Diode Laser Kit

Assembly Instructions

Model Numbers:
IF-RL08K

INDUSTRIAL FIBER OPTICS

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Copyright © 2008
by Industrial Fiber Optics, Inc.
Revision - C

Printed in the United States of America

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All rights reserved. No part of this publication may be reproduced,

stored in a retrieval system, or transmitted in any form or by any means
(electronic, mechanical, photocopying, recording, or otherwise)
without prior written permission from Industrial Fiber Optics.

* * * * *
 TABLE OF CONTENTS
LASER CLASSIFICATIONS............................................................ ii

TOOLS & TEST EQUIPMENT NEEDED.....…..............…..……..… 1

KIT COMPONENTS…………..................................……..…...…….. 1

LASER DIODE MODULATOR BOARD…...............................……. 2

Assembly Guidelines................................................................. 2

Parts List................................................................................... 3

Board Assembly Steps.............................................................. 4

DC POWER CORD.......................................................................... 5

LASER DIODE ASSEMBLY............................................................. 6

Parts List................................................................................... 6

BOARD FINAL ASSEMBLY............................................................. 7

POWERING & BEAM FOCUSING.................................................. 8

FINAL ASSEMBLY AND TEST....................................................... 10

WARRANTY..................................................................................... 11

SHIPMENT DAMAGE CLAIMS....................................................... 11

–i–
LASER CLASSIFICATIONS
All manufacturers of lasers used in the United States must conform to regulations admin-
istered by the Center for Devices and Radiological Health (CDRH), a branch of the U.S.
Department of Health and Human Services. CDRH categorizes lasers as follows:

Class Description

I A laser or laser system, which does not present a hazard to skin or

eyes for any wavelength or exposure time. Exposure varies with
wavelength. For ultraviolet, 2 to 4 μm exposures is less than from
8 nW to 8 μW. Visible light exposure varies from 4 μW to 200 μW,
and for near-IR, the exposure is < 200 μW. Consult CDRH regula-
tions for specific information.

II Any visible laser with an output less than 1 mW of power. Warning

label requirements – yellow caution label stating maximum output
of 1 mW. Generally used as classroom lab lasers, supermarket
scanners and laser pointers

IIIa Any visible laser with an output over 1 mW of power with a maxi-
mum output of 5 mW of power. Warning label requirements – red
danger label stating maximum output of 5 mW. Also used as class-
room lab lasers, in holography, laser pointers, leveling instruments,
measuring devices and alignment equipment.

IIIb Any laser with an output over 5 mW of power with a maximum out-
put of 500 mW of power and all invisible lasers with an output up
to 400 mW. Warning label requirements – red danger label stating
maximum output. These lasers also require a key switch for opera-
tion and a 3.5-second delay when the laser is turned on. Used in
many of the same applications as the Class IIIa when more power
is required.

IV Any laser with an output over 500 mW of power. Warning label

requirements – red danger label stating maximum output. These
lasers are primarily used in industrial applications such as tooling,
machining, cutting and welding. Most medical laser applications
also require these high-powered lasers.

– ii –
TOOLS & TEST EQUIPMENT NEEDED

To assemble this laser kit you will need the following tools:

Wire cutters
Wire strippers
Needle-nose pliers
Size 1 Phillips screwdriver
3/32 inch flat-blade screwdriver
Small adjustable wrench
3/32 inch Allen wrench
25-watt soldering iron
Heat gun
Rosin-core solder
Variable DC power supply
Photometer1 or optical power meter
Laser audio receiver2
Banana to banana test lead
Microphone with 3.5 mm plug2
Spanner or 3/8 inch wide flat-blade screwdriver

1
Industrial Fiber Optics part number IF-PM or any other optical power meter
calibrated at 635 nm. This equipment is critical for proper adjustment of laser
power or damage to laser diode may result.

2
Industrial Fiber Optics part number IF-LSL-2 consists of a receiver, a microphone
and a power adapter

KIT COMPONENTS

This laser kit has four major sub-assemblies. With the exception of the “Laser chassis” (it
comes pre-assembled); parts list tables for each sub-assembly can be found near the instruc-
tions for the particular sub-assembly. The major sub-assemblies are:

1. Laser diode modulator board

2. DC power cord
3. Laser diode heat sink and collimator lens assembly
4. Laser chassis

–1–
LASER DIODE MODULATOR BOARD
Assembly Guidelines

To assemble the laser diode modulator board, read the following guidelines then complete
the numbered assembly steps.

• Mount all components (except for LED D5) on the side of the printed wir-
ing board with the white lettering.
• Use the white markings on the printed wiring board to determine where
each part is to be placed.
• All soldering is to be completed on the side opposite the components
except for the LED D5.
• Use a water-soluble or rosin core solder such as Radio Shack P/N 64-001.
Do not use an acid or caustic flux solder such as used in industrial applica-
tions.
• Avoid prolonged heat to any part of the modulator board or component to
prevent damage.
• After soldering each component, trim its lead length flush with the surface
of the solder.
• Integrated circuit (IC) chips are sensitive to the direction in which they
are installed. The pins are numbered 1 through the number of pins on the
chip. A notch, dimple or dot on one end of the chip shows pin 1’s location.
The pin to the lower left of the notch is always pin 1, as shown in the
figure below. When inserting an IC into a board, it is important that pin 1
is placed in the square pad.

Resistor

Transistor

Integrated Circuit

–2–
 Table 1. Laser Diode Modulator Board Parts List

D/N P/N Description Color-Code

C1 150 pf axial capacitor Brown Green Brown
C2 .047 μf axial capacitor Yellow Violet Orange
C3 .047 μf axial capacitor Yellow Violet Orange
C4 10 μf electrolytic capacitor
C5 10 μf electrolytic capacitor
D3 1N914 Switching diode
D4 1N914 Switching diode
D5 Green 5 mm LED in right angle mount
D6 LM336Z-2.5 Voltage reference, 2.5 volts
H1 4-40 x 3/8 inch Phillips head screw
H2 4-40 self-locking nut
J1 2.1 mm power jack
J2 Microphone jack
PWB1 Modulator printed wiring board
Q1 PN2222 NPN transistor
R1 6.8 kΩ resistor Blue Gray Red
R2 39 kΩ resistor Orange White Orange
R3 Not used
R4 22 kΩ resistor Red Red Orange
R5 390 Ω resistor Orange White Brown
R6 220 Ω resistor Red Red Brown
R8 1 kΩ resistor Brown Black Red
R9 2.2 kΩ resistor Red Red Red
R10 Select Packaged w/laser diode
R11 47 kΩ resistor Yellow Violet Orange
R12 10 kΩ resistor Brown Black Orange
R13 15-turn 50 kΩ potentiometer
R14 1-turn 50 kΩ potentiometer
R15 1 kΩ resistor Brown Black Red
R16 47 kΩ resistor Yellow Violet Orange
U1 DB101 Bridge rectifier
U3 MC34074P High-speed quad op-amp
U5 DB101 Bridge rectifier
VR1 LM7805 5-volt positive linear regulator

–3–
Board Assembly Steps

1. Insert all of the axial leaded resistors, one at a time into the modulator
board and solder them in place.
2. R13 is a 15-turn potentiometer. Insert it and solder it in place.
3. The potentiometer R14 adjusts circuit gain. Insert it into the board and
solder in place.
4. Insert capacitors C1, C2 and C3 one at a time into the board and solder
them in place.
5. The two electrolytic capacitors (C4 and C5) are sensitive to the direction in
which they are installed. Locate the respective areas on the printed wiring
board for C4 and C5 and insert their wire leads through the holes so their
shapes match the printed profiles. Solder in place.
6. The rectifier diodes and switching diodes
(D3 and D4) are sensitive to the direction
in which they are installed. Insert them into
their designated area of the board so that the Rectifier diode with printed band
bands printed on the diodes match up with the bands in the white profiles
printed. Solder in place.
7. D5 (the green LED) is installed on the solder side of the board, directly be-
neath the white profile of SW1. Insert it with its shorter leg (the cathode)
in the square pad, and solder it into place.
8. Trim the leads of D5 and solder SW1 in place above it.
9. Insert U1, U3 and U5 one at a time, matching pin 1 of each IC with the
square pad in its designated area of the board. Solder each lead of the IC to
the board.
10. Bend the three leads of VR1 to line up with the pads on the board when
the mounting holes in VR1 and the board line up. Secure it to the board
with the 4-40 x 3/8 inch Phillips head screw (H1) and self-locking nut
(H2) and solder the leads in place.
11. Insert D6 and Q1 into the board so that their top-view shapes match up
with the profiles printed on the board and solder in place.
12. Mount jacks J1 and J2 in their designated places. Hold each firmly against
the board and solder in place.
13. Clean the board with soap and warm water to remove solder residue.
Soapy water will not harm the components as long as electrical power is
not being applied. If you used a rosin-core solder, clean the board with
flux remover before washing in soap and water. Rinse thoroughly. Shake
the board to remove water from under the ICs. Wipe everything dry with
paper towels and let air-dry for 30 minutes.

–4–
DC POWER CORD

1. Locate the end of the jacketed 2-conductor 22 AWG wire with the 1/2
inch split. (The other end has the conductors split for 2 inch.) Using wire
strippers, remove the insulation from the last 1/8 inch of both wires.
2. Unscrew the black protective cap from the 2.1 mm plug and solder one
wire to the inner terminal of the plug and the other wire to the outer
terminal. (Wire polarity does not matter due to the compensation circuitry
on the modulator board.)
3. Slip the speaker wire through the black protective cap and screw the black
protective cap back onto the 2.1 mm plug.
4. On the other end of the 2-conductor wire remove 1/2 inch of insulation
using a wire stripper. Heat the newly stripped wires with soldering iron
and lightly coat the wires with solder. (This procedure is known in the
electronic industry as “tinning”.)

–5–
LASER DIODE ASSEMBLY
Laser diodes are very sensitive to electrostatic discharge (ESD), and special precautions
must be followed when handling and installing. The laser diode leads are inserted into
black conductive foam to keep them electrically shorted together, preventing electrical
charges from entering the sensitive internal component. While handling the laser
diode without the protective foam installed, and before all three leads are soldered
to the electrical circuit, keep both of your elbows on the work surface to avoid static
charge buildup on your body.

1. The laser diode heat sink has the glass collimating

optics and laser diode pre-installed and focused.
Do not remove the black anti-static foam block
from the leads of the laser diode yet. Also, do
not attempt to adjust the focus of the collimating
1203
optics at this time.
Rear view of heat sink with
2. Insert the resistor packaged with this assembly
laser diode installed
(R10) and solder in place.

Table 2. Laser Diode and Lens Assembly Parts List

D/N P/N Description

H10 Laser diode heat sink

H11 Glass collimating optics

H12 76 0010 635 nm, 3 mW laser diode

H14 2-56 x 1/8 inch Phillips head screw

H15 4-40 x 1/4 inch socket cap screw

H16 Wire 28 AWG red, 2 inch long

H17 Wire 28 AWG white, 2 inch long

H18 Wire 28 AWG black, 2 inch long

H19 1/16” x 1/2” heat shrink, 3 pieces

–6–
BOARD FINAL ASSEMBLY

1. Set the laser diode heat sink and collimator assembly within the square
white outline on the modulator board with the collimating lens facing
away from the circuitry on the board. Insert the two 4-40 x 1/4 inch
socket cap screws (H5) through the holes in the bottom of modulator
board and screw into heat sink. Tighten the cap screws with the 3/32 inch
Allen wrench to secure the laser diode assembly to the modulator board.
2. Solder the 2 inch lengths of black, white and red wire into the modulator
board in the pads labeled BLK (E1), WHT (E2), and RED (E3) respectively.
Slip a 1/2 inch length of heat shrink over each wire.
3. Touch the tip of your soldering iron to one of the 2-56 screw heads holding
the laser diode into the heat sink. Remove the black foam block from the
leads of the laser diode. Using the figure below as a guide for proper pin
identification, solder the black wire to lead 1, the red wire to lead 2 and
the white wire to lead 3.
4. Slide the three lengths of heat shrink over the laser diode leads and the
wires solder joints. With a heat gun, carefully heat the heat shrink until it
contracts around the solder joints.

–7–
POWERING & BEAM FOCUSING
MAKE CERTAIN YOU HAVE A CALIBRATED OPTICAL POWER METER FOR THE
FOLLOWING PROCEDURE OR DAMAGE TO THE LASER DIODE MAY RESULT.

A variable DC power supply must be used to control voltage to the electrical circuit
until correct circuit assembly can be verified and laser diode power is stabilized.

DO NOT USE THE 110 VAC TO 12 VDC POWER ADAPTER TO ELECTRICALLY

POWER THE MODULATOR BOARD YET.

1. Using a small flat-blade screwdriver, adjust R13 fully clockwise (approxi-

mately 20 turns).
2. Adjust the variable DC power supply output to zero volts and turn it on.
3. Connect one lead of the DC power cord assembled in previous steps to the
positive terminal of the variable power supply, and the other to the ground
terminal.
4. Insert the 2.1 mm plug of the DC power cord into the 2.1 mm power jack
of the input panel marked PWR.
5. Set the main modulator board on several books or in a small vise so its
surface is level and horizontal and in a manner that the laser beam will
be pointed in a safe direction. Make sure the modulator board support or
holder is not electrically conductive.
6. At this time please read the “Rules for Laser Safety” located on the back
cover of this manual.
7. Hold a piece of white paper 3 inches in front of the laser diode assembly
on the modulator board. Very slowly increase the voltage output from the
power supply, and watch for a small faint red dot to appear on the paper
due to the collimated laser diode light. As soon as a visible red dot appears,
stop increasing the power supply voltage.
8. Align the laser beam to the active area inside the detector head of an opti-
cal power meter or radiometer. The optical power read by the meter should
be 0.5 milliwatts (mW) or less. If the reading is greater than 0.5 mW, there
has been a mistake in assembly. Adjust the power supply voltage to zero
volts immediately and check location and installation of all components.

–8–
 9. You will now very slowly further increase the input voltage while monitor-
ing the output power on the optical power meter. If the board has been
assembled properly, you should be able to increase the adjustable power
supply to 12 volts without the laser beam reaching a power of 0.8 mW.
10. If the output power of the laser measures 0.8 mW before the power supply
reaches 10 volts, either a component has been installed improperly or there
is a shorted connection on the board. Inspect all solder joints and assembly
procedure.
11. Adjust R13 until the laser beam measures 0.8 mW with the optical power
meter.
12. Point the laser beam at a flat, vertical surface about 15 feet away and re-
adjust the collimating lens if necessary.
13. Turn the power supply on and measure the laser diode’s output power
again, and adjust R13 so the laser beam measures 0.80 mW with the opti-
cal power meter. Turn adjustable power supply off. Remove the 2.1 mm
plug and power cord from the power jack.
14. You can now safely use the 110 VAC to 12 VDC power adapter to power
the laser.

Table 3. Common abbreviations used in this manual

Numerical
Abbr. Long version
representation
mW milliwatts 1 x 10-3 Watts

μW microwatts 1 x 10-6 Watts

nW nanowatts 1 x 10-9 Watts

cm centimeters 1 x 10-2 meters

mm millimeters 1 x 10-3 meters

μm micrometers 1 x 10-6 meters

nm nanometers 1 x 10-9 meters

–9–
FINAL ASSEMBLY AND TEST

1. Position the modulator board with the laser diode heat sink assembly on
top and align it with the slots inside the laser chassis. Slide the modulator
board completely into the chassis
2. Place the backplate over the open end of the chassis such that the jacks,
LED and switch knob protrude through the holes
3. Secure the backplate in place with the four pan head Phillips sheet metal
screws.
4. Point the laser toward a wall or other non-reflecting surface.
5. Push the beam stop handle to its closed position.
6. Make sure the laser’s ON/OFF switch is in its OFF position (the push but-
ton should be in its extended position.)
7. Plug the 12 VDC power adapter into an AC wall outlets, and plug the cord
into the power jack.
8. Depress the ON/OFF switch until it clicks into the ON position.
9. Push the beam stop handle upward to its open position.
10. Insert the 3.5 mm plug on the end of the microphone cord into the micro-
phone jack marked MIC.
11. Following the instructions for your laser receiver set it up to demodulate
the laser beam and convert the amplitude-modulated laser beam to sound
waves produced by the speaker.
12. Aim the laser beam onto the detector of a laser receiver and speak into the
microphone. Your voice should be heard from the speaker of the receiver.
The single-turn potentiometer, R14, on the modulator board adjusts the
gain of the laser. With appropriate gain settings of the laser and the volume
of the receiver, your voice should be clearly audible.

At this time you have assembled and tested a laser with a semiconductor laser diode as the
active element. Congratulations and welcome the fascinating world of lasers and optoelec-
tronics.

– 10 –
WARRANTY INFORMATION

This kit was carefully inspected before leaving the factory. If any components were dam-
aged in shipping, Industrial Fiber Optics will repair or replace them at its discretion. Since
soldering and incorrect assembly can damage electrical components, no warranty can be
made after assembly has begun. If any electrical parts become damaged, replacements may
be obtained from most radio/electronics supply shops. Refer to the parts lists of this manual
for part numbers.

NOTE: This kit contains a laser diode which can be damaged if operated at excess power
levels. A calibrated optical power meter is crucial for proper adjustment of this
device.

Industrial Fiber Optics recognizes that responsible service to our customers is the basis of
our continued operation. We welcome and solicit your feedback about our products and
how they might be modified to best suit your needs.

SHIPMENT DAMAGE CLAIMS

If damage to an Industrial Fiber Optics product should occur during shipping, it is impera-
tive that it be reported immediately, both to the carrier and the distributor or salesperson
from whom the item was purchased. DO NOT CONTACT INDUSTRIAL FIBER OPTICS.

Time is of the essence because damage claims submitted more than five days after delivery
may not be honored. If shipping damage has occurred during shipment, please do the fol-
lowing:

• Make a note of the carrier company; the name of the carrier employee; the
date, and the time of the delivery.
• Keep all packing material.
• In writing, describe the nature of damage to the product.
• Notify the carrier immediately of any damaged product.
• Notify the distributor from whom the purchase was made.

– 11 –
 12 0093

Rules for Laser Safety

• Lasers produce a very intense beam of light. Treat them with respect. Most
educational lasers have an output of less than 3 milliwatts, and will not harm the
skin.

• Never look into the laser aperture while the laser is turned on! PERMANENT
EYE DAMAGE COULD RESULT.

• Never stare into the oncoming beam. Never use magnifiers (such as binoculars or
telescopes) to look at the beam as it travels – or when it strikes a surface.

• Never point a laser at anyone’s eyes or face, no matter how far away they are.

• When using a laser in the classroom or laboratory, always use a beam stop, or
project the beam to areas, which people won’t enter or pass through.

• Never leave a laser unattended while it is turned on – and always unplug it when
it’s not actually being used.

• Remove all shiny objects from the area in which you will be working. This
includes rings, watches, metal bands, tools, and glass. Reflections from the beam
can be nearly as intense as the beam itself.

• Never disassemble or try to adjust the laser’s internal components. Electric shock
could result.