R207 Operator’s Manual
January 8, 2007
Version 1
ROGER’s 207 Laser Safety System
R207 Operator’s Manual
January 8, 2007
Version 1
Table of Contents
1)
Introduction ................................................................................................................. 4
1)
Operation..................................................................................................................... 8
Access Control System ................................................................................................... 8
Laser Interlock System Operation .................................................................................. 9
2)
Test and Maintenance ............................................................................................... 11
3)
Troubleshooting ........................................................................................................ 11
LSS System Test .................................................................................................................. i
R207 Operator’s Manual
January 8, 2007
Version 1
The Laser Interlock System is one part of an overall laser safety
protection program. All aspects of the program must be in place
before operating the class IV laser. Additional measures include but
are not limited to:
 Appropriate laser safety training and medical approval
 Appropriately selected and donned PPE
 Appropriate use of light barriers
 Use of materials and equipment selected, designed, and
approved for the application.
Refer to ANSI Standard Z136.1 for requirements for a complete laser
safety program.
Failure to follow required safety measures could result in
permanent injury to the eyes and skin.
HIT THE NEAREST ESTOP IMMEDIATELY IF THERE IS ANY
QUESTION OF THE IMPROPER OPERATION OF THE LASER
SAFETY SYSTEM.
DANGER: The AC Contactor box contains 208VAC and the ILU contains
115VAC.
R207 Operator’s Manual
January 8, 2007
Version 1
1) Introduction
The R207 laser safety system is composed of an access control system, laser interlock
logic unit, and AC power switch. Combined, the components of the system assist the
laser user in securing and safely operating a Class IV laser.
The access control system prevents unauthorized entry in to the laser operating area. The
programmable Interlock Logic Unit (ILU) monitors the status of the access control
system and provides safety functions such as operating modes, shutter operation, and
emergency shutdown. The AC power switch is composed of a manual cutoff switch and
an AC contactor controlled by the ILU.
The manual switch is used for manual AC
power control and OSHA Lock-out/Tag-out of the laser AC power. The AC contactor is
normally only used for emergency shutdown of the laser.
AC manual
lockout switch
208VAC
Contactor
R207 Operator’s Manual
January 8, 2007
Version 1
Access
Control
Unit
Entry
Keypad
Maglock
Exit
Request
208VAC
Power from
Breaker #35 & #37
Panel *R-206
Door
Interlock
Switch
AC
Lockout
Switch
Exit
ESTOP
AC
Emergency
OFF
Contactor
Interlock Logic
Door
Entry
ESTOP &
Emergency
Entry
Unit (ILU)
Entry
Status
Indicator
208VAC
Switched
External
Laser Enable
Laser
Power Unit *
Laser * Shutter *
Note: Items marked with an * or dotted
lines are not part of the laser safety system
R207 Laser Safety System
R207 Operator’s Manual
January 8, 2007
Version 1
Normal operation of the laser safety system entails resetting the system, clearing the laser
room of unauthorized personnel, and enabling the laser’s internal shutter. There are three
basic operating modes. The modes are selected by the ILU front panel key switch and
indicated by three indicator lamps.
SAFE, indicated by the green lamp, is
the default start-up mode. In this mode
the access controls are operational but
SAFE
ARM
OPERATE
the laser shutter interlock output is
closed.
This is the normal mode for
experiment
maintenance.
set-up
and
room
The operating mode
RESET
selection key switch can be removed in
SAFE for safe keeping.
Before operating the laser the user must
clear
the
room
of
unauthorized
Mode Selection
Key switch
personnel. In ARM mode the laser
shutter is disabled (OFF) but all other
ILU Front Panel
systems are ready for laser operation.
When transitioning between SAFE and ARM the ILU will sound a warning tone for ten
seconds. The tone is to alert personnel in the room that the laser will soon be operable.
Personnel should don Personal Protective Equipment such as goggles when in the ARM
mode. The final mode is OPERATE. In OPERATE mode the laser’s internal shutter is
enabled by the ILU after a ten second delay. The operator is then free to operate the
laser.
R207 Operator’s Manual
January 8, 2007
Version 1
When personnel enter and exit the laser room the system will drop to ARM.
AFTER THE DOOR IS OPENED PERSONNEL HAVE TEN
SECONDS TO ENTER/EXIT AND RECLOSE THE DOOR.
Failure to do so is considered an access control violation and the system will drop back to
SAFE mode. If the door is reclosed within the ten second window, the system will
automatically return to the OPERATE mode.
Control of the laser’s internal shutter is the normal method used to shut off the laser
beam. This can be accomplished by use of the Interlock Logic Unit (ILU) key control or
whenever the entrance door is opened.
The second method of shutting down the laser is through the use of the emergency cutoff
switches (ESTOPs) located on either side of the entry doorway.
AN ESTOP WILL SHUT OFF AC POWER TO THE LASER SYSTEM AND
RELEASE THE MAGNETIC DOOR LOCK. ESTOPS SHOULD NOT BE USED TO
CONTROL POWER TO THE LASER.
R207 Operator’s Manual
January 8, 2007
Version 1
1) Operation
Access Control System:
Power to the access control system is provided by the Interlock Logic Unit (ILU). When
the ILU is OFF, the keypad entry and magnetic lock are not
powered.
1. Turn on the ILU AC power.
a. The keypad will beep, signaling it is powered and
operational.
b. The magnetic lock will engage.
2. Entry
EMERGENCY ENTRY
TO ENTER IN AN EMERGENCY, PULL UP THE PLASTIC
COVER AND PUSH THE RED ILLUMINATED ESTOP
SWITCH AT THE DOOR. This will shut off the laser AC power
and open the magnetic lock.
Normal Entry
a. Enter a valid User Code at the entry keypad.
Note: If five invalid codes are entered sequentially, the keypad will lock
itself out for 30 seconds.
b. The magnetic lock will release and the red LED on the key pad will
illuminate for ten seconds.
c. The user must enter the room and close the door before the ten seconds is
complete.
d. IF THE DOOR IS NOT CLOSED AND LOCKED AFTER THE
ALLOTTED TIME, THE ILU WILL FAULT AND MUST BE RESET.
User codes should be changed by the system administrator on a regular basis.
3. Exit
R207 Operator’s Manual
January 8, 2007
Version 1
TO EXIT IN AN EMERGENCY, PUSH THE RED ILLUMINATED ESTOP
SWITCH AT THE DOOR. This will shut off the laser AC power and open
the magnetic lock.
Note: The laser interlock system should not be left unattended in the ARM or
OPERATE modes.
a. To exit push the green “EXIT” button to release the magnetic lock.
b. The magnetic lock will release for ten seconds.
c. The user must exit the room and close the door before the ten
seconds is complete.
d. IF THE DOOR IS NOT CLOSED AND LOCKED AFTER THE
ALLOTTED TIME, THE ILU WILL FAULT AND MUST BE RESET.
Laser Interlock System Operation
To enable the laser interlock system:
1. If the AC Power is not on, use the AC power switch on the right side of the
Interlock Logic Unit (ILU) box to turn it on. The ILU will perform start up selftests for about six seconds.
2. Likewise, if the AC Lockout switch is OFF, switch it to the ON position.
a. The laser’s Power Unit may be turned on at this time.
3. Press the blue reset button. (Note: press it twice to get it to return to the outer
position.) You should hear a click. That is the contactor energizing.
4. Set the selector key switch on the ILU front panel from
ARM to SAFE (leftmost position). The green lamp
should now be on steady state. If there is no click or the
green lamp continues to blink, check the ESTOP switches
to ensure they are pulled to the OUT position.
5. Close the door to the room. Make checks in preparation
for laser operation – e.g. laser curtains closed, goggles
ready, dumps in place.
R207 Operator’s Manual
January 8, 2007
Version 1
6. When ready to sweep the room, clear all unauthorized
personnel from the room. Set the selector key switch to the
ARM (Middle) position. A 10 second timer will start. The
yellow lamp will be flash and the beeper will sound for this
time. At the end of the 10 second timer, the Yellow lamp will
be on steady state. This is to indicate the room is armed and
presumed free of unauthorized personnel.
IT IS UP TO THE USER/OPERATOR TO ENSURE THAT
ONLY AUTHORIZED PERSONNEL ARE IN THE LASER ROOM DURING
LASER OPERATIONS.
7. When ready to operate the laser:
a. Don the appropriate PPE and make one more visual check of the laser
room.
b. Set the selector key switch to the OPERATE
(Rightmost) position. There is a ten second delay
between when the system is switched to OPERATE
and when the laser interlock shutter is enabled. During
the 10 second delay, a short beep will be heard and the
RED lamp will flash rapidly.
c. At this point, when personnel enter and exit the shutter
will automatically close. When the room is again secure, the ILU will
automatically switch to OPERATE mode and the shutter will be enabled
after the ten second delay.
8. When laser operations are complete, the unit should be switched back to SAFE
mode. Access controls will still be in force but the laser shutter is CLOSED and
the area will require a sweep before operations.
THE LASER ROOM SHOULD NOT BE LEFT ARMED WHEN PERSONNEL
ARE NOT IN THE ROOM.
R207 Operator’s Manual
January 8, 2007
Version 1
2) Test and Maintenance
The Laser Safety System should be tested on a regular basis, after long down periods, and
whenever there is a change to the system. Weekly tests are recommended during regular
use. The sheet given in Appendix A can be copied and used as a checklist. A test record
template is also given in Appendix A.
3) Troubleshooting
Most problems can be diagnosed through the front panel lamps. Table 1 describes
several failure modes and solutions.
R207 Operator’s Manual
January 8, 2007
Version 1
Table 1
Indication
No lamps are
ON
Symptom
1) AC Power to the unit is
OFF
2) The ILU 24VDC fuse is
blown.
3) The AC power fuse is
blown.
4) The ILU programmable
Possible Solution
1) Switch AC Power ON. Check the
AC circuit breakers at the power
panel: Beakers #35 & #37 208VAC outlet on power pole;
Breakers #35 & #36 – laser power
to AC contactor.
2) Open the ILU. If the fuse is blown
safety relay is faulted.
the black fuse holder on the lower
5) The DC Power supply has
left will have a red LED lit. Spare
failed.
fuses are inside the ILU box.
3) Remove the AC power cord.
Open
the
fuse
tray
on the left side of the AC power
switch. Replace the fuse and return
the tray. Plug in the AC power and
switch on.
4) Open the ILU. If there are several
red LEDs on the lower left portion
of the yellow Pilz safety relay,
cycle AC power to the ILU. If the
Pilz programmable safety relay
does not reset there is an unsafe
fault in the laser safety system
wiring. Call for repair.
5) Call for repair.
R207 Operator’s Manual
January 8, 2007
Indication
Symptom
Only the Blue
1) There was a fault when the
lamp is ON
Version 1
Possible Solution
1) Set the selection key switch back
unit was in the ARM or
to SAFE. Push the blue RESET
OPERATE mode.
button.
Green
There is a system fault.
Blinking
1) AC Power has been cycled
to the ILU.
2) An ESTOP has been
activated.
1) Set the selection key switch back
to SAFE. Push the blue RESET
button.
2) Check the ESTOPS and reset any
3) The door has been open for
switched that have been pushed in.
longer than the allotted
Follow the steps for (1) to reset the
entry/exit time.
system.
3) Close the door. Follow the steps
for (1) to reset the system.
Green Steady
The system is in SAFE mode
Normal operating condition.
State
and ready to be ARMED.
Green steady
The operating mode key has
Cycle the key to ARM then back to
state but
not been cycled to the SAFE
SAFE. Now back to ARM.
yellow will
position.
not turn on
when
switched to
ARM mode.
Steady Green
The sweep timer is active for
with Yellow
10 seconds. At the end of ten
Blinking
seconds the Green lamp should
go out and the Yellow stay on.
Normal operating condition.
R207 Operator’s Manual
Indication
January 8, 2007
Version 1
Symptom
Red rapid
The system is preparing to
blinking
enable the laser shutter. After
Possible Solution
Normal operating condition.
10 seconds the shutter should
open and the red lamp should
blink at a slow rate.
Magnetic lock 1) An ETOP is activated.
1) Reset the ESTOP.
will not
2) Check that the ILU has power.
2) There is no DC power to
engage.
the magnetic lock.
3) There is an error with the
3) Cycle the AC power on the ILU.
4) Verify that the door closes
keypad access control unit.
properly. Have the magnetic lock
4) The maglock is not mating
adjusted if necessary.
with the strike plate.
The magnetic
1) An incorrect keycode has
1) Check the keycode being used.
lock will not
been entered. 5
2) Use the emergency entry switch to
release.
consecutive incorrect codes
gain access. Cycle the AC power
will disable the keypad for
on the ILU.
30 seconds.
2) There is an error with the
keypad access control unit.
Any
problems
other
For
any
other
problems
contact
Director, EH&S at 221-2146(office) or
345-9549 (cell).
R207 Operator’s Manual
24VDC
Power Supply
January 8, 2007
Version 1
115VAC
Power
Pilz Safety
Controller
Internal Fuse
A red LED
will light if a
fuse blows
Appendix A
January 8, 2007
pp i
LSS System Test
Performed by:_________________________________
Date:_____________
1. Turn off the AC power to the Laser using the AC Lockout Switch.
2. Turn off power to the Interlock Logic Unit (ILU).

All system lights should be OFF and the door unlocked.
3. Turn on the power to the Interlock Logic Unit.

All lights to the ESTOP and EXIT request switches illuminate.

The Green lamp on the ILU front panel should be blinking.
4. Set the operating key switch to the ARM position.

The Green lamp should continue to blink. The system should NOT go to ARM
mode.

Push the blue RESET button on the ILU front panel.

The Green lamp should go out. The ILU should NOT go to ARM mode.
5. Switch the operation key to the SAFE position.

The Green lamp should stay ON steady state.
6. Switch the operation key to the ARM (Middle) position.

The ILU should beep for 10 seconds.

The Yellow lamp should flash for 10 seconds.

The Laser shutter should NOT be enabled.
7. Set the operation key switch to the OPERATE position.

The ILU should beep for 2 seconds.

The RED lamp should flash rapidly for 10 seconds.
After 10 seconds the red lamp should flash at a slow rate.
8. Hit the “EXIT” switch.

The red lamp should go out and the yellow lamp light for 10 seconds.

After 10 seconds the ILU should beep and the red lamp flash rapidly.
9. Hit the exit “ESTOP” switch.
The red and yellow lamp are OFF, the green lamp is flashing.
Appendix A
January 8, 2007
pp ii
10. Reset the exit ESTOP.
11. Push the blue RESET switch.
12. Set the operating mode key to SAFE then to ARM.
13. After the 10 second time-out, set the key to OPERATE and wait 10 seconds.
14. Push the EXIT switch and open the door.

After 10 seconds, the ILU should drop, indicated by a blinking green lamp.
15. Close the door.
16. Re-arm the LSS using steps 11-13.
17. Push the EXIT button, exit the room and close the door.
The yellow lamp outside the door should be on for 10 seconds. After 10 seconds
the red lamp should flash rapidly for 10 seconds then flash slowly.
18. Key in a valid key code.
19. Re-enter the laser room and close the door.
The yellow lamp on the ILU should be on for 10 seconds. After 10 seconds the
red lamp should flash rapidly for 10 seconds then flash slowly.
20. Set the operating mode to ARM.
21. Turn on the AC lockout switch.
22. Turn on the laser unit.
23. When the laser unit is ready to operate, switch the ILU operating mode key switch
to OPERATE.
24. Turn on the laser.
25. Switch the operating mode key switch back to ARM.
The laser should shut OFF.
If the test is completed successfully the laser may now be operated.
If any problems are found during this test DO NOT OPERATE THE LASER. CALL
EH&S OFFICE, 221-2146 for assistance.
Appendix A
January 8, 2007
pp iii
R207 Laser Safety System Test Record
Tested
By
Date