J TECH Dual PRO 14W Laser and Compliant Dual Driver Kit Instruction Manual

Dual PRO 14W Laser and Compliant Dual Driver Kit

Product Information

• Version: 1.0 April 1, 2021
• J Tech Photonics, Inc. | www.jtechphotonics.com Copyright 2022

CONTENTS

• General
• Dual Driver Overview
• Safety
• Disclaimer
• Getting Started
• Unpacking
• Operation
• Front of Driver Board
• Back of Driver Board
• Current Limit Settings and Test Points
• Safety Interlocks
• Safety Features and Resetting the laser driver
• Remote Reset Switch
• Key Switch
• Mode Selector Switch
• Control Signal and performance
• First Operation
• General Operation

Dual Driver Overview

The Dual Driver Board is a laser diode driver designed to power and control two laser diodes independently. It is capable of providing up to 4.5 amps of current to each diode with a maximum voltage of 24V DC. The board includes several safety features to protect the user and the laser diodes from damage.

Safety

The Dual Driver Board has several safety features including over-current protection, over-voltage protection, and safety interlocks. The board should only be operated by trained professionals who are familiar with laser safety protocols. Always wear appropriate eye protection when operating the board.

Getting Started

Unpacking: When unpacking the Dual Driver Board, make sure that all components are included and undamaged. The package should include the board, a user manual, and any necessary cables or connectors.

Operation

• Front of Driver Board:
  The front of the Dual Driver Board includes two laser diode connectors, a mode selector switch, a key switch, and a remote reset switch.

• Back of Driver Board:
  The back of the Dual Driver Board includes several current limit settings and test points.

• Current Limit Settings and Test Points:
  The Dual Driver Board includes several test points for monitoring the current and voltage of the laser diodes. It also includes several current limit settings that can be adjusted using a screwdriver.

• Safety Interlocks:
  The Dual Driver Board includes several safety interlocks that prevent the laser diodes from operating if certain conditions are not met. These interlocks include a laser emission indicator, a key switch, and a remote reset switch.

• Safety Features and Resetting the laser driver:
  The Dual Driver Board includes several safety features including over-current protection, over-voltage protection, and safety interlocks. If a safety interlock is triggered, the board will shut down and the laser diodes will turn off. To reset the board, use the remote reset switch or turn off the power and then turn it back on.

First Operation

General Operation:
Before operating the Dual Driver Board, make sure that all safety interlocks are in place and that appropriate eye protection is worn. Connect the laser diodes to the board using the included cables or connectors. Adjust the current limit settings to the desired values using a screwdriver. Turn on the power using the key switch. Select the desired mode using the mode selector switch. Use the remote reset switch to reset the board if necessary.

Product Usage Instructions

1. Unpack the Dual Driver Board and ensure that all components are included and undamaged.
2. Before operating the board, make sure you are familiar with laser safety protocols and wear appropriate eye protection.
3. Connect the laser diodes to the board using the included cables or connectors.
4. Adjust the current limit settings to the desired values using a screwdriver.
5. Turn on the power using the key switch.
6. Select the desired mode using the mode selector switch.
7. To reset the board, use the remote reset switch or turn off the power and then turn it back on.
   Note: The board includes several safety features including over-current protection, over-voltage protection, and safety interlocks. Always make sure that all safety interlocks are in place before operating the board. If a safety interlock is triggered, the board will shut down and the laser diodes will turn off. To reset the board, use the remote reset switch or turn off the power and then turn it back on.

GENERAL

DUAL DRIVER OVERVIEW

• This is the new DUAL LASER driver to couple with the 14W DUAL LASER HEAD. As with the previous generations, the driver is designed to follow the federal guidelines for safety compliance for high power Class 4 laser operation. This includes the use of a key enable switch, safety interlock system, power off reset, and laser LED indicators. All of these features make for a safer laser operation and will comply with federal laws regulating such operations.
• At the heart of the driver is a current level controller with an inductive loop and a power mosfet to give constant current with enough power capability and control for laser use. Couple this with inherent safety features like soft starting, current isolation, reverse protection, ESD protection, and thermal shutdown control and you have all you need in a small package.
• The power level can be controlled via external PWM signal at the recommended frequency of 1Khz. If external PWM is not available, then there is an internal power level adjustment by switching to internal mode.
• The Dual laser diode driver is cost effective and easily integrated into industrial, research, or enthusiast projects and products. The driver can be operated in CW mode or in Input Control Mode to be interfaced to remote electronics. This design uses optical isolators for super fast response and input range while protecting the laser from deadly ground loops. The board has screw terminal connections as well as Molex mini-fit Jr. connectors for easy connections to external equipment for control and the laser diode output.

Specification

Shutdown

Integrated Safety Features

| Laser Enable Key Switch, Integrated Laser Interlock, Power off Reset, LED Indicators

AC Adapter Input Voltage:

|

100 – 240 VAC

Control Signal Digital Isolation Voltage:| 4500 Vrms
Minimum Control Signal ”Turn On”

Voltage:

|

2.8 Volts

Control Signal Maximum Voltage:

|

24 Volts

Control Signal Maximum Current:| 50 ma
Control Signal Maximum Frequency:| 3KHz
Connectors:| Screw Terminal and JST PH Connectors
---|---
Operating Temperature:| 0 to 40 °C
Storage Temperature:| -40 to 70 °C
Dimensions:| 4.2” x 3”
 |

SAFETY

• Operate the Dual Driver Board in an explosion free area.
• The Dual Driver Board may reach high temperatures under operation. Make sure there is adequate airflow to the Driver Board. Also, make sure there is adequate protection around the Driver Board and that it is not in contact with other materials.
• When connected to laser diode components, the output of the laser can be up to several watts of power. Always use proper safety eyewear and laser safety protection when connecting to laser components in your final system. When operated incorrectly the laser component can cause severe damage to eyes and health.

DISCLAIMER

• All statements of safety are only applied when the driver board is used in its intended purpose.
• You are legally responsible for any injury to anybody resulting from the use of or assembly of the driver board or their finished products.
• You Accept this driver board as a COMPONENT for integration in a system of YOUR OWN design and will be legally responsible from any and all LIABILITIES.

GETTING STARTED

UNPACKING

• Inspect the shipping container for damage.
• Verify the contents of the package:
  • High Current Driver Board
  • 2- Key switches
  •  Power Adapter with connector according to ordering country (Some OEM packages will not have a power adapter).

OPERATION

FRONT OF DRIVER BOARD

The front contains:

• Power / Enable Switch: Down = OFF, Up = ON
• Laser Enable Key Switch: Key Up = OFF, Key to Right = Enabled
• Safety Interlock: Screw Terminals for “Normally Closed” interlock switches. (shown defeated)
• Reset Switch: Press momentarily to reset interlock and power faults
• Mode Selector Switch: Left = CW Mode, Right = Input Control Mode
• LED Indicators: Left = Laser Enabled, Right = Laser Emission ON

BACK OF DRIVER BOARD

The back contains:

• H3 – Laser / LED Output Connector: Top = Negative Output, Bottom = Positive Output
• H1 – Laser / LED Output Screw Terminal: Left = Negative Output, Right = Positive Output
• H4 – Input Control Connector: Top = Negative Input, Bottom = Positive Input
• H2 – Input Control Screw Terminal: Left = Negative Input, Right = Positive Input
• VR1 – Potentiometer for Analog Current Level
•  Power Adapter Plug (center pin positive)
• Laser Fan Connector
• Remote Reset Switch Connector

CURRENT LIMIT SETTINGS AND TEST POINTS

• Jumper J1 Current Limit Selector: This will limit the output current of the driver to the selected level. Factory set is 3amps with J1 1&2&3 jumpers in place.
  Current Limit

(Amps)

| Jumper Position

On

---|---
1| 1
2| 1,2
3| 1,2,3
4| 1,2,3,4

• J2 – Power Modulation:
  • External PWM side will allow for software control of the laser via PWM signal.
  • Internal Adjustment side will allow for current level adjustment using the variable potentiometer.

SAFETY INTERLOCKS

• The laser driver has an interlock system which is NORMALLY CLOSED and contains a voltage in the cable of 12V supplied by the laser driver board. This means if any switch along the interlock chain becomes OPEN, then the circuit will open and the laser will disengage the laser.
• Examples of use of the interlock system include the emergency stop button switch and an enclosure door switch. When integrating the laser driver and laser into an OEM machine, all entrances to the machine (enclosure doors) must have an interlock switch in order to be considered compliant with Class 4 laser rules. Multiple switches can be added along the chain when integrating the laser driver into OEM machines as long as they are wired in series.
• Here is an example of an interlock system:

• In the example above the switches are connected in series so if ANY of the switches are opened, the interlock will engage.
• If the laser driver was purchased in a kit including the emergency stop button, it will be wired to the interlock key. If not, then the key will be shipped with a jumper, defeating the interlock system. It is up to the consumer to make sure the interlocks implemented correctly before use of the laser.

SAFETY FEATURES AND RESETING THE LASER DRIVER

• The safety features of this laser driver include both a safety interlock and a power monitor to watch for power outages. If either of these features is activated, they will disable the laser and the user MUST reset the laser driver to continue operation of the laser. Here are the situations for each of these safety features and how to reset the feature:
• Safety Interlock: If the interlock is tripped, either by an emergency stop switch being activated or by an enclosure door switch opening you must:
  1. Make sure the situation is clear for laser operation and make sure the laser is not being controlled in an ON position.
  2. Clear all switches that have been activated back to the Normally Closed position.
  3. Press the reset switch on the board (or remote reset switch if installed)
  4. The laser is then ready for use again.
• Power Outage Monitor: If the power adapter is either unattached from the laser driver or there is a power outage, then the laser driver will disable the laser. This is in case there is a power outage situation in which the laser was left ON and to prevent unknowing persons being injured when the power comes back on and not realizing the laser was left ON.
  1. Make sure the situation is clear for laser operation and make sure the laser is not being controlled in an ON position.
  2. Plug back in the power adapter (if it was removed from the board).
  3.  Press the reset switch on the board (or remote reset switch if installed)

REMOTE RESET SWITCH
The remote reset switch option allows for placement of another reset switch to a more convenient location, like the front of the machine for example. The switch can be mounted on a panel and attached tight with the provided locking nut. Attach the connector to the back of the driver board on the farthest right connector.

KEY SWTICH

• The laser driver includes a key switch to enable or disable the laser. This is a requirement for Class 4 laser operation. The key is only removable in the “unlocked” position with the key facing up.
• The key can then be stored in a safe place to prevent unwanted use of the laser by children or others who are not authorized to use the equipment.
• When the key is turned clockwise to the right, the laser will be enabled. The key cannot be removed when the laser is enabled. The laser driver can be turned off with the power switch while the key is still in the Enabled position.
• The key can sometimes be a bit difficult to turn so be gentle with it as it might break away the plastic housing if forced.

MODE SELECTOR SWITCH
The driver board has a selector switch for the two different modes of the board.

• Input Control Mode: This is when the switch is on the RIGHT. This mode allows for a signal to be connected to connectors H2 or H4 for a signal to turn the laser on and off. Use this input with your controller to turn the laser on and off with G Code commands.
• CW Mode: This is when the switch is on the LEFT. This mode stands for “Constant Wave”, which means that the laser will turn on and stay on until the switch is turned back to the right or the power on the board is turned off.

CONTROL SIGNAL AND PERFORMANCE

• The input connection provides an optically isolated input for control of the laser diode. The connection and the jumper settings were described in the previous sections. The voltage required to turn on the opto-isolator is 2.8 volts. The input can handle up to 24 volts. The input can be cycled with no degradation up to 3KHz. It will work with 3.3V, 5.0V and 12V, 24V logic boards from various manufacturers like National Instruments.

• Typical Control Signal with “non inverting” set running at 3KHz. Ch 1 control, Ch 3 output.

• Typical Control Signal with “inverting” set running at 3KHz. Ch 1 control, Ch 3 output.

FIRST OPERATION

• Before operation read the Safety section of this manual.
• Properly connect the output of the driver to the laser or LED to be driven. Ensure the connections are correct.
• If using input control, connect the input signal to the driver board.
• Make sure the jumpers are correctly set for current limit and input control to the desired settings.
• Plug in the adapter to the AC power.
•  Plug in the adapter to the Driver Board.
•  Make sure the safety interlocks are correctly assembled or the defeat jumper is on the interlock key.
• Turn the key switch clockwise to the ENABLED position
• Press the RESET button on the driver board. You should hear an audible “click” which is the safety relay connecting. If you do not hear a click, check your interlock circuit and make sure the driver has power.
• Push the power switch to the ON position.
•  Your driver is now ready to produce current for your laser. If in CW mode, the “enabled” and “laser on” LEDs will light up and the output will be enabled. If in input control mode and the input signal is not enabled, the “enabled” LED will only light up. When the input control signal gets enabled, the “laser on” LED will light up and the driver output will be enabled.

GENERAL OPERATION

•  Laser Diodes and LEDs are meant to be driven within their specifications. Degradation of the diode will occur when diodes are overdriven beyond their specifications.
•  Keeping laser diodes on for a long continuous time will degrade the diode is thermal issues are not addressed.
• The high current driver board will reach high temperatures if the board is continuously driving high current for long durations. Make sure it has adequate airflow.
• Keep the driver board in a well ventilated area.
• Using the Mode Selector Switch as an ON/OFF switch for the laser:
  • When there is no input control, you can keep the power switch on and use the Mode Selector Switch to control the output of the laser.

CURRENT RANGES AND ADJUSTING CURRENT

• There are two sets of adjustment for controlling the current output. There are the current limit jumpers and the internal potentiometer. The current limit jumpers are J1 and have the “1 2 3 4 ” on them will set the MAX current the board can provide with the potentiometer set to FULL (all the way turned clockwise). The numbers are in 1amp increments:
  •  1 – 1amp limit
  • &2 – 2amp limit
  • 1&2&3 – 3 amp limit (factory recommended)
  • &2&3&4 – 4 amp limit
• Having all four jumpers on gives a maximum of 4 amps possible. Having three jumpers on gives a maximum of 3 amps. We recommend keeping it below the maximum current for your laser diode if you don’t want the possibility of overdriving the laser which will probably kill it quickly.
• Set the jumper on J1 to the appropriate range you desire to drive the diode. For example, a 2Amp range will have the jumper 1 and 2 on. This will give an output current of greater than 2 Amps within 10%.
• You can use the external PWM to software control the power from this point. If you do not have software control, then you can use J2 to put it into internal mode and use the potentiometer to control the output level.
• To get a specific current, adjust the potentiometer VR1 with a small flat head screwdriver.
  • To REDUCE current, turn counter clockwise
  •  To INCREASE current, turn clockwise
• To get exactly 2 Amp of current, adjust the potentiometer VR1 counter counter-clockwise to decrease the current to the diode and clockwise to increase the current to the diode.
• The potentiometer has 21 turns of adjustment and can achieve a resolution of 1% or better.

CHECKING THE OUTPUT CURRENT ON A METER

• The output current has been set to your factory set current level at the factory. There is not a need to verify this current if you purchased a laser from J Tech Photonics.

• If you do want to check the current output, we recommend using a clamp style current meter to check the output of the driver board before hooking up the laser to verify the output is within the limits of operation of the diode laser. This is a very useful tool when adjusting the current to a specific value with the potentiometer.

• Alternatively, you can use a clamp style meter to check the current on the output wire to the laser. This method is normally not as accurate as the multi meter but can provide a view of the current as the laser is in operation.

• Depending on your laser efficiency you can estimate the output power of the diode. Many lasers are 1:1 to 1:7 for current to Watts. For J Tech Lasers, it normally is about 1:5.

• Do not use a normal digital multimeter to check the current on the newest 5amp driver. It will quickly overheat the driver as it is not designed for this type of load.

• Do not use a typical digital meter on current setting. It will overload the driver. You can use it as a “pass through” current sense.

COMPLIANCE VOLTAGE AND POWER ADAPTERS

• Depending on the compliance voltage of the laser diode, it is preferable to choose the correct power adapter to meet the needs of the laser while minimizing excess voltage dissipated as heat across the regulators.
• There are several AC/DC wall adapters in the accessories section of www.jtechphotonics.com to choose from, or you can purchase your own. The requirements are:
  •  AC to DC current
  • Positive center
  • 2.1mm I.D. x 5.5mm O.D
  • Female
  • Output voltage of 12.3V recommended

OEM POWER SUPPLY SELECTION

• If you purchased the OEM version of the laser driver, you can either purchase your own adapter or connect it to your own power supply. For integration into other systems, it is advisable to use the system power supply as long as it is in the range of the laser diode you are driving.
• It is necessary to choose a power supply that will have enough voltage to run the laser diode at maximum current as well as be not more than a few volts over the compliance of the laser diode.
• Any additional voltage above the compliance voltage of the laser diode will be dissipated as heat. Excessive additional voltage can lead to overheating of the laser driver. To figure out how much voltage is needed for a minimum, take the compliance voltage of the laser diode and add the voltage drop from the laser driver.
• We recommend a 12V supply for all 445nm blue diodes.

MOUNTING

The following drawing is provided for mounting. Units are in inches.

References

• Laser Upgrade Products | J Tech Photonics, Inc.

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