK300P JK125P Pre installation and User Manual Issue 2 0 Page 124 of 172 Part No 1EA300E01 9 8 2 Replacement Procedure Figure 19 Arc lamp Petitioners Canadian Solar Inc and Canadian Solar...

Page 139: ...ft the Pumping Chamber Lid item 3 clear of the Pumping Chamber item 5 and place in a clean area CAUTION The Arc lamps are made of glass and may splinter or shatter Eye protection must be worn whilst r...

Page 140: ...on JK300HP JK300P JK125P Pre installation and User Manual Issue 2 0 Page 126 of 172 Part No 1EA300E01 9 8 3 Installation Procedure Figure 20 Arc lamp Petitioners Canadian Solar Inc and Canadian Solar...

Page 141: ...AUTION Make sure that the lamp leads are formed such that they DO NOT TOUCH the sides of the pumping chamber 6 Push the Arc lamp item 4 gently into Lamp Terminal Socket item 1 making sure PTFE Lamp Su...

Page 142: ...item 5 for signs of leaks If leaks are detected shut down the Laser immediately 15 If necessary rectify cause of the leak Wipe up any spillage using paper towels 16 If the Laser was shut down in step...

Page 143: ...p Laser Division JK300HP JK300P JK125P Issue 2 0 Pre installation and User Manual Part No 1EA300E01 Page 129 of 172 Intentionally blank Petitioners Canadian Solar Inc and Canadian Solar USA Inc Ex 102...

Page 144: ...sed to Maintenance Level 2 can carry out this procedure 9 9 1 Materials Parts Required Part Number PIPA Fibre Cable Refer to Section 1 15 Tools Equipment Spares Consumables Standard Tool Kit Fibre Ter...

Page 145: ...d open the laser head lid 3 Pull back the Blue Protective Cover item 1 to expose the PIPA Fibre Termination item 2 4 Unscrew but do not remove the clamping screw item 6 to loosen the Retaining Clamp 5...

Page 146: ...JK300P JK125P Pre installation and User Manual Issue 2 0 Page 132 of 172 Part No 1EA300E01 9 9 3 Installation Procedure Figure 22 PIPA Fibre Cable Installation Petitioners Canadian Solar Inc and Cana...

Page 147: ...Fibre Termination item 2 7 Ensure that the rear edge of the PIPA Fibre Termination item 2 IS chamfered 8 Ensure the Locating Pin item 3 on the PIPA Fibre Termination item 2 is aligned with the Locatin...

Page 148: ...125P Pre installation and User Manual Issue 2 0 Page 134 of 172 Part No 1EA300E01 9 9 4 Fibre Output Termination Replacement Procedure Figure 23 Fibre Output Termination Petitioners Canadian Solar Inc...

Page 149: ...m 2 2 Inspect the Focus Head item 7 for damage Replace if necessary 3 Pull back the protective Cover item 1 from the Fibre Output Termination item 2 4 Ensure that the rear edge of the Fibre Output Ter...

Page 150: ...d User Manual Issue 2 0 Page 136 of 172 Part No 1EA300E01 9 9 5 Alignment Procedure Personnel authorised to Maintenance Level 2 can carry out this procedure Figure 24 Fibre Optic Cable Alignment Petit...

Page 151: ...ALL SAFETY PROCEDURES ARE OBEYED 6 Set the Height to 10 and switch the Laser ON 7 The DVM should indicate approximately 350mV Note This value is a guideline only the actual value can vary depending up...

Page 152: ...0 1 Materials Part Required Part Number Cover Slide 1234123YA Tools Equipment Spares Consumables Standard Tool Kit O Ring Kit Rubber Bulb Puffer PROPAN 2 OL Small Vacuum Cleaner Lint Free Tissues Plas...

Page 153: ...FATAL INJURY 1 Carry out Power OFF Sequence 2 Remove excess dust from the area around Cover Slide item 8 using a small vacuum cleaner 3 Unscrew and remove the Cover Slide holder item 7 cover slide 8...

Page 154: ...installation and User Manual Issue 2 0 Page 140 of 172 Part No 1EA300E01 9 10 3 Cleaning and Installation Procedure 1 2 3 4 5 7 8 9 6 Figure 26 Cover Slide Installation Procedure Petitioners Canadian...

Page 155: ...st slightly narrower than Cover Slide item 8 5 Dampen tissue using PROPAN 2 OL or approved cleaner Wipe tissue across the full area of Cover Slide item 8 in a single stroke Note Do not use multiple pa...

Page 156: ...t Required Part Number Focus lens cell Various Lens Ring Tool 60mm SQ Head ML123431B Tools Equipment Spares Consumables Standard Tool Kit O Ring Kit Rubber Bulb Puffer PROPAN 2 OL Finger Cots Lens Fre...

Page 157: ...ut Power OFF Sequence 2 Using a 3mm allen key unscrew the captive screws item 6 on the focus lens cell body item 5 3 Holding the lens cell body slowly slide down and remove the lens cell item 5 Instal...

Page 158: ...JK300P JK125P Pre installation and User Manual Issue 2 0 Page 144 of 172 Part No 1EA300E01 9 11 3 Cleaning Procedure 1 2 3 4 5 7 8 9 6 Figure 28 Focus lens cell Petitioners Canadian Solar Inc and Cana...

Page 159: ...st be taken when handling optical components Always handle optical components in a clean environment 3 Place Focus lens cell Item 3 in a clean environment 4 Carefully fold a lens tissue into a pad tha...

Page 160: ...terials Part Required Part Number Focus lens cell Various Lens Ring Tool 60mm SQ Head ML123431B Tools Equipment Spares Consumables Standard Tool Kit O Ring Kit Rubber Bulb Puffer PROPAN 2 OL Finger Co...

Page 161: ...ion 9 10 to remove the coverslide assembly 3 Using the correct tool remove the locking ring item 1 in a counter clockwise direction 4 Remove the spacer if fitted 5 Using lens cleaning tissues push the...

Page 162: ...JK300P JK125P Pre installation and User Manual Issue 2 0 Page 148 of 172 Part No 1EA300E01 9 12 3 Installation Procedure 1 2 3 4 5 7 8 9 6 Figure 30 Focus Lens Petitioners Canadian Solar Inc and Cana...

Page 163: ...overslide end lower the lens item 3 into position The lens should be fitted flat side down 5 Check that the lens item 3 is sitting flat in the lens cell item 5 6 Check that the PTFE seal item 2 is ser...

Page 164: ...Suppressor Replacement Procedure Personnel authorised to Maintenance Level 1 can carry out this procedure 9 13 1 Materials Part Required Part Number Surge Suppressor 85D884501 Tools Equipment Consuma...

Page 165: ...ARDS EXIST ELECTRIC SHOCK CAN CAUSE SERIOUS OR FATAL INJURY 1 Carry out Power OFF Sequence Wait for 2 minutes This ensures that the capacitors have discharged to a safe level 2 Unlock and open End Bay...

Page 166: ...ion WARNING ELECTRIC SHOCK HAZARDS EXIST ELECTRIC SHOCK CAN CAUSE SERIOUS OR FATAL INJURY 1 Carry out Power OFF Sequence 2 Unscrew remove and retain coloured outer Cover of the Lamp 3 Remove and retai...

Page 167: ...PIPA Fibres used in robot applications 9 15 1 Assembly Instructions 1 Fit the two Bendlock adaptors using the 4 M3 screws 2 Remove Locator Screw 3 Fit the 18 rings over the Fibre Termination onto the...

Page 168: ...ersonnel authorised to Maintenance Level 2 can carry out this procedure 9 16 1 Materials Part Required Part Number Pointing Diode Assembly PC120150X Tools Equipment Consumables Standard Tool Kit Door...

Page 169: ...ode assembly from the shutter 6 Place some tape over the hole at the rear of the shutter to prevent optics from any airborne contamination Installation Procedure CAUTION If a blanking plate is fitted...

Page 170: ...P JK125P Pre installation and User Manual Issue 2 0 Page 156 of 172 Part No 1EA300E01 9 16 3 Alignment Procedure 4 3 off 3 4 off 5 1 2 3 off Figure 33 Pointing Diode Petitioners Canadian Solar Inc and...

Page 171: ...and focus head assembly 4 If no beam is present loosen the screws item 2 holding the pointing diode assembly 5 Reposition the diode assembly on the oversized holes looking for a beam at the workpiece...

Page 172: ...p Laser Division JK300HP JK300P JK125P Pre installation and User Manual Issue 2 0 Page 158 of 172 Part No 1EA300E01 Intentionally blank Petitioners Canadian Solar Inc and Canadian Solar USA Inc Ex 102...

Page 173: ...ating in Continuous Wave mode spot size governs both depth and maximum travel speed achievable when welding and cutting At a given demand Mean Power smaller spot size achieves greater intensity and hi...

Page 174: ...a certain weld depth for a given material The energy per pulse in Joules E is related to the average power P and the pulse frequency f as follows E Joules P Watts f Hz 10 2 2 Peak Power Refer to Figu...

Page 175: ...acteristics of the weld depth width cross sectional area etc are controlled by the following parameters Laser average power Welding speed Focused spot size Increased power with other parameters consta...

Page 176: ...plane relative to the Laser beam Figure 36 shows two simple arrangements A clamping from below and B clamping from above Figure 36 Position Control Methods Clamping from above allows high pressures to...

Page 177: ...ence of gas shielding when welding thin sheet mild steel 0 3 mm may not adversely affect the properties of the weld and will in general allow welds to be produced at higher speeds and with greater pen...

Page 178: ...c However some materials require material addition to give high quality welds with acceptable properties At the high power level of the JK300HP JK300P 125P Series Laser welding with material addition...

Page 179: ...welded are held with the joint 0 5mm relative to the Laser beam focus position 10 12Cutting Assist Gas The co axial assist gas used in Laser cutting facilitates removal of molten material from the cut...

Page 180: ...curacy work handling is used then it may be necessary to use a longer focal length focusing lens This will increase process tolerance but will limit maximum processing speed 10 15 3 Weld Shape Cut Wid...

Page 181: ...focus beam position The focus beam position is a fixed distance from the end of the Focus Head i e the cover slide position Refer to Section 7 2 for details 10 15 7 Welding 10 15 7 1 Gas Shielding Wh...

Page 182: ...the Cross jet is placed too close to the workpiece the jet of air can interact with the flow of shielding gas and reduce shielding effectiveness If it is placed too close to the Cover Slide the cross...

Page 183: ...tasks the Laser beam focus position should be 1mm below the end of the nozzle The workpiece should be positioned coincident with the Laser beam focus position The distance between the end of the nozzl...

Page 184: ...ach zero when switched from ON to READY When welding the Ramp Down feature can be used to decrease weld penetration gradually in a controlled manner at the end of welding to fade out the weld smoothly...

Page 185: ...P JK125P Issue 2 0 Pre installation and User Manual Part No 1EA300E01 Page 171 of 172 11 Spares Refer to the Spares Navigator CD for all consumable spares information Petitioners Canadian Solar Inc an...

Page 186: ...p Laser Division JK300HP JK300P JK125P Pre installation and User Manual Issue 2 0 Page 172 of 172 Part No 1EA300E01 Intentionally blank Petitioners Canadian Solar Inc and Canadian Solar USA Inc Ex 102...

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