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VersaPulse PowerSuite SERVICE MANUAL
This service manual is to be used in conjunction with the operator manual for the product. The operator manual contains important information regarding instrument description, location of controls, specifications, and normal operating procedures.
LASER CLASS 4/IV Holmium:YAG: 2.1 µm, 5J Max, 600 µs pulse Nd:YAG: 1064nm, 2J Max, 2.0 ms pulse LASER CLASS 3A/IIIa Diode Laser: 650nm, 5mW Max CW
VISIBLE AND INVISIBLE LASER RADIATION AVOID EYE OR SKIN EXPOSURE TO DIRECT OR SCATTERED RADIATION
CLASS 4 LASER PRODUCT per EN 60825-1/1994 CLASS IV LASER PRODUCT per 21 CFR 1040
2400 Condensa Street Santa Clara, CA 95051 (408) 764-7000
0636-499-00 REV. C
This manual is copyrighted with all rights reserved. Under the copyright laws, this manual cannot be copied in whole or part without express written permission of Lumenis, Inc. Permitted copies must carry the same proprietary and copyright and copyright notices as were affixed to the original. Please note that while every effort has been made to ensure that the data given is accurate, the information, figures, illustrations, tables, specifications, and schematics are subject to change without notice. Lumenis and the Lumenis Logo are registered trademarks of Lumenis, Inc. Please direct all inquiries about this manual to: Lumenis, Inc. Technical Support C-35 2400 Condensa Street Santa Clara, CA 95051 (408) 764-3638
Lumenis, Inc. 0636-499-00 REV. C
DISCLAIMER
Lumenis service manuals are written specifically for use by Lumenis service engineers who have received formal training in the servicing of Lumenis Equipment, and by customers who have taken and passed a Lumenis certification service training course for the equipment being serviced. Information on certification service training courses offered to customers can be obtained by contacting the Technical Coordinator at (800) 367-7899. Lumenis does not accept responsiblity for personal injury or property damage resulting from the servicing of Lumenis equipment by its customers or by third parties, except where such injury or property damage is a direct result of Lumenis's negligence. Customers, by accepting the service manual, agree to indemnify Lumenis against any claims alleging personal injury or property damage resulting from the servicing of Lumenis equipment by the customer or by third parties, except where such injury or property damage is a direct result of Lumenis's negligence. These limitations include situations where Lumenis personnel are advising customers on the repair of Lumenis equipment over the telephone, via fax or e-mail. The servicing of Lumenis equipment by persons who have not passed a current Lumenis certification service training course for that equipment will void Lumenis's product warranty.
VersaPulse PowerSuite Service Manual Disclaimer 0636-499-00 REV. C
REVISION INFORMATION
This is the REV. C release of the VersaPulse® PowerSuiteTM Service Manual . Contact Lumenis Technical Support to determine if this is the most current release of this service manual. Each page of this manual has a revision level at the bottom. This indicates the release level for the individual sections. Note that when the manual is updated, not all of the sections are necessarily updated, so some sections may have a revision level earlier than the release revision level for the manual (the revision level for the manual is the revision letter that appears on the cover and in the first sentence of this revision information page). The following list provides a complete list of the revision information, by section, for this release of the service manual. Cover page, copyright page, disclaimer page, this page, table of contents page(s) are all revision C with the corresponding section(s) of the manual.
SECTION 1 SECTION 2 SECTION 3 SECTION 4 SECTION 5 SECTION 6 SECTION 7
0636-499-01 0636-499-02 0636-499-03 0636-499-04 0636-499-05 0636-499-06 0636-499-07
REV. B REV. B REV. B REV. B REV. B REV. B REV. C
ECO# 69741 ECO# 69741 ECO# 69741 ECO# 69741 ECO# 69741 ECO# 69741 ECO# 69741
DATE: July 2001 DATE: July 2001 DATE: July 2001 DATE: July 2001 DATE: July 2001 DATE: July 2001 DATE: July 2001
NOTE: Field Service Bulletins (FSBs) released for this service manual are listed in the VersaPulse PowerSuite FSB Index. Each time an FSB for this manual is released or updated, the Index is also updated and distributed with the FSB. The current index is placed behind the single sheet that makes up Section 7, and the FSB's are placed in order behind the Index. Contact Lumenis Technical Support for the date of the most current FSB Index. SECTION 8 0636-499-08 REV. C ECO# 69741 DATE: July 2001
VersaPulse PowerSuite Service Manual Revision Information 0636-499-00 REV. C
TABLE OF CONTENTS
1.0 2.0 3.0 4.0 5.0 6.0 7.0 8.0 GENERAL INFORMATION 5 INSTALLATION 5 CALIBRATION, ALIGNMENT & ADJUSTMENT 5 THEORY OF OPERATION 5 TROUBLESHOOTING 5 SELECTED PART NUMBERS 6 FIELD SERVICE BULLETINS 6 SCHEMATICS & DRAWINGS 6
1.0 GENERAL INFORMATION 1
1.1 1.2 1.3 1.4 1.5
USE OF THIS MANUAL 1 CONVENTIONS USED IN THIS MANUAL
1
SERIAL NUMBERS 2
CERTIFICATION OF COMPLIANCE 3 SERVICE INFORMATION & FDA COMPLIANCE
3
2.0
2.1 2.1.1 2.1.2 2.1.3 2.1.4 2.1.5 2.1.6 2.2
INSTALLATION 1
INTRODUCTION 1 SITE INSPECTION 1 UNPACK & INSPECT LASER 2 CONFIGURE AC CONTROL PCB 3 ADD COOLANT 5 TURN ON 5 CUSTOMER DEMONSTRATION 6 PRODUCT SPECIFICATION 7
3.0 CALIBRATION, ADJUSTMENT & ALIGNMENT 1
3.1 3.1.1 3.1.2 3.2 3.2.1 3.2.2 3.2.2.1 3.2.2.2 3.2.2.3 3.2.3 3.2.4
INTRODUCTION 1 OVERVIEW 1 SAFETY PRECAUTIONS 2 OPTICAL ALIGNMENT 3 FOLDING MIRROR ALIGNMENT 3 YAG CHANNEL ALIGNMENT 4 MAKING TEST BURNS 4 ADJUSTING THE YAG CHANNEL OPTICS RESONATOR ALIGNMENT 9 SERVO MIRROR ALIGNMENT 11 FIBER ALIGNMENT 13
7
3.2.5 3.2.6 3.3 3.3.1 3.3.2 3.3.3 3.4 3.4.1 3.4.2 3.5 3.6 3.6.1 3.6.2 3.6.3 3.7 3.8
PYRO DETECTOR ALIGNMENT 15 AIMING BEAM ALIGNMENT 16 ELECTRICAL ADJUSTMENTS 16 VOLTAGE CONFIGURATION 16 FAN SPEED ADJUSTMENT 18 SPEAKER VOLUME ADJUSTMENT 19 MECHANICAL ADJUSTMENTS 19 EXTERNAL FIBER SENSE SWITCH ADJUSTMENT 19 BLASTSHIELD SENSE SWITCH ADJUSTMENT 21 ENERGY MONITOR AND AUTO CALIBRATION 21 SYSTEM OPTIMIZATION CHECK 24 FIBER ALIGNMENT TEST 24 VERIFY CALIBRATION - DELIVERED POWER OUT OF THE FIBER 26 FLASHLAMP PERFORMANCE CHECK 27 OPERATIONAL AND SAFETY CHECKOUT 28 PERIODIC MAINTENANCE REQUIREMENT 32
4.0 THEORY OF OPERATION 1
4.1 4.1.1 4.1.2 4.2 4.2.1 4.2.2 4.2.4 4.2.4.1 4.2.4.2 4.2.5 4.2.6 4.3 4.3.1 4.4 4.4.1 4.4.2 4.4.2.1 4.4.2.2 4.4.2.3 4.4.2.4 4.4.3 4.4.4 4.4.5 4.4.6 4.4.7 4.4.8 4.4.9
INTRODUCTION 1 OPERATIONAL OVERVIEW 1 FUNCTIONAL OVERVIEW 2 POWER SWITCHING, CONDITIONING, DISTRIBUTION 6 INPUT POWER 6 POWER DISTRIBUTION 6 TURN ON 7 CIRCUIT BREAKER ON, KEYSWITCH OFF 7 TURN ON SEQUENCE 7 SHUTDOWN 8 LOW VOLTAGE POWER SUPPLIES 8 COOLING 9 COMPONENTS 12 CONTROL ELECTRONICS 13 OVERVIEW 13 MICROPROCESSOR 14 DIGITAL I/O CIRCUITS 16 D/A & A/D CONVERSION CIRCUITS 17 DC POWER SUPPLY MONITOR CIRCUITS 17 AUDIO AMPLIFIER CIRCUIT 17 SHUTTER/FOOTSWITCH/REMOTE INTERLOCK CIRCUITS 18 SERVO MOTOR CONTROL CIRCUIT 19 HVPS & CONTROL CIRCUITS 20 ENERGY MONITOR CIRCUITS 21 USER INTERFACE AND REMOTE CONTROL CIRCUITS 23 AIMING DIODE LASER CIRCUIT 23 FIBER AND BLAST SHIELD POSITION SENSE CIRCUITS 24
4.4.10 4.4.11 4.5 4.6 4.7
SERVICE ATTENUATOR CIRCUIT 24 LOW ENERGY ATTENUATOR CIRCUIT 25 FLASHLAMP POWER CIRCUITS 26 OPTICS 27 SOFTWARE 29
5.0 TROUBLESHOOTING 1
5.1 5.1.1 5.1.2 5.2 5.3 5.4 5.4.1 5.4.2 5.4.3 5.5 5.5.1 5.6 5.6.1 5.6.2 5.6.3 5.7
OVERVIEW 1 SERVICE PHILOSOPHY 1 SAFETY PRECAUTIONS 2 INTERIOR ACCESS & PARTS LOCATION
3 SERVICE MODE 14 FAULT ISOLATION 21 TURN ON AND SHUT DOWN FAULT ISOLATION 22 "NO FAULT CODE REPORTED" FAULT ISOLATION 22 "FAULT CODE REPORTED" FAULT ISOLATION 23 TEST POINTS & LED ARRANGEMENT 28 CONTROLLER PCB LEDS 34 REMOVE/REPLACE PROCEDURE 38 FLASHLAMP REPLACEMENT 38 CONTROLLER PCB REPLACEMENT 39 WATER FILTER REPLACEMENT 41 TROUBLESHOOTING 41
6.0 SELECTED PARTS 1
SPECIAL TOOLS 1 USER REPLACEABLE SUB-ASSEMBLIES 1 CONTROL SYSTEM PRINTED CIRCUIT BOARDS 2 HIGH VOLTAGE POWER SUPPLY 2 CHASSIS & SKINS 2 CHASSIS ELECTRICAL/MAJOR SUB-ASSEMBLIES 3 CABLE SETS/HARNESSES 4 COOLING SYSTEM 4 OPTICS, COMMON 5 OPTICS, HOLMIUM 5 OPTICS, NEODYMIUM 5
7.0 FIELD SERVICE BULLETINS 1
7.0
FIELD SERVICE BULLETINS 1 VERSAPULSE POWERSUITE FIELD SERVICE BULLETIN INDEX
- 2 JULY 2001 1
NUMBER
DATETITLE 1 CODING INSTRUCTIONS: VERSAPULSE PRODUCT LINE
2 JULY 2001 2 VERSAPULSE POWERSUITE FSB #1: REV. H HIGH VOLTAGE POWER SUPPLY CONTROLLER PCB (P/N 0626-695-01)22 MAY 2000 7 INTRODUCTION 7 0626-695-01 REVISION "H" CONTROLLER PCB 7 INTRODUCTION 9 PARTS REQUIRED 9 RETROFIT INSTRUCTIONS 9 VERSAPULSE POWERSUITE FSB #2: SOFTWARE CHANGES & NEXT CALL RETROFIT (9800)2 JULY 2001 9
8.0 SCHEMATICS AND DRAWINGS 1
1.0 GENERAL INFORMATION
1.1
USE OF THIS MANUAL
This manual contains service instructions for the Lumenis VersaPulse® PowerSuiteTM series of Holmium and Neodymium YAG surgical lasers. The content of this manual is intended solely for use by Lumenis Field Service Engineers and Lumenis trained and certified customer technicians. Lumenis, Inc. cannot be responsible for service or repairs attempted by uncertified persons, and the use of this manual by such persons is prohibited.
This manual is to be used in conjunction with the Lumenis Operator Manual for the VersaPulse PowerSuite laser. The operator manual contains important information regarding instrument description, location of controls, specifications and normal operating procedures.
As necessary, Lumenis Service Technical Support releases Field Service Bulletins (FSB) for the VersaPulse PowerSuite laser. These FSB's supplement the information in this manual. As they are released, the FSB's become a part of this manual (Section 7).
1.2
CONVENTIONS USED IN THIS MANUAL
Within the text, logic signals that are active low ("notted") will appear inside of slash marks, as illustrated below.
/ATTENIN/
These signals are "active", or true, when the logic level is low. When the logic signal /ATTENIN/ is low, the attenuator loop is "OK" (complete). When the logic signal /ATTENIN/ is high, the attenuator loop is not OK (open). In most of the schematic diagrams such signals are indicated by the usual solid line above the signal name, as illustrated below.
ATTENIN
The schematics in this manual do not include individual numbers for the logic elements or operational amplifiers within a single component. For example, U1 which is illustrated on the next page, contains two VersaPulse® PowerSuiteTM Series Service Manual 0636-499-01 REV. B GENERAL INFORMATION 1-1
operational amplifiers. The top op amp would be referred to as U1-1 (its output is pin 1) and the other would be referred to as U1-7.
2 3 6 5
1
U1
7
U1
1.3
SERIAL NUMBERS
Serial numbers for the VersaPulse PowerSuite laser are in the following format:
MYPHWVXXX
where M is the month produced ("A" is January, "B" is February, etc..) Y is the last digit of the year produced (0 is 2000, etc..) P is a number indicating maximum system power (9=100W, 6=60W, 4=45W, 3=30W) ( D=60W Ho/100W Nd, E=80W Ho/100W Nd) H is the number of laser heads installed (1, 2, 3 or 4) W is a number indicating the mix of rods intalled (see below) V is a number indicating power supply configuration (1= 220VAC single phase) 2XXX is the number of the laser built (2001, 2002, etc..)
W:
3 = Holmium only 4 = Ho/Nd:YAG
GENERAL INFORMATION 1-2
VersaPulse® PowerSuiteTM Series Service Manual 0636-499-01 REV B
1.4
CERTIFICATION OF COMPLIANCE
The VersaPulse PowerSuite laser is designed and tested in accordance with Lumenis's procedures for self certification for a CE mark.
The CE mark is a certification label which allows Lumenis to sell the VersaPulse PowerSuite Lasers throughout the European community. This label certifies that the VersaPulse PowerSuite laser meets all regulations set forth by various countries in Europe. It is important to ensure that this label is on the laser chassis.
93/42/EEC 0086
1.5
SERVICE INFORMATION & FDA COMPLIANCE
In compliance to the FDA, brochures and specifications sheets must include a reproduction of a complete warning logotype or Class IIa warning statement as required on the product (1040.10(h)(2)(i)). Servicing information must contain the following (1040.10(h)(2)(ii)):
· Procedures for service with appropriate warnings to avoid exposure. (Refer to Section 3)
· A schedule of maintenance to maintain the product in compliance (Refer to Section 3)
· A list of controls that could increase the level of accessible radiation.
·· The energy UP/DN buttons on the LCD touch screen display.
·· The power UP/DN buttons on the LCD touch screen display.
·· The energy UP/DN buttons on the remote control display.
VersaPulse® PowerSuiteTM Series Service Manual 0636-499-01 REV. B
GENERAL INFORMATION 1-3
·· The power UP/DN buttons on the remote control display.
· Identification of removable portions of protective housings. (Refer to Section 5)
· Procedures to avoid exposure. (Refer to Section 3)
· Reproductions of required labels and warnings.
·· Below are illustrations of required labels and warnings applicable to this Service Manual:
LASER CLASS 4/IV Holmium:YAG: 2.1 µm, 5J Max, 600µs pulse Nd:YAG: 1064nm, 2J Max, 2.0 ms pulse LASER CLASS 3A/IIIa Diode Laser: 650nm, 1mW Max CW
VISIBLE AND INVISIBLE LASER RADIATION AVOID EYE OR SKIN EXPOSURE TO DIRECT OR SCATTERED RADIATION
CLASS 4 LASER PRODUCT per EN 60825-1/1994 CLASS IV LASER PRODUCT per 21 CFR 1040
Remote Interlock
(REAR VIEW) GENERAL INFORMATION 1-4 VersaPulse® PowerSuiteTM Series Service Manual 0636-499-01 REV B
Laser aperture at distal end of fiber
(FRONT VIEW)
VersaPulse® PowerSuiteTM Series Service Manual 0636-499-01 REV. B
GENERAL INFORMATION 1-5
GENERAL INFORMATION 1-6
VersaPulse® PowerSuiteTM Series Service Manual 0636-499-01 REV B
2.0
INSTALLATION
2.1
INTRODUCTION
WARNING: Installation by untrained persons is a potential hazard to the persons doing the installations, others present, and to the equipment itself. In addition, improper installation is a potential hazard to the user, persons present during use, and patient.
These installation instructions are provided for use by Lumenis Service Engineers who have completed certification service training on the VersaPulse® PowerSuiteTM laser. Installation by untrained persons is a potential hazard to the person or persons performing the installation, others present and to the equipment itself. In addition, improper installation is a potential hazard to the user, persons present during use and patient.
2.1.1
1.
Site Inspection
Check for proper site set up. This includes proper AC service and adequate space for the console.
AC power configuration: The VersaPulse PowerSuite requires 220 VAC±10%, 50/60 Hz, 30 Amps (32 Amps for 100W Holmium) single phase electrical service. The power cord is a 26 ft. cable with two conductors and a ground. An AC Control PCB behind the right side cover allows for tapping of the isolation transformer to the setting closest to the incoming electrical service. The system can be hard wired to the electrical service or installed to the electrical service with a plug and receptacle. Customers are responsible for supplying electrical connections (i.e., electrical receptacle and mating plug).
Console dimensions and weight: The console measures 36" L x 18" W x 39" H. It weighs approximately 350 lbs. A minimum of 18" of air space is required around the unit to provide adequate cooling air circulation.
The system requires approximately 2.5 gallons of distilled water for its closed loop cooling system. The coolant must be added as described in this procedure.
Complete specifications for the VersaPulse PowerSuite laser are included later in this section and in the VersaPulse PowerSuite laser Operator Manual. Contact Technical Support in Santa Clara, CA. if there are any questions concerning site preparation. VersaPulse® PowerSuiteTM Series Service Manual 0636-499-02 REV. B INSTALLATION 2-1
2.
Verify the AC mains voltage at the site.
Frequency: Voltage: Current: Phase:
50/60Hz 220 VAC ±10% 30A (32A for 100W Holmium) Single ()
2.1.2
1.
Unpack & Inspect Laser
Check the crate/carton for any shipping damage.
The shipper is responsible for any damage to the system in shipment. If the crate/carton appears to be damaged, report the damage to the customer and shipper.
2.
Remove the console and accessories from the crate (refer to Fig. 2.1).
a. Loosen the six butterfly clamps securing the side door and lower the side door (the side door is used as a ramp to remove the console from the crate). Remove the protective foam and accessories box. Install the ramps onto the base, then roll the unit down the ramps.
b. Return all packing material to the crate and save for future use.
INSTALLATION 2-2
VersaPulse® PowerSuiteTM Series Service Manual 0636-499-02 REV. B
ACCESSORY BOX
FOAM PADDING (6) INSIDE THE CRATE
DISTILLED WATER
FIG. 2.1 SHIPPING CRATE
BUTTERFLY CLAMPS (6) SECURE THE SIDE DOOR
COVER RAMP
3.
Move the system to its installation location.
The VersaPulse PowerSuite laser rolls best when pushed from the front handles. The front wheels swivel, the rear wheels do not.
4.
Open/remove covers and do a visual inspection of the interior.
Refer to Section 5 for information on removing the covers. Open the front cover, then remove the top and two side covers. Inspect the interior carefully for loose or broken electrical or optical connections, loose or broken plumbing connections, or any indication of shipping damage.
2.1.3
Configure AC Control PCB
Refer to Section 3.3.1 for additional details.
1.
AC voltage configuration preparation.
a. Measure the mains voltage and record. VersaPulse® PowerSuiteTM Series Service Manual 0636-499-02 REV. B INSTALLATION 2-3
b. Verify the VersaPulse PowerSuite is not connected to the AC mains.
2.
Locate the AC Control PCB (behind the right side panel) and identify TB5 & TB2 (top of the PCB). Refer to Fig. 2.2.
TB6 TB3
TB2
TB5 TB1
TB4 F3 F4 F5 F6 TACH FAN SPEED CONTROLLER PCB F7 T1 ISOLATED TRANSFORMER FOR FAN SPEED CONTROL CIRCUIT BOARD U2 TB8
K1 - SOFTSTART RELAY
240
220
200
R1 - SOFTSTART RESISTOR R2 - SOFTSTART RESISTOR
INTERLOCK CONTROL ELECTRONICS
SRG1 SURGE PROTECTOR
T2 - 24 V INTERLOCK LOOP ISOLATION TRANSFORMER
F10
F8
F9
K2 - MAIN CONTACTOR RELAY
FIXED - 0 120 100 J45 0 120 100 K3 - CPU HOLD-ON RELAY TB7 J44
J32
J31
J33
J47
J40
J43
J41
J46
J49
FIG. 2.2 AC CONTROL PCB
3.
Locate the large brown wire in TB5-1 and position the other end in TB2 as follows:
a. For mains voltage in 190 - 210 VAC range, connect TB5-1 to TB2-2.
b. For mains voltage in 211 - 230 VAC range, connect TB5-1 to TB2-3.
c. For mains voltage in 231 - 264 VAC range, connect TB5-1 to TB2-4.
4.
Locate the two small blue jumper wires in TB7 (bottom right). Position the jumpers as follows:
a. For mains voltage in 190 - 210 VAC range, jumper TB7: 1-3, 4-6.
b. For mains voltage in 211 - 230 VAC range, jumper TB7: 1-3, 5-6.
INSTALLATION 2-4
VersaPulse® PowerSuiteTM Series Service Manual 0636-499-02 REV. B
c. For mains voltage in 231-264 VAC range, jumper TB7: 2-3, 5-6.
5.
Record the voltage range on the Certification Report.
6.
Connect to AC service.
CAUTION: Once connected to the site electrical service, lethal voltages are present inside the unit. The AC power is present at the circuit breaker, main contactor and the AC Control PCB. Review and understand the safety subtopic in Section 5 before proceeding.
The system can be hard wired to electrical service, but is more typically connected by a plug to an electrical outlet.
If the system is to be hard wired, the customer must provide an electrician to wire the cord end into the electrical service outlet. A lockable electrical service disconnect switch must be installed if the system is hard wired.
If the system is to be plugged into an electrical receptacle, the appropriate receptacle should already be installed by the customer's electrician. The installing engineer connects the plug to the end of the VersaPulse PowerSuite electrical cable.
2.1.4
Add Coolant
Add coolant (distilled water) to the fill reservoir. The coolant will drain out of the fill reservoir and into the main reservoir. The system uses approximately 2.5 gallons of coolant. Most coolant can be added at this time - until the fill reservoir level stays up. The system coolant level will be "topped off" after the system is turned on (in a later step).
NOTE: Use distilled water only! Do not use alcohol or glycol based additives.
2.1.5
Turn On
CAUTION:
· Once the circuit breaker is turned on and power is applied to the VersaPulse PowerSuite laser, wait a few minutes and observe for any indication of failure of the mains or turn-on components. Check for any coolant leaks.
VersaPulse® PowerSuiteTM Series Service Manual 0636-499-02 REV. B
INSTALLATION 2-5
· The system will fire during the turn-on sequence regardless if SW3 (Autocal) on the CPU PCB is left or right and the BRH plug is installed. Only those persons required should be present during this portion of the installation - those present must wear appropriate laser safety eyewear and follow all laser safety precautions.
· The cooling fan blades are not covered. The fan is located on top of the heat exchanger. It operates whenever the system is turned on. Keep tools, system parts and body parts clear of the fan blades.
1.
Turn and hold the keyswitch to the START position, then after approximately two seconds, release it to the ON position. The system will go through its start up sequence. Observe for normal start up, and for any indication of leaks in the cooling system.
2.
Add additional coolant if necessary.
NOTE: Only add water if disconnected from AC mains.
Turn system off and disconnect from the AC mains. Top off the fill reservoir. Reconnect to AC mains and cycle the machine off and on several times, adding coolant as necessary until the fill reservoir level stays up to approximately half full as the system runs.
3.
Perform Fiber Alignment Test, Verify Calibration procedure and the Operational & Safety checks in Section 3.
4.
Replace all covers and prepare the system for demonstration to the customer.
2.1.6
1.
Customer Demonstration
Demonstrate the system operation to the customer.
2.
Fill out and mail the "self mailer" installation quality audit report (for U.S. Field Service).
3.
Fill out the System Certification report.
INSTALLATION 2-6
VersaPulse® PowerSuiteTM Series Service Manual 0636-499-02 REV. B
2.2
PRODUCT SPECIFICATION
Specifications are subject to change without notice.
VersaPulse Power Suite Dual Wavelength laser
Treatment beam wavelengths
Ho:YAG (2.1µm) Nd:YAG (1.06µm)
Table 1: 60/100W Model
Wavelength Ho:YAG (2.1µm) Nd:YAG (1.06µm) Power 0 - 60W 0 - 100W** Energy 0.2 - 3.5 J* 0.08 - 1.67J Exposure Time n/a 0.1 - 180 sec.* or continuous Pulse Rate 5 - 40 pulses/ sec.* 60 pulses/ sec. Pulse Width 600µs Max 2ms Max
Table 2: 80/100W Model
Wavelength Ho:YAG (2.1µm) Nd:YAG (1.06µm) Power 0 - 80W 0 - 100W** Energy 0.2 - 3.5 J* 0.08 - 1.67J Exposure Time n/a 0.1 - 180 sec.* or continuous Pulse Rate 5 - 40 pulses/ sec.* 60 pulses/ sec. Pulse Width 600µs Max 2ms Max
* adjustable in variable increments ** adjustable in 5 Watt increments
VersaPulse PowerSuite Holmium laser
Treatment beam wavelength VersaPulse® PowerSuiteTM Series Service Manual 0636-499-02 REV. B INSTALLATION 2-7
Table 3: Ho:YAG (2.1µm)
Model 30 Watt Ho:YAG 45 Watt Ho:YAG 60 Watt Ho:YAG 100 Watt Ho:YAG Power 30W 45W 60W 100W Energy 0.2 - 3.5J 0.2 - 3.5j 0.2 - 3.5J 0.2 - 3.5J Pulse Rate 5 - 25 pulses/ sec. 5 - 40 pulses/ sec. 5 - 40 pulses/ sec. 5 - 50 pulses/ sec. Pulse Width 600µs Max 600µs Max 600µs Max 600µs Max
VersaPulse PowerSuite Dual Wavelength and Holmium lasers
Laser Classifications:
US FDA CDRH laser classification: Class IV European EN 60825 laser classification: Class 4
Aiming Beam:
Type: Diode Power: 1 mW maximum, Continuous Wave US FDA CDRH laser classification: Class IIIa European EN 60825 laser classification: Class 3A Principal output: Red, 650nm (±10 nm)
Input Power
Frequency: 50/60 Hz Voltage: 220 VAC ±10% Phase: Single Current: Holmium 100W systems, 32A All other Holmium systems, 30A Dual wavelength systems, 30A
Cooling
Internal water-to-air heat exchanger or optional secondary cooling system
INSTALLATION 2-8
VersaPulse® PowerSuiteTM Series Service Manual 0636-499-02 REV. B
Cooling air requirements
Minimum 46 cm (18 in.) from walls
Physical characteristics
Width: 46 cm (18 in.) Length: 91 cm (36 in.) Height: 99 cm (39 in.) Weight: 163kg (360 lbs.)
Power cord length
8.0 m (26 ft.)
Footswitch cable length
3.7 m (12 ft.)
Environmental requirements (operating)
Maximum altitude: 3,050 m (10,000 ft.) Temperature range: 10º C to 30º C (50º F to 86º F) - must be above dew point Maximum humidity: 90% at 27º C (81º F) non-condensing
Environmental requirements (non-operating)
Maximum altitude: 9,144 m (34,564 ft.) Temperature range: 10º C to 50º C (50º F to 122º F) - must be above dew point Maximum humidity: 90% at 55º C (131º F) non-condensing
Optional external cooling system
Cooling capacity: 4.5 kW Flow rate: 0.25 lps (4gpm) Temperature set point: 20º C (68º F) Connections: Quick connect Line size: 1/2 inch minimum
Compatible delivery systems: (The laser is intended for use only with Coherent-qualified delivery systems) VersaPulse® PowerSuiteTM Series Service Manual INSTALLATION 0636-499-02 REV. B 2-9
INSTALLATION 2-10
VersaPulse® PowerSuiteTM Series Service Manual 0636-499-02 REV. B
3.0 CALIBRATION, ADJUSTMENT & ALIGNMENT
3.1
INTRODUCTION
3.1.1
Overview
This section contains procedures for the checks and adjustments required to maintain the Lumenis VersaPulse® PowerSuiteTM Laser. The procedures assume the reader has successfully completed a Lumenis service training course on the VersaPulse PowerSuite laser. Service performed by untrained or unqualified persons can be a hazard to the person or persons doing the service and to others present during the servicing. An improperly serviced medical system can be a hazard to the equipment user, to others present during use, and to the patient upon whom the laser is used.
The procedures should be performed in the order presented, from beginning to end. If only a portion of the procedures are done, the servicing engineer must consider the possible effect of doing just that portion of the procedures (i.e., there may be adjustments done earlier or later in the procedures that impact or are impacted by the portion performed).
Optical Alignment, Topic 3.2, this is performed when the System Check out procedure indicates a problem, any of the various optical/electro-optical/servo components have been adjusted/replaced or the system cannot meet specifications during the various calibration procedures.
Electrical Adjustments, Topic 3.3, verifies the Fan Speed Controller PCB is properly adjusted for optimal cooling and the speaker volume is properly adjusted.
Mechanical Adjustments, Topic 3.4, verifies that various mechanical switches and latches are properly set.
Energy Calibration, Topic 3.5, calibrates the voltage output of the two energy monitor circuits to the Field Service Engineer's calibrated power meter.
System Optimization Check, Topic 3.6, verifies that the system is operating optimally after the preceeding procedures (i.e., optical, electrical and etc.) have been completed and test the calibration at all operating points.
VersaPulse® PowerSuiteTM Series Service Manual 0636-499-03 REV. B
CAL, ADJUST, ALIGN 3-1
Operational and Safety Check, Topic 3.7, is an operational check of the system. It confirms that the system turns on properly, responds properly to operator inputs, delivers the multiplexed YAG beam into the center of an attached fiber, and provides an adjustable aiming beam through the fiber. It also confirms that the proper fault messages are displayed when various connectors (i.e., footswitch and remote interlock plug) are disconnected and the system is prevented from firing.
Periodic Maintenance, Topic 3.8, provides information on periodic maintenance checks to ensure optimum performance of the system.
TOOLS & EQUIPMENT REQUIRED:
Power Calibration Test Fibers for Ho/Nd 0623-973-01 Field Master Cross-Hair Alignment Tool 0621-131-51 Zap-It paper 3207-0091 Ink/Burn Test Fiber 0621-675-01 DVM & Leads
10mm Aperture Alignment Tool 0622-919-51 Transimpedance Amplifier 0614-868-51 Calibrated Oscilloscope FSH Head Berol 8800 red Marker Poly Bags
Two test fibers are shipped with the system. Check the fiber focus as described in Section 3, Topic 3.2.
3.1.2
Safety Precautions
Lethal voltages and laser emission are the primary dangers to the servicing engineer. In addition to the general safety precautions which always apply when working on electronics and lasers, the servicing engineer must be aware of the following specific precautions:
· Only Lumenis certified VersaPulse PowerSuite YAG service engineers should attempt any service on this system.
· Even with the keyswitch and the breaker in the "OFF" position there are lethal voltages present inside the console. Always disconnect the main electrical service before working on the console.
· Storage capacitors inside the system are capable of holding a lethal charge, even after power has been removed from the unit. A charge level indicator LED located on the Simmer/Start Control PCB flashes at a rate proportional to the level of charge on the main charging capacitor. The LED can be seen through a small access window on the High Voltage Power Supply cover next to the Controller PCB. Do not rely on this indicator to determine that the main charging capacitor has been discharged. Before contacting the main charging capacitor, disconnect the system from the primary power.
CAL, ADJUST, ALIGN 3-2
VersaPulse® PowerSuiteTM Series Service Manual 0636-499-03 REV. B
· Do not touch the YAG Cavity Module when the system is on - IT IS A SHOCK HAZARD. The YAG Cavity Module is electrically isolated from the chassis and can be at a voltage potential much higher than ground. A Neon lamp on the Starter Indicator PCB indicates lamp start high voltage is present when flashing. B+ is always on the pod's terminal block.
· Both Holmium & Nd:YAG laser emissions are invisible to the human eye. Because the YAG laser energy can not be seen, there is no visible indication of the primary or reflected beam. Eye protection that attenuates the YAG wavelengths to a safe level must be worn by all persons in the area of the laser system, whenever the laser is being serviced.
· The YAG laser light and its reflections are potential burn hazards and can ignite flammable materials. Use extreme caution when operating the system with covers opened or removed. The covers contain the beam and reflections safely within the console. Only those persons required should be present during servicing and eye protection that safely attenuates the YAG wavelengths must be worn by all present.
· The YAG laser light and its reflections are potential hazards to the eye and skin. Use extreme caution when operating the system with the covers opened or removed. The covers contain the beam and reflections safely within console. Only those persons required should be present during servicing and eye protection that safely attenuates the YAG wavelengths should be worn by all those present.
3.2
OPTICAL ALIGNMENT
Perform the Optical Alignment procedures whenever any optical or electro-mechanical device have been replaced or adjusted in the optics bench or in the laser head. Note that the procedures should be performed in the order presented, from beginning to end. If only a portion of the procedures are done, the servicing engineer must consider the possible effect of doing just that portion of the procedures (i.e., there may be adjustments done earlier or later in the procedures that impact or are impacted by the portion performed).
3.2.1
Folding Mirror Alignment
This is not normally performed in the field. contact Lumenis Technical Support Department for additional tooling and instructions if required to perform this alignment.
VersaPulse® PowerSuiteTM Series Service Manual 0636-499-03 REV. B
CAL, ADJUST, ALIGN 3-3
3.2.2
YAG Channel Alignment
When properly adjusted the YAG channel will meet each of the following three criteria.
· The cavity HR will be positioned to direct the YAG output to the center of the first relay mirror, and the cavity OC will be positioned to provide maximum power for that HR position.
· The first relay mirror and second (plano) relay mirror will direct the YAG energy off the two folding mirrors so that it is centered through the wedge optic apertures and centered into the proximal end of the fiber.
The adjustment procedure for a single channel follows. The procedure is a complete check out and alignment for a single channel. The procedure is meant to be done in the order given, from beginning to end.
It may often be appropriate to do less than the complete adjustment, but in such a case the field service engineer must consider the possible effect of doing only a portion, i.e., the adjustment may have an effect on some other portion of the alignment. As an example, if a single channel is only slightly out of center at the fiber port, it can usually be corrected by simply adjusting the first relay mirror (using the fiber detector signal) and then confirming the adjustment using a test fiber burn.
When replacing a damaged optic, it should not be necessary to do the entire procedure. Try to bring the system back into alignment by adjusting the optic that was replaced.
3.2.2.1 Making Test Burns
(Refer to Fig 3.2 and 3.3) Checking out and aligning the YAG channels requires making burns on photopaper to check alignment. The Alignment Aperture and Cross Hair Aperture are two special purpose tools used when making burns.
In general, when making burns, lower pulse energies and fewer total pulses are better. As the total energy of the burn increases, the footprint becomes "blurred". In some cases it will be necessary to get a "multiplexed footprint", i.e., the paper is burned by more than one channel, allowing the YAG beam positions to be compared. In other cases a single channel burn will be required. The service engineer can select the channels to be fired, a lamp current and a pulse rate at the service screens. Setting a lower pulse rate allows the footswitch to be operated to obtain just a single pulse from a channel, or from each selected channel.
The alignment aperture is used to center the YAG beam(s) in front of the second wedge optic. It holds a piece of burn paper (covered on both sides with plastic to contain splatter). A good burn will fall inside the aperture (the aperture will not clip the beam). The tool is keyed with two small posts that fit into holes on the face of the second wedge optic housing block. To use the aperture, slide burn paper and plastic in through the side, then insert it on the second wedge optic housing.
CAL, ADJUST, ALIGN 3-4
VersaPulse® PowerSuiteTM Series Service Manual 0636-499-03 REV. B
The cross hair aperture is used to align an individual cavity (OC and HR) into the center of the first relay mirror. To install it, the first relay mirror mount is removed, then the aperture slides into a hole in the wall directly behind the spot the channel first relay mirror was mounted (insert from the outside of the wall, so that it is further from the channel OC). The aperture has two small wires running across it that block a small portion of the beam (perpendicular to each other and crossing in the center of the aperture). The resulting burn will have the cross hairs superimposed on it. The cavity optics are adjusted to center the burn in the cross hairs.
FIG. 3.1
INSERT THE TEST APERTURE HERE IN THE MOUNTING HOLE FOR THE SECOND WEDGE OPTIC, BE SURE THE TWO KEY POSTS ON THE APERTURE IS INSERTED INTO THE TWO HOLES ON THE MOUNT.
VersaPulse® PowerSuiteTM Series Service Manual 0636-499-03 REV. B
CAL, ADJUST, ALIGN 3-5
Insert the test aperture here, in the mounting hole for the second wedge optic, inserting the two key posts on the aperture into the two holes on the mount.
Towards fiber Burn paper
Towards laser
Clear plastic over burn paper, slides into slot on the test aperture.
FIGURE 3.2 USING THE TEST APERTURE
Remove the channel first relay m irror mount, then insert the cross hair aperture in the hole from the back (further away from the OC).
Servo M irror CROSS HA IR A PERTURE
BURN S THRO UGH TH E CROSS HA IR APERTURE:
FIG. 3.3: USING THE CROSS HAIR APERTURE
Out in vertical and horizontal.
Out in vertical
Properly centered
CAL, ADJUST, ALIGN 3-6
VersaPulse® PowerSuiteTM Series Service Manual 0636-499-03 REV. B
3.2.2.2 Adjusting the YAG Channel Optics
WARNING! When the optics bench cover is removed, exposure to hazardous high voltages is present. 10kV is present on the pod assembly when the lamps are starting, and may be present any time the system is turned on. B+ is present on the terminal block whenever the system is on, and is present up to 15 minutes after the system is turned off.
Refer to Fig. 3.4 The channel HR, OC and relay mirrors all have the same basic adjustment mechanics. The mirror is held in a mirror mount by a metal retainer. The mount attaches to one of the optics bench walls by a single mounting screw with spring. The spring pulls the mount towards the wall - two adjusting screws and a ball bearing hold the mount out away from its mounting surface against the tension of the spring. One adjusting screw provides horizontal movement and the other provides vertical movement.
A locking nut is threaded onto each adjusting screw. To unlock the screw for adjustment back the locking screw away from the collar. Once adjustment is complete, lock down the adjustment screw by turning the nut down against the collar. As is common in such mechanical lock down set ups, the locking down process will change the adjustment a bit, so use the locking down to bring the optic to its optimum position. It is best to use the hex wrench to hold the adjusting screw in place while tightening down the locking nut with the box end wrench. The adjusting screws require a 7/64th hex head wrench. The locking nuts require a 7/16th box end wrench.
The channel HR and OC must first be aligned to each other through the length of the YAG rod in order to achieve lasing. Once the two mirrors are aligned to provide a usable output (will make a burn on photopaper), the two optics are adjusted together to "walk" the YAG output so that it is centered in the first relay mirror. Finally, the OC is adjusted to peak the power out of the cavity into the center of the first relay mirror.
The channel first and second (plano) relay mirrors are adjusted to center the channel YAG beam through the wedge optics and into the center of the fiber port. The first relay mirror is the far (fiber port) adjustment (it is concave, and provides less positional change to the beam downstream at the fiber port). The second relay mirror is near (wedge optic) adjustment, it moves the beam much more than the first relay mirror. In general, unless the beam is grossly out of center at the second wedge aperture, the second relay mirror should not be adjusted.
There are also two turning mirrors that steer all the YAG channels off the galvo/servo mirror down towards the fiber port. These mirrors do not normally require adjustment. Obviously, adjusting one of these mirrors will affect all four YAG channels. The adjustment and mounting scheme is the same as that for the channel optics.
VersaPulse® PowerSuiteTM Series Service Manual 0636-499-03 REV. B
CAL, ADJUST, ALIGN 3-7
SIDE VIEW
LOCKING NUT
ADJUSTING SCREW (typical, 2 per mount)
MOUNTING SCREW (one per mount)
Ball bearing is the pivot point about which the optic mount is moved by the two adjusting screws Mounting Screw threads into this hole. OPTIC RETAINER
MOUNTING WALL
MIRROR MOUNT
MIRROR OUTS IDE SURFACE (away from wall)
INSIDE SURFACE (towards wall)
Rounded end of the adjusting screws contact the optic mount here.
FIG. 3.4: ADJUSTMENT AND REPLACEMENT OF THE CHANNEL OPTICS
SE V R O M RR IR O
RELAY MIRRORS
PLANO RELAY MIRRORS
PLANO RELAY MIRRORS
VIEW FROM OC END
CAL, ADJUST, ALIGN 3-8
FIG. 3.5: RELAY AND PLANO MIRRORS (Ho/Nd:YAG) VersaPulse® PowerSuiteTM Series Service Manual 0636-499-03 REV. B
First Relay Mirror - far (fiber) alignment
Plano Mirror - near (wedge) alignment
3.2.2.3 Resonator Alignment
1. Remove the optics bench cover.
2.
Examine the optics for any visual sign of damage. Replace damaged HR, OC, or Relay mirrors.
(Refer to Fig 3.4 on the previous page) To replace a channel relay mirror, HR or OC, first remove the mirror mount by carefully removing the mounting screw (it has a spring around its shaft to place tension on the mount) while supporting the mount. Once the mount is free, set it down face up and remove the retainer (held in place by three hex screws) that hold the optic. The old optic can then be removed and the new optic inserted (ball bearings inside the mounting hole center and the optic in the hole). Reinstall the retainer, then the mirror mount. Note that the mount should return to its former position, since the adjustment screws were not removed.
3.
Examine the end of the rod for visual damage.
The rod will be illuminated by the flash lamp when the unit is on (if not, the flash lamp has failed or the simmer supply circuitry has a problem). Replace a damaged rod or failed flash lamp.
4.
Center and peak the cavity output into the first relay mirror.
When the cavity OC and HR are correctly aligned, the YAG beam will be centered in the relay mirror directly across from the OC, and the cavity power output will be peaked.
a. Remove the first relay mirror mount and place a piece of "Zap-it" or Dioptron paper just in front of where the first Relay Mirror was removed.
b. Set the laser in service mode with the following parameters:
VersaPulse® PowerSuiteTM Series Service Manual 0636-499-03 REV. B
CAL, ADJUST, ALIGN 3-9
A Typically, the burn diameter is approximately 4mm in diam eter. If the burn is small, perform the cavity alignm ent and increase the lamp current. The burn diameter may get larger.
B Good cavity power is shown. A large diameter burn (approx. 4m m) indicates good power. No adjustment of the HR or OC is necessary.
An oblong burn spot indicates that the HR and OC optics are not properly aligned for maxim um pow er. Burn "A " shows mis-alignm ent in the X-axis, w hile burn "B" show s m isalignm ent in both X and Y.
For Ho: (for power measurementLamp Volts 800V Lamp Energy 50J Repetition Rate 10 Hz
(For Centering) Lamp Volts 800V Lamp energy 50J Repetition Rate 1.3 Hz
For Nd: (for power measurement) Lamp Volts 800V (For Centering) Lamp Volts 800V Lamp current 50A Lamp current 50A Repetition Rate 60 Hz Repetition Rate 5 Hz
Turn on only one flashlamp when aligning the cavity. After one channel is aligned, turn off the flashlamp for that particular channel and then turn on the flashlamp for the next channel to be aligned.
c. Make a single burn on the paper and compare the burn to the drawing below.
d. Adjust the X or Y axis on the OC mirror mount to optimize the alignment of the beam.
e. Install the cross hair aperture (as described in 3.5.1).
f. Make a burn (single channel) through the cross hair aperture onto a piece of burn paper.
g. Examine the burn to determine if the YAG beam is centered.
The burn should be centered over the cross hairs. If not, adjust ("walk" as described in the following subparagraph) the OC/HR positions to bring the burn into center, rechecking as necessary as in step "b" above. Continue adjustment until the burn footprint is centered in the cross hairs.
"Walking" the beam refers to the method of adjusting the OC and HR in the same direction and distance, so that the two mirrors remain in the same orientation with each other, but are brought to a new orientation with respect to the rod. Each mirror mount has a horizontal and a vertical adjustment screw. For example, to walk the beam "up" with respect to the hole, the OC vertical adjustment would be turned in, then the HR vertical adjustment would be CAL, ADJUST, ALIGN 3-10 VersaPulse® PowerSuiteTM Series Service Manual 0636-499-03 REV. B
turned out the same amount (do not be fooled as to the direction to turn the adjustment screw by the fact that the two screws are mounted in opposite directions - one screw is being turned in and the other is being turned out, but because the screws are mounted in opposite directions the screws rotate in the same direction).
h. Once the burn has been centered in the cross hairs, remove the cross hair aperture and place the power meter head behind the hole, so that the YAG energy through the hole will strike the power meter head. Fire the laser into the head and adjust the OC to peak the cavity power output.
i. Replace the cross hair aperture and recheck the beam centering through the hole as in step "b" above. Some slight readjustment of the HR may be necessary to recenter the burn in the cross hairs.
j. Repeat steps "d" and "e" until the power is peaked and the burn is centered in the cross hairs, with the HR and OC adjustment mechanisms locked down.
k. Reinstall the first Relay Mirror and perform the Fiber Alignment Procedure in Topic 3.6.
3.2.3
Servo Mirror Alignment
NOTE: Only perform this procedure if either the servo mirror or servo motor are replaced.
1.
Turn off the laser and disconnect from the wall.
2.
Removing and replace the motor/encoder assembly.
a. Disconnect the cables from the motor/encoder assembly and remove the mirror mount from the motor shaft.
b. Remove the six screws behind the mirror and remove the motor/encoder assembly.
c. Install the new motor/encoder assembly in the same orientation as the old one, and reconnect the cables.
NOTE: Shaft rotation is not important at this time.
3.
Reconnect the power, disable autocal and turn the laser on.
VersaPulse® PowerSuiteTM Series Service Manual 0636-499-03 REV. B
CAL, ADJUST, ALIGN 3-11
The motor shaft must always slowly rotate to find the index position on the encoder. LED30 (INDEX) will illuminate green and TP75 "INDEX" will go high.
NOTE: If the service software has lamp #1 turned off, the motor will find the index position and rotate to the next active brick.
4.
Install the Servo Mirror.
a. Using the servo alignment tool (P/N 0622-782-51), install the servo mirror on the motor shaft. Be sure the mirror mount is pushed all the way onto the shaft. Refer to Fig. 3.6.
b. Rotate the mirror toward brick #1.
The mirror mount will fit into the servo alignment tool in two different ways. But only one orientation is the correct way.
c. Once the alignment tool is attached properly use the hex key to lock the mirror mount down.
CHA NN EL #1
CHA NN EL #4
RELAY M IRRORS
RELA Y M IRRORS
SE V R O M R R IR O
Hex Wrench
CHANNEL #2 CA ST HEAD SERVO WA LL (Inside View )
CHA NNEL #3
FIG. 3.6: SERVO MIRROR INSTALLATION
CAL, ADJUST, ALIGN 3-12
VersaPulse® PowerSuiteTM Series Service Manual 0636-499-03 REV. B
5.
Perform the Fiber alignment for all channels in Section 3.2.4.
If no laser energy is detected between the two folding mirrors, the mirror is probably not oriented toward the correct brick. Go back and repeat step 3, then rotate the mirror 180º on the shaft in step 4.
3.2.4
Fiber Alignment
For each channel, two optics are adjusted to position the YAG beam down the intended optical path into the center of the fiber; the first relay mirror and the second (plano) relay mirror.
The second relay mirror seldom needs to be adjusted. It provides a much wider range of movement of the beam than the first relay mirror. The four second relay mirrors are all mounted on the cavity OC wall. Although the second relay mirror mounts are shaped differently than the other channel mirror mounts, the mounting and adjusting hardware is the same - each is held in place by a spring loaded mounting screw and each has a horizontal and vertical adjusting screw with locking nut.
The first relay mirror is normally the only adjustment needed to get the YAG beam centered through the wedge optics and centered into the fiber port.
a. Set the system to the following operating parameters.
Holmium: Lamp Volts Lamp energy Repetition Rate
800V 50J 5 Hz
Ho/Nd:YAG: Lamp Volts 800V Lamp Current 50A Repetition Rate 5 Hz
b. Use the test aperture to check the YAG channel centering into the second wedge optic opening. Examine the burn and proceed as follows:
NOTE:
·An acceptable burn is to be centered and clipping must not be seen. If the burn is acceptable, go on to step "b" below.
·An unacceptable burn will be well off center (more than a fourth of the burn is clipped). In this case, the second relay mirror must be adjusted to bring the YAG beam closer to the center of the aperture as described below.
VersaPulse® PowerSuiteTM Series Service Manual 0636-499-03 REV. B
CAL, ADJUST, ALIGN 3-13
Beam is clipping the 10mm burn aperature tool. Adjust plano relay m irror dow n and to the right to center the burn.
An oblong or small burn spot or distorted burn spots usually indicates that the cavity is not peaked or some of the cavity optics are damaged. Check HR, OC, and rod for burn spots.
The burn is round and centered in the aperature. The goal is to get all four channels centered, at the same time each beam is centered (peak signal) on the transimpedance detector.
All four burns are centered. The overall diameter of the burn is slightly larger than any one single burn. This is OK.
FIG. 3.7
Make a slight adjustment to the second relay mirror, then check the result by making a burn on photopaper at the second wedge optic. Because a number of burns may be required to complete the adjustment, using the test aperture can slow things down (the aperture would have to be reloaded with a clean piece of paper after each shot). As an alternative, find a second channel that is already centered in the aperture, and then use the service screen to turn that channel on as well as the channel to be adjusted. When the laser is fired the two channels will each fire in turn. Instead of using the aperture, make the burns on a larger piece of paper held in front of the aperture, moving to a clean spot for each check. The known good channel becomes the reference - adjust the second relay mirror for the channel out of adjustment until the burn footprints are on top of each other. Once the channel is roughly positioned over the aperture, lock down the mirror and go to step "c" below.
c. Set the system to the following repetition rate and align the YAG beam into the fiber port using the Fiber Alignment Detector Box (Transimpedance Amp).
Holmium: Nd:YAG:
Repetition rate = 40 Hz Repetition rate = 60 Hz
Insert the service attenuator into the beam path (SW4 on the CPU PCB to the left). Connect the fiber alignment detector box to the fiber port and oscilloscope. Select the proper repetition rate according to the type of system being worked on. Then adjust as indicated in the subparagraph below.
Fire the laser while observing the oscilloscope. Each laser pulse will produce a squarish pulse on the screen. Make slight adjustments to the channel first relay mirror to peak the amplitude of the pulses on the oscilloscope. Use the highest scope gain and adjust for the highest peak.
CAL, ADJUST, ALIGN 3-14
VersaPulse® PowerSuiteTM Series Service Manual 0636-499-03 REV. B
d. Check the burn at the second wedge optic using the test aperture.
The beam must be unclipped. If not, repeat steps "a" and "b" above until both pass with the adjustments mechanisms locked down.
e. Make a burn into the test aperture with all four channels turned on.
The resulting burn footprint should be circular in shape and contained in the aperture (no clipping).
f. Remove the service attenuator (SW4 on the CPU PCB to the right).
g. Perform the System Checkout as outlined in Topic 3.4
3.2.5
Pyro Detector Alignment
In order for the calibration of the system to be as accurate as possible, the pyro detector mirrors must be properly aligned. This alignment may also be required if the Optics Bench PCB is changed.
1.
Set up of the laser.
a. Go into the service screen and enter the following parameters. Turn on one Holmium flashlamp and set the lamp energy at 50 Joules, lamp volts at 800V and repetition rate of 10 Hz.
b. Set the oscilloscope for 1V/Div. with sweep time of 200µS.
2.
Align the pyro mirror.
a. Connect channel A from the oscilloscope to TP1 (MPREA) on the Optics Bench PCB. Use TP2 as ground.
b. Adjust the pyro mirror in both X-Y axis to peak the signal as seen on the scope.
VersaPulse® PowerSuiteTM Series Service Manual 0636-499-03 REV. B
CAL, ADJUST, ALIGN 3-15
3.2.6
Aiming Beam Alignment
The aiming beam can be adjusted by repositioning the aiming diode mount or by adjusting the position of the folding mirror (the mirror that directs the aiming beam onto the beam combiner). Observe the aiming beam output from the fiber and adjust to obtain a full spot of bright red light (no doughnut). Note: A faint halo is acceptable. Refer to Fig. 3.8.
ACCEPTABLE (Ideal)
ACCEPTABLE (Faint Halo)
UNACCEPTABLE (Bright Halo)
UNACCEPTABLE (Aiming Beam is out of Alignment)
FIG. 3.8: AIMING BEAM PROFILE
3.3
ELECTRICAL ADJUSTMENTS
3.3.1
Voltage Configuration
The VersaPulse Select PowerSuite can be configured to operate with the AC mains voltage at 220VAC ±10% by setting various jumpers on the AC Control PCB. Refer to Figure 3.9 and the procedure below in configuring the AC Control PCB.
1.
Set up
a. Measure the AC mains voltage and record on the Certification Report.
b. Verify the VersaPulse PowerSuite is not connected to the AC mains.
c. Open the front door and remove the right side cover. (Refer to Section 5).
CAL, ADJUST, ALIGN 3-16
VersaPulse® PowerSuiteTM Series Service Manual 0636-499-03 REV. B
2.
Locate the AC Control PCB (behind the right side panel) and identify TB5 & TB2 (top of the AC Control PCB). Refer to Fig. 3.9.
3.
Locate the large brown wire in TB5-1 and position the other end in TB2 as follows in Fig. 3.9:
TB2 TB3 4 3 2 1 2
TB5 1
240 TB6 TB3 TB2 TB5 TB1 TB4 F3 F4 F5 F6 TACH FAN SPEED CONTROLLER PCB F7 T1 ISOLATED TRANSFORMER FOR FAN SPEED CONTROL CIRCUIT BOARD U2 TB8
220
200
BRN - TAPPING WIRE
K1 - SOFTSTART RELAY
240
(4)
220
(3)
200
(2) (1)
(2)
(1)
R1 - SOFTSTART RESISTOR R2 - SOFTSTART RESISTOR
190-210V: TB5-1 TO TB2-2 211-230V: TB5-1 TO TB2-3 231-264V: TB5-1 TO TB2-4
INTERLOCK CONTROL ELECTRONICS
SRG1 SURGE PROTECTOR
190-210V OPERATION
T2 - 24 V INTERLOCK LOOP ISOLATION TRANSFORMER F10 F8 F9
211-230V OPERATION
231-264V OPERATION
K2 - MAIN CONTACTOR RELAY
FIXED - 0 120 100 J45 0 120 100 K3 - CPU HOLD-ON RELAY TB7 J44
FIXED - 0 120 100 FIXED - 0 120 100 TB7 J44
6 5 4 3 2 1
FIXED - 0 120 100 FIXED - 0 120 100 TB7 J44
6 5 4 3 2 1
FIXED - 0 120 100 FIXED - 0 120 100 TB7 J44
6 5 4 3 2 1
J32
J31
J33
J47
J40
J43
J41
J46
J49
TB7: 1-3, 4-6
TB7: 1-3, 56
TB7: 2-3, 56
FIG. 3.9: AC CONFIGURATION ON THE AC CONTROL PCB
4.
Locate the two small blue jumper wires in TB7 (bottom right). Position the jumpers as illustrated in Fig. 3.9.
5.
Connect to system to the AC service.
CAUTION: Once connected to the site electrical service, lethal voltages are present inside the unit. The AC power is present at the circuit breaker, main contactor and isolation transformer. In addition, the isolation transformer secondary outputs are "hot". Review and understand the safety subtopic in Section 5 before preceeding.
The system can be hard wired to electrical service, but ismore typically connected by a plug to an electrical outlet.
VersaPulse® PowerSuiteTM Series Service Manual 0636-499-03 REV. B
CAL, ADJUST, ALIGN 3-17
If the system can be hard wired, the customer must provide an electrician to wire the cord end into the electrical service outlet. A lockable electrical service disconnect switch must be installed if the system is hard wired.
If the system is to be plugged into an electrical receptacle, the appropriate receptacle should already be installed by the customer's electrican. The installing engineer connects the plug to the end of the VersaPulse Power Suite electrical cable.
3.3.2
Fan Speed Adjustment
The Fan Speed Controller PCB monitors and varies the speed of the fan in relation to the temperature of the coolant. As the coolant temperature rises above a specified temperature, the fan speed will increase to bring the temperature of the coolant to within a specified temperature range. When the temperature of the coolant is at the proper temperature level, the fan speed will also decrease in speed (idle). The fan speed is monitored by a Tachometer PCB.
1.
Disable system autocalibration (SW3 to the left on the Controller PCB).
2.
Turn the system on and let the system complete the self-test start up routine.
Allow the laser to operate at idle (no firing) in a temperature stable environment for 5 minutes.
3.
Adjust R21 on the Fan Speed Controller PCB for -1.0 VDC as measured across TP5 and ground (TP7 or TP8).
NOTE: The Fan Speed Controller PCB is located on the AC Control PCB between the K2 relay and the T1 transformer.
4.
Insert the Service Attenuator (slide SW4 on the Controller PCB to the left) in the beam path and attach any test fiber.
5.
Select the HIGHEST pulse rate in the User Mode and increase the pulse energy to maximum.
6.
Fire the laser for a few minutes and verify that the fan speeds up when the voltage at TP5 reaches -2.0 VDC.
7.
Stop firing and verify that the fan speed returns to idle speed and the voltage at TP5 returns to -1.0 VDC within a few minutes.
CAL, ADJUST, ALIGN 3-18
VersaPulse® PowerSuiteTM Series Service Manual 0636-499-03 REV. B
8.
Return the switches on the Controller PCB to their normal positions.
SW3 to the RIGHT (enable autocalibration) SW4 to the RIGHT (Service Attenuator out of the beam path)
3.3.3
Speaker Volume Adjustment
The VersaPulse PowerSuite emits various tones by way of a speaker as the system receives inputs from the user, fires the laser or detects a fault condition. The volume of the tone can be raised or lowered by adjusting a potentiometer on the Controller PCB. Use the following procedure to raise or lower the speaker volume.
1.
Locate R8 on the Controller PCB.
2.
Alternating between the READY and STANDBY buttons on the touchscreen display,
3.
Adjust R8 on the Controller PCB until the volume out of the speaker is about mid-range.
4.
Close the front door and repeat step 2. Verify the speaker can be heard. If not, adjust R8 until the speaker can be heard (with the front door closed).
3.4
MECHANICAL ADJUSTMENTS
These procedures set the External Fiber Sense switch and the Blastshield Sense switch.
3.4.1
External Fiber Sense Switch Adjustment
Refer to Fig. 3.10 when performing the External Fiber Sense switch adjustment procedure.
VersaPulse® PowerSuiteTM Series Service Manual 0636-499-03 REV. B
CAL, ADJUST, ALIGN 3-19
SPRING PLUNGER SMA THREADS FIBER NUT
LENS CELL BODY
FIBER NUT PLATE
EXTERNAL MOMENTARY SWITCH
SET SCREW (AT BOTTOM)
FIG. 3.10: SMA FIBER PORT ASSEMBLY
1.
Open the front door and locate LED12 on the Controller PCB or connect a DVM across TP51 (FBRIN) and TP46 (GND).
2.
Connect a Coherent test fiber loosely onto the SMA port, but do not thread the nut fully on the SMA threads. Observe the LED12 or the DVM voltage.
3.
Adjust the position of the Fiber Sense switch so that LED12 comes ON or TP51 on the DVM goes HIGH with approximately 1/4 to 1/2 turns before the nut is fully seated.
NOTE:
· If LED12 comes ON with 1/4 or less turns to go before the fiber is fully threaded, remove the fiber, the fiber nut plate, and pull the Fiber Sense switch out of the lens cell body slightly and recheck.
· If LED12 comes ON with more than 1/2 turns to go before the fiber nut is fully threaded, push the external switch IN to the lens cell body slightly and recheck.
CAL, ADJUST, ALIGN 3-20
VersaPulse® PowerSuiteTM Series Service Manual 0636-499-03 REV. B
3.4.2
Blastshield Sense Switch Adjustment
Perform this procedure if the blast shield has been inserted and the INSERT DEBRIS SHIELD message remains ON. Refer to Fig. 3.11.
Blastshield Assembly Blastshield Alignment Pin Blastshield Sense Switch
1.
Open the front door and remove the blastshield access door from the front door; locate LED11 on the Controller PCB or connect a DVM across TP50 (BLST) and TP46 (GND).
2.
Reach around the right side of the laser head casting and locate the blastshield; remove the blastshield.
Blastshield Sense Switch set screw
3.
Adjust the blastshield switch.
FIG. 3.11: BLASTSHIELD SENSE SWITCH The blastshield switch is located behind the blastshield alignment pin. Loosen the set screw securing the blastshield sensing switch and adjust the switch so that LED11 comes ON or TP50 goes HIGH on the DVM just before the blastshield is fully seated in the detent.
a. If LED11 comes ON with more than 2mm of travel before the blastshield snaps into the detent, loosen the set screw and slightly push the blastshield switch IN to the casting and recheck.
b. If LED 11 does not come ON or intermittently comes ON when in the detent position, loosen the set screw and pull the blastshield switch OUT of the laser head casting and recheck.
3.5
ENERGY MONITOR AND AUTO CALIBRATION
The energy monitor calibration procedure adjusts energy monitor amplifier circuit gains to establish a conversion factor in terms of Volts/Joule by referencing delivered Holmium and Nd:YAG laser energy as measured on a calibrated external power meter. The optical calibration procedure determines optical transmission characteristics of an intra-beam attenuator optic for Holmium wavelength (Ho & Nd of a dual wavelength system) and if the laser is a dual wavelength system, the procedure determines the reflectivity characteristics of the pick-off mirrors for the Neodymium wavelength. Then at each system turn-on cycle, the software executes an automatic laser calibration (autocal) which allows the computer to determine and store (in NVRAM) the flashlamp drive parameters required to generate minimum and maximum pulse energies for each installed laser channel.
NOTE: All Laser Safety procedures must be followed while performing this procedure (i.e., safety glasses/goggles must be worn).
VersaPulse® PowerSuiteTM Series Service Manual 0636-499-03 REV. B
CAL, ADJUST, ALIGN 3-21
1.
Set up.
a. Open the front door and remove the top (external) cover including the inside laser head cover.
b. Disable the AUTOCALIBRATION by moving the calibration switch (SW3) on the Controller PCB to the left.
2.
Turn the laser on.
3.
Access SERVICE MODE by moving sliding the service switch (SW2) on the Controller PCB to the left.
4.
Initialize the NVRAM.
On the first service screen, depress the INIT NVRAM button and hold until the second tone is heard. This clears and initializes the battery back-up memory, then loads the default values.
5.
Set the laser to the following parameters:
a.
Voltage Pulse Rate Lamp Energy
800V 10 Hz 45J
b. Turn on the first laser channel (all other laser channels should be OFF).
6.
Attach a Power Calibration Fiber (P/N 0623-973-01) and turn ON the aiming laser.
Direct the fiber output toward the external power meter. The aiming beam should approximately 10mm in diameter.
7.
Place the laser in READY mode.
8.
Depress the footswitch and fire the laser.
Adjust the LAMP ENERGY until 6 Watts is delivered out of the fiber.
9.
Setting the Differential and Gain amplifiers.
a. Attach oscilloscope probes to TP15 (SDIF) and GND on the Controller PCB, and adjust potentiometer SGAIN (R4) on the Optics Bench PCB until the signal amplitude is 4.0 ±0.1 VDC. CAL, ADJUST, ALIGN VersaPulse® PowerSuiteTM Series Service Manual 3-22 0636-499-03 REV. B
b. Move the oscilloscope to probes to TP24 (MNDIF) and GND on the Controller PCB, and adjust potentiometer MGAIN (R3) on the Optics Bench PCB until the amplitude is 4.0 ±0.1 VDC.
10. Depress the footswitch and adjust the LAMP ENERGY until 10 Watts is delivered. Verify pulse rate is at 10 Hz. NOTE: 10 Watts ÷10 Hz = 1 Joule Pulse
11. Preparing the main and safety energy channels.
a Attach a DVM to TP38 and GND on the Controller PCB.
b. Fire the laser and adjust the potentiometer MAIN 2.1 (R32) on the Controller PCB until 1.0 ±0.02 VDC is measured on the DVM (1V/Joule).
c. Move the DVM probes to TP36 and TP38 and fire the laser.
d. Adjust the potentiometer SAFE 2.1 (R15) on the Controller PCB until 0.00 ±0.02 VDC is measured on the DVM.
(If the laser is a Dual Wavelength system, proceed with the following steps, otherwise, skip to step 19).
12. Set the laser to the following parameters:
Turn lamps 1, 3, & 4 off, and turn lamp 2 on.
a.
Voltage Pulse Rate Lamp Current
800V 50 Hz 65 Amps
b. Verify laser channel #2 is ON a