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MKS Ophir HELIOS PRO User Manual
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MKS Ophir HELIOS PRO User Manual

High power industrial laser measurement
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User Manual
HELIOS PRO
HIGH POWER INDUSTRIAL LASER MEASUREMENT
HEADQUARTERS:
POB 45021, HAR HOTZVIM 9145001
JERUSALEM, ISRAEL
PHONE + 972-2-548 4444
REV 1.14-1 - 17/SEP/2024
WWW.OPHIROPT.COM

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Summary of Contents for MKS Ophir HELIOS PRO

  • Page 1 REV 1.14-1 - 17/SEP/2024 User Manual HELIOS PRO HIGH POWER INDUSTRIAL LASER MEASUREMENT WWW.OPHIROPT.COM HEADQUARTERS: POB 45021, HAR HOTZVIM 9145001 JERUSALEM, ISRAEL PHONE + 972-2-548 4444...

  • Page 2: Table Of Contents

    USER MANUAL REV 1.14-1 - 17/SEP/2024 Table of Contents About this Manual ............................5 How the Document is Organized ......................5 Chapter 1 – Helios Operating Principle ..................... 6 Overview ..............................6 Physical Principle ..........................6 Example of Use: Laser Welder in a Robotic Cell ................. 7 Chapter 2 –...
  • Page 3 USER MANUAL REV 1.14-1 - 17/SEP/2024 Chapter 7 – Registers & Commands .......................23 LED indicators table ...........................23 Modules and Registers ........................23 Status: 16-bit Register ........................24 Constants: .............................24 Measurement Results & Information: ....................25 Commands: ...........................25 Example of sequence of commands and status: ................26 Querying and Changing wavelength options: ..................26 Analysis of Example Data, BIG Endian: .....................27 Analysis of Example Data, LITTLE Endian: ..................29...
  • Page 4 USER MANUAL REV 1.14-1 - 17/SEP/2024 12.3 Opening the TwinCAT tool: ......................49 12.4 Opening a new TwinCAT Project: ....................50 12.5 First time installation of compatible drivers for the Ethernet card: ..........51 12.6 Connecting to Slave Device: ......................52 12.7 Viewing raw data from the Helios device & sending commands: ..........53 12.8 Viewing formatted data from the Helios: ..................55 12.9 Restarting communications with the device: ................57 Appendix 1 –...

  • Page 5: About This Manual

    USER MANUAL REV 1.14-1 - 17/SEP/2024 About this Manual This manual provides information for the Ophir Helios series: • “Helios – Profinet” power meter (P/N 7Z02768) (End of life) • “Helios – EtherNet/IP” power meter (P/N 7Z02789) (End of life) •...

  • Page 6: Chapter 1 - Helios Operating Principle

    USER MANUAL REV 1.14-1 - 17/SEP/2024 Chapter 1 – Helios Operating Principle Overview The Helios sensor measures high power industrial lasers by measuring the energy of a short time exposure of the CW laser. The laser should be set to pulse from 0.3 to several seconds. The Helios measures the energy and exposure time of this sample of the power, and from this calculates the CW power (averaged over the entire pulse).

  • Page 7: Example Of Use: Laser Welder In A Robotic Cell

    USER MANUAL REV 1.14-1 - 17/SEP/2024 Helios-Pro uses a photodiode to characterize the pulse shape enabling measurement of the time dependent power level throughout the pulse. Example of Use: Laser Welder in a Robotic Cell A typical application of the Helios is to check the power of a laser welder in between welds. This process can be automated and optimized to take the least time away from production possible.

  • Page 8: Chapter 2 - Specifications

    USER MANUAL REV 1.14-1 - 17/SEP/2024 Chapter 2 – Specifications == Subject to change. Check our website for latest version spec: www.ophiropt.com 1.1.2.11 Short Exposure High Power Sensors 1.1.2.11.1 Helios Pro 100W to 12000W Features • No water cooling, up to 12,000W •...
  • Page 9 USER MANUAL REV 1.14-1 - 17/SEP/2024 Specifications of Helios Pro High power industrial laser measurement Absorber Type LP2, absorption ~94% 100W – 12kW Power Range 100J – 5kJ Energy Range Exposure Time (see table below) 0.3 - 4s (a) Wavelength Without Diffuser 450 - 550nm, 900 - 1100nm With Diffuser 450-550nm, 940-1100nm Aperture...
  • Page 10 USER MANUAL REV 1.14-1 - 17/SEP/2024 Helios Pro Drawings Helios Pro - Profinet / Helios Pro - EtherNet/IP / Helios Pro - EtherCAT Helios Pro - EtherNet/IP-M 10 | HELIOS PRO USER MANUAL...

  • Page 11: Chapter 3 - Setup

    USER MANUAL REV 1.14-1 - 17/SEP/2024 Chapter 3 – Setup There are four ways to interface with the Helios laser power meter: Profinet EtherNet/IP RS232 commands (e.g., with HyperTerminal) PC application The setup of Helios depends on the mode of operation. Important note: When using the Helios Pro with an optional diffuser (P/Ns:7Z07143, 7Z07145 and 7Z07147), the wavelength setting will have two options, with or without diffuser.
  • Page 12 USER MANUAL REV 1.14-1 - 17/SEP/2024 • Set up device addresses as marked inside the red circle: Zoomed-In: • Integrate the power measurement into the customer software (controlled by the PLC) as fits their application and needs. • See Chapter 7 for more details on Profinet setup and read/write registers (called “submodules”). •...

  • Page 13: Ethernet/Ip Setup

    USER MANUAL REV 1.14-1 - 17/SEP/2024 EtherNet/IP Setup • Place the Helios where it will be convenient to measure the laser. • Connect 24 V DC to standard Profinet / EtherNet/IP jack. (Use Ophir Power Cable for Helios P/N 7Z10458A, see Chapter 6 “Connectors”...

  • Page 14: Rs232 Setup

    USER MANUAL REV 1.14-1 - 17/SEP/2024 • Change the PC IP address to match the same gateway as the Helios but do NOT use the same exact IP address, for example if the Helios is set to default settings, choose IP address 10.0.0.3, Subnet Mask 255.255.255.0, Default Gateway 10.0.0.1.

  • Page 15: Chapter 4 - Check Before Use

    USER MANUAL REV 1.14-1 - 17/SEP/2024 Chapter 4 – Check before Use Be sure to check the laser parameters before turning it on to ensure no damage to Helios. Specifically, the power, beam size, and exposure time must be within the specifications. (Use this calculator to easily find the power density from laser power and beam size.)

  • Page 16: Chapter 5 - Mechanical Dimensions

    USER MANUAL REV 1.14-1 - 17/SEP/2024 Chapter 5 – Mechanical dimensions Helios Pro models – Cover Open (Without/With Diffuser): 16 | HELIOS PRO USER MANUAL...
  • Page 17 USER MANUAL REV 1.14-1 - 17/SEP/2024 Helios Pro models – Cover Closed: Helios Pro: (connector NOT included) Cover closed: 200 x 103 x 86 mm (length x width x height) Cover open: 200 x 114 x 146 mm Helios Pro: (connector included) Cover closed: 200 x 107 x 86 mm (length x width x height) Cover open:...
  • Page 18 USER MANUAL REV 1.14-1 - 17/SEP/2024 Helios Pro-M model – Cover Closed: Helios Pro-M: (connector NOT included) Cover closed: 200 x 103 x 86 mm (length x width x height) Cover open: 200 x 114 x 146 mm Helios Pro-M: (connector included) Cover closed: 200 x 125 x 86 mm (length x width x height) Cover open:...

  • Page 19: Chapter 6 - Connectors

    USER MANUAL REV 1.14-1 - 17/SEP/2024 Chapter 6 – Connectors Helios Pro models: From left to right, the connectors above are: (1) Two power connectors, both 5-pin AIDA compatible Han Push-Pull Power. (2) Two RJ45 Profinet / EtherNet/IP connectors, both AIDA compatible Han Push-Pull RJ45 PN (compatible with Ophir 7E01299 or Harting part 09 35 226 0401.

  • Page 20: Rj45 Connectors

    USER MANUAL REV 1.14-1 - 17/SEP/2024 RJ45 Connectors The RJ45 sockets are AIDA compatible Hirose (RJ45 connector), part TM21R5C88(50) and Harting (metal hood), part 09 35 002 0301. They are compatible with Ophir P/N 7E01299 or (for example) Harting part 09 35 226 0401, or Phoenix Contact part 1408972.

  • Page 21: Helios Pro-M Model

    USER MANUAL REV 1.14-1 - 17/SEP/2024 Helios Pro-M model: From left to right, the connectors above are: (1) One power-in connector, 4-pin 7/8” male (2) One power-out connector, 4-pin 7/8” female (3) Two M12 4-pin Ethernet connectors, female (4) One D9 connector for RS232 Power Connectors The input power connector is a male 7/8”...

  • Page 22: Ethernet Connectors

    USER MANUAL REV 1.14-1 - 17/SEP/2024 Ethernet Connectors The two Ethernet connectors are female 4-pin D-coded M12 connectors, manufacturer Phoenix Contact, p/n 1551529 (see www.phoenixcontact.com). They are compatible with Ophir P/N 7E11211, Phoenix Contact p/n 1403499 or similar. Function Summary of connector P/Ns for Helios Plus-M model: Conn.

  • Page 23: Chapter 7 - Registers & Commands

    USER MANUAL REV 1.14-1 - 17/SEP/2024 Chapter 7 – Registers & Commands This chapter is relevant when using the Profinet or EtherNet/IP protocols. It describes the registers and data that can be read from the Helios, and the commands that can be sent to the Helios. LED indicators table There are seven LEDs for different status/error indications.

  • Page 24: Status: 16-Bit Register

    USER MANUAL REV 1.14-1 - 17/SEP/2024 Status: 16-bit Register NOTE: In Big Endian mode, the UPPER (top) byte is output first (byte 1). In Little Endian mode, the bytes are swapped over and the LOWER byte is output first (byte 0). NOTE: In earlier versions of this manual the “Cover”...

  • Page 25: Measurement Results & Information

    USER MANUAL REV 1.14-1 - 17/SEP/2024 Measurement Results & Information: Byte Register Units Length Read/Write 22-25 Latest power measurement 4 bytes Read Μs 26-29 Latest irradiation time measurement 4 bytes Read 30-33 Latest energy measurement 4 bytes Read 34-37 Present power (* Note 3) 4 bytes signed Read 38-39...

  • Page 26: Example Of Sequence Of Commands And Status

    USER MANUAL REV 1.14-1 - 17/SEP/2024 * Note : The active wavelength option can be set to index 1 by sending command 0xA1, or to index 2 by sending 0xA2, etc. The number of wavelength options available is reported in bytes 20-21, ‘Number of supported wavelength options’.

  • Page 27: Analysis Of Example Data, Big Endian

    USER MANUAL REV 1.14-1 - 17/SEP/2024 Bytes 46-47 = active wavelength option index. This value reports the active (presently chosen) wavelength option index, between 1 and N where N = number of supported wavelength options. Bytes 48-51 = Active wavelength name, characters 1..4. These 4 bytes report the NAME of the active wavelength option as Ascii characters.
  • Page 28 USER MANUAL REV 1.14-1 - 17/SEP/2024 In this example, the data was obtained when the Helios was first powered up, before any measurements are taken. 11 02 - status 00 98 96 80 00 00 27 10 27 10 00 64 2E E0 00 64 00 3C 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 81 00 1E 00 01 00 00 27 10 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 - data The data can be analyzed by splitting it up into groups as defined above, Constants and Measurement Results.

  • Page 29: Analysis Of Example Data, Little Endian

    USER MANUAL REV 1.14-1 - 17/SEP/2024 00 3C - max allowed temperature of Helios. Hex value 0x003C, decimal 60 degrees C. 00 00 - spare (2 bytes) 00 00 00 00 - last power measurement (mW) 00 00 00 00 - last time measurement (μs) 00 00 00 00 - last energy measurement (mJ) 00 00 00 81 - current power (mW).
  • Page 30 USER MANUAL REV 1.14-1 - 17/SEP/2024 Other Examples of Status Register values: Status register = 01 01 (01 = “open”; 01 = ready to measure) Status register = 01 81 (01 = “open”; 81 = ack from cover command, ready to measure) Status register = 02 01 (02 = “closed”;...

  • Page 31: Chapter 8 - Rs232

    USER MANUAL REV 1.14-1 - 17/SEP/2024 Chapter 8 – RS232 This chapter gives details about the Helios RS232 command set. The RS232 connection allows the user an alternative method to connect to the Helios, in addition to the Industrial Protocols. RS232 Setup: 8 data bits, 1 stop bit, no parity, 9600 baud (default) General Information:...
  • Page 32 USER MANUAL REV 1.14-1 - 17/SEP/2024 Write Head Range: $WN 0[CR] –> *[CR] {changes range: 0,1,2 parameter, 0=highest, or least sensitive, range. Power-up settings will be defined using $HC command, see below. NOTE that after using the $WN command, the software should wait ~3s before resuming power measurements with the $SP command.} Read Head Range: $RN[CR] –>...
  • Page 33 USER MANUAL REV 1.14-1 - 17/SEP/2024 Send Exposure Time (Photodiode): $SW[CR] ->*<Latest exposure time measurement in μs>[CR] {This command sends the latest laser exposure time measurement or zero if the sensor is in the middle of measuring a pulse. It can return measurements up to a maximum rate of 15 times per second.} Examples: *123456 for 0.123456s...

  • Page 34: Chapter 9 - Pc Application

    USER MANUAL REV 1.14-1 - 17/SEP/2024 Chapter 9 – PC Application Getting Started The PC application can be found in the Helios product page on the website. Copy the executable file to your local computer and run it (as an administrator) to install. Follow the steps in the installation wizard to complete.
  • Page 35 USER MANUAL REV 1.14-1 - 17/SEP/2024 Note: when using Helios devices that are not the Pro model, the section with results related to the Pro model will not be displayed (see the screen below): Use the “Wavelength” dropdown to select the desired wavelength range. In this example there are two available wavelength ranges with and without diffuser, NIR (Near Infrared e.g.
  • Page 36 USER MANUAL REV 1.14-1 - 17/SEP/2024 Use the “Range” dropdown to select the desired energy range (or scale). Keep in mind that the expected energy should be lower than this number, but greater than 10% of it. For example, a laser of 5 kJ should use the 10.0KJ range, but 900 J should use 1.00KJ. 36 | HELIOS PRO USER MANUAL...

  • Page 37: Options

    USER MANUAL REV 1.14-1 - 17/SEP/2024 Options For advanced operations using the commands from the previous chapter, select Options > Terminal. The Terminal section can be seen at the bottom of the screen. Commands are entered after the ‘$’ sign and are sent by clicking “Send.”...
  • Page 38 USER MANUAL REV 1.14-1 - 17/SEP/2024 Click “Open Log File Folder” to open the directory in which the log files are generated: Note, the log file is found inside a folder named by the serial number of Helios device used. This folder is found within the Helios installation directory.

  • Page 39: Cover Operation

    USER MANUAL REV 1.14-1 - 17/SEP/2024 Select Help > About to find this screen: It contains: • Software name • Company name • Software version • Device name and serial number • Firmware version • MAC Address The “Help” menu also contains an option for upgrading firmware as new versions are released.
  • Page 40 USER MANUAL REV 1.14-1 - 17/SEP/2024 After clicking “Open,” the message “IN MOTION” appears until the cover is in a fully open or closed position. After opening completely, the status changes to “OPEN” and the button will now close the cover, if pressed again. If the message "IN MOTION"...

  • Page 41: Pulse Capture

    USER MANUAL REV 1.14-1 - 17/SEP/2024 Pulse Capture When Helios Pro device is used with RS232 communication, the pulse shape can be characterized and the power at any given moment during the pulse will be logged to a CSV file by using the “Capture Next Pulse” button as follow: 1.
  • Page 42 USER MANUAL REV 1.14-1 - 17/SEP/2024 3. The "Waiting for next pulse" message will appear • Note: If it is necessary to cancel the logging at this stage, the "Cancel" button can be clicked. 4. Once the Helios detects the pulse, the message "Working" will appear 42 | HELIOS PRO USER MANUAL...
  • Page 43 USER MANUAL REV 1.14-1 - 17/SEP/2024 5. At the end of the pulse, the data will be downloaded while the "Downloading" message appears 6. The file is saved as "Pulse- (Pro Mode power) date time.csv" in the same folder as the other log files (see above (page 38) how to get to the folder) 7.

  • Page 44: Chapter 10 - Getting Started With Ethernet/Ip

    USER MANUAL REV 1.14-1 - 17/SEP/2024 Chapter 10 – Getting Started With EtherNet/IP This chapter describes how to control the Helios using the EtherNet/IP protocol, and how to read data from the Helios. Examples are shown using a PC based tool called “EIP_TOOL”, available on the internet from Molex/ODVA. The principles described in this chapter should be applicable to any EtherNet/IP tools running on a PLC or a PC.
  • Page 45 USER MANUAL REV 1.14-1 - 17/SEP/2024 Instance: 101 (0x65) - output, to read data from Helios, 66 bytes. 100 (0x64) - input, to write command to Helios, 1 byte. The value should be entered in the window as “101” or “100”. Instance Attribute: 3 - To perform the request (read data from Helios or send command to Helios) 4 - To query number of bytes supported in Attribute 3;...
  • Page 46 USER MANUAL REV 1.14-1 - 17/SEP/2024 Examples of values from the Status Register are given above in the Registers and Commands chapter. Settings used to write command (0x8 = Open Cover) to the Helios: Analyzing the data from the Helios: An example of data read from the Helios is shown below.

  • Page 47: Chapter 11 - Getting Started With Profinet

    USER MANUAL REV 1.14-1 - 17/SEP/2024 Chapter 11 – Getting Started With Profinet This chapter describes how to control the Helios using the Profinet protocol, and how to read data from the Helios. Examples are shown using the tool “ProfinetCommander” to provide examples. The tool “ProfinetCommander”...
  • Page 48 USER MANUAL REV 1.14-1 - 17/SEP/2024 Type the data (in HEX) into the window and click on “OK” to send the data to the Helios. Check the status and ResultsConst again to see updated status information from the Helios. 48 | HELIOS PRO USER MANUAL...

  • Page 49: Chapter 12 - Getting Started With Ethercat

    USER MANUAL REV 1.14-1 - 17/SEP/2024 Chapter 12 – Getting Started With EtherCAT This chapter describes how to control the Helios using the EtherCAT protocol, and how to read data from the Helios. Examples are shown using the PC based tool “TwinCAT”, available from Beckhoff on their website. (Note that the TwinCAT tool can also provide support for Profinet and EtherNet/IP protocols as described in earlier chapters).

  • Page 50: Opening A New Twincat Project

    USER MANUAL REV 1.14-1 - 17/SEP/2024 12.4 Opening a new TwinCAT Project: 1. Select “New TwinCAT Project”: 2. Choose "TwinCAT XAE Project" from the "Installed Templates: 3. At the bottom of the screen, choose a name for the project; the “Solution name” will update automatically as you type: 50 | HELIOS PRO USER MANUAL...

  • Page 51: First Time Installation Of Compatible Drivers For The Ethernet Card

    USER MANUAL REV 1.14-1 - 17/SEP/2024 4. Ensure “Create directory for solution” is checked, and define a location for the project. Click OK. The new project will be loaded. 12.5 First time installation of compatible drivers for the Ethernet card: Not all NIC cards are compatible with TwinCAT.

  • Page 52: Connecting To Slave Device

    USER MANUAL REV 1.14-1 - 17/SEP/2024 In this example, a StarTech USB 3.0 to Gigabit Ethernet Adapter P/N USB31000S was connected to the PC USB port, and the Ethernet side was connected to the Helios. TwinCAT identifies this adapter as one that can work in demo use only: Click “Install”...

  • Page 53: Viewing Raw Data From The Helios Device & Sending Commands

    USER MANUAL REV 1.14-1 - 17/SEP/2024 You will see this pop-up, click “OK” to continue: TwinCAT will locate and display available NICs. Choose the correct NIC and press “OK” After clicking OK, you may see one or more of these pop-ups, answer “Yes” to each one: 12.7 Viewing raw data from the Helios device &...
  • Page 54 USER MANUAL REV 1.14-1 - 17/SEP/2024 In order to send commands to the Helios (for example, to open or close the cover) click on the icon “RxPDO”, 54 | HELIOS PRO USER MANUAL...

  • Page 55: Viewing Formatted Data From The Helios

    Select “Device 3 (EtherCAT), right click and select “Add New Item” A drop down of all available XML files from folder C:\TwinCAT\3.1\Config\Io\EtherCAT\ will be displayed: Navigate to the bottom of the list and locate MKS Instruments and choose the correct Helios file. Press “OK”. 55 | HELIOS PRO USER MANUAL...
  • Page 56 USER MANUAL REV 1.14-1 - 17/SEP/2024 The formatted Helios will appear in the list on the left as “Box 2”. At this point it is necessary to delete “Box 1” to allow “Box 2” to continue working. Right click “Box 1” and choose “Remove”.

  • Page 57: Restarting Communications With The Device

    USER MANUAL REV 1.14-1 - 17/SEP/2024 12.9 Restarting communications with the device: It is possible to restart communications with the device if this should be necessary by clicking on the icon “Restart TwinCAT” The s/w will give the pop-up “Restart TwinCAT System in Config Mode? Choose After that you can choose to load the I/O devices (“Yes”), or not (“No”) if you want to disconnect the device from EtherCAT to connect in another tool.

  • Page 58: Appendix 1 - Flow Chart & Timing Diagrams

    USER MANUAL REV 1.14-1 - 17/SEP/2024 Appendix 1 – Flow Chart & Timing Diagrams Measurement Flow Chart 58 | HELIOS PRO USER MANUAL...

  • Page 59: Power Measurement Timing Diagram

    USER MANUAL REV 1.14-1 - 17/SEP/2024 Power Measurement Timing Diagram Shutter Timing Diagram Helios Pro User Manual 17 Sep 2024 Rev 1.14-1 For the latest version, please visit our website: www.ophiropt.com 59 | HELIOS PRO USER MANUAL...