NORTHROP GRUMMAN Iklwa II TEM00 Service Manual Download Page 15 | Manualshive

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Chapter 1: General Instructions

© 2019 Cutting Edge Optronics

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Patara II and Iklwa II Service Manual

Figure 1-1: Laser Alignment and Test Set-up Diagram

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Figure 1-2: Optical Bench Overview

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Summary of Contents for Iklwa II TEM00

Page 1: ...uble Shooting Guid SVC UMAN 0007 C JANUARY 2019 Service Manual Iklwa II TEM00 Green Laser Patara II TEM00 Green laser ...

Page 2: ...ours 8 00 a m to 5 00 p m Central time Technical Support 636 916 4900 follow prompts for department directory Email ngceoservice ngc com Cutting Edge Optronics Headquarters 20 Point West Blvd St Charles MO 63301 USA Sales Support 636 916 4900 follow prompts for department directory After office hours please leave a voice mail message Outside North America contact an NG sales office or distributor ...

Page 3: ...cal including photocopying recording storing in an information retrieval system or translating in whole or in part without the prior written consent of Northrop Grumman Corporation Patents Northrop Grumman Corporation products are covered by U S and foreign patents issued and pending Information in this publication supersedes that in all previously published material Specifications and price chang...

Page 4: ... the instrument you must properly transfer it according to local regulations concerning WEEE equipment Contact NG or your local distributor for shipping instructions Please package the products as directed for a return for repair ROC ROHS Declaration In accordance with the Clause 6 2 of Marking for Control of Pollution Caused by Electronic Information Products SJ T11364 2006 for Measures for the A...

Page 5: ...ence of button pushes e g MENU CHANNEL SETUP PULSE WIDTH means that you push the MENU button then push the CHANNEL SETUP soft key and then push the PULSE WIDTH soft key italic Italic text denotes references to other resources that may be helpful to you or to bring attention to important information This icon denotes a note which alerts you to important information I O Power Switch Position Symbols...

Page 6: ...n Shock Hazard Use caution Caution Risk of danger Refer to manual Chassis Ground Additional Resources NG is committed to providing support for all customers Installation how to videos technical manuals and descriptions and specifications of products can be found by visiting http www ngceoservice com ...

Page 7: ... and Tack Locations 6 Servicing the Laser 7 Chapter 2 Laser Component Replacement Procedures 12 Align HeNe to Optic 12 Aperture Removal 13 Aperture Replacement 14 Coolant Line Purge 14 Desiccant Replacement 14 Emission Light Replacement 16 Flow Switch Assembly Replacement 16 Fold Mirror Output Coupler Replacement 17 HM Replacement 17 HR Replacement 18 Install Cover 19 Interlock Replacement 20 Lase...

Page 8: ...ment and Alignment 30 Shutter Replacement 34 Steering Mirror Replacement 35 Waveplate Replacement 37 Chapter 3 Tuning and Testing Procedures 39 Align for Q Switch Hold Off 39 Power the Laser for Alignment 39 Check Hold Off 40 Check for Bullseye 40 Defeating the Cover Interlock 41 HR HM Alignment 41 Laser Optimization 43 Leak Test 45 Walking the Cavity 46 Appendix A Customer Service 47 Questions 48...

Page 9: ...artridge Bottom 15 Figure 2 4 50 Gram Refill and Refill Tool 15 Figure 2 5 Flow Switch Assembly 177594 16 Figure 2 6 Optical Mount MM64 Exploded View 17 Figure 2 7 Optical Mount Showing Screw Locations 18 Figure 2 8 Optical Mount Showing Screw Locations 19 Figure 2 9 Shutter Rotated Out of Beam Path 21 Figure 2 10 HeNe Bullseye Pattern 21 Figure 2 11 Pinhole Alignment with Pinless Aperture 22 Figu...

Page 10: ...ure 2 25 Ball Plunger Holding Components in Place 32 Figure 2 26 Finished SHG assembly 33 Figure 2 27 Alignment Process 34 Figure 2 29 Location of 2216 on Mount 36 Figure 2 30 Location of 2216 on Optic 36 Figure 2 31 Steering Mirror Layout 37 Figure 3 1 Location of Q Switch Attachment Hardware 39 Figure 3 2 HeNe Bullseye Pattern 41 Figure 3 3 The Cover Interlock Switch 41 Figure 3 4 Accessible Hol...

Page 11: ...r operation limit access to those trained in the principles of laser safety Post readily readable warning signs in prominent locations near the laser operation area Use safety interlocks on all entryways All NG system control electronics are provided with interlock inputs to preclude operation with an open safety door NOTE when multiple interlocks are used they must be connected in SERIES for prop...

Page 12: ...r We recommend the use of protective eyewear at all times selection depends on the energy and wavelength of the laser beam as well as operating conditions Consult ANSI ACGIH or OSHA standards for guidance WARNING Use of controls adjustments or performance of procedures other than those specified herein may result in hazardous radiation exposure WARNING At all times during installation operation ma...

Page 13: ...HE CLEANEST ENVIRONMENT AVAILABLE Do not use any unauthorized epoxy or glue in the laser housing DO NOT TOUCH THE OPTICAL SURFACES Optical surfaces should be inspected using a 10x microscope with 15 W illumination Optical surfaces should only be cleaned if there is visible contamination Only optical grade methanol or acetone should be used with lint free lens tissue Failure to keep a clean environ...

Page 14: ...e NG part no 42 228 Desiccant Refill part number 643665 Desiccant Refill tool 980412 McMaster Disposable Tube Fitting Filter part no 4795K22 McMaster Female QD part no 5012K83 McMaster Hose part no 52375K32 McMaster 3 16 Hose part no 52375K31 Male QD O Rings 011 Black Viton 2 required Output Window O Rings 020 Black Viton 2 required 8 Nylon clear cable ties Side cutters 3M 2216 two part epoxy X AC...

Page 15: ...Chapter 1 General Instructions 2019 Cutting Edge Optronics 5 Patara II and Iklwa II Service Manual Figure 1 1 Laser Alignment and Test Set up Diagram c Figure 1 2 Optical Bench Overview ...

Page 16: ...should be tightened unless otherwise specified to the recommended torque value contained in Table 1 1 below Table 1 1 Recommended Torque Values Fastener Size Recommended Torque IN LBS 4 40 5 5 0 5 6 32 14 1 8 32 25 1 10 32 40 2 1 4 20 80 3 Tack locations are shown in Figure 1 3 NG recommends using 3M 2216 for tacking components and fasteners as indicated Allow for a minimum of 12 hours of curing t...

Page 17: ...ontained in this service manual for detailed instructions Table 1 2 Service Action Table Service Operation Order of procedures Replacing the Aperture 1 Remove Cover page 28 2 Aperture Removal page 13 3 Aperture Replacement page 14 4 Tack Components page 6 5 Install Cover page19 6 Laser Optimization page 43 Replace Desiccant 1 Desiccant Replacement page 14 Replacing the Emission Light 1 Remove Cove...

Page 18: ...oncentric go to step 7 6 HR HM Alignment page 17 18 HR first if replacing Fold Mirror HM first if replacing OC 7 Check Hold Off page 40 8 Install Cover page19 9 Laser Optimization page 43 10 Check Hold Off page 40 Replace the HM 1 Remove Cover page 28 2 Align HeNe to Optic page 12 reference point 3 HM Replacement page 17 Use HM adjustment screws to align HeNe reflection back to reference point 4 D...

Page 19: ...lacement page 18 4 Defeat Cover Interlocks page 41 5 Power Laser for Alignment page 39 6 Check for Bullseye page 40 If concentric go to step 8 7 HR HM Alignment page 17 18 HM alignment may not be necessary 8 Check Hold Off page 40 9 Tack Components page 6 10 Install Cover page19 11 Laser Optimization page 43 12 Check Hold Off page 40 Replacing the Interlocks 1 Remove Cover page 28 2 Interlock Repl...

Page 20: ...e 27 Replacement Steps Only 5 Polarizer Removal and Installation page 26 Installation Only 6 Leak Test page 45 7 Defeating the Cover Interlocks page 41 8 Power the Laser for Alignment page 39 9 SHG Replacement and Alignment Step 15 20 10 HR HM Alignment page 17 18 11 Align Q switch for Hold Off page 39 12 Aperture Replacement page 14 13 Tack Components page 6 14 Install Cover page19 15 Laser Optim...

Page 21: ...cks page 41 3 SHG Replacement and Alignment page 3 4 HR HM Alignment page 17 18 HR alignment may not be necessary 5 Aperture Replacement page 14 6 Tack Components page 6 7 Install Cover page19 8 Laser Optimization page 43 9 Check Hold Off page 40 Replacing the Shutter 1 Remove Cover page 28 2 Shutter Replacement page 34 3 Tack Components page 6 4 Install Cover page19 Replacing Steering Mirrors 1 R...

Page 22: ...1 Mount HeNe at least 2 meters from the laser housing HR or HM access port See Figure 1 1 The HR access port is the plug on the front of the laser housing The HM access port is the screw below the J1 connector on the rear of the laser housing 2 For HR alignment remove the pin hole from location 1 For HM alignment remove the pin hole from location 4 See Figure 1 2 3 Mark the location of the HeNe re...

Page 23: ... locking hardware holding the aperture mount to the laser bench Care should be taken to clean any debris from the inside of the laser housing that may be generated from breaking the epoxy bonds 2 Place the aperture assembly on a flat surface If applicable heat the epoxy on the 4 40 screws of the aperture mount with a heat gun and remove the epoxy Remove any residual epoxy from the mount ...

Page 24: ...e 4 40 screws to 5 5 in lbs NOTE Typical aperture size is 1 2 mm If the insertion loss decrease of output power of the aperture is not approximately 1 Watt then the aperture size should be changed To increase the insertion loss decrease output power install a 1 1 mm aperture To decrease the insertion loss increase output power install a 1 3 mm aperture Contact NG technical service for replacement ...

Page 25: ...ams of desiccant Fill the cartridge to the counter bore surface where the filter is mounted Do not overfill Fill as shown in Figure 2 4 Figure 2 4 50 Gram Refill and Refill Tool 4 Make sure that there are no desiccant beads on the surface where the filter is mounted Install the paper filter then the screen then the retainer ring Hand tighten the retainer ring with the refill tool Replace the desic...

Page 26: ...card to the laser housing using the 4 6 32 screws and locking hardware and torque to 14 in lbs Flow Switch Assembly Replacement 1 Cut wire bundle zip ties as needed and disconnect the electrical quick disconnect 2 Note the coolant flow direction as indicated on the flow switch housing The flow switch is on the return side of the coolant loop The arrow should point towards the Coolant Out quick dis...

Page 27: ... wrench to remove the retaining ring Carefully remove the o ring metal washer and optic from the cell 3 Inspect the new optic and clean as needed Identify the coated surface an arrow on the side of the optic points toward the coated surface 4 Place the new optic in the cell with the coated surface oriented as shown in Figure 2 6 Install the o ring the metal washer and the retaining ring Hold the o...

Page 28: ...c in place approximately 120 degrees apart Only a very small amount of epoxy is needed Place the optic in the 9774 mount with the coated surface facing up An arrow on the side of the optic points toward the coated surface Avoid getting the epoxy on the optical coatings Additional epoxy may be used on the front edges of the optic as seen in the Optics Bonding page 24 section Allow 12 hours to cure ...

Page 29: ... in place approximately 120 degrees apart Only a very small amount of epoxy is needed Place the optic in the 9774 mount with the HR coating facing up An arrow on the side of the optic points toward the HR coating Avoid getting the epoxy on the optical coatings Additional epoxy may be used on the front edges of the optic as seen in the Optics Bonding page 24 section Allow 12 hours to cure the epoxy...

Page 30: ...40 fasteners using a cross pattern to a torque of 5 5 in lbs Interlock Replacement 1 Remove the two 2 6 32 sealing screws holding the interlock onto the side of the laser housing Remove any debris 2 Disconnect the leads from the interlock 3 Attach the leads onto the new interlock 4 Mount the interlock using the 2 6 32 sealing screws and hand tighten Laser Module Alignment 1 Align the HeNe laser to...

Page 31: ...odule rod reflection back to pinhole location 1 as described below a Adjust Fold Mirror for tip tilt shims required and rotation to get a bullseye b Verify module rod reflection on pinhole location 1 If needed move fold mirror forward and backward to adjust module rod reflection horizontally c Repeat steps a and b as needed to obtain the correct bullseye pattern and module rod reflections in the h...

Page 32: ...just the HM reflection back onto the pinless alignment aperture NOTE Pinless alignment aperture may not be perfectly aligned in the vertical axis during HM alignment It is acceptable as long as a significant amount of green light passes through the pinhole for alignment 11 Replace SHG assembly and mount in the center of the mounting slots Ensure that the HeNe passes through the center of the cryst...

Page 33: ...hrough the use of properly installed and maintained grounding wrist straps or other ESD control devices Subjecting the module to static shock can seriously damage or destroy the diode bars and will void the product warranty Figure 2 12 Location of Laser Module yellow HR Mirror green and Polarizer red 2 If applicable carefully cut the clear insulation around the electrical lugs on the laser module ...

Page 34: ...w heat shrink insulation on the electrical wire leads and connect each lead to the laser module Ensure the polarity is correct with red to positive Do not over torque 10 Inspect the work to ensure proper installation Optics Bonding 1 Using a dental pick place three drops of 2216 epoxy on the ledge of the inner diameter of the mirror mount The diameter of the drops should be 1 16 to 1 8 The three d...

Page 35: ...for that epoxy to cure at room temperature Output Window Replacement 1 Blow off debris on outside of laser housing and cover using nitrogen or clean dry air 2 Wipe the housing clean using TechniCloth III wipes and isopropyl alcohol 3 Remove the 4 4 40 screws and locking hardware from the output window frame 4 Remove the output window frame o ring and output window Ensure the o ring between the out...

Page 36: ...ly out of the laser 3 Install new polarizer assembly with the mounting hardware The mounting hardware self aligns the polarizer assembly Torque the 8 32 fasteners to 25 in lbs Q Switch Replacement CAUTION Do not run the chiller or laser with the coolant hoses and RF cable disconnected from the Q switch WARNING Flexible tubing can be easily damaged Use caution when handling 1 Disconnect the coaxial...

Page 37: ...ount out of the laser 5 Remove the base from the Q switch by loosening the three 3 M3x15 screws accessible from the bottom of the mounting plate 6 Inspect and mount the new Q switch onto the base using the three screws identified in Step 4 above Torque the screws to the 14 in lb Remove the dust caps from the new Q switch 7 Inspect the Q switch optical surfaces 8 Install the new Q switch assembly i...

Page 38: ...plumbing lines Figure 2 19 Cables Secured Out of Beam Path Remove Cover NOTE Gloves must be worn while servicing the laser Service must be performed in a clean room environment 1 Blow debris off outside of laser housing and cover using nitrogen or Class 0 dry air 2 Wipe the housing clean using TechniCloth wipes and isopropyl alcohol 3 Remove the fasteners and lift the cover from the laser housing ...

Page 39: ...cable tie and remove BNC connector 3 Mark both SwageLok pieces with permanent marker as reference for reinstallation Carefully remove the hard plumbing using two 2 9 16 14mm wrenches See Figure 2 20 Figure 2 20 Removal of the Q Switch Hard Plumbing 4 Remove the three 3 8 32 x 1 screws holding the Q switch assembly to the laser bench See Figure 2 21 below Figure 2 21 Location of Q Switch Attachment...

Page 40: ...ntire second harmonic generator SHG assembly HG24 0011 proceed to step 14 3 Loosen all 4 ball plunger screws as shown in Figure 2 23 Use tweezers to carefully remove the conductive copper block aluminum load spreader two macor insulators and SHG crystal seen in Figure 2 24 Discard used indium foil Figure 2 23 Ball Plunger Screw Locations 4 Cut 0 002 thick indium foil into 2 4x9mm pieces and 010 th...

Page 41: ...gure 2 24 Insulators Crystal and Load Spreader 7 Press the other 0 002 piece of indium onto the top of the crystal making sure it is centered on the crystal and none of the indium is hanging over the edge Using a pair of tweezers carefully move the insulators crystal and load spreader and place them into the SHG mount Make sure that the Indium foil remains in place on the crystal as shown in Figur...

Page 42: ...gainst the side opposite the ball plungers Thread in the ball plunger circled in yellow Figure 2 27 until it presses the contact block into the wall of the mount as shown in Figure 2 27 Back it off an eighth turn Figure 2 25 Ball Plunger Holding Components in Place 10 Thread in the ball plunger on the top of the assembly until tight then back it off an eighth turn 11 Repeat step 10 with the 3 rema...

Page 43: ... parameters specified on the ATP Test Report Data Summary Open the shutter Set the drive current slightly above the threshold Set the TEC temperature at 30ºC for the starting point 17 Verify the beam hits the center of the SHG crystal See Figure 2 28 for ideal alignment Base screws can be loosened to center the beam through the SHG crystal 18 See Figure 2 27 If reflections are not vertical rotate ...

Page 44: ...et the TEC to this value Shutter Replacement CAUTION Removing the shutter compromises one of the safety features of the laser Only remove when absolutely necessary and use precautions to avoid exposure to any laser radiation 1 Unplug the electrical connector from the shutter solenoid and cut the cable tie 2 Locate and remove the 2 8 32 7 16 screws used to hold the shutter mount in position 3 Remov...

Page 45: ...nly replace one steering mirror at a time 1 Turn laser on just above threshold 2 Place an aperture just outside of the output window Mark a reference point at least 1 meter from the output window of the laser This point will be used to target the laser after steering mirror replacement 3 Turn off laser 4 Remove the 8 32 screw and locking hardware holding the steering mirror assembly to the post Ca...

Page 46: ...Location of 2216 on Mount 9 Place optic into mount and bond at the locations as shown in Figure 2 31 below Use 8 32 screw and 002 shims red to secure and center optic Be sure that the assembly remains flat until the 2216 is cured 10 Cure at 66 C for 2 hours or for a minimum of 12 hours at room temperature 11 Remove 8 32 screw and shims See Figure 2 30 for how it should look Figure 2 30 Location of...

Page 47: ...dge tacked to the post holder 2 Place the rotation mount on a flat surface and use a spanner wrench to remove the retainer ring Care should be taken to clean any debris that may be generated from breaking any epoxy bonds 3 Remove the waveplate optic 4 Inspect the new waveplate optic and clean if necessary 5 Install the new waveplate optic Replace the retainer ring and tighten using the spanner wre...

Page 48: ... onto the laser test bench in front of the output window Ensure the 532 nm polarizer cube retro reflection is on axis with the laser beam Ensure that the 532 nm polarizer cube is oriented to transmit horizontal polarized light and reject vertical polarized light c Loosen the set screw on the top of the waveplate assembly Using the dial on the rotation mount adjust for minimum transmission through ...

Page 49: ...operational value The proper Hold off condition is met when no green light is visible through the current range If no green light is observed skip to step 7 4 Loosen the three screws holding the Q switch in place Figure 3 1 Location of Q Switch Attachment Hardware 5 Rotate the Q switch until no green beam is observed Proper Hold off conditions are met when no green light is visible 6 Tighten the s...

Page 50: ...er the operating current to 10 A 3 Ensure that the RF driver signal is at maximum power with no triggers or gates 4 Observe the beam output on the power meter while turning up the current to the operational value Hold off condition is met when no green light is visible 5 If green light is observed the laser does not hold off refer to Align for Q switch Hold off 6 Reduce the current to 10 A 7 Retur...

Page 51: ...ced and the laser needs to be operated with the cover off in order to adjust an optical component 1 Pull the pin up to disable the cover interlock switch See Figure 3 3 2 Repeat for the second cover interlock switch Figure 3 3 The Cover Interlock Switch HR HM Alignment 1 Locate the access holes for high reflection HR and harmonic mirrors HM Notice the positions of HR and HM mirrors with respect to...

Page 52: ...e reduce operating current by 2 A Return to normal operating current when making small and fine adjustments 4 The screws for the adjustments of the vertical tilt angle and the horizontal tilt angle are illustrated in Figure 3 4 Figure 3 4 Accessible Holes for HR and HM Cavity Mirror Adjustment 5 Make small adjustments to the horizontal angle of HM mirror and observe the output power 6 Once a maxim...

Page 53: ...ficant impact on the laser performance 4 Run the laser for a minimum of 1 hour and wait for the laser to reach thermal stabilization Both the laser bench temperature and environmental temperature significantly impact the laser power Wait for the laser to be thermally stabilized before attempting any adjustment 5 Peak up the laser power by tuning the temperature of the TEC controller Do not adjust ...

Page 54: ...rates an example of the dependency of the output power and pulse to pulse instability of the laser to operating current Notice that the laser power increases as the operating current is increased The laser reaches peak power around 23 A In this example 23A is the rollover current and the operating current would be 22 5 A to 22 7 A Fine tune the current to optimize pulse to pulse stability and roun...

Page 55: ...nsure the laser has been purged of any coolant 2 Attach a nitrogen source to the COOLANT IN port on the laser see Figure 3 7 3 Open the inlet valve and adjust the regulator to obtain 80 psi on the pressure gauge 4 Close the inlet valve Wait 5 minutes and repeat step 3 once 5 Return after 30 minutes and record pressure on the gauge Subtract this pressure from starting pressure of 80 psi to get the ...

Page 56: ...stment is 15 degrees to 20 degrees rotation If coarse adjustments are needed to obtain performance reduce operating current by 2 A Return to normal operating current when making small and fine adjustments 4 The screws for the adjustments of the vertical tilt angle and the horizontal tilt angle are illustrated in Figure 3 3 5 Make a horizontal adjustment to the HM mount Recover the laser power by m...

Page 57: ...anuals Call or write our customer service department to bring attention to problems that you may not have personally experienced We are always interested in improving our products and manuals and we appreciate all suggestions Date Name Company or Institution Department Address Laser Model Number Serial Number Chiller Model Number Serial Number Laser Drive Electronics Model Number Serial Number Las...

Page 58: ...et and actual reading from TEC controller oC What are the set current and actual current from laser drive electronics A Is Q switch enabled yes no Is Q switch triggered internally or externally What is the pulse repetition frequency Hz Is the output power measured directly from the laser yes no What is the measured power W When did the problem happen Have you changed any settings recently yes no H...

Page 59: ...t are the changes made recently to the system Please describe the problem or laser behavior as detailed as possible Suggestions Email or fax to Northrop Grumman Cutting Edge Optronics Inc 20 Point West Boulevard Saint Charles MO 63301 USA Phone 636 916 4900 Fax 636 916 4994 Email ngceoservice ngc com ...

Page 60: ...am g tera 1012 T length meter m giga 109 G time second s mega 106 M frequency Hertz Hz kilo 103 k force Newton N deci 10 1 d energy Joule J centi 10 2 c power Watt W milli 10 3 m electric current Ampere A micro 10 6 µ electric charge Coulomb C nano 10 9 n electric potential Volt V pico 10 12 p resistance ohm Ω femto 10 15 f inductance Henry H atto 10 18 a magnetic flux Weber Wb magnetic flux densi...

Page 61: ... and Drug Administration CFR Code of Federal Regulations CW Continuous Wave DC Direct Current DPSS Diode Pumped Solid State EO Electro Optical type of Q switch ESD Electro Static Discharge FET Field Effect Transistor FDA U S Food and Drug Administration FPS First Pulse Suppression FWHM Full Width at Half Maximum GaAlAs Gallium Aluminum Arsenide GPM Gallons Per Minute HeNe Helium Neon HG Harmonic G...

Page 62: ...rium Lithium Fluoride NG Northrop Grumman NIR Near Infrared OC Output Coupler OSHA Occupational Safety and Health Administration PRF Pulse Repetition Frequency psi Pounds per Square Inch QCW Quasi Continuous Wave QSW Q switch RF Radio Frequency RH Relative Humidity RMS Root Mean Square SHG TEC Second Harmonic Generator Thermal Electric Cooler TEM Transverse Electromagnetic Mode TTL Transistor Tran...

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