USER MANUALOEM 65iX
Sealed CO2 laser source© 2022 Luxinar Ltd. All rights reserved.
Revision history
12
3
4

18/01/2022 — CR 651478: Reorder and modularise content, change to XML format. Update DC PSU and safety sections.
28/09/2022 — CR 651729: Green diode pointer.
28/10/2022 — CR 651940: UKCA marking and safety section updates
05/07/2023 — CR 652584: Safety label updates

This manual is copyrighted with all rights reserved. Under copyright laws, this manual may not be copied inwhole or part or reproduced in any other media without the express permission of Luxinar Ltd. Permitted
copies must carry the same proprietary and copyright notices as were affixed to the original. Under law,
copying includes translation into another language.
Please note that while every effort has been made to ensure that the data given in this document is accurate,
the information, figures, illustrations, tables, specifications and schematics contained herein are subject tochange without notice. Contact Luxinar Aftersales to verify that you have the latest version of this manual.

Aftersales contact details
Luxinar Ltd
Meadow Road
Bridgehead Business Park
Kingston upon Hull
HU13 0DG
U.K.
Tel.: +44 (0) 1482 650088
www.luxinar.com
For Aftersales Service, contact: aftersales.uk@luxinar.com
For Parts, contact: parts.uk@luxinar.com
Luxinar GmbH (Germany)
Röntgenstrasse 621465 Reinbek
Germany
Tel.: +49 (0)40 883624-60
www.luxinar.com/de
Luxinar Ltd (Italy branch office)Via Pavia 11/B
10098 Rivoli
TorinoItalyTel.: +39 (0)11 19118353
www.luxinar.com/it
Luxinar Ltd (Korea branch office)#409, A-dong (Bundang Suji U-Tower)
767, Sinsu-ro, Suji-gu, Yongin-si, Gyeonggi-do
Republic of Korea 16827
Tel.: +82 (0)31 546 0861
www.luxinar.com/ko
Luxinar Laser Technology (Shanghai) Co., Ltd (China)
Room 02, 5th Floor, 8# Jiafeng Road
Shanghai Pilot Free Trade Zone
Shanghai, China
200131
Tel.: +86 21 6106 9917
www.luxinar.com/zh-CN
Luxinar Inc (USA)51047 Celeste Dr
Shelby Township
MI 48315
USA
Tel.: +1 (0)586 291 2709
www.luxinar.com

Warranty shipments, returns and adjustments
Warranty claims must be made promptly and must be received by Luxinar Ltd during the applicablewarranty period.
Always identify the product, by both model number and serial number, when contacting Luxinar Aftersales.

If it becomes necessary to return a product for repair and/or adjustment, the instructions as to how andwhere these products should be shipped must be obtained from Luxinar Aftersales.

Service and repair
Servicing or calibration of the system can only be carried out by trained Luxinar service engineers or
customers who have undertaken and passed a Luxinar approved service training course. Details of training
courses and servicing can be obtained from the local Luxinar Aftersales address.

Table of contents
Preface
Audience
Other publications
How to use this manual
Admonitions
Connector labels and signal names
1. Safety........................................................................................................................................................... 1
1.1. General safety information................................................................................................................. 1
1.2. Label locations.....................................................................................................................................2
1.3. Labels.................................................................................................................................................. 4
1.4. Emission warning indicator................................................................................................................. 6
1.5. Maximum Permissible Exposure and Nominal Ocular Hazard Distance............................................. 7
1.6. Decommissioning and disposal........................................................................................................... 7
2. General description..................................................................................................................................... 92.1. Principle of operation.......................................................................................................................... 92.2. Laser head — standard version........................................................................................................... 92.3. Laser head — shutter version........................................................................................................... 10
2.4. DC power supply (optional)...............................................................................................................10
2.5. OEM 65iX three-phase DC power supply (016-0031-00).................................................................. 11
2.5.1. General description.................................................................................................................... 11
2.5.2. Specification............................................................................................................................... 11
2.5.3. Installation..................................................................................................................................122.5.4. Operation................................................................................................................................... 15
2.6. OEM 65iX three-phase DC power supply (016-0033-00).................................................................. 19
2.6.1. General description.................................................................................................................... 19
2.6.2. Specification............................................................................................................................... 19
2.6.3. Installation..................................................................................................................................20
2.6.4. Operation................................................................................................................................... 23
2.7. OEM-sourced DC power supply and Luxinar controller.................................................................... 26
2.7.1. General description.................................................................................................................... 26
2.7.2. Specification............................................................................................................................... 26
2.7.3. Installation..................................................................................................................................27
2.8. Absorbing Thin Film Reflector (ATFR)/circular polariser................................................................... 29
2.8.1. Back reflection considerations................................................................................................... 30
2.9. Specifications.................................................................................................................................... 30
2.9.1. RF power supply......................................................................................................................... 30
2.9.2. RF cable — RF power supply to laser head................................................................................ 30
2.9.3. OEM sourced DC power supply requirements........................................................................... 31
2.9.4. Dimensions................................................................................................................................. 31
2.9.5. Weights...................................................................................................................................... 31
2.9.6. Customer connections............................................................................................................... 31
2.9.7. Cooling system........................................................................................................................... 31
2.9.8. Optics purge gas......................................................................................................................... 32
2.9.9. Environmental specifications..................................................................................................... 33
2.9.10. Performance............................................................................................................................. 33
2.9.11. Laser diode pointer option....................................................................................................... 33
3. Operation................................................................................................................................................... 35
3.1. Overview of control options..............................................................................................................35
3.1.1. Hand-held MCU (Mobile Control Unit).......................................................................................35
3.1.2. Host machine commands using the U1 connector.....................................................................36
3.2. General considerations before starting the laser..............................................................................36
3.3. Start-up............................................................................................................................................. 37
3.4. Shutdown.......................................................................................................................................... 37
3.5. Emergency stop................................................................................................................................. 37
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Table of contents

4. Diagnostics and troubleshooting.............................................................................................................. 39
4.1. Laser status indicator diagnostics controller.....................................................................................39
4.2. RS232 error codes............................................................................................................................. 42
5. Routine maintenance................................................................................................................................ 45
5.1. General cleaning................................................................................................................................45
5.2. Safety shutter.................................................................................................................................... 45
5.3. Purge gas filter.................................................................................................................................. 45
5.4. Fuse replacement.............................................................................................................................. 47
5.5. Cooling system contamination.......................................................................................................... 48
5.6. Frost protection.................................................................................................................................49
6. Installation................................................................................................................................................. 51
6.1. Installation procedure....................................................................................................................... 51
6.2. Unpacking, mounting and connections............................................................................................. 52
6.2.1. Unpacking...................................................................................................................................52
6.2.2. Lifting techniques and precautions............................................................................................ 52
6.2.3. Mechanical fixing........................................................................................................................54
6.2.4. Laser output aperture location.................................................................................................. 55
6.2.5. Coolant connections and pipework............................................................................................56
6.2.6. Beam delivery optics purge gas..................................................................................................57
6.2.7. Luxinar combined controller/DC power supply......................................................................... 57
6.2.8. OEM-sourced DC power supply and Luxinar controller............................................................. 60
6.2.9. DC cabling................................................................................................................................... 62
6.2.10. DC connectors.......................................................................................................................... 63
6.2.11. RF cables...................................................................................................................................66
6.2.12. Cables for robotics applications............................................................................................... 67
6.2.13. Beam delivery system.............................................................................................................. 67
6.2.14. Absorbing Thin Film Reflector (ATFR)/circular polariser.......................................................... 68
7. Transport and recommissioning............................................................................................................... 69
8. Interfacing.................................................................................................................................................. 71
8.1. Standard interface............................................................................................................................. 72
8.2. SCX 30 emulation mode interface..................................................................................................... 77
8.3. Connector U2 —all modes................................................................................................................ 81
8.4. Connector U1 — standard connections for laser output.................................................................. 83
8.4.1. Minimum connections — internal PWM mode......................................................................... 84
8.4.2. Minimum connections — Auto mode........................................................................................ 84
8.4.3. Minimum connections — external PWM mode......................................................................... 85
8.4.4. Connector U1 SCX 30 emulation connections for laser output..................................................85
8.4.5. Timing diagrams......................................................................................................................... 86
Appendix A. Acoustic zones.......................................................................................................................... 89
Appendix B. Dimensional drawings.............................................................................................................. 91
Appendix C. Coolant requirements and additives........................................................................................ 99
C.1. Coolant quality.................................................................................................................................. 99
C.2. Suspended particle removal..............................................................................................................99
C.3. Corrosion and anti-bacterial inhibitor............................................................................................... 99
Appendix D. Cooling system pressure drop curves.................................................................................... 101
Appendix E. Parts list................................................................................................................................... 103
Appendix F. Applications troubleshooting................................................................................................. 105
F.1. Common issues................................................................................................................................105
Table of contentsii

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F.2. Causes and corrective actions......................................................................................................... 107

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Table of contents

Table of contentsiv

906-0238-00 REV 4

Preface
Audience
This manual should be read by all personnel who install or operate OEM 65iX lasers.
Important!
Read this manual carefully before operating the laser for the first time. Pay special attention to
the Safety chapter.

The OEM 65iX is designed and sold for use in Original Equipment Manufacturer (OEM) systems and is
not to be used as a stand-alone laser. The OEM is responsible for compliance with all applicable safety
regulations.

Other publications••••

Luxinar part number 906-0251-xx; Safety manual
Luxinar part number 906-0109-00; Serial interface specification
Luxinar part number 906-0104-xx; Optical isolation (ATFR)
Luxinar part number 906-0202-99; Chiller coolant temperature tables

How to use this manual
The following conventions are used in this manual.

Admonitions
The use of controls, replacement parts, adjustments, or procedures other than those specified within
this manual may result in exposure to any of these hazards.
• Laser hazards• Electrical hazards• Environmental hazards• Mechanical hazards
The degree of seriousness of the hazard is indicated by the use of the following signal words:

DANGER
Indicates an imminent hazard which, if not avoided, is extremely likely to result in death or serious
injury.

WARNING
Indicates a potentially hazardous situation which, if not avoided, could result in death or serious
injury.

CAUTION
Indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate
injury. It is also used to alert the user against unsafe working practices and potential damage to theequipment.

Connector labels and signal names
Connector labels and signal names are shown in bold serif font to aid identification.
For example; RF Enable, external interlock

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PrefacePrefacevi

906-0238-00 REV 4

1. Safety
1.1. General safety information
It is strongly recommended that any personnel who are involved with the installation, operation or
maintenance of this laser equipment should first read and fully understand the contents of this manualand Safety manual 906-0251-xx.
If there are any questions or doubts on any of the safety aspects of the equipment, then do not hesitate
to contact your nearest Luxinar Aftersales office or distributor for advice before proceeding.
The installation, operation, maintenance and repair of this laser equipment must only be carried out by
Luxinar service personnel or trained staff who have received correct instruction concerning the hazards
associated with this particular equipment.
Important!
All safety critical instructions contained within this document are framed with a border andidentified by CAUTION, WARNING or DANGER depending on the severity of the risk involved. In
addition, the safety symbol indicates that care should be taken when working with or on thelaser equipment.

Luxinar does not accept liability for any damage or injury howsoever caused or arising.
The symbol given below is also used on the equipment and indicates that the user should refer to the
OEM equipment operator’s manual for more information on the safe operation or installation of theequipment.

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1

1. Safety

1.2. Label locations
Version with covers

A1

A2

A5
A3

Figure 1 - Location of safety labels - Version with covers

1. Safety

2906-0238-00 REV 4

Version without covers

A1

A2

A6

A4
A5
A3
Figure 2 - Location of safety labels — Version without covers

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3

1. Safety

Shutter
A7

A5

A1

A2

Figure 3 - Location of safety labels — Shutter option

1.3. Labels

Figure 4 - Label A1 — Output specification without diode option

Figure 5 - Label A1 — Output specification with red diode option

1. Safety

4906-0238-00 REV 4

Figure 6 - Label A1 — Output specification with green diode option

WARNING
Disconnect the mains supply
before removing this cover
Figure 7 - Label A2 — Mains supply warning
AVOID EXPOSURE INVISIBLE
LASER RADIATION IS
EMITTED FROM THE APERTURE

Figure 8 - Label A3 — Laser aperture without shutter option

Figure 9 - Label A4 — Non-interlocked panel

Figure 10 - Label A5 — Laser hazard

Figure 11 - Label A6 — High temperature hazard
AVOID EXPOSURE INVISIBLE AND
VISIBLE LASER RADIATION IS
EMITTED FROM THE APERTURE

Figure 12 - Label A7 — Laser aperture with shutter option

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5

1. Safety

5

6

1
2
4

3

1

Model number

2

Part number

3

Serial number

4

Input

5

Revision

6

Weight7

IP rating7

Figure 13 - Label A8 — Product identification and certification

1.4. Emission warning indicator
An emission warning indicator is fitted to the laser head cover adjacent to the output aperture. Whenthe indicator is illuminated, the laser is capable of emitting harmful laser radiation.

DANGER
Risk of injury to eyes and exposed skinThis is a Class 4 (Class IV) laser product. All precautions relevant to this class of laser productshould be strictly observed. Use of controls or adjustments or performance of procedures otherthan those specified herein may result in hazardous radiation exposure. Strict compliance withthe safety precautions set out and referred to in this manual and extreme care in use are
essential to minimise the chance of accidental damage to the equipment or personal injury.
Luxinar does not accept liability for any damage or injury howsoever caused or arising.

1. Safety

6906-0238-00 REV 4

1

1

Emission warning indicator

Figure 14 - Emission warning indicator location

1.5. Maximum Permissible Exposure and Nominal Ocular Hazard Distance
The Maximum Permissible Exposure (MPE) is the level of radiation to which, under normal
circumstances, persons may be exposed without adverse effects. The MPEs represent the maximum
level to which the eye or skin can be exposed without consequential injury and are related to thewavelength of the laser radiation, the pulse duration or exposure duration, and the tissue at risk.
The MPEs given in the following tables are informative and provided so that the integrator can calculate
the Nominal Ocular Hazard Distance (NOHD), perform a risk analysis and inform the user about the safe
usage of the product. However, exposure limits for the eye and the skin of employees in the work place
and the general public are in many countries specified in national laws. These legally-binding national
exposure limits might differ from the MPEs given in the tables below.
The NOHD is the distance from the output aperture beyond which the beam irradiance or radiantexposure remains below the appropriate MPE. Importantly, the NOHD is dependent upon the beam
waist size and the divergence of the beam. Therefore, the NOHD is dependent upon the opticalcomponents acting on the beam. The NOHDs given in the tables below are relevant only when the laser
is operated without external beam delivery attached. When beam delivery is attached it is the
responsibility of the integrator or end-user to recalculate the NOHDs. Further details of the safe use oflasers are given with IEC/ TR 60824-14 "Safety of laser products – Part 14: A user’s guide."
Wavelength (µm)

10.6

10.25

MPE (W/m²)

1000

1000

NOHD (m)

1700

1700

1.6. Decommissioning and disposal
Dispose of the system according to appropriate local regulations.

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1. Safety

1. Safety

8906-0238-00 REV 4

2. General description
2.1. Principle of operation

1

Output laser beam

2

Output window

3

Resonator output mirror

4

Coolant out

5Radio frequency input electrode

6

Coolant in

7

Resonator rear mirror

8

Gas discharge (active laser medium)

9

Wave guide electrodes

10

Ground electrode

Figure 15 - Diffusion cooled slab laser components

Figure 15 shows the principle of operation of a slab laser. A gas discharge (8) forms the active laser
medium and is established between the wave guide electrodes (9) by a radio frequency voltage (5, 10).
The rear mirror (7) and output mirror (3) form the optical resonator. The laser beam (1) is produced
within the resonator and is emitted through an output window (2). Liquid coolant flowing between the
input (6) and output (4) is used to cool the electrodes.

2.2. Laser head — standard version
The OEM 65iX laser is a high-frequency RF excited, diffusion-cooled CO2 slab laser designed for industrial
use as a cutting, welding or marking tool.
Due to the configuration of the electrodes in a slab laser, the emitted laser beam diverges at different
rates in the x (free space) and the y (waveguide) directions. In order to make the beam circular the
output beam is reshaped using reflective correction optics. This may be achieved by using single opticalelements or the combination of cylindrical and spherical elements.
Depending on the configuration of the resonator, there may also be diffraction effects due to the output
optic of the resonator. This can produce secondary lobes on the main output beam that need to be
scraped or filtered out. This is achieved by the use of a spatial filter.
After beam reshaping and spatial filtering, the beam quality is ideal for any material processing
operation that requires excellent mode quality and stability.

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9

2. General description

1

Laser resonator

2

Beam turning block3

Spatial filter

4

Beam correction module5

Output window

6

Coolant flow sensor

Figure 16 - Laser head layout

2.3. Laser head — shutter version
The OEM 65iX can be fitted with a safety shutter to block the laser output. The shutter is designed as asafety device and is not intended to operate as a continuous beam block or process shutter.
When closed, a mirror within the shutter assembly deflects the beam into a beam dump. The beam
dump absorbs all the energy of the laser beam and will become very hot if the laser is run for a long
period with the shutter in the closed position.
Safety circuitry in the OEM 65iX controller provides interlocking so that laser output is disabled
whenever the shutter is in the closed position. In addition, opto-sensors continuously monitor the open
and closed status of the shutter.
The shutter module contains a laser diode pointer that outputs a low-power visible red laser beamcoaxial with the main laser beam. This visible beam provides an indication of where the main laser beam
will hit the material to be processed.

2.4. DC power supply (optional)
Contact Luxinar for more details of power supply options.

2. General description

10906-0238-00 REV 4

2.5. OEM 65iX three-phase DC power supply (016-0031-00)
2.5.1. General description
Note: This equipment is designed for indoor use only, pollution degree 2 and overvoltage category II as
defined within EN 61010-1:2010+A1:2019.
The OEM 65iX three-phase power supply is a free-standing/ rack mountable, AC to DC liquid-cooled
power supply (PSU).

Figure 17 - OEM 65iX three-phase DC power supply

2.5.2. Specification

WARNING
Heavy equipment — risk of severe lumbar injury
The weight of the DC power supply exceeds the single person lift limit of 18kg, as specified in
EN 61010-1:2010+A1:2019. Ensure a minimum of two people lift the power supply or thatsuitable lifting equipment is employed.

Table 1 - Dimensions, weight and cooling
Dimensions (mm) LxWxH

445x627x243

Weight50kg

Coolant type

Demineralised, deionised or distilled water withcorrosion inhibitor & anti-bacterial additive

Coolant pipe

10mm OD, fitted with 10mm – 12mm push-fit fittings

Coolant flow rate

Refer to section 2.9.7

Protection classIP51

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2. General description

Figure 18 - Overall dimensions
Table 2 - Electrical specifications
OEM 65iX
Input voltage range

360-440VAC (50/60Hz) three-phase (1)Mains input fuse rating (per phase)

32A

AC inrush current (max)80A

Output voltage (DC)50 ± 2%

Output current

300A

Power factor>0.90 at full power

Power consumption (max)

16kW at full power

Earth leakage current<8mA

Important!
An external disconnect device must be fitted at the time of installation, and must be accessible
without needing to use a tool. This must be suitably located and easily reached and must be
marked as the disconnecting device for the power supply.

2.5.3. Installation
Mechanical installation
Using suitable fasteners, mount the power supply within the OEM machine racking using the four
mounting holes shown in the following figure.

Figure 19 - Fixing locations

1. No neutral connection is required. Connection to neutral will cause irreparable damage to the power supply.

2. General description

12906-0238-00 REV 4

Mains AC power connections
Important!
Under certain conditions, it may be possible for high voltage and current cables to emit noise
energy levels that may interfere with control signal cables. To eliminate the possibility ofinterference, cables carrying control signals should be routed along a different path to power
cables.

The power supply is provided with a 4mm2 mains supply cable. If this cable needs to be replacedwith a longer cable, ensure the replacement cable is of the correct rating for the power supply.

DANGER
Risk of electric shock or severe damage to the equipment
Ensure that the equipment is disconnected from the mains supply before making thisconnection.

Connect the three-phase cable to the L1, L2 and L3 terminals on the rear panel of the power supply.
Connect the earth wire to the earth terminal.

1
1

L1

2

L2

3

L3

4

Earth

3

2

4

Figure 20 - Three-phase mains supply connection

Important!
An earth connection is essential. Ensure that the earth wire is connected before connecting
the mains supply.

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13

2. General description

CAUTION
Risk of irreparable damage to the power supply
Do not connect the power supply to neutral.

DC laser supply cables
DC power and DC control cables must be securely fitted to the connectors provided on the rear
panel of the power supply and on the laser system.

1
1

DC cable 1

2

DC cable 2

2

Figure 21 - Cable connectors

Figure 22 - Cable connectors

DC power cables of the correct specification can be supplied by Luxinar.

Cooling system connections
The power supply requires a liquid cooling source. It is recommended that it is connected in series
with the laser system cooling circuit. The coolant connections are located on the rear of the power
supply. See section 6.2.5 and the following figure.

2. General description

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1
1

Coolant OUT

2

Coolant IN

2

Figure 23 - Coolant connections

The coolant inlet and outlet connectors are labelled as shown in the following table.
Coolant IN

Coolant OUT

Note: The DC power supply has internal temperature monitors. If the internal temperature exceeds predefined limits, the power supply will shut down.

2.5.4. Operation
The power supply requires a user input to enable it. When powered up, it will automatically carry out
diagnostic checks, which will take a maximum of 7 seconds to complete. If no faults are detected, thenthe DC power supply is ready for use.

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15

2. General description

1
1

2

3

4

Control electronics power switch

2

Power supply LED indicators

3

MCU connection (optional)

4

System LED indicators

Figure 24 - Power supply front panel connections and LED indicators

Control electronics power switch
When mains voltage is connected to the power supply (see section 2.5.3) the electronics to control
the OEM 65iX can be switched on and off using this switch. This switch does not turn the mains
supply on or off

Power supply indicators
The LED indicators on the front panel provide information about the power supply operating status.

Table 3 - Power supply LED indicators
LED

Meaning

READY

The three-phase mains supply is correctly connected
(2)

Uok

Once the PSU Enable signal is applied, the DC output
will turn on. The output voltage is internally comparedto the set reference voltage. If this is correct, the Uok
indicator will illuminate(3)TEMPWThis indicator warns that the internal temperature is
too high. Check that the coolant flow and temperatureare correct.

2. The power supply uses a soft-start circuit during power up and the FAULT indicator will illuminate momentarily during this time. This is normal. If the mains
supply is switched on and off too often, the soft-start resistors heat up and the FAULT indicator illuminates. If this happens, switch off the mains supply andwait for 5 minutes for the resistors to cool down.
3. If the external voltage is not correct, the DC output is turned off and the FAULT indicator illuminates. Check external wiring.

2. General description

16906-0238-00 REV 4

LEDMeaning

FAULT

This indicator illuminates when corrective action isrequired. At the same time DC output is turned off.
Switch off the three-phase mains supply to reset thepower supply. If Faults are detected, 1 or more statusindicators will be off or displaying red/amber.
Disconnect and reconnect the mains supply to restart
the power supply. Refer to Table 4

Important!
If the TEMPW indicator is illuminated and no action is taken and the internal temperature
continues to rise, the FAULT indicator will illuminate and the DC output is turned off.

System indicators
The 16 LEDs are used to identify the status of the laser operation, and what action, if any, is requiredfor correct operation.

The LEDs are split into 3 colour groups (Red, Orange and Green).
• Red indicates a fault or the control electronics is waiting corrective action. The laser will not
operate.
• Orange indicates a potential fault or the control electronics is waiting for corrective action.
Investigation is required.
• Green indicates correct operation. The laser is ready to operate.
When the laser is operating correctly, only green LEDs will be displayed.
Table 4 - System indicators

906-0238-00 REV 4

LEDFunction1

DC power supply status

2

RF enabled3

Modulation mode

4

Modulation present

5

Diode pointer enabled

6

Shutter closed monitor

7

RF VSWR status

8

PWM input out of range (Over modulation)

9Interlock fault

10

RF disabled

17

2. General description

LED

Function

11

RF temperature fault

12

RF fault

13

Shutter fault

14

Shutter disabled15

Laser temperature fault

16

Coolant flow fault

MCU connection (optional)
Connection for MCU, if available.

2. General description

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2.6. OEM 65iX three-phase DC power supply (016-0033-00)
2.6.1. General description
Note: This equipment is designed for indoor use only, pollution degree 2 and overvoltage category II as
defined within EN 61010-1:2010+A1:2019.
The OEM 65iX three-phase power supply is a free-standing/ rack mountable, AC to DC liquid-cooled
power supply (PSU).

Figure 25 - OEM 65iX three-phase DC power supply

2.6.2. Specification

WARNING
Heavy equipment — risk of severe lumbar injury
The weight of the DC power supply exceeds the single person lift limit of 18kg, as specified in
EN 61010-1:2010+A1:2019. Ensure a minimum of two people lift the power supply or thatsuitable lifting equipment is employed.

Table 5 - Dimensions, weight and cooling
Dimensions (mm) LxWxH

559x483x223

Weight24kg

Coolant type

Demineralised, deionised or distilled water withcorrosion inhibitor & anti-bacterial additive

Coolant pipe

10mm OD, fitted with 10mm – 12mm push-fit fittings

Coolant flow rate

Refer to section 2.9.7

Pressure

Maximum 88psi (6bar)

Protection classIP51

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2. General description

Figure 26 - Overall dimensions
Table 6 - Electrical specifications
OEM 65iX
Input voltage range

380-480VAC (50/60Hz) three-phase (4)Mains input fuse rating (per phase)

40A

AC inrush current (max)80A

Output voltage (DC)50 ± 2%

Output current

330A

Power factor>0.90 at full power

Power consumption (max)

16.5kW at full power

Earth leakage current<5mA

Important!
An external disconnect device must be fitted at the time of installation, and must be accessible
without needing to use a tool. This must be suitably located and easily reached and must be
marked as the disconnecting device for the power supply.

2.6.3. Installation
Mechanical installation
Using suitable fasteners, mount the power supply within the OEM machine racking using the four
mounting holes shown in the following figure.

Figure 27 - Fixing locations
4. No neutral connection is required. Connection to neutral will cause irreparable damage to the power supply.

2. General description

20906-0238-00 REV 4

Mains AC power connections
Important!
Under certain conditions, it may be possible for high voltage and current cables to emit noise
energy levels that may interfere with control signal cables. To eliminate the possibility ofinterference, cables carrying control signals should be routed along a different path to power
cables.

The power supply is provided with a 4mm2 mains supply cable. If this cable needs to be replacedwith a longer cable, ensure the replacement cable is of the correct rating for the power supply.

DANGER
Risk of electric shock or severe damage to the equipment
Ensure that the equipment is disconnected from the mains supply before making thisconnection.

Connect the three-phase cable to the L1, L2 and L3 terminals on the rear panel of the power supply.
Connect the earth wire to the earth terminal.

1

2
1

L1

2

L2

3

L3

4

Earth

3

4

Figure 28 - Three-phase mains supply connection

Important!
An earth connection is essential. Ensure that the earth wire is connected before connecting
the mains supply.

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21

2. General description

CAUTION
Risk of irreparable damage to the power supply
Do not connect the power supply to neutral.

DC laser supply cables
DC power and DC control cables must be securely fitted to the connectors provided on the rear
panel of the power supply and on the laser system.

2

1
1

DC cable 1

2

DC cable 2

Figure 29 - Cable connectors

Figure 30 - Cable connectors

DC power cables of the correct specification can be supplied by Luxinar.

Cooling system connections
The power supply requires a liquid cooling source. It is recommended that it is connected in series
with the laser system cooling circuit. The coolant connections are located on the rear of the power
supply. See section 6.2.5 and the following figure.

2. General description

22906-0238-00 REV 4

1
1

Coolant IN

2

Coolant OUT

2

Figure 31 - Coolant connections

The coolant inlet and outlet connectors are labelled as shown in the following table.
Coolant IN

Coolant OUT

Note: The DC power supply has internal temperature monitors. If the internal temperature exceeds predefined limits, the power supply will shut down.

2.6.4. Operation
The power supply requires a user input to enable it. When powered up, it will automatically carry out
diagnostic checks, which will take a maximum of 7 seconds to complete. If no faults are detected, thenthe DC power supply is ready for use.

1
1

2

3

4

Control electronics power switch

2

Power supply LED indicators

3

MCU connection (optional)

4

System LED indicators

Figure 32 - Power supply front panel connections and LED indicators

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23

2. General description

Control electronics power switch
When mains voltage is connected to the power supply (see section 2.6.3) the electronics to control
the OEM 65iX can be switched on and off using this switch. This switch does not turn the mains
supply on or off

Power supply indicators
The LED indicators on the front panel provide information about the power supply operating status.

FAULT

M1

M2

STATUS

M3

DC

AC

Table 7 - Power supply LED indicators
Indicator

Status definition

STATUSNo AC voltage detected
AC

AC input voltage within range (correct operation)
AC input voltage out of range
DC output voltage disabledDC

DC output voltage present (correct operation)
DC output voltage out of range

FAULT
PSU disabled
M1, M2, M3

PSU module enabled (correct operation)
PSU module fault

System indicators
The 16 LEDs are used to identify the status of the laser operation, and what action, if any, is requiredfor correct operation.

The LEDs are split into 3 colour groups (Red, Orange and Green).
• Red indicates a fault or the control electronics is waiting corrective action. The laser will not
operate.
• Orange indicates a potential fault or the control electronics is waiting for corrective action.
Investigation is required.
• Green indicates correct operation. The laser is ready to operate.

2. General description

24906-0238-00 REV 4

Table 8 - System indicators
LED

Function1

DC power supply status

2

RF enabled3

Modulation mode

4

Modulation present

5

Diode pointer enabled

6

Shutter closed monitor

7

RF VSWR status

8

PWM input out of range (Over modulation)

9Interlock fault

10

RF disabled

11

RF temperature fault

12

RF fault

13

Shutter fault

14

Shutter disabled15

Laser temperature fault

16

Coolant flow fault

MCU connection (optional)
Connection for MCU, if available.

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25

2. General description

2.7. OEM-sourced DC power supply and Luxinar controller
2.7.1. General description
Note: This equipment is designed for indoor use only, pollution degree 2 and overvoltage category II as
defined within EN 61010-1:2010+A1:2019.
The OEM 65iX controller is free-standing/rack mountable and must be used to interface the laser system
to the DC power supply.

Figure 33 - OEM 65iX controller

2.7.2. Specification
Table 9 - Dimensions and weight
Dimensions (mm) LxWxH

465x225x88

Weight5kg

Protection class

IP51

Figure 34 - Overall dimensions

2. General description

26906-0238-00 REV 4

Table 10 - Electrical specifications
OEM 65iX
Input voltage range

380-480VAC (50/60Hz) three-phase (5)Mains input fuse rating (per phase)

0.5A

Mains inrush current (max)5A

Output voltage (DC)50 ± 2%

Output current

1A

Power factor>0.90 at full power

Power consumption (max.)

50W at full power

Earth leakage current<1mA

Important!
An external disconnect device must be fitted at the time of installation, and must be accessible
without needing to use a tool. This must be suitably located and easily reached and must be
marked as the disconnecting device for the power supply.

2.7.3. Installation
Mechanical installation
Using suitable fasteners, mount the power supply within the OEM machine racking using the four
mounting holes shown in the following figure.

Figure 35 - Fixing locations

Interface connections
The controller requires user interface connections for correct operation.

1
1

2

3

50V DC power connector

2

DC enable output connector (optional)

3

Mains AC power connector

Figure 36 - Controller interface connections

5. Only two phases are required. No neutral connection is required. Connection to neutral will cause irreparable damage to the controller.

906-0238-00 REV 4

27

2. General descriptionImportant!
An earth connection is essential. Ensure that the earth wire is connected before connecting
the mains supply.

CAUTION
Risk of irreparable damage to the power supply
Do not connect the power supply to neutral.

Mains AC power connections
Important!
Under certain conditions, it may be possible for high voltage and current cables to emit noise
energy levels that may interfere with control signal cables. To eliminate the possibility ofinterference, cables carrying control signals should be routed along a different path to power
cables.

The power supply is provided with a 1.5mm2 mains supply cable. If this cable needs to be replacedwith a longer cable, ensure the replacement cable is of the correct rating for the power supply.
A pre-configured two-phase and earth cable (part number 091-0359-00) is supplied with thecontroller. Wires are identified as L1 and L2.

Figure 37 - Mains cable (091-0359-00)

DANGER
Risk of electric shock or severe damage to the equipment
Ensure that the equipment is disconnected from the mains supply before making thisconnection.

2. General description

28906-0238-00 REV 4

Connect the two-phase cable to the L1 and L2 terminals on the rear panel of the power supply.
Connect the earth wire to the earth terminal.
Important!
An earth connection is essential. Ensure that the earth wire is connected before connecting
the mains supply.

50V DC power connection
The controller requires 50VDC from the power supply to monitor and use for driving the OEM 65iX
laser head electronics.
This must be provided on the two-way plug provided on the controller.

Figure 38 - 50V DC power connection

DC Enable output connector (optional)
A volt-free contact connector is provided to allow the controller to enable and disable the OEM 50V
power supply if required. The internal relay type is NEC EA2-12NU.

Figure 39 - DC Enable output connector

Controller system connections

Figure 40 - Controller system connections

2.8. Absorbing Thin Film Reflector (ATFR)/circular polariser
The OEM 65iX can be supplied with an ATFR/circular polariser assembly that provides optical isolation toprotect the system from back reflections. The assembly mounts directly onto the system front flange
output aperture.
906-0238-00 REV 4

29

2. General descriptionRefer to document part number 906-0104-xx; Optical isolation (ATFR) for fitting instructions.

2.8.1. Back reflection considerations
Laser radiation can be reflected back from a workpiece or its supporting fixture within a material
processing machine. For example, if plastic sheet is cut on an aluminium supporting plate, a large
fraction of the laser beam could be reflected back from the supporting plate into the beam delivery
system and the laser head once the laser has cut through the plastic sheet.

CAUTION
Risk of severe damage to the laser and beam delivery system
To prevent damage or destruction of internal laser and beam delivery optics, ensure that backreflections are unable to enter the beam delivery system.

Note: Damage caused by back reflections is not covered by the equipment warranty. It is the
responsibility of the system integrator to protect the laser and its optics from back reflections.

2.9. Specifications
Note: This equipment is designed for indoor use only and Pollution Degree 2 as defined within EN
61010-1:2010+A1:2019

2.9.1. RF power supply
Table 11 - RF power supply characteristics
DC input (RF)50VDC ± 12%

DC input (RF) load capacitance

220mF

DC input (RF) average current

280A

Peak RF output (envelope)

16kW @ 81.36MHz

Maximum average RF output power

9.6kW @ 60%

Duty cycle

Single pules to 60%

Pulse width range

2–400µs

Frequency range(6)0–130kHz

2.9.2. RF cable — RF power supply to laser head
Cable type

Coaxial, double shielded

Cross section diameter

15mm

Static minimum bend radius

152mm

Dynamic minimum bend radius

400mm

RF connector torque setting

25Nm

Cable length

Contact Luxinar Aftersales for details of available cable
lengths and other properties.

6. 500Hz–5kHz unavailable for 10.25µm variant

2. General description

30

906-0238-00 REV 4

2.9.3. OEM sourced DC power supply requirements
Table 12 - OEM sourced 50VDC power supply requirements
Output voltage

50V ± 2%Average output current

280A

Output power≥ 14kW

2.9.4. Dimensions
Table 13 - External dimensions
Laser head — LxWxH (mm)1206x350x288

Laser head (without covers) — LxWxH (mm)1152x350x288

RF power supply — LxWxH (mm)726x783x243

Mobile control unit — LxWxH (mm)220x115x51

2.9.5. Weights
Note: All weights are approximate.
Table 14 - Laser head and RF power supply weights
Laser head Including covers

134kg

Laser head excluding covers

113.50kg

RF power supply

51kg

Mobile control unit (including cable)

0.72kg2.9.6. Customer connections
Refer to Chapter 8 for interfacing details.

2.9.7. Cooling system
The OEM 65iX requires a temperature stabilised recirculating coolant circuit in order to operatecorrectly.
The preferred coolant is deionised water or deionised water with anti-bacterial additive. See
Appendix C.
Important!
To prevent condensation on optical surfaces, the coolant temperature must be maintained
above the dew point.

The following look-up table defines minimum coolant temperatures (above the dew point) that avoid
condensation with respect to ambient temperature and relative humidity.

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31

2. General description

Table 15 - Minimum laser resonator coolant temperatures
Ambient temperature (°C)

Relative
humidity

20

25

30

35

40

45%

19

19

19

24

29

50%

19

19

20

25

30

55%

19

19

21

26

60%

19

19

22

27

65%

19

19

23

28

70%

19

19

24

29

75%

19

20

25

30

80%

19

21

26

85%

19

22

27

90%

19

23

28

95%

19

24

29

45

Table 16 - Coolant specification
Minimum flow rate (L/min)

10

Maximum flow rate (L/min)

15

Maximum pressure

4.0–6.0bar (58–88psi)

Dissipation

16kW

Required refrigeration capacity

16kW

Coolant temperature
Note: Coolant temperature must be above the dew
point.

19–25°C (Optimum temperature 21°C. Allow 1% output
power drop per 1°C increase.)
Refer to document 906-0202-99 for more details.

Inline particle filter

100µm particle size

Pipe connections

12mm, push-fit fittings
Hose tail fittings with 12mm ID and 12.7mm OD are
supplied with the equipment.

2.9.8. Optics purge gas
Table 17 - Optics purge gas specification
Purge gas pressure

0.07–0.21bar (1–3psi)

Flow rate

1–2L/minNitrogen purity
Nitrogen purity grade≥ 4.6 (O2 ≤ 3vppm, H2O ≤ 2vppm )Compressed air contamination limits
Oil≤ 0.005mg/m3

Water≤ 0.05g/m3

Particles≤ 0.05µm

2. General description

32

906-0238-00 REV 4

2.9.9. Environmental specifications
Note: This equipment is designed for indoor use only and Pollution Degree 2 as defined within EN
61010-1:2010+A1:2019
Table 18 - Environmental specifications
Ambient working temperature

5–40°C

Storage temperature (with drained cooling circuit)

5–70°C

Relative humidity (non-condensing)

10–85%

Maximum altitude< 2000m

2.9.10. Performance
Table 19 - OEM 65iX output characteristics
Output wavelength

10.6µm (10.45–10.7µm)

10.25µm (10.17–10.33µm)

Rated average power range at 400µs
maximum duty (1.5kHz)

35–650W

30-540W

Peak power

1640W

1360W

Pulse energy

26–520mJ

22-430mJ

Pulse rise and fall time

< 60µsTypical power stability± 4.10%

Typical power stability with power
feedback± 1%

Guaranteed power stability± 7%

Guaranteed power stability withpower feedback± 2%

Optical pulse rise time (10–90%)

60µs

Excitation frequency

81MHz

Expected tube lifetime

20000 hours

Beam diameter (1/e2)

11.6 ± 1mm (1/e2) at the laser output optic

M2 (K)< 1.2 (> 0.83)

Beam divergence< 1.75mrad (1–10m)

Beam ellipticity< 1.2:1

Pointing stability< 0.25mrad (half angle)

Polarisation

Linear parallel to the laser base

2.9.11. Laser diode pointer option

WARNINGClass 3R visible laser radiation
Avoid eye exposure to direct and scattered radiation.

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33

2. General description

Table 20 - Laser diode pointer specification (Red)
Wavelength

635 ± 10nm @ 25°C

Maximum output power

4mW

Power stability

5% @ 25°C

Divergence<2.5 mrad

Beam diameter (at the output aperture)

0.25mm @ the output aperture

Pointing stability<0.2mrad per °C
Table 21 - Laser diode pointer specification (Green)

Wavelength

520 ± 10nm @ 25°C

Maximum output power

5mW

Power stability<5% @ 25°C

Divergence<2.0 mrad

Beam diameter (at 1m)

4.0 x 2.0mm

Pointing stability<0.2mrad per °C

2. General description

34

906-0238-00 REV 4

3. Operation
3.1. Overview of control options
Two options may be used to control the OEM 65iX laser:

3.1.1. Hand-held MCU (Mobile Control Unit)
The MCU (Mobile Control Unit) may be used to set up and program the system controller. This option isnormally used for initial system setup and for troubleshooting or servicing.
The MCU also displays the system operating status, IO status and laser power output.
For full programming details, see the MCU user manual, part number 906-0106-xx.

Figure 41 - Hand-held MCU
Press the F1 key to increase the value in the selected
field or to select the F1 menu option.
Press the F2 key to increase the value in the selected
field or to select the F2 menu option.
Press the F3 key to step the cursor to the next field or to
select the F3 menu option.
Press the F4 key to escape from the current screen
without saving changes or to select the F4 menu option.
Press the ACCEPT key to escape from the current
screen and save any changes.

906-0238-00 REV 435

3. Operation

3.1.2. Host machine commands using the U1 connector
The system controller may be directly set up and programmed by the host machine using the U1connector. This option is used for normal operation of the laser in a production environment. Forinterfacing details see Chapter 8.

Figure 42 - Combined controller/DC power supply — U1 & U2 connectors

U2

U1

Figure 43 - Stand-alone controller — U1 & U2 connectors

3.2. General considerations before starting the laser••

Ensure that the beam path is free from obstructions.
If the machine is in a maintenance or installation situation with machine guards removed, check that
there are no personnel within the area and that safety warning notices are prominently displayed.
• Ensure all interlocks are operating correctly.
• Verify that the material to be processed is suitable for CO2 laser processing.
• Verify that the material to be processed is correctly positioned and ready for processing.
Note: At operational frequencies between 300–400Hz, 600–800Hz, 1400–1800Hz and 2000–2500Hz
acoustic resonance may occur causing an unpleasant sound and possible degradation of the beam
quality.
Refer to Appendix A for details of frequencies to avoid.

3. Operation

36

906-0238-00 REV 4

3.3. Start-up
1.

Ensure that all machine safety features are present and activated.
If the machine is in maintenance mode with enclosure panels removed, ensure that the areasurrounding the machine complies with local laser safety regulations and that laser safety warning
notices are displayed prominently. All persons in the area must wear laser protection eyewear.

DANGER
Risk of injury to eyes and exposed skinThis is a Class 4 (Class IV) laser product. All precautions relevant to this class of laser productshould be strictly observed. Use of controls or adjustments or performance of procedures
other than those specified herein may result in hazardous radiation exposure. Strict
compliance with the safety precautions set out and referred to in this manual and extreme
care in use are essential to minimise the chance of accidental damage to the equipment or
personal injury. Luxinar does not accept liability for any damage or injury howsoever causedor arising.
2.
3.
4.
5.
6.
7.

Turn on the coolant circulating system and check for correct flow and temperature.
Turn on the optics purge gas.
Verify that all interlocks are closed.
Switch on mains power to the laser and controller.
Set the operating parameters on the machine controller.
Enable the RF power supply.

DANGER
Laser radiation hazard
Avoid exposure to direct and scattered radiation.
8.

Enable the shutter (shutter version only).
Important!
Certain pulsing regimes can cause acoustic resonance phenomena that perturb beam pointing
characteristics. See Appendix A for parameters to avoid.

3.4. Shutdown
1.
2.
3.
4.
5.

Close the shutter (shutter version only).
Disable the RF power supply.
Switch off mains power to the laser and controller.
Turn off the optics purge gas.
Turn off the coolant circulating system.

3.5. Emergency stopAn emergency stop is initiated by the OEM machine. The machine should automatically:• Remove the trigger signal (shutter version and power feedback version only).
• Close the shutter (shutter version only).

906-0238-00 REV 4

37

3. Operation

••

Remove the RF enable signal.
Break the laser interlock circuit.
Important!
For the shutter version and power feedback version, the laser will not restart unless the trigger
signal is removed and re-applied. Control signal timings must be respected when restarting. See
section 8.4.5.

3. Operation

38

906-0238-00 REV 4

4. Diagnostics and troubleshooting
4.1. Laser status indicator diagnostics controller
Table 22 - Laser status indicator diagnostics – Luxinar PSU with integrated controller
Indicator display

StatusActionIndicators 1–8

Normal operation — internal modeNo action required

Normal operation — external modeNo action required

Normal operation — internal mode.
Waiting for trigger signal.

Trigger signal required

VSWR error — internal mode

Contact Luxinar Aftersales••

Shutter closed — internal mode
Laser diode pointer OFF

Shutter open signal required••

Shutter closed — internal mod
Laser diode pointer ON

Shutter open signal required

Shutter disabled — internal mode

Shutter enable signal required

Shutter error — internal mode

Contact Luxinar Aftersales

•
•

•
•

Indicators 9–16

Indicators 1–8
Indicators 9–16

Indicators 1–8
Indicators 9–16

Indicators 1–8
Indicators 9–16

Indicators 1–8
Indicators 9–16

Indicators 1–8
Indicators 9–16

Indicators 1–8
Indicators 9–16

Indicators 1–8
Indicators 9–16

Indicators 1–8

DC PSU error — internal mode
System in standby mode

Check the DC PSU
Activate the system

Indicators 9–16

906-0238-00 REV 4

39

4. Diagnostics and troubleshooting

Indicator display

StatusActionIndicators 1–8

Interlock fault

Check for open machine interlocks

Coolant flow error — internal mode

Check the coolant flow rate andtemperature

Temperature fault — internal mode

Contact Luxinar Aftersales

Indicators 9–16

Indicators 1–8
Indicators 9–16

Indicators 1–8
Indicators 9–16

Table 23 - Laser status indicator diagnostics – OEM PSU with separate Luxinar controller
Indicators — left

Indicators — right

DC

INT

RF EN

RF DISOP

RF TEMPMOD

RF FLT

DIODSHTR FLTSHTRSHTR DISVSWRLAS TEMP

OMOD

FLOW

DC

INT

RF IN

RF PSUOP

RF TEMPMOD

RF FLT

DIODSHTR FLTSHTRSHTR DISVSWRLAS TEMP

CMOD

FLO

DC

INT

RF IN

RF PSUOP

RF TEMPMOD

RF FLT

DIODSHTR FLTSHTRSHTR DISVSWRLAS TEMP

CMOD

FLOW

4. Diagnostics and troubleshooting

StatusActionNormal operation — internalmode

No action required

Normal operation — externalmode

No action required

Normal operation — internal
mode

Trigger signal required

40

906-0238-00 REV 4

Indicators — left

906-0238-00 REV 4

Indicators — right

StatusActionVSWR error — internal mode

Contact Luxinar Aftersales•

Shutter closed — internal
mode
Laser diode pointer OFF

Shutter open signal required

Shutter closed — internal
mode
Laser diode pointer ON

Shutter open signal required

DC

INT

RF IN

RF PSUOP

RF TEMPMOD

RF FLT

DIODSHTR FLTSHTRSHTR DISVSWRLAS TEMP

CMOD

FLOW

DC

INT

RF IN

RF PSUOP

RF TEMPMOD

RF FLT

DIODSHTR FLTSHTRSHTR DISVSWRLAS TEMP

CMOD

FLOW

DC

INT

•

RF IN

RF PSU•OP

RF TEMPMOD

RF FLT

DIODSHTR FLTSHTRSHTR DISVSWRLAS TEMP

CMOD

FLOW

DC

INT

RF IN

RF PSUOP

RF TEMPMOD

RF FLT

DIODSHTR FLTSHTRSHTR DISVSWRLAS TEMP

CMOD

FLOW

DC

INT

RF IN

RF PSUOP

RF TEMPMOD

RF FLT

DIODSHTR FLTSHTRSHTR DISVSWRLAS TEMP

CMOD

FLOW

Shutter disabled — internal mode Shutter enable signal required

Shutter error — internal mode

41

Contact Luxinar Aftersales

4. Diagnostics and troubleshooting

Indicators — left

Indicators — right

StatusAction
•
•

DC

INT

•

RF IN

RF PSU•OP

RF TEMPMOD

RF FLT

DIODSHTR FLTSHTRSHTR DISVSWRLAS TEMP

CMOD

FLOW

DC

INT

RF IN

RF PSUOP

RF TEMPMOD

RF FLT

DIODSHTR FLTSHTRSHTR DISVSWRLAS TEMP

CMOD

FLOW

DC

INT

RF IN

RF PSUOP

RF TEMPMOD

RF FLT

DIODSHTR FLTSHTRSHTR DISVSWRLAS TEMP

CMOD

FLOW

DC

INT

RF IN

RF PSUOP

RF TEMPMOD

RF FLT

DIODSHTR FLTSHTRSHTR DISVSWRLAS TEMP

CMOD

FLOW

DC PSU error — internal
mode
System in standby mode

Check the DC PSU.
Activate the system.

Interlock fault — internal mode

Check for open machineinterlocks.

Coolant flow error — internal
mode

Check the coolant flow rate andtemperature.

Temperature fault — internal
mode

Contact Luxinar Aftersales

4.2. RS232 error codes
Table 24 - RS232 error codes
Error code ID

Description

Action01

Shutter error

The shutter module must be replaced. Contact Luxinar
Aftersales.

02

Emission indicator failure••

4. Diagnostics and troubleshooting

42

Check the emission indicator wiring loom for damage.
The emission indicator array is faulty and must be
replaced. Contact Luxinar Aftersales.

906-0238-00 REV 4

Error code ID

Description

Action03

DC voltage low

•
•
•
•

Check J1 and J2 are connected correctly.
Check the power supply status indicators.
Check the DC output voltage.
Replace the DC module. Contact Luxinar Aftersales.

04

DC voltage high•••Check the power supply status indicators.
Check the DC output voltage.
Replace the DC module. Contact Luxinar Aftersales.

05

DC current too high••Check the error log for previous problems. (1)Record the output power and performance of thesystem. Contact Luxinar Aftersales with the results.

06

Emergency stop

Contact Luxinar Aftersales.

07

External interlock

•
•
•

08

Laser head disconnected••

Reset the external interlock on the OEM machine.
Check all cable connections between the laser head
and the PSU/control unit.
Link connector U1, pins 9 and 21 to override theexternal interlock circuit. If the error clears, check theoperation of all external interlocks connected to thesystem. (2)Check that cable 093-0026-xxxx is connected between
the laser head and the controller connector LI.
Check that the cable is not damaged.

09

Laser head disabled

Check the error log history for the last error.

10

RF over temperature

11

T1 over temperature

12

T2 over temperature

•
•
•

13

Coolant flow low

14

Coolant flow high

•
•
•

15

VSWR

•
•

Check all coolant connections for leaks.
Check that all system components are connected.
Check the inline coolant filter for blockage and replace
if required.
Check that the chiller is filled to the correct level andthat the output pressure is within specification.
Check that coolant pipe diameters are as specified andthat the pipes are not damaged.
Check that the coolant temperature and the ambient
temperature of the surrounding area are within
specification.
Check that the RF cables are securely connected to thecorrect terminals.
Check that the RF cables are not damaged.

16

Overmodulation — External
mode

Check that the External input modulation signal is within
the specified operating parameters.

16

Overmodulation — Internalmode•

Test the system using Engineering mode.

••

Check the PID parameters. (3)Test the system with adaptive control switched off.

1. For information concerning use of the OEM 65iX controller, refer to 906-0106-00.
2. Pins 19 and 20 if system is operating in SCX 30 Emulation Mode.
3. For information concerning use of the OEM 65iX controller, refer to 906-0106-00.

906-0238-00 REV 4

43

4. Diagnostics and troubleshootingError code ID

Description

Action17

Laser power low

•
•

•
•
•
•

Check the output mode quality.
Isolate the system from the mains supply and check theoutput lens and beam delivery system mirrors forcontamination or signs of damage.
Check the laser system for any signs of external
damage.
Check that the RF cables are securely connected to thecorrect terminals.
Purge the internal and external beam delivery systems
using a purge gas supply.
Measure the laser output power using a calibrated
power meter.

18

Laser power highTest the system with adaptive control switched off. If theerror clears, reset the PID correction tables. (4)19At control limit

Test the system with adaptive control switched off. If theerror clears, reset the PID correction tables. (5)20

CanBus fault

•
•

21

User PWM limited

Check that all control cables are correctly attached andfree from damage.
Restart the system. If the error persists, contact Luxinar
Aftersales.

Check the external modulation signal is within thespecified operating parameters.

4. For information concerning use of the OEM 65iX controller, refer to 906-0106-00.
5. For information concerning use of the OEM 65iX controller, refer to 906-0106-00.

4. Diagnostics and troubleshooting

44906-0238-00 REV 4

5. Routine maintenance
The OEM 65iX has been designed to be low maintenance. Internal routine maintenance procedures are
not required. The system's sealed construction and limited number of moving parts ensure trouble-freeand reliable operation.

5.1. General cleaning

WARNING
Laser radiation and electrical hazards
Use of controls or adjustments or performance of procedures other than those specified herein
may result in hazardous laser radiation exposure. This is a Class 4 (Class IV) laser and the beam isinvisible to the eye.
Please review all safety instructions and precautions given in the Safety chapter before
attempting to operate or service this system.
Always ensure that the laser system is switched off and isolated from the mains supply before
attempting any cleaning or maintenance procedures.

••

The external surfaces of the system can be cleaned with a mild detergent. It is advisable to use adamp cloth to facilitate the cleaning of the external cabinets, etc.
Take care not to allow entry of water into any of the electrical cabinets or onto the output window
or final beam delivery optic.

5.2. Safety shutter
Under normal operating conditions, the shutter has been designed for a lifetime of two million
open/close operations. The shutter should be inspected during each routine maintenance procedureand must be replaced if there is any sign of damage to the reflector blade, solenoid mechanism, blade
sensors or electronic parts, or if the operational lifetime has been reached.

5.3. Purge gas filter
The purge gas maintains a slight positive pressure within the internal and external beam delivery system
to prevent ingress of contamination that could degrade the optical components. The purge gas
specification is detailed in section 2.9.8.
The purge gas inlet is fitted with a filter which must be inspected on a regular basis. If the filter appears
discoloured or contaminated, the filter must be replaced immediately and the gas supply must be
checked to find the cause of the contamination. Filter locations are shown in the following figures.

906-0238-00 REV 445

5. Routine maintenanceFigure 44 - Purge gas filter — version with covers

Figure 45 - Purge gas filter — version without covers

Replacement filters (part number 402-0006-00) are available from Luxinar Aftersales.
Important!
Damage caused by a contaminated purge gas supply is not covered by the warranty. It is the
responsibility of the OEM system integrator to ensure a correct and adequate purge gas supply is
installed.

5. Routine maintenance46906-0238-00 REV 4

5.4. Fuse replacement

DANGER
Risk of electric shock
Ensure that the equipment is disconnected from the mains supply before replacing fuses.

Table 25 - Fuses and circuit breakers (DC PSU 016-0031-00)
Part number

Current and type

Quantity

Location

Function

552-0035-00

500mA fuse

2

Inside the control
unit, rear panel(OEM-supplied DC
power supply)

Control unit
protection

552-0007-00

Fuse 5x20mm CERM
T HRC 1A

1

Inside the control
unit, rear panel(OEM-supplied DC
power supply)

Add 1A fuse to rear ofcontroller (OEMsupplied DC PSU) Part
552-0007-00, FUSE
5x20mm CERM T HRC
1A

569-0002-00

32A miniature circuit 1
breaker

DC power supply rear Mains input
panel
protection for the DC
power supply.

552-0019-00

1A fuseLaser head power
supply board(009-0092-00)

3

•
•
•

F1 — Pre-ioniser 1
F2 — Pre-ioniser 2
F3 — Shutter
driverNote: If a fuse fails again after replacement, this may indicate a more serious fault. For more information
and advice, contact Luxinar Aftersales.

1

2

3

4

Figure 46 - Control unit rear panel fuse holder location
906-0238-00 REV 447

5. Routine maintenance1

Figure 47 - Laser head power supply location

1

2

1

12V supply

2

18V supply

3

3

50V pre-ioniser supply 2

4

50V pre-ioniser supply 1

4

Figure 48 - Laser head power supply fuses and indicators

5.5. Cooling system contamination
If the coolant is contaminated with bacteria or has been treated with other chemicals it will benecessary to clean the cooling circuit:
The pH value, conductivity and dissolved solids levels can be measured using a portable meter. The
bacterial contamination level can be checked using a test kit. For more information and advice, contact
Luxinar Aftersales.
Pay particular attention to the instructions provided by the manufacturer of the NALCO water treatment
kit:
1. Drain off the contaminated coolant.
5. Routine maintenance48

906-0238-00 REV 4

2.
3.
4.
5.
6.
7.

Ensure that disposal of all the materials used in this product is conducted according to all local andnational regulations.
Flush the coolant circuit with tap water by filling and draining once only.
Mix tap water with deionised water in a 1:1 ratio and fill the coolant circuit.
Add a NALCO biocide water treatment kit and mix well with the cooling water.
Operate the system for two to four days, then drain off the coolant.
Flush the coolant circuit twice.
Fill the cooling system with fresh deionised water and add the contents of a fresh NALCO water
treatment kit.

5.6. Frost protection
If the cooling system or chiller which supplies the cooling for the laser system is located in an area
where the temperature may drop below 0°C, then the cooling circuit must be equipped with a winterproof heating tank to prevent the coolant temperature from dropping below 15°C.

906-0238-00 REV 449

5. Routine maintenance5. Routine maintenance50906-0238-00 REV 4

6. Installation
6.1. Installation procedure
Before unpacking the laser, prepare for the installation by making sure that the required equipment,
resources and materials are available. Carefully inspect the package contents for shipment damage andnotify Luxinar immediately if any damage is found.
Ensure that the following are available before starting installation:• The means to transport and lift the laser into position. See section 2.9.5 for equipment weights.
• A flat surface with prepared fixing locations to match the laser mounting feet. See section 6.2.3.
• A DC power supply supplied by Luxinar or sourced locally.
• A beam delivery system and support brackets with a prepared connection for the laser output
window mounting point• A source of cooling water or a chiller for laser cooling. See section 6.2.5.
• A source of high purity nitrogen or compressed air to provide a positive purge pressure for the laser
optics. See section 6.2.6.
• An emergency stop interlock circuit.
• Laser control interface circuitry.
Perform the following steps to install the laser:
1. Carefully unpack the laser and place it on the prepared mounting surface, then fasten it in placeusing M8 bolts. Do not remove the protection cap from the laser output window at this stage.
See section 6.2.3.
2. Connect the laser to the cooling water source or chiller using 10mm OD tubing (see section 6.2.5).
To connect the cooling tubing:a. Push the tube into the connector until it reaches the stop. Pull back on the tube to ensure thatthe connector has gripped the tube firmly.
b. To remove the tube, press the release ring on the end of the connector end and pull out the
tube.
3. Connect the optics purge gas supply using 6mm OD tubing (see section 6.2.6). To connect the gas
purge tubing:a. Push the tube into the connector until it reaches the stop. Pull back on the tube to ensure thatthe connector has gripped the tube firmly.
b. To remove the tube, press the release ring on the end of the connector end and pull out the
tube.
4. Connect the laser to the DC power supply.

DANGER
Exposed terminals — risk of electrocution
Switch off and disconnect the equipment from the mains electrical supply before exposing
electrical terminals. Only trained and authorised personnel should make electricalconnections.
5.
6.
7.
8.

906-0238-00 REV 4

Connect the DC power supply to the mains. See section 6.2.7.
Connect the emergency stop interlock circuit.
Connect the control interface circuitry.
Test the laser output before fitting the beam delivery system.
Place a suitable beam block or power monitoring device in the beam path. Do not place it close to
optical surfaces to avoid risk of contamination by evaporated material.

51

6. Installation

WARNING
Hazardous laser radiation
Always wear protective eyewear matched to the emission wavelength and output power ofthe laser. Instruct all personnel in the vicinity to wear identical protective eyewear.

9.

Mount the beam delivery system and connect it to the laser output window using the prepared
connector. See section 6.2.13.

6.2. Unpacking, mounting and connections
Refer to section 2.9 for details of weights and dimensions.

6.2.1. Unpacking
1.

2.
3.
4.
5.
6.

Perform a delivery check
An itemised list of the ordered equipment is provided by Luxinar on delivery. Check the equipment
against the list to ensure that all items are present. If any equipment is missing inform Luxinar
immediately.
Check the outside of the packing boxes for obvious signs of damage or change of the shock or tiltlabels.
If any damage to the packaging or change to the tilt or shock labels has occurred in transit, inform
both Luxinar and the relevant shipping company, before taking any other action.
Cut the bands on the outside of each of the three packing boxes. Open the box lids and remove the
cardboard outer packaging.
Remove the cables, spares kit, documentation and store them in a secure location in preparation
for installation.
Remove the top and side sections of the support packaging to expose the laser head, the RF power
supply and the controller or combination controller/DC power supply.
Check each component for signs of damage. If any damage has occurred in transit, inform both
Luxinar and the relevant shipping company before taking any other action.
Carefully lift each component out of its packaging.
Important!
This will require the correct lifting equipment for the weights involved. See 6.2.2

7.

Place each component on a clean, flat, dry surface in preparation for installation.

6.2.2. Lifting techniques and precautions
Before attempting to install the laser system, all installation staff should be made aware of the advice
given regarding manual handling, for example in European Directive 90/269/EEC 29 May 1990.

WARNING
Heavy equipment — risk of severe lumbar injury
Do not manually lift the laser head. The RF power supply must be lifted by at least two people.

Due to the size and weight of the laser head, a forklift truck must be used when lifting or moving it.
For a laser head with covers, wide webbing lifting strops should be placed underneath the head outside
the mounting feet. Do not place the strops between the mounting feet.

6. Installation

52

906-0238-00 REV 4

Figure 49 - Lifting strop positioning — laser head with covers

Important!
Do not under any circumstances manually lift the head using the stainless steel covers.

For a laser head without covers, fit lifting eyes to the M10 threaded holes on the mounting feet andattach lifting strops to the eyes.

Figure 50 - Lifting strop positioning — laser head without covers

Due to the weight of the RF power supply, the lifting and positioning of the unit should only beundertaken by two people. The RF power supply unit handles are fitted on opposite ends of thestructure and are fixed to the frame of the unit. These handles cannot be removed. When installing the
RF power supply, care must be taken to ensure that it is in such a position that the RF cables are nottwisted or stretched in any way. This could cause the premature failure of the cable and this may in turn
eventually damage the power supply or laser head.
Note: Luxinar can supply a mounting rail kit (part number 120-0001-00) to assist with system
integration.
906-0238-00 REV 4

53

6. Installation

Figure 51 - Manual lifting with two people — RF power supply

6.2.3. Mechanical fixing
Secure the laser head to the host machine using the mounting feet on the base. Each mounting position
has an M10 threaded hole and two Ø9 holes.
Secure the RF power supply to the host machine using the four M8 threaded holes in the base.
Mounting position dimensions are shown in the following figure.

Figure 52 - Laser head and RF power supply fixing locations

Note: For more detailed dimensional drawings, refer to Appendix B.
To ensure correct operation, the laser head must be mounted in one of the approved orientations
identified by the check mark in the following figure.
For the shutter version, the A orientations must not be used. Safe operation of the shutter requires thatthe laser is mounted horizontally with the feet underneath.

6. Installation

54

906-0238-00 REV 4

CAUTION
Risk of optical damage due to vertical orientation
Vertical mounting, as shown by orientations B and C, can result in premature failure of laser
optics and should be avoided. Mounting with the output window on top of the laser, shown inorientation B, is totally prohibited.

Figure 53 - Correct and incorrect mounting orientations

6.2.4. Laser output aperture location

Figure 54 - Laser output aperture location

Note: The aperture location relative to the mounting feet is identical for the shutter version.

906-0238-00 REV 4

55

6. Installation

6.2.5. Coolant connections and pipework
If the optional Luxinar DC power supply is fitted and the power supply is connected in series with thelaser and RF power supply, the coolant must flow through the DC and RF power supplies before thelaser head.
The following figure shows the coolant flow direction for serial and parallel power supply connections
and the position of the 100µm particle filter (marked "A"). Coolant flow rate is monitored by a direction
sensitive flow sensor within the laser head.
If it is not possible to achieve the required flow rate with the DC power supply in series with the laser it
is also possible to connect it in parallel with the laser and RF power supply.

Figure 55 - Coolant connections and flow direction

Coolant inlet and outlet connectors are marked on each module with the following symbols:• Coolant in•

Coolant out

Use 12mm OD tubing for all connections.
Important!
Materials used in the external cooling circuit must be chosen to avoid corrosion. Never use
aluminium, zinc, mild steel or cast iron components. Suitable materials are stainless steel,copper, copper alloys and opaque plastics. Only use pipework that is impervious to light in orderto reduce the possibility of bacterial contamination of the cooling system.
The coolant temperature must be kept above the dew point in order to prevent formation ofcondensation on internal laser components.
Completely drain the cooling system before shipment or storage.

See section 2.9.7 for coolant specification details.
Important!
Damage caused by insufficient coolant flow, corrosion, condensation or freezing are not coveredby the warranty.

6. Installation

56

906-0238-00 REV 4

6.2.6. Beam delivery optics purge gas
If the internal or external beam delivery system is contaminated with fume, water vapour or debris thenthese contaminants can absorb the laser energy and cause laser power fluctuations and deviation of thelaser beam. In severe cases, laser optics can be contaminated and damaged.
The laser internal beam delivery system is fitted with an optics purge system using contaminant-freecompressed air or nitrogen. See section 2.9.8 for purge gas specification details.

11Purge gas input connector

Figure 56 - Internal optics purge gas connector

CAUTION
Risk of contamination of laser head optics
Do not remove the red blanking plug from the input connector if purge gas is not used. Removalof the plug exposes a contamination path into the laser head.

Use 6mm OD tubing for the purge gas supply connection.
Important!
If compressed air is used as a purge gas, the inlet to the compressor intake must be sited awayfrom fume or debris contamination sources, such as the laser processing zone or the exhaust
port of a fume extraction system.

6.2.7. Luxinar combined controller/DC power supply
The laser requires a 50VDC power supply, either sourced locally or available from Luxinar as part of a
combined controller/DC power supply module. For specifications refer to sections 2.5 and 2.6.

906-0238-00 REV 4

57

6. Installation

DANGER
Risk of electric shock or severe damage to the equipment
Ensure that the equipment is disconnected from the mains supply before making theseconnections.
Respect the polarity of the terminals on the DC power supply and the RF power supply.

The Luxinar combination controller/DC power supply requires a three-phase mains supply with a supply
voltage of 360–440VAC. The cable connections are:• L1 — Brown• L2 — Black• L3 — Grey
• N — Blue (Neutral) — Not used

CAUTION
Irreparable damage to the DC power supply
Under no circumstances connect the neutral (blue) wire.
•

Earth — Green & yellow
Ensure that a good earth connection is made to the terminal stud on the rear panel.

Figure 57 - Mains terminal cover and earth terminal studRemove the cover next to the mains circuit breaker for access to the three-phase terminal strip.

L1 L2 L3 EARTH

Figure 58 - Three-phase terminal strip

6. Installation

58

906-0238-00 REV 4

Figure 59 - Three-phase terminal strip (016-0033-00)

The cross-section of the cable connecting the DC power supply to the RF power supply depends on thecable length. Contact Luxinar Aftersales for details of pre-configured cables.

Figure 60 - Pre-configured DC cable

Two DC cables are required to link the DC power supply and the RF power supply. Two four-pin
connectors are provided on the rear panel of the DC power supply as shown in the following figure.

906-0238-00 REV 4

59

6. Installation

Figure 61 - DC power supply rear panel connectors

WARNING
Risk of electric shock and irreparable damage to the controller and DC power supply
Before separating the control unit from the DC power supply, ensure that the system is isolated
from the mains supply. Hazardous energy levels are present at the rear of the controller.

6.2.8. OEM-sourced DC power supply and Luxinar controller
The laser requires a 50VDC power supply, either sourced locally or available from Luxinar as part of a
combined controller/DC power supply module. For specifications refer to section 2.9.3.
The power supply must be capable of responding to rapidly changing, high-current demands. If its
voltage control loop response is too slow it may result in significant over-voltage spikes that activate thelaser protection circuits. In this case, the laser will switch off. If this happens on a regular basis, buffer
capacitors must be connected to the power supply output in order to smooth out current demands.
The buffer capacitors must be fitted close to the DC supply connector on the laser and must be able tosupport ripple currents up to 60A. It is recommended to use at least two capacitors with a rating of
47000µF at 63V and a ripple current of > 25A.
Note: In order to get optimum performance from the laser, check the capacitor life-time at the nominal
operating temperature when specifying the capacitors.
Contact Luxinar Aftersales for help and advice concerning selection and installation of buffer capacitors.

6. Installation

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906-0238-00 REV 4

DANGER
Risk of electric shock or severe damage to the equipment
Ensure that the equipment is disconnected from the mains supply before making theseconnections.
Respect the polarity of the terminals on the DC power supply and the RF power supply.

2

1

4
1

3

50VDC input

2

Volt-free relay contact3

Two-phase mains input

4

1A fuse for 50VDC input part number 552-0007-00)

Figure 62 - Controller rear panel connections

The Luxinar controller requires a three-phase mains supply with a supply voltage of 360–440VAC,
however, only two phases are required to power the controller. The cable connections are:• L1 — Brown• L2 — Black• L3 — Grey — Not used
• N — Blue (Neutral) — Not used

CAUTION
Irreparable damage to the DC power supply
Under no circumstances connect the neutral (blue) wire.
•

Earth — Green & yellow
Ensure that a good earth connection is made to the terminal stud on the rear panel.
A pre-configured two-phase and earth cable (part number 091-0359-00) is available from Luxinar.
Contact Luxinar Aftersales for details.

906-0238-00 REV 4

61

6. Installation

Figure 63 - Two-phase and earth mains cable

The mains input is protected by two 500mA fuses located within the controller.
The OEM integrator must provide a 50VDC @1A to the controller. The controller monitors this voltage
which is used to power electronics within the laser head. The input is protected by a 1A fuse locatedbelow the connector. A connector (Phoenix part number 1777989) is supplied with the controller.

+

50V
0V

Figure 64 - 50V socket and connector

A volt-free contact socket is provided to allow the controller to enable and disable the OEM power
supply. The internal relay type is NEC EA2-12NU. A connector (Phoenix part number 1850851) is
supplied with the controller.

Figure 65 - Volt-free socket and connector

6.2.9. DC cabling
Choice of the cabling required to deliver the correct DC voltage to the laser depends on the cable length.
The cable cross-sectional area must be calculated to ensure a maximum voltage drop of 1V at peakcurrents.
The following table shows recommended cross-sections for typical cable lengths.
6. Installation

62

906-0238-00 REV 4

Table 26 - Recommended DC cable cross-sections
Cable length range (m)Recommended cross-sectional area
(mm2)

2–9

10–13

25
Note: Tighten the terminal to 7Nm

35
Note: Tighten the terminal to 8Nm

Important!
Eight cables (four pairs) are required, each with the recommended cross-section.

Important!
Under certain conditions, it may be possible for power cables carrying high voltages and currents
to emit electrical noise levels that may interfere with control cable signals.
To eliminate the possibility of interference, control signal cables must be screened and routed
along a different path to power cables.

6.2.10. DC connectors
A DC connector kit (part number 010-0163-00) is provided for connection from the OEM sourced power
supply to the laser system and comprises the following components:

Harting 0914 002 2751 female axial module (Luxinar part number 558-0177-00)

906-0238-00 REV 4

63

6. Installation

Harting 0914 016 0361 hinged frame (Luxinar part number 558-0179-00)

Harting 0930 016 0521 side entry hood (Luxinar part number 558-0182-00)

6. Installation

64

906-0238-00 REV 4

Harting 0900 000 5106 PG cable gland (Luxinar part number 551-0010-00)

To fit a connector:
1. Insert a 4mm hexagonal key into the front of the Harting axial module and turn it anti-clockwise to
fully open the module.
2. Strip back the DC cable 12–14mm and push the stripped end fully into the back of the axial module,
then tighten the terminal to the torque shown in Table 26.
• Connect the positive cable to pin 1.
• Connect the negative cable to pin 2.
3. Insert the axial module into the frame.
Note: The connectors are polarised and will only fit in one orientation.
4. Add a 4mm2 earth cable to the frame screw terminal.
Important!
The connector kit provides the parts to build two connectors. Both connectors must be used. The
laser system requires two connectors.

906-0238-00 REV 4

65

6. Installation

1

2

3
1

Connector 1

2

Connector 2

1

OEM sourced 50VDC PSU

Figure 66 - OEM sourced power supply — DC connections

6.2.11. RF cables
RF cables linking the RF power supply to the laser head are supplied with the system. RF cables are
manufactured to a matched cable length and must not be altered.
The RF power supply has been designed to be installed in close proximity to the laser head to ensurethat the RF cable lengths are kept to a minimum. The OEM integrator must ensure that any bends in thecables are not reduced below the minimum bend radius specified for the particular RF cable used.
The RF cables supplied with the system, are matched to RF connectors on the RF power supply and laser
head. RF connectors are identified by labels showing red circles on a black background. Typical examples
are shown in the following figure.

Figure 67 - RF connector and cable labels

The RF connections on the laser head are not matched to a specific cable i.e. either cable can be fitted
to either of the RF connectors. The cables should be fitted in line with the following good practiceguidelines:• Use the shortest length of RF cable possible.
6. Installation

66

906-0238-00 REV 4

•Allow as large a bend radius on the cable as possible. Pay close attention to the minimum bend
radius specification for the cable.
• When connecting the cable, ensure that the connectors at either end of the cable are not overstressed i.e. do not try to bend the cable as soon as it exits the connector. Note that right-angle RFconnectors and/or converters are available for the cable and may help to alleviate this installation
issue.
• Do not hard clamp the RF cable with ‘cable ties’ or other clamping devices — allow free movementof the cable.
• Do not run the RF cable with other cables or coolant pipes — use a separate cable routing.
• Always ensure that the RF connectors are tightened to the required torque setting. Do not overtighten.
In addition, for applications where the laser head moves:• Ensure that the RF cable can move freely over the full range of motion of the system with no dangerof abrasion to the cable.
• Where possible, allow the complete RF cable to move and bend freely to avoid repeated bending of
the cable in the same position.
• Ensure that the RF cable is oriented or positioned to avoid twisting along the axis of the cable.

6.2.12. Cables for robotics applications
If the OEM 65iX will be used as part of a robotics system, Luxinar can supply a range of high flexibility
cables. For details, contact Luxinar Aftersales.

6.2.13. Beam delivery system

CAUTION
Risk of damage to the laser output window mountThe laser output window mount is not capable of supporting a beam delivery system. Always
provide strong and stable mechanical support for the beam delivery system and other external
optics.

Important!
Remove the blanking cap from the output window before attempting to attach the beam
delivery system.

Attach the beam delivery system to the M5 mounting hole group on the output window mount. The
hole group has a 44.0mm pitch circle diameter and is identical for standard and shutter versions.

906-0238-00 REV 4

67

6. Installation

110.00
105.00
20.00

C

E

E

2.10

C

36.00
52.00

C 'SINK

4.2 THRU ALL &8 x DRILLTAP M5 - 6H THRU ALL THEN
5.5 X 90° EQUI-SPACED ON 44.0 PCD

Figure 68 - Beam delivery system mounting dimensions

Note: The shutter version has a visible light laser diode pointer to assist with beam delivery systemalignment. The rated power of the laser diode pointer is 4mW.

WARNINGClass 3R visible laser radiation
Avoid eye exposure to direct and scattered radiation.

6.2.14. Absorbing Thin Film Reflector (ATFR)/circular polariser
An optional ATFR/circular polariser can be fitted to the laser output to protect the laser from damaging
back reflections. For details, refer to document part number 906-0104-xx.

6. Installation

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7. Transport and recommissioning
Before transporting the laser, observe the following precautions:• Completely drain the laser cooling system to prevent damage during shipping. Use clean compressed
air, at a maximum pressure of 2bar, to blow out all traces of coolant in the cooling system pipework.

WARNING
Risk of contamination due to leaking coolant
Failure to remove coolant from the system prior to transport can cause damage to the laser.
Damage caused in this way will invalidate the warranty.

•

906-0238-00 REV 4

If the external beam delivery system has been removed, replace the output window protection cap
to prevent damage or contamination during shipping.

69

7. Transport and recommissioning7. Transport and recommissioning

70906-0238-00 REV 4

8. Interfacing
User interface connections for the OEM 65iX are made through the 25-pin connectors on the rear panelof the combined controller/DC power supply or the stand-alone controller.
Important!
Under certain conditions, it may be possible for power cables carrying high voltages and currents
to emit electrical noise levels that may interfere with control cable signals.
To eliminate the possibility of interference, control signal cables must be screened and routed
along a different path to power cables.

Figure 69 - Combined controller/DC power supply — U1 & U2 connectors

U2

U1

906-0238-00 REV 4

Figure 70 - Stand-alone controller — U1 & U2 connectors

71

8. Interfacing8.1. Standard interface
Table 27 - Standard interface — U1 pin designations

8. Interfacing

Pin N°

FunctionI/O type

Description

1

Program 4

Opto-isolated input

Remote program selector bit 5–24V @ 10mA
4
(max)

2

Shutter enable

Opto-isolated input

Enables operation of the
5–24V @ 10mA
shutter (shutter version only) (max)3

Program 1

Opto-isolated input

Remote program selector bit 5–24V @ 10mA
1
(max)

4

12V

Output12V voltage source forexternal use

12V @ 300mA

5

NC voltage

Input

NC mode control voltage(when in NC control mode)

0–10V @ 140µA
(max)

6

GroundGroundSignal ground reference

0V

7

RS232 Tx

Output

RS232 transmit

± 10V

8

Trigger

Opto-isolated input

Fires the laser in any of theinternal modes

5–24V @ 10mA
(max)

9

External interlock

OutputConnect to pin 21 if anexternal interlock voltage
source is required

12V @ 300mA

10VSWR status

Volt-free output

Relay 1 (NO)30VDC @ 1A
(max)

11

Laser enable

Opto-isolated input

Enables the laser in Automode

5–24V @ 10mA
(max)

12

Shutter open

Open-drain output

Shutter open position sensor < 30V @ 50mA
(max)

13

Laser onOpen-drain output

Laser ready to fire

14

External PWM

Input

Used in external PWM mode TTL levels, 5V @
5mA (max)

15

Shutter closed 2

Open-drain output

Shutter closed position
sensor 2

16

Program 2

Opto-isolated input

Remote program selector bit 5–24V @ 10mA
2
(max)

17

Not used——18

Program 3

Opto-isolated input

Remote program selector bit 5–24V @ 10mA
3
(max)

19

GroundGroundSignal ground reference

0V

20

RS232 Rx

Input

RS232 Receive

± 10V

21

External interlock

Opto-isolated input

Connect to pin 9 or an
external voltage source

5–24V @ 10mA
(max)

22

VSWR status

Volt-free output

Relay 1 (P)

30VDC @ 1A
(max)

23

Shutter control

Opto-isolated input

Operates the shutter when in 5–24V @ 10mA
Auto mode (shutter version
only)

24

Laser diode pointerenableOpto-isolated input

Enables the laser diode5–24V @ 10mA
pointer (shutter version only) (max)72

Signal< 30V @ 50mA
(max)

< 30V @ 50mA
(max)

—

906-0238-00 REV 4

Pin N°

FunctionI/O type

Description

Signal

25

Shutter closed 1

Open-drain output

Shutter closed position
sensor< 30V @ 50mA
(max)

External interlock (pin 21)
This input signal is always required and forms part of the safety channel. Removing this signal willturn off the DC power supply and will stop the laser firing. If fitted, the shutter will also close.
EXTERNAL INTERLOCK RTN

3LM317LZ

Vin

Vout

2

120R

7

ACPL-247

8

10
9

1

PTVS24V

A DJ

21

GND

A voltage input of 5–24V is required on U1, pin 21. A 12V source is available on U1, pin 9 and can belinked to pin U1, pin 21.

Trigger input (pin 8)
This input signal is required to fire the laser in all internal modes of operation. A transition of the
input signal is required to fire the laser if operation is stopped and needs to be restarted.
TRIGGER3

LM317LZ

Vin

6, 19

Vout

2

120R

7

ACPL-247

8

10
9

1

PTVS24V

A DJ

8

GND

To enable, a voltage input of 5–24V is required on U1, pin 8. A 12V source is available on pin U1, pin
4.

Shutter enable input (pin 2)
For the shutter version, this input signal is required to enable operation of the shutter. The shutter
can only be opened by the control electronics, but can always be closed by removing the signal fromthis pin.
SHUTTER ENABLE

3

LM317LZ

Vin

6, 19

Vout

2

120R

7

ACPL-247

8

10
9

1

PTVS24V

ADJ

2

GND

To enable, a voltage input of 5–24V is required on U1, pin 2. A 12V source is available on pin U1, pin
4.

Laser diode pointer enable input (pin 24)
For the shutter version, this input is used to show the location of the laser beam without firing thelaser. The shutter must be in the closed position for the laser diode beam to be visible.
Note: When the shutter is opened, the laser diode pointer is turned off by the control electronics.
DIODE ENABLE

3

LM317LZ

Vin

6, 19

Vout

2

120R

7
8

ACPL-247

10
91

PTVS24V

ADJ

24

GND

To enable, a voltage input of 5–24V is required on U1, pin 24. A 12V source is available on pin U1, pin
4.

906-0238-00 REV 4

73

8. Interfacing

Laser enable (pin 11) — Auto mode onlyThis input will enable the laser from standby without using the MCU. Removal of the input returns
the laser back to standby.
3

LASER ENABLE

LM317LZ

Vin

Vout

120R

2

7

ACPL-247

8

10
9

1

PTVS24V

A DJ

11

6,19

To enable, a voltage input of 5–24V is required on U1, pin 11. A 12V source is available on pin U1, pin
4.

Shutter control (pin 23) — Auto mode only
For the shutter version, this input will open and close the shutter without using the MCU.
Note: A shutter enable input on pin 2 is also required to activate the shutter.
3

LM317LZVin

PTVS24V
6, 19

A DJ

SHUTTER CONTROL

Vout

120R

2

7

ACPL-247

8

10
9

1

23

GND

To enable, a voltage input of 5–24V is required on U1, pin 23. A 12V source is available on pin U1, pin
4.

External PWM (pin 14) — External PWM mode only
In this mode, an external modulation input signal can be applied. If signal parameters exceed thepreset limits of the system, an overmodulation signal is generated and the signal is limited by thecontrol electronics.
• Maximum frequency = 130kHz• Maximum duty cycle = 60%• Maximum pulse width = 400µs• Minimum pulse width = 2µs
14

6, 19

2

EXTERNAL_PWM

HCPL-0201

1K

7
3

GND

8

5

Note: In external PWM mode, the trigger input is not required. If a valid PWM signal is received, andthe shutter is open the laser will fire.

NC voltage (pin 5) — NC power mode only
When NC power mode is selected, a voltage between 0–10V must be applied to this input to control
the laser output power. Maximum power is achieved with an input of 10V. An input below 1V turns
off laser output. Any voltage above 10V is ignored and is interpreted as 10V for maximum laser
output.
Note: Shutter enable and trigger inputs are still required before any laser output is emitted.
5

NC VOLTAGE

100K

100K

PTVS10V
22K6, 19

8. Interfacing

74906-0238-00 REV 4

Shutter open/closed monitoring (pins 12, 15 and 25) — Shutter version only
The safety shutter unit includes three shutter position sensors. One sensor to detect the shutter
open position and two sensors to detect the shutter closed position. The sensors are monitored by
the controller, and will prevent the laser from firing when a fault condition is detected. The signals
are open drain and active high.
• Shutter open (pin 12)
12

SHUTTER OPEN
50mA

6, 19

•

PTVS24V
ZXMS6004FF

GND

Shutter closed (pins 15 and 25)
25

SHUTTER CLOSED 1
50mA

PTVS24V
ZXMS6004FF

6, 19

15

SHUTTER CLOSED 2
50mA

PTVS24V
ZXMS6004FF

Sensor 1, shutter open
(pin 12)

Sensor 2, shutter closed 1 Sensor 3, shutter closed 2 Status(pin 25)(pin 15)00

0

Shutter open sensor
failure/system disabled

0

0

1

Shutter closed sensor 1
failure/system disabled

0

1

0

Shutter closed sensor 2
failure0

1

1

Shutter closed/normal
operation

1

0

0

Shutter open/normal
operation

1

1

1

Sensor fault

Laser on (pin 13)
This open drain output is high once the laser is enabled and ready to fire.
13

LASER_ON
50mA

6, 19

906-0238-00 REV 4

PTVS24V
ZXMS6004FF

GND

75

8. Interfacing

RS232 transmit and receive (pins 7 and 20)
The RS232 interface can be used to communicate with a remote PC in order to monitor the laser

7

Tx

16

20

Rx

15

T

R
ADM3251E

For details refer to the Serial interface manual, part number 906-0109-00.

VSWR status (pins 10 and 22)
The VSWR signal is used to monitor the health of the system. If a fault occurs, the volt-free relay
closes. In normal operation, the relay is open.
10

22

VSWR STATUS (NO)VSWR STATUS (P)Program select (pins 1, 3, 16 and 18)
For each internal mode of operation, a total of 16 programs can be selected to match processing
requirements. The chosen program can be selected using a combination of the four digital inputs onconnector U1. If the inputs remain unconnected, the controller will select the default program 0.

PTVS24V

3

PROGRAM 3

3

PROGRAM 4

PTVS24V

8. Interfacing

A DJ

120R

7

ACPL-247

8

10
9

Vout

2

120R

7

ACPL-247

8

10
9

1

Vin

A DJ

LM317LZ

LM317LZ

Vin

A DJ

3

PROGRAM 2

PTVS24V

1

2

GND

PTVS24V

18

Vout

Vout

2

120R

7

ACPL-247

8

10
9

1

16

Vin

LM317LZ

Vin

A DJ

6, 19

LM317LZ

1

3

PROGRAM 1

Vout

2

120R

7

ACPL-247

8

10
9

1

3

B4 (pin 1)

B3 (pin 18)

B2 (pin 16)

B1 (pin 3)

Program number

0

0

0

0

0 (default)

0

0

0

1

1

0

0

1

0

2

76

906-0238-00 REV 4B4 (pin 1)

B3 (pin 18)

B2 (pin 16)

B1 (pin 3)

Program number

0

0

1

1

3

0

1

0

0

4

0

1

0

1

5

0

1

1

0

6

0

1

1

1

7

1

0

0

0

8

1

0

0

1

9

1

0

1

0

10

1

0

1

1

11

1

1

0

0

12

1

1

0

1

13

1

1

1

0

14

1

1

1

1

15

Auto mode
In Auto mode, once the system is enabled, the system can be operated without using the MCU.
Laser enable (U1, pin 11) and Shutter control (U1, pin 23) are used to enable the DC power supply
and to open and close the shutter.
Note: Shutter enable and trigger inputs are still required before any laser output is emitted.

Voltage output (pin 4)
If required, this 12V @ 300mA voltage source is available to interface with the machine I/O throughconnectors U1 and U2.
4

12V @ 300mA
RX E 030

PT V S 12V

GND

8.2. SCX 30 emulation mode interface
Table 28 - SCX 30 emulation mode interface — U1 pin designations
Pin N°

FunctionI/O type

Description

Signal

1

Shutter enable

Opto-isolated input

Enables operation of the DC
power supply and shutter (iffitted)

5–24V @ 10mA
(max)

2

Not used

—

—

—

3

Shutter open

Open-drain output

Shutter open position sensor < 30V @ 50mA
(max)

4

GroundGroundSignal ground reference

0V

5

Shutter closed 1

Open-drain output

Shutter closed position
sensor 1< 30V @ 50mA
(max)

6

GroundGroundSignal ground reference

0V

7

DC power supply status

Opto-isolated output DC power supply monitor

906-0238-00 REV 477< 30V @ 50mA
(max)

8. Interfacing

Pin N°

FunctionI/O type

Description

Signal8

Emission indicatorstatusOpto-isolated output Emission indicator monitor< 30V @ 50mA
(max)

9

Not used

—

—

—

10

Not used

—

—

—

11

Not used

—

—

—

12

RF enable

Opto-isolated input

Connect to an external
voltage source or pin 19

5–24V @ 10mA
(max)

13

Modulation +Input

RS422 modulation

0.5–5V

14

Modulation -Input

RS422 modulation

5–0.5V

15

Overmodulation

Opto-isolated output Modulation status monitor,
active low

0 or 5V

16

VSWR status +OutputRS422 VSWR status monitor

0.5–3.5V

17

VSWR status -OutputRS422 VSWR status monitor

3.5–0.5V

18

RS232 Tx

Output

RS232 transmit

± 10V

19

External interlock 12V
sourceOutputConnect to pin 20 if anexternal interlock voltage
source is required

12V @ 300mA

20

External interlock

Opto-isolated input

Connect to an external
voltage source or to pin 19

5–24V @ 10mA
(max)

21

Laser diode pointerenableOpto-isolated input

Enables the laser diode5–24V @ 10mA
pointer (shutter version only) (max)22

RS232 Rx

Input

RS232 receive

± 10V

23

Shutter closed 2

Open-drain output

Shutter closed position
sensor 2< 30V @ 50mA
(max)

24

Not used

—

—

—

25

GroundGroundSignal ground reference

0V

External interlock (pin 20)
This input signal is always required and forms part of the safety channel. Removing this signal willturn off the DC power supply and will stop the laser firing. If fitted, the shutter will also close.

PT V S 24V

L M317L Z
Vin

A DJ

E X T E RNA L I NT E RL OC K RT N 3

Vout

2

120R

7

A C PL -247

8

10
9

1

20

A voltage input of 5–24V is required on U1, pin 20. A 12V source is available on U1, pin 19.

DC power supply and shutter enable (pin 1)
This input signal is taken high to enable the DC power supply from the standby state.
For the shutter version, this input signal also enables operation of the shutter. The shutter can only
be opened by the control electronics, but can always be closed by removing the signal from this pin.
3
PT V S 24V4, 6

L M317L Z
Vin

A DJ

S H UT T E R E NA B L E

Vout

2

120R

7

A C PL -247

8

10
9

1

1

GND

A voltage input of 5–24V is required on U1, pin 1. A 12V source is available on U1, pin 19.
8. Interfacing

78906-0238-00 REV 4

Laser diode pointer enable (pin 21)
For the shutter version, this input is used to show the location of the laser beam without firing thelaser. The shutter must be in the closed position for the laser diode beam to be visible.
Note: When the shutter is opened, the laser diode pointer is turned off by the control electronics.
D IOD E E NA B L E

3

L M317L Z
Vin

4, 6

Vout

120R

2

7

A C PL -247

8

10
9

1

PT V S 24V

A DJ

21

GND

To enable, a voltage input of 5–24V is required on U1, pin 21. A 12V source is available on pin U1, pin
19.

RF enable (pin 12)
This input signal is always required in SCX 30 emulation mode. It enables the controller to turn on
the RF power supply. Without this signal, there can be no laser output.
Note: For all fault modes, the RF power supply is disabled by the control electronics.
RF E NA B L E

3

L M317L Z
Vin

4, 6

Vout

120R

2

7

A C PL -247

8

10
9

1

PT V S 24V

A DJ

12

GND

To enable, a voltage input of 5–24V is required on U1, pin 12. A 12V source is available on pin U1, pin
19.

RS422 modulation (pins 13 and 14)
A modulation signal using RS422 signal levels must be applied in order to fire the laser. If modulation
parameters exceed the preset system limits, an overmodulation signal is generated and themodulation signal is automatically limited by the control electronics.
• Maximum frequency = 130kHz• Maximum duty cycle = 60%• Maximum pulse width = 400µs• Minimum pulse width = 2µs
10K 0603
GND
13

MOD UL AT I ON+

8

180R
14

MOD UL AT I ON-R7

D S 8921M

Overmodulation (pin 15)
When the modulation signal exceeds any of the preset system limits, the overmodulation output isswitched to active low.
U5V
14
15

OV E R MOD UL AT I ON

3

13

4
A C PL -247

10K

4, 6

906-0238-00 REV 4

79

8. Interfacing

RS422 VSWR status (pins 16 and 17)
The VSWR signal is used to monitor the health of the system. If a fault occurs, the signal becomes
active and laser output power is automatically reduced.
16

17

V S WR_S TAT US+

6
5

V S WR_S TAT US-

D
D S 8921M

Shutter open/closed monitoring (pins 3, 5 and 23) — Shutter version only
The safety shutter unit includes three shutter position sensors. One sensor to detect the shutter
open position and two sensors to detect the shutter closed position. The sensors are monitored by
the controller, and will prevent the laser from firing when a fault condition is detected. The signals
are open drain and active high.
• Shutter open (pin 3)
3

S H UT T E R OPE N
50mA

4, 6

•

PT V S 24VZ X MS 6004FF

GND

Shutter closed (pins 5 and 23)
5

S H UT T E R C L OS E D 1
50mA

PT V S 24VZ X MS 6004FF

4, 6

23

S H UT T E R C L OS E D 2
50mA

8. Interfacing

PT V S 24VZ X MS 6004FF

Sensor 1, shutter open
(pin 3)

Sensor 2, shutter closed 1 Sensor 3, shutter closed 2 Status(pin 5)(pin 23)

0

0

0

Shutter open sensor
failure/system disabled

0

0

1

Shutter closed sensor 1
failure/system disabled

0

1

0

Shutter closed sensor 2
failure0

1

1

Shutter closed/normal
operation

1

0

0

Shutter open/normal
operation

1

1

1

Sensor fault

80

906-0238-00 REV 4

RS232 transmit and receive (pins 18 and 22)
The RS232 interface can be used to communicate with a remote PC in order to monitor the laser.

18

Tx

16

22

Rx

15

T

R
A DM3251E

For details refer to the Serial interface manual, part number 906-0109-00.

Emission indicator status monitor (pin 8)
The laser emission indicator is located on top of the laser head, close to the laser output window.
When illuminated, it warns that the laser is enabled and is capable of emitting a laser beam. The
emission indicator is monitored for correct operation. If the indicator does not illuminate when thelaser is enabled, the monitor output circuit is switched to active.
8

E MI S S I ON INDICATOR

10
180R

7

9

8
A C PL -247

4, 6

DC power supply status (pin 7)
The 50VDC power supply is monitored for correct operation. If the power supply output exceeds thepreset limits, the system will turn off and the monitor output circuit is switched to active.
7

DC S TAT US
180R

10

7

9

8
A C PL -247

4, 6

8.3. Connector U2 —all modes
Table 29 - U2 pin designations
Pin N°

FunctionI/O type

Description

1

Analogue power (Vin)

OutputAnalogue laser power control 4–20mA

2

Not used

—

—

—

3

Not used

—

—

—

4

Not used

—

—

—

5

Not used

—

—

—

6

Not used

—

—

—

7

Not used

—

—

—

8

Ground (0V)

GroundGround reference for I/O pins —9

VSWR status

Volt-free output

Relay 1 (NO)30VDC @ 1A
(max)

10

VSWR status

Volt-free output

Relay 1 (NC)

30VDC @ 1A
(max)

11

Laser ready (1)Volt-free output

Relay 2 (P)

30VDC @ 1A
(max)

906-0238-00 REV 4

81

Signal8. Interfacing

Pin N°

FunctionI/O type

Description

Signal12

System enable

Volt-free output

Relay 3 (NO)30VDC @ 1A
(max)

13

System enable

Volt-free output

Relay 3 (NC)

30VDC @ 1A
(max)

14

Analogue power (RTN)

Input

Analogue laser power control 4–20mA

15

Not used

—

—

—

16

Not used

—

—

—

17

Not used

—

—

—

18

Not used

—

—

—

19

Not used

—

—

—

20

Not used

—

—

—

21

Ground (0V)—

Ground reference for I/O pins —22

VSWR status

Volt-free output

Relay 1 (P)

30VDC @ 1A
(max)

23

Laser ready

Volt-free output

Relay 2 (NO)30VDC @ 1A
(max)

24

Laser ready

Volt-free output

Relay 2 (NC)

30VDC @ 1A
(max)

25

System enable

Volt-free output

Relay 3 (P)30VDC @ 1A
(max)

4–20mA current output
A loop-powered 4–20mA current output circuit is available on connector U2, pins 1 and 14. The laser
power output can be mapped against the current signal using the following graph.

Figure 71 - Output loop current to laser output power mapping

Connect a 7–40V source and load resistor between pins 1 and 14. Ensure that the load resistor
allows a current of 20mA for the chosen voltage (R=V/I).

1. The Laser Ready relay will activate once the shutter has opened and the RF signal is present.

8. Interfacing

82906-0238-00 REV 4

PIN 14 - U2
4 - 20mA
Regulator Circuit

Q6
BC337GVOLTAGE(7 - 40V)

LOAD

I = 4-20mA

PIN 1 - U2
Figure 72 - Loop current circuit

VSWR status, relay 1 (pins 9, 10 and 22)
The VSWR relay is used to monitor the health of the system. If a fault occurs, the volt-free relay
closes. In normal operation, the relay is open.
22
9

10

RE L AY 1 (P)RE L AY 1 (NO)RE L AY 1 (NC )Laser ready status, relay 2 (pins 11, 23 and 24)
The laser ready relay is used to indicate if the laser is ready to fire with DC power supply enabled andthe shutter open (shutter version only).
11
23

24

RE L AY 2 (P)RE L AY 2 (NO)RE L AY 2 (NC )System enabled, relay 3 (pins 12, 13 and 25)
The system enabled relay is used to indicate a fault condition. If a fault occurs, the volt-free relay
closes. In normal operation, the relay is open.
25
12

13

RE L AY 3 (P)RE L AY 3 (NO)RE L AY 3 (NC )8.4. Connector U1 — standard connections for laser output
These are the minimum connections required to achieve laser output and should only be used when
testing or installing the system.
For normal machine operation, safety interlock circuits must be added to conform to the relevant safety
standards. See Chapter 1 for details of safety standards.

906-0238-00 REV 4

83

8. Interfacing

8.4.1. Minimum connections — internal PWM mode
WITH SHUTTER

U1
1
14
2
15
3
16
4
17
5
18
6
19
7
20
8
21
9
22
10
23
11
24
12
25
13

WITHOUT SHUTTER

U1
1
14
2
15
3
16
4
17
5
18
6
19
7
20
8
21
9
22
10
23
11
24
12
25
13

SHUTTER ENABLE

USER 12V

TRIGGER
EXTERNAL INTERLOCK RTN
EXTERNAL INTERLOCK OUT

USER 12V

TRIGGER
EXTERNAL INTERLOCK RTN
EXTERNAL INTERLOCK OUT

Figure 73 - Internal PWM mode connections

8.4.2. Minimum connections — Auto mode
Note: When operating in auto mode, the system defaults to standby at power up and the shutter andmode of operation can be controlled by external signals.
WITH SHUTTER

U1
1
14
2
15
3
16
4
17
5
18
6
19
7
20
8
21
9
22
10
23
11
24
12
25
13

WITHOUT SHUTTER

U1
1
14
2
15
3
16
4
17
5
18
6
19
7
20
8
21
9
22
10
23
11
24
12
25
13

SHUTTER_ENABLE

USER 12V

TRIGGER
EXTERNAL INTERLOCK RTN

SHUTTER_CONTROLLASER ENABLE

USER 12V

TRIGGER
EXTERNAL INTERLOCK RTN
EXTERNAL INTERLOCK OUT

LASER ENABLE

Figure 74 - Auto mode connections

8. Interfacing

84906-0238-00 REV 4

8.4.3. Minimum connections — external PWM mode
WITH SHUTTER

U1
1
14
2
15
3
16
4
17
5
18
6
19
7
20
8
21
9
22
10
23
11
24
12
25
13

WITHOUT SHUTTER

U1
1
14
2
15
3
16
4
17
5
18
6
19
7
20
8
21
9
22
10
23
11
24
12
25
13

EXTERNAL_PWM
SHUTTER_ENABLE

GND

EXTERNAL INTERLOCK RTN
EXTERNAL INTERLOCK OUT

EXTERNAL_PWM

GND

EXTERNAL INTERLOCK RTN
EXTERNAL INTERLOCK OUT

Figure 75 - External PWM mode

8.4.4. Connector U1 SCX 30 emulation connections for laser output

Figure 76 - SCX 30 emulation connections

906-0238-00 REV 4

85

8. Interfacing

8.4.5. Timing diagrams

Figure 77 - Auto mode timing

•
•
•
•
•

•

When using the Luxinar DC power supply, there will be a 7 second setup time delay before thepower supply can be used. This is only valid when mains voltage is first applied.
External Interlock (U1.21) must be taken high at any point before Laser Enable (U1.11).
User Shutter Enable (U1.2) can be taken high at any point before or after Laser Enable(U1.11).
Laser Enable (U1.11) will take the system from standby mode to execute mode and enable theLuxinar DC power supply. The Luxinar DC power supply takes 120ms to fully turn on.
Shutter Control (U1.23) should be applied at least 120ms after Laser Enable (U1.11). The
shutter will not open until 50V has been detected. The shutter will be fully open 100ms after thecommand to open is made.
Once the shutter is open, the laser is ready to fire. Apply the Trigger Signal (U1.8) or
Modulation Signal (U1.14) depending on the mode of operation chosen, for laser output. (2) (3)2. If using EXT PWM mode, there will be a delay of 21ms from the shutter opening and the laser firing.
3. If using any internal modes, there will be a delay of 1ms from the trigger signal (U1.8) being applied and the laser firing.

8. Interfacing

86906-0238-00 REV 4

Figure 78 - Emulation mode timing

•
•
•
•
•
•

906-0238-00 REV 4

When using the Luxinar DC power supply, there will be a 7 second setup time delay before thepower supply can be used. This is only valid when mains voltage is first applied.
External Interlock (U1.20) must be taken high at any point before Shutter Enable(U1.1).
RF Enable (U1.12) can be taken high at any point before PWM Input (U1.13 and U1.14)
User Shutter Enable (U1.1) will take the system from standby mode to execute mode andenable the Luxinar DC power supply. The Luxinar DC power supply will take 320ms to fully turn on.
DC PSU Status (U1.7) will become high once the DC PSU output has reached 50V (A delay
between 500ms and 1000ms will be seen).
The shutter will be fully open 100ms after the DC PSU Status (U1.7) becomes high, and thesystem is ready to fire.
Once PWM Input (U1.13 and U1.14) is applied, there will be a delay of 21ms from the shutter
opening and the laser firing.

87

8. Interfacing

User Shtr Enable (U1.2)

Laser Enable (U1.11)

2s

DC turn on
1ms

Open Shutter (U1.23)

200ms

20ms

Shutter position

Trigger or PWM input

Figure 79 - "Open Shutter" command within DC turn-on period

User Shtr Enable (U1.2)

Laser Enable (U1.11)
2s

DC turn on

T > 0ms

Open Shutter (U1.23)
200ms

20ms

Shutter position

Trigger or PWM input

Figure 80 - "Open Shutter" command after DC turn-on period

8. Interfacing

88906-0238-00 REV 4

Appendix A. Acoustic zones
Under certain pulsing regimes, acoustic resonances are set up in the laser which perturb the beam
pointing characteristics. To ensure stable beam pointing, avoid operating the laser within the grey
shaded areas in the graphs.

Operating pulse width (μs)

OEM 65iX Acoustic zones

Operating frequency (Hz)Figure 81 - OEM 65iX acoustic zones

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89

A. Acoustic zones

A. Acoustic zones

90906-0238-00 REV 4

Appendix B. Dimensional drawings
Laser head overall dimensions — version without covers

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91

B. Dimensional drawings

RF power supply overall dimensions

B. Dimensional drawings

92906-0238-00 REV 4

Complete system with minimum length RF cables

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93

B. Dimensional drawings

Complete system with mounting plates

B. Dimensional drawings

94

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System centre of gravity — version with covers

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95

B. Dimensional drawings

System centre of gravity — version without covers

B. Dimensional drawings

96

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Controller for use with OEM DC power supply

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97

B. Dimensional drawings

B. Dimensional drawings

98

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Appendix C. Coolant requirements and additives
The following requirements concerning water quality and permitted additives must be complied with.

C.1. Coolant quality
Table 30 - Coolant quality
Description

Value

Coolant typeDe-mineralised, deionised or distilled water withcorrosion inhibitor & anti-bacterial treatment

Conductivity<1000µS/cm

Total hardness<10ppm

pH value

7–8.5

Bacteria level<1000cfu/ml

The pH value, conductivity and dissolved solids levels can be measured with a portable meter and thebacteria level can be checked with a test kit. For more information contact your local Luxinar Aftersales
office.

C.2. Suspended particle removal
To remove particulate contamination, an in-line filter with a pore size of 100µm must be fitted as close
as possible to the laser coolant inlet. The filter should be regularly checked for blockages and cleaned or
replaced where necessary. This is particularly important after bacterial growth has been detected andanti-bacterial treatment applied.

C.3. Corrosion and anti-bacterial inhibitor
To prevent bacterial formation and corrosion of the cooling water circuit, Luxinar has tested andapproved a specialist water treatment kit which is manufactured by NALCO.
Three water treatment kits are available, dependant on the total volume of the cooling water circuit to
be used:Circuit volume

Reference

50–199L

Order No.: 480-Luxinar 20.88

200–350L

Order No.: 480-Luxinar 60.88

351–500L

Order No.: 480-Luxinar 100.88

Order water treatment kits directly from NALCO at:
Nalco Deutschland GmbH,
Solmstraße 41
60486 Frankfurt am Main
Germany
Tel.: +49 69 7934-0
Customer service tel.: +49 7141 703 216
E-mail: custserv.germany@nalco.com
NALCO are equipped to ship kits worldwide.
• Expiration period
Two years• Storage temperature
0–25°C

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99

C. Coolant requirements and additives

••

Disposal of used material
Ensure that the disposal of all the materials used in this product is conducted according to all local
and national regulations.
Instructions for use
Completely empty both inhibitor bottles which are included with the NALCO kit into the coolingwater reservoir tank. After mixing the NALCO chemicals with the cooling water, the pH value should
be between 6.5 and 9.0.

WARNING
Risk of injury to eyes
Use appropriate eye protection when handling chemicals used in the NALCO water treatmentkit.

•➢ NALCO 460-RS200 is a multi-metal corrosion inhibitor to ensure effective protection against
corrosion of stainless steel, copper and copper alloys and it also works as a bacteriostatic andhardness stabiliser.
➢ NALCO 7330 is a biocide which removes bacteria and organic contamination (algae and slime)
from the water circuit.
NALCO RS200 and 7330 are completely compatible with glycol. The glycol should be without any
inhibitor (concentration 30–35% glycol in demineralised water).
The use of inhibitors, biocides, other substances or hardness stabilisers other than the specialist
NALCO kit may cause premature failure of the laser. It is the user's responsibility to ensure that the
specification of any alternative additive is equivalent to that of the NALCO additive.
Cooling system maintenance
After six months of operation, drain off the coolant and refill with fresh water treated with theappropriate NALCO kit or equivalent anti-bacterial product, as specified in Table 30.
Ensure that the disposal of all the materials used in this product is conducted according to all local
and national regulations.

C. Coolant requirements and additives

100

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Appendix D. Cooling system pressure drop curves
OEM 65iX — laser head and power supply circuits in series
3.5
Pressure drop (bar)

3
2.5
2
1.5
1
0.5
0
0

2

4

6

8

10

Flow (litres/min)

OEM 65iX — laser head and power supply circuits in parallel
1.6
Pressure drop (bar)

1.4
1.2
1
0.8
0.6
0.4
0.2
0
0

2

4

6

8

10

12

14

16

Flow (litres/min)

OEM 65iX — laser head and power supply (016-0033-00)
3Pressuer Drop
Pressure
drop (Bar)
(bar)

2.5
2
1.5
1
0.5
0
0

2

4

6

8

10

Flow (litres/min)(Liter/min)Flow

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D. Cooling system pressure drop curves

D. Cooling system pressure drop curves

102

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Appendix E. Parts list
The following parts list details consumable parts that may be required during maintenance andtroubleshooting procedures. To order parts, contact Luxinar Aftersales.
Table 31 - Parts list
Luxinar part number

Description

402-0006-00

Purge gas filter assembly

552-0019-00

Fuse, Plas 1A T TE5

552-0024-00

Fuse, 500mA T Cerm HRC

552-0035-00

Fuse, 500mA T Cerm 600V

569-0002-00

Mains circuit breaker, 32A

553-0015-00

Emission indicator, 12V 95mA LED

552-0007-00

Fuse 5x20mm Cerm T HRC, 1A

Note: These parts should only be fitted by trained Luxinar personnel.

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103

E. Parts list

E. Parts list

104906-0238-00 REV 4

Appendix F. Applications troubleshootingThis appendix addresses common materials processing issues, their causes and corrective actions.

F.1. Common issues
Fluctuations in beam intensity at the workpiece
The intensity changes can cause variations in marking intensity on some materials.

Focus spot height changing relative to the workpiece
When beam delivery optics heat up and distort, the focus spot height can change relative to theworkpiece. The machining result initially appears correct but degrades in a short time as if the laser
power is reducing. The reverse effect is also possible where the initial result is poor but improves
with time.
When cutting, the kerf width varies. When marking, the mark intensity reduces.

Directionality
When kerf width or marking intensity changes with machining direction, this directionality can be fora number of reasons. Most causes are due to beam distortion giving rise to an elliptic or distorted
focus spot, or beam misalignment through a cutting head nozzle. If the beam is asymmetrical thenthe focus spot will also be asymmetrical.

Low machining speed
Line speeds at lower powers can be used to predict an expected line speed at a higher power. When
predicted speeds cannot be achieved, common causes are optics distorting due to heating or backreflections causing mode size changes.

Beam distortion
There are many causes for beam distortion, including misalignment through the beam delivery
system, contamination and clear apertures being too small. At higher powers, light absorbed bymoisture in the air can lead to heating of the air which distorts the beam. To prevent this, purge thebeam path with a flow of clean, dry air or dry nitrogen.

Unstable power
All lasers have a natural variation in power over time, commonly known as laser power signature.
However, certain issues, for instance back reflections from the workpiece, can cause larger anderratic fluctuations in power than laser power signature alone.
The following graphs show sampled power (mW) versus time (s) measured by placing a beam splitterin the final beam delivery system to sample a small fraction of beam power while running repeatedpatterns lasting approximately 50s.

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105

F. Applications troubleshooting

1

Sampled power with the beam blocked by a power meter placed after the beam splitter.

2

Sampled power from the beam splitter while running the machining process.

Figure 82 - Sampled power comparison

Important!
Small back reflections from the surface of an external power sensor can contribute to poor
power stability. To prevent this, tilt the sensor around 5 degrees to the beam axis when
taking measurements.

F. Applications troubleshooting

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F.2. Causes and corrective actions
Table 32 - Corrective actions for common issues
Root cause

Observed effects

Back reflections from transmissive•
optics, beam delivery components or
the workpiece.
•••

Intensity fluctuation at theworkpiece
Directionality
Lower than predicted machining
speed
Unstable power

Corrective actions
•

•

•
•

•

Contamination of beam delivery
components or in the beam path.

•
•
•
•
•
•

Thermal lensing or distortion of
optical components

•
•
•
•

Fluctuations in intensity at theworkpiece
Focus beam height changing
Directionality
Lower than predicted machining
speed
Beam distortion
Unstable power•

Focus spot height changing
relative to the workpiece
Lower than predicted machining
speed
Beam distortion
Unstable power

•

•
•

•

•

Acoustic beam steering

•
•
•
•

906-0238-00 REV 4

Directionality
Lower than predicted machining
speed
Beam distortion
Unstable power

107

•
•

Check for scratches, dirt orcontaminant on the final beam
delivery optics and the laser headoutput window.
Ensure the final beam delivery
transmissive optics are tilted 2 to
5 degrees to the beam axis.
Check for small apertures thatcause back reflections.
Observe in-line power sensor
measurements while machining.
Compare them to measurements
made with the beam running
directly into a power head at thelaser beam exit.
Contact Luxinar Aftersales
regarding optical isolation
methods.
Check for scratches, dirt orcontaminant on the final beam
delivery optics and the laser headoutput window.
Purge the final beam delivery
system.
Purge the laser head.

Check for scratches, dirt orcontaminant on the final beam
delivery optics and the laser headoutput window.
Contact Luxinar Aftersales
regarding suitability of beam
delivery optics for OEM 65iX
incident power.
Observe the effect of focussing inand out relative to theworkpiece.
Refer to acoustic curves in
section Appendix A.
Operate using a different pulse
frequency range.

F. Applications troubleshootingRoot cause

Observed effects

Final beam delivery system apertures •too small for the beam diameter or •poor beam delivery systemalignment.
•

Directionality
Lower than predicted machining
speed
Beam distortion

Corrective actions
•

•

•

•

•

Intermittent RF power•••

F. Applications troubleshooting

Fluctuations in intensity at theworkpiece.
Lower than predicted machining
speed
Unstable power

108

Refer to beam propagation data
and measure aperture sizes andmirror clear apertures to be surethat no clipping is taking place.
Remove the final beam delivery
system and check the mode fromlaser – ideally through focus.
Check alignment onto beam
delivery mirrors and that thebeam is centred through all
apertures.
Check for distortion caused bystress in final beam delivery optic
mounts.
Contact Luxinar Aftersales
regarding optical mounting
methods.

Check the laser log history for errors.

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Please note that while every effort has been made to ensure that thedata given in this document is accurate, due to a policy of continuous
improvement, the information, figures, illustrations, tables, specificationand schematics contained herein are subject to change without notice.

DANGER
Class 4
Visible and Invisible laser radiation
Avoid eye or skin exposure
to direct or scattered radiation
Luxinar Ltd
Meadow Road
Bridgehead Business Park
Kingston upon Hull
HU13 0DG UK
Registered in England: 3477444

Tel: +44 1482 650088
sales.uk@luxinar.com
www.luxinar.com