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FLUX Ador LSO Training

FLUX Support Team
  • Updated

Introduction

The safe operation of your FLUX Ador requires a trained Laser Safety Officer (LSO). FLUX has consulted with laser experts to design these FLUX Ador LSO Training Materials to help you in complying with your LSO responsibilities and ensure that you operate your FLUX Ador safely.

 

The first document, the FLUX Ador LSO training, has three parts:

  • The first section, “FLUX Ador Safe Operation,” describes the procedures to ensure safe operation.
  • The second section, “Laser Safety Officer Responsibilities,” describes your role as the Laser Safety Officer for your FLUX Ador.
  • The third section, “About Lasers and Laser Safety,” describes general information about lasers and laser safety as well as regulations pertaining to lasers.

The second document, “FLUX Ador Laser Safety Program,” is a laser safety program document that you, as the LSO for your FLUX Ador, may adopt.

The third document, “FLUX Ador Laser Standard Operating Procedure”, is an SOP document that you may adopt that is a part of the FLUX Ador Laser Safety Program.

The fourth document, “Warning Sign”, is a sign you may choose to use as a compliance measure described in the SOP if you decide not to operate your FLUX Ador in Class 1 conditions.

 

FLUX Ador Safe Operation:

Class 1 Conditions

Your FLUX Ador is a Class 4 laser. However, certain safety precautions may create “Class 1 conditions” around the laser. Class 1 conditions mean that the conditions are incapable of producing damaging radiation levels during normal operation.

That means that if you choose to use the Ador Extension Base in the Non-passthrough Assembly as described below, additional protections such as safety glasses, signs, and warning lights are not necessary.

However, even with Class 1 conditions, every person who uses the FLUX Ador must read and abide by the user manual and all instructions in the FLUX App.

 

Ador Extension Base Non-passthrough Assembly

Ador Extension Base Non-passthrough Assembly will be available for your FLUX Ador.

In the Non-passthrough Assembly, the base's front and rear frames will be installed and serve as beam blocks for the passthrough openings.

When the pass-through function of the FLUX Ador is not in use, these may be screwed in tightly to close the front and rear openings. See the photos below.

When the Ador Extension Base is installed in a Non-passthrough Assembly, and all instructions in the manual and the FLUX Software, Beam Studio are followed, Class 1 conditions exist, and no further laser safety precautions are required beyond compliance with the manual and FLUX Software, Beam Studio.

Passthrough Assembly Non-Passthrough Assembly

 

 

Operation Outside of Class 1 Conditions

If your FLUX Ador is not being operated under Class 1 conditions, you are responsible for ensuring safe operation. The provided SOP does not permit safe operation in Class 4 conditions, so the LSO must create an SOP that does. Ultimately, the LSO is responsible for defining what that entails and describing and enforcing it with that SOP, and the laser operator is responsible for ensuring compliance and safe operation. Some key elements of a Class 4 SOP may include:

 

  • Appropriate safety goggles
    FLUX Ador does not provide safety goggles, but relevant goggles can be purchased separately from FLUX. For more information, please contact support@flux.com, visit the FLUX Web Shop, or visit the FLUX Help Center.

 

  • Sign
    An appropriate laser safety sign is placed at the entryway to alert people to the hazards inside. FLUX has provided a sample sign (below).

 

  • Light and visual indications
    A built-in LED light on the machine front lights up when the machine is turned on, and a built-in colored touch screen shows the machine's status. These indicate that the laser is in use, has an error, or is off.
Machine in Use Machine Off

 

 

  • Laser interlock
    • The built-in physical door sensors will detect the door’s status being opened or closed. The machine will only operate when the door is fully closed, meaning it will not output any laser when the door is opened. During a laser task, if the door is opened, the machine will stop working immediately, and an error will pop up on the screen to remind the user to close the door and continue.
    • Another built-in sensor on the machine's bottom detects whether the extension base or the machine’s original bottom plate is installed correctly. The machine won’t operate unless either is installed correctly. 
Door Opened Bottom Opened

 

 

Laser Safety Officer Responsibilities:

 

The LSO and Your Laser Safety Program

ANSI Z136.1 describes guidelines for a safety program that will minimize the hazards of a Class 4 laser like the FLUX Ador. Primary safety responsibility rests with someone designated as the Laser Safety Officer, or LSO. This document is designed to assist you in acting as the LSO for one or more FLUX Ador units. It does not provide sufficient information to advise you in acting as the LSO for any other laser.

The LSO verifies the classification of the laser. The LSO determines the level of hazard by considering the details of the laser and creates a standard operating procedure (SOP) that determines what control measures (like additional interlocks, training, and safety glasses) should be used.

The LSO is then responsible for helping and training other laser users, ensuring safe compliance, analyzing any possible hazards, providing safety equipment, ensuring all regulations are complied with, including (in the US) CDRH, OSHA, and state regulations, and auditing the use of the laser to make sure it’s used safely.

Beyond these responsibilities, the LSO must also recommend and approve signs, labels, protective equipment, facilities, equipment, and any modifications, maintain records, approve laser system operation, and investigate accidents should one occur. The LSO is ultimately responsible for determining if and how a laser may be safely operated.

 

Standard Operating Procedure

Based on the Hazard Analysis, the LSO must create a Standard Operating Procedure (SOP) that describes the control measures required to minimize hazards. FLUX has also created a sample SOP (provided below) that you may use or adapt to your FLUX Ador laser safety program.

 

About Lasers and Laser Safety:

How Lasers are Different

Lasers are a special kind of light source. Most light is made of many different colors, all shining out in lots of directions at once. Laser light is different in three ways.

First, laser light is monochromatic—just one color. Sometimes, that color is visible, like the FLUX Ador 10W/20W Diode Laser Module, which outputs a visible blue laser. Sometimes, it's invisible, like the FLUX Ador 2W Infrared Module, which human eyes can't see the laser output.

In technical discussions, people describe lasers as producing “nonionizing electromagnetic radiation”. That describes a broad category that includes everything from sunshine to radio waves. Instead of talking about color, they use the term “wavelength”. The wavelength of the low-power measuring laser on your Ador with the default 10W/20W Diode Laser Module is 455 nanometers, which is blue. The wavelength of the Ador 2W Infrared Module is 1064 nanometers, which is invisible.

The second difference between laser light and regular light is that laser light is directional. That means that it can be made to travel in a straight line, in a beam, without spreading out much.

The third difference is that laser light is coherent. This means that each light wave is synchronized with the others.

It’s very hard to get light to move in a straight line without spreading out. If the waves aren’t lined up, or if there’s a mix of colors and directions, the beam will spread out. Lasers, however, can stay lined up for a long distance - and, importantly, can be focused down to a point.

Lasers' greatest effectiveness and danger, as compared to ordinary light, comes from lasers' ability to be focused.

 

Laser Background

The very first laser used a strobe light and a ruby crystal. The light from the strobe was amplified in the ruby crystal, stimulating it to emit non-ionizing electromagnetic radiation at 694 nanometers. The acronym “LASER” comes from this experiment - light amplification through stimulated emission of radiation.

These first lasers were called “solid-state” lasers because the action parts were solid crystals. Shortly after the development of solid-state lasers came gas lasers, which can resemble neon signs. Electricity causes gas in a tube to glow. Specially tuned mirrors amplify the light, and the laser beam emerges. The infrared printing laser in your FLUX is a gas laser. It uses a mixture of gasses, but the gas that actually creates the beam is Carbon Dioxide, also known as CO2.

One of the most recent lasers to be invented is the diode laser. Diode lasers are small electrical devices that are made like microchips and LEDs. They turn power directly into laser light. You may have seen one before in a laser pointer. The Ador’s default 10W/20W laser module laser is a diode laser.

 

Measurements

Four measurements are used to describe the effect of a laser.

Joules measure energy. If you shine a light on a gram of water until it absorbs 1 joule of energy, the water will heat by about a quarter of a degree Celsius.

Watts measures power. If you turn on a one-watt light for a second, it will put out 1 joule during that time.

Joules per square centimeter measures radiant exposure. If you focus down that one-watt light to a square centimeter of paper and shine it for a second, that one joule will spread over the paper, and it will heat up slightly, just like the water. However, if you focus it down to 1/100th the size, the paper may singe and turn brown.

Finally, watts per square centimeter measure irradiance. If you keep shining that one watt light on the paper, it will keep adding joules of energy. If it’s focused to one square centimeter, it will slowly warm. If it’s focused to 1/100th the size, the paper may catch fire.

 

Laser Beam Hazards

Laser beams can be hazardous because the energy of the laser can damage eyes and skin. If the main infrared laser in your FLUX Ador strikes tissue, it will heat the tissue. This can cause damage to both eyes and skin. The risk is higher if the laser is more powerful, if it is more focused, and if it stays in one place for a longer time, so all of these factors are considered when assessing safety.

The laser beam can strike a person in one of three ways. First, the laser can be pointed at the person directly. Second, in ‘specular reflection’, the laser can be reflected towards a person. Third, in ‘diffuse reflection’, the laser strikes a surface that is not a mirror, and scatters the light in all directions. Because the light from a diffuse reflection is scattered, it is not as hazardous as the direct or reflected light - but there may still be enough intensity to cause damage.

While any part of the body may be damaged by a laser beam, the eye is particularly sensitive and vulnerable. The far-infrared, like the beam from CO2 lasers, is absorbed by the cornea in front of the eye; therefore, unlike many other lasers, it is not a retinal hazard.

 

Laser Hazard Classes

Lasers are classified by the level of radiation that may be encountered during normal operation.

Class 1 lasers are incapable of causing injury during normal operation. Class 1M lasers are the same, except unless magnifying optics are used. The FLUX Ador with the non-passthrough assembly is a Class 1 laser.

Class 2 lasers are incapable of causing injury in less than 0.25 seconds. Class 2M lasers are the same unless magnifying optics are used.

Class 3R lasers are marginally unsafe if the beam is directed at the eye. Class 3B lasers are hazardous if the beam is directed at the eye but are usually not an eye hazard if the beam is scattered.

Class 4 lasers are eye and skin hazards for both direct and scattered exposure. The FLUX Ador with the passthrough assembly is a Class 4 laser.

 

Laser Regulations

In the US, laser manufacturers like FLUX are regulated by the Center for Devices and Radiological Health (CDRH), and required to follow 21 CFR 1040.10 and 1040.11, which are federal law. In many other countries (but not the US), both laser manufacturers and laser users are required to follow IEC60825.

ANSI Z136.1 is a voluntary standard that describes how to use lasers safely. OSHA (a US federal law that applies to workplaces but not to private homes) requires a safety program like that described in the ANSI standard.

The CDRH requires that Class 4 laser devices have a defined set of safety features. 

The case of the FLUX Ador prevents access to excess laser radiation and serves as the protective housing. Safety interlocks disable the laser if the lid is opened. 

The password to your FLUX Software Beam Studio account and the optional setting of a password on the touch screen serve as the master key control for your FLUX Ador that prevents unauthorized laser operation. 

The FLUX Ador's colored touch screen serves as the emission indicator; it shows the exact machine status and indicates whether the laser light is present. 

The controls are located so that laser exposure protection is not required to operate them, and all viewing optics limit exposure to Class 1 levels. 

There are also certain labels on the machine required by the US and certain international laws.

There may be other laser regulations depending on your country, state, and even city, and regulations may change. This information is provided to assist you in creating a safety program as described by ANSI Z126.1, but cannot advise you on legal compliance.

 

Non-Beam Hazards

Your FLUX Ador may be exposed to additional hazards. To minimize hazards, always operate your FLUX Ador in accordance with the manual and follow all instructions in the Beam Studio.

 

Electrical

Your FLUX Ador uses a 100V-240V to DC24 power adapter. Overriding the safety, functions, or sensors, operating a laser where the case is damaged, unauthorized service, or any other use in violation of the manual may expose you to hazardous and even lethal voltages.

 

Laser Generated Air Contaminants

When using a laser to process materials, a variety of air contaminants may be produced that can be hazardous. The air must be filtered to remove those contaminants. Follow the user manual in your FLUX Ador to ensure that all exhaust is either properly treated or discharged outdoors where it can safely dissipate.

 

Process Nonionizing Radiation

Processing metals with a laser may release ultraviolet light. If your FLUX Ador produces a bright light that cannot be viewed comfortably, look away.

 

Collateral Nonionizing Radiation

The material that produces the laser beam may emit harmful levels of UV and/or IR light. The FLUX Ador has been tested to ensure that harmful levels are not present outside the case or when viewed through the door lid.

 

 

FLUX Ador Laser Safety Program


SCOPE

This program applies to FLUX Ador Laser operated by FLUX Ador Owner. This program is based on the guidance of ANSI Z136.1-2014, American National Standard for Safe Use of Lasers. The proper implementation of this program will assure that laser exposures are always below the maximum permissible exposure (MPE) limits.

 

LASER SAFETY OFFICER

An individual designated as the Laser Safety Officer (LSO) shall have the responsibility and authority to ensure compliance with this program. The LSO shall:

  • Provide hazard evaluations for FLUX Ador laser
  • Specify control measures for the FLUX Ador laser and ensure implementation
  • Approve procedures, SOPs, protective equipment, signs and labels
  • Assure that all laser personnel receive appropriate safety training
  • Monitor the program and ensure compliance
  • Maintain program records

The LSO shall have final authority in determining FLUX Ador laser control measures and may approve alternate controls when these are appropriate based on the judgment of the LSO. FLUX Ador laser shall be operated only with approval of the LSO. The LSO shall have the authority to terminate laser operations at any time.

 

LASER CLASSES

Class 1 laser systems are incapable of producing damaging radiation levels during normal operation and are exempt from any control measures. Class 1 laser systems may contain higher class lasers and may produce laser hazards if operated with interlocks defeated. Only authorized personnel may operate class 1 laser systems with interlocks defeated. Operators of class 1 laser systems with embedded class 3B or class 4 lasers shall receive a laser safety briefing.

 

Class 1M laser systems are incapable of producing hazardous exposure conditions during normal operation unless the beam is viewed with optical instruments. Operators of Class 1M laser systems shall receive a laser safety briefing.

 

Class 2 laser systems emit visible light only at a power level of 1 milliwatt or less. The normal aversion response to bright light is adequate protection. Staring into the beam of a class 2 laser is hazardous. Operators of class 2 laser systems shall receive a laser safety briefing.

 

Class 2M laser systems emit visible light only. The normal aversion response to bright light is adequate protection for unaided viewing. However, viewing the beam with optical aids is potentially hazardous. Operators of Class 2M laser systems shall receive a laser safety briefing.

 

Class 3R laser systems are potentially hazardous under some viewing conditions, but the probability of an actual injury is small, and the control measures for safe use are straightforward. Most laser pointers fall in this class. Operators of class 3R laser systems shall receive a laser safety briefing. (Most lasers previously classified as class 3a fall in this category.)

 

Class 3B laser systems are eye hazards for intrabeam viewing and specular reflections, even for momentary exposures, but diffuse reflections are not usually hazardous. Class 3B laser systems shall be operated only in laser controlled areas by authorized operators. Operators of class 3B laser systems shall receive approved laser safety training.

 

Class 4 laser systems are eye hazards and skin hazards for intrabeam exposures, specular reflections, and diffuse reflections. They are also fire hazards and may produce laser generated air contaminants. Class 4 laser systems shall be operated only in laser controlled areas by authorized operators. Operators of class 4 laser systems shall receive approved laser safety training. A written Standard Operating Procedures (SOP) is required for class 4 laser operation. The FLUX Ador Laser is certified with the FDA under the Code of Federal Regulations Title 21 as a class 4 laser system.

 

TRAINING REQUIREMENTS

When operating in Class 1 conditions, all users will read and obey the safety manual and FLUX software, Beam Studio. When operating in Class 4 conditions, additional laser safety training is required and must be prepared and administered by the LSO.

If there are bystanders, children, or if the FLUX Ador Laser is used in a public setting where untrained individuals may be present, feed-through beam blocks must be securely installed.

 

CONTROL MEASURES

The LSO shall determine the requirements for the FLUX Ador Laser-controlled area. The minimum standards considered by the LSO for the FLUX Ador Laser controlled area are:

  • Entryway controls allow only authorized personnel or approved spectators to enter the FLUX Ador Laser control area if needed. (Administrative controls are acceptable.)
  • Laser safety eyewear is available and used in accordance with the SOP for the FLUX Ador Laser.
  • Beam control (barriers and beam blocks) to limit laser hazards within the controlled area.
  • Written SOP for the FLUX Ador Laser.
  • Training of the FLUX Ador Laser operators.

 

EYEWEAR POLICY

Laser safety eyewear is not normally required for the operation of the FLUX Ador Laser when operating in Class 1 conditions as described in the SOP. The LSO will require eyewear or approve laser operation without eyewear based on a hazard evaluation performed by the LSO or the LSO may choose to delegate this responsibility.

 

RESPONSIBILITIES OF EMPLOYEES WORKING WITH LASERS

Employees who work with the FLUX Ador Laser with the beam exposed shall:

  • Energize or work with lasers only when authorized to do so.
  • Comply with laser safety rules and work procedures.
  • Notify their supervisor or the LSO in case of potential accident or injury or suspected unsafe condition.

LASER SAFETY AUDIT

At an interval determined by the Laser Safety Officer, the FLUX Ador Laser will be audited for safety:

  1. It will be visually inspected for damage.
  2. The most recent user version of the manual will be re-read.
  3. The laser will be powered up, and the lid will be opened to confirm that the door sensors correctly interrupt operation.
  4. The Laser Safety Program will be reviewed to ensure that the program is current and compliant.

A record of this audit will be completed, printed, signed, dated, and retained.

 

RECORDS

The LSO shall maintain records that document the Laser Safety Program. These records shall include:

  • Laser hazard analysis reports for the FLUX Ador Laser
  • A list of operators who have been trained and permitted to use the FLUX Ador Laser
  • Standard Operating Procedures for the FLUX Ador Laser
  • Approvals of alternate laser control measures, if implemented
  • Laser Safety Audit checklist

 

FLUX Ador Laser Standard Operating Procedure (SOP)

Scope: This SOP applies to the regular operation of the FLUX Ador Laser as specified by the manufacturer.

  1. System Description
    Two-axis diode laser material processing system. This class 4 laser system is usually operated under class 1 conditions (ANSI Z136.1, 4.4.2.7.2.1).
    1. Wavelength: 1064nm or 445nm (Depending on the module being used.)
    2. Maximum Power: 20W
    3. Operating Mode: Continuous Wave
    4. Beam Diameter: 0.06 ~ 0.11 mm
    5. Beam Divergence: 4 mrad (M2 =1) 
  2. Potential Hazards
    1. Eye hazard from direct, reflected, or scattered beam.
    2. Skin hazard and fire hazard.
    3. Electrical hazard inside power adaptor.
    4. Laser Generated Air Contaminants.
  3. Control Measures
    1. The LSO will only allow physical access to the laser to users who have been enrolled in the FLUX software, Beam Studio, and thereby received safe operating instructions.
    2. All users of the FLUX Ador Laser will comply with the user manual and all instructions in the FLUX software, Beam Studio, at all times.
    3. The FLUX Ador Laser shall be operated in class 1 conditions per ANSI Z136.1, 4.4.2.7.2.1 (reference Hazard Analysis Report). Class 1 conditions shall be considered fulfilled when operating under the following guidelines.
      1. The laser system shall be operated with all manufacturer safety features fully functional.
      2. When the passthrough function is not in use, the Ador extension base shall be changed back to the non-passthrough assembly.
      3. When utilizing the passthrough function, door sensors and the bottom sensors must be checked before starting a task.
    4. Keep your eyes away from the passthrough openings if you are not wearing any eye-protections. 
    5. Keep all combustibles, tools, and reflective surfaces away from the beam path. Make sure you know where the beam is and stay clear.
    6. Work involving access to the power adaptor shall be done only by the manufacturer, with no exceptions.
    7. Maintenance shall be done when the laser system is turned off.
    8. When functioning normally, the exhaust system will remove LGACs to maintain levels that are not hazardous or irritating.
  4. Required Training:
    When operating in Class 1 conditions, all users will read and obey the safety manual and FLUX software, Beam Studio. When operating in Class 4 conditions, additional laser safety training is required and must be prepared and administered by the LSO.
  5. For emergency medical response call             .
  6. Report all incidents to the LSO.
  7. Authorized Personnel
    The following personnel are authorized to operate this system:
    ___________________________________
    ___________________________________
    ___________________________________
    ___________________________________
    ___________________________________
      

Notes:

The worst case Optical Density (OD) requirement for laser-protective eyewear is 3.67. The eyewear provided by the laser manufacturer is rated at a minimum of OD 4. The exposure duration used to determine the OD is the ANSI default duration for an accidental exposure of 10 seconds.

With all the manufacturer safety features fully functioning and the laser operating per the SOP, the only source for a possible exposure above the Maximum Permissible Exposure (MPE) is a diffuse reflection that could scatter the laser output through the feed-through opening. Very conservative assumptions are made in this analysis. The exposure duration used is 600 seconds, which assumes intentional viewing. The scattered power is assumed to be 45 watts, which is an absolute worst-case. The viewing angle is assumed to be 80 degrees. Greater viewing angles create a smaller hazard distance. The viewing angle, in this case, is closer to 85 degrees or more, so a conservative assumption is 80 degrees. Given the assumptions, the diffuse nominal hazard zone (NHZ) is about 5 centimeters or just under 2 inches. This NHZ is insignificant. Operating per the SOP, the laser system fulfills the ANSI 4.4.2.7.2.1 requirement for operation under class 1 conditions.

 

Warning Sign 

 

 

Disclaimer:

This training document is based on existing searchable documents, including but not limited to 21 CFR Part 1040.10, 1040.11, ANSI Z136.1 Standard - Guidance for Implementing a Safe Laser Program, OSHA, the U.S. Occupational Safety and Health Alliance, the U.S. Laser Protocol: the Laser Regulators and the Center for Devices and Radiological Health, and other publicly available documents and standards issued by the above agencies at the time of this document's development. The documents and standards issued by these organizations and available in the public domain have been prepared, and the courses and presentations of some laser safety experts in the public domain have also been taken into account. The final right of interpretation of this document belongs to FLUX.

 

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