User Manual For 4 in 1 Laser Welding machine-2KW

2KW Handheld Laser Processing Head (Single Galvo Type)- User Manual

Disclaimer

 We reserve the right to change the design in order to improve the quality or expand the
application or comply to manufacturing workmanship.
 We will not bear any responsibility for losses and accidents caused by wrong operation or
improper handling of our products.
 Dismantling of product will lose all warranty claims excluding the normal replacement of
worn parts and components required for maintenance or commissioning operations.
 Unauthorized modification of products or use of non-original spare parts will directly lead to
the invalidation of warranty and liability exemption.
 It is recommended to only use the spare parts provided by us or submit them to us or the
designated professional team for installation.

Use Regulations

 Ensure that the product is used in a dry environment.

 Ensure that the product is used in the environment required by EMC standards.
 The product is only allowed to run within the parameters specified in the technical data.
 Personnel Responsibilities

 Be familiar with the basic provisions of work safety & accident prevention and have received
equipment operation guidance.
 Read and understand basic safety instructions and operations.
 You must have studied the relevant regulations and safety instructions and understand the
possible hazards.
 Comply with relevant regulations and implement corresponding protective measures

Safety Instructions

Prevent Electric Shock

 Parts of the laser head such as nozzle, sensor, sensor interface and attached fasteners
may not be fully protected by the ground wire due to function fault. These parts may have
lowvoltage. When installing electrical equipment, please pay attention to taking anti electric
shockmeasures for relevant personnel

Guard against Danger

 Never put your hands or other body under the laser head.
 Repair and maintenance work can only be carried out after the power is turned off.
 Do not exceed the specified maximum pressure.
 It must be ensured that the laser head is in normal condition at all times.
 All fasteners such as bolts and nuts must be tightened

Laser Caution
 Avoid direct laser radiation or scattering to the skin.

 Do not stare at the laser beam even when wearing optical equipment.

 Use special laser protective eyeglasses that meet the requirements of safety standards
IEC60825-1.

Prevent Waterway Corrosion

 In order to avoid corrosion, use the specified coolant and comply with relevant
requirements and specified maintenance intervals.

Noise Prevention

 The corresponding measures shall be specified or explained and observed in order to

prevent personnel from being harmed by noise when the cutting air pressure is high.
 Storage and Transportation

 Observe the storage temperature range allowed by the technical data.

 Take reasonable measures to prevent fire, vibration or impact.
 Do not store in or near the magnetic field.
 Index

1 Laser Processing Head ............................................................................................................1

1.1 QBH Connection ...................................................................................................................1

1.2 Dismantling and Mounting of Cover Glass ...........................................................................2

1.3 Daily Inspection ....................................................................................................................3

2 Controller ................................................................................................................................4

2.1 Overall Wiring .......................................................................................................................4

2.2 Wiring from HMI Panel to Controller ...................................................................................6

2.3 Wiring from Laser to Controller ...........................................................................................6

2.4 Wiring from Laser Processing Head to Controller ................................................................7

2.5 Wiring from Power Supply to Controller ..............................................................................7

2.6 Wiring from Gas Valve and Chiller to Controller ..................................................................9

2.7 Wiring from Wire Feeder to Controller ..............................................................................10

3 Wire Feeder ...........................................................................................................................10

3.1 Installation of Wire Feeder .................................................................................................11

3.2 Operation of Wire Feeder ..................................................................................................13

3.3 Troubleshooting of Wire Feeder ........................................................................................16

3.4 Daily Maintenance of Wire Feeder.....................................................................................17

3.5 Supplementary Regulation of Auto Wire Feeding ..............................................................18

4 Connection of Wire Feeding Mechanism to Laser Processing Head ....................................18

5 HMI ........................................................................................................................................19

5.1 Home ..................................................................................................................................19

5.2 Setting .................................................................................................................................20

5.3 Process ................................................................................................................................22

5.4 Monitoring ..........................................................................................................................23

5.5 Function Switch ..................................................................................................................24

5.6 About ..................................................................................................................................25

6 Auxiliary Function .................................................................................................................25

6.1 Cut ......................................................................................................................................25

6.2 WeldSeam Clean .................................................................................................................29

6.3 Remote Clean .....................................................................................................................33

7 Option Table of Welding Nozzle and Wire Feeding Nozzle ...................................................36

8 Troubleshooting Table ...........................................................................................................37

9 Reference Table of Welding Process ......................................................................................38

1 Laser Processing Head

1.1 QBH Connection

 Remove the dust cover of optical fiber and check whether the protective cap of fiber crystal
head is locked.Clean the optical fiber head with a dust-free cotton swab and absolute
ethanol to ensure that the optical fiber section is clean and dust-free.

 Place the welding head horizontally.

 Align the red point at the end of the QBH interface to the red point of the handwheel.
 Remove QBH dustproof cover.
 Align the red mark of male fiber end to red mark on female QBH of cutting head when you
insert the fiber end straightly to bottom of QBH interface of cutting head.
 Turn the QBH handwheel clockwise. It is in place when you hear the "Da" voice, then pull
the handwheel up and turn clockwise to end
1.2 Dismantling and Mounting of Cover Glass

1.2.1 Dismantling and Mounting of Middle Cover Glass

 Unscrew the bolt of focus lens holder in dust free environment to take out focus lens holder.
The openings shall besealed with textured paper to prevent dust
 Take out seal ring and cover glass by lens tool for cleaning or replacement.

1.2.2 Dismantling and Mounting of Bottom Cover Glass

 Manually loosen the screw of the cover glass to pull out the holder. The openings shall be
sealed with texturedpaper to prevent dust. This cover glass is the outer one of double cover
glasses.
 Remove the seal ring and carefully take out the cover glass for cleaning or replacement.

1.3 Daily Inspection

 Check whether the cover glass is polluted before daily use and replace it if necessary.
 Check whether the QBH connector is loose before daily use and ensure that the lock does
not shake before it canwork normally.
 Check whether the copper nozzle is blocked and whether it is conductive between copper
nozzle and safety lockbefore daily use. If it is blocked and the welding slag cannot be
removed, replace the copper nozzle. If theconductivity is poor, replace the copper nozzle.
 Check whether there is water leakage to wiring before daily use.
 Pay attention to the right connection of gas (middle) and water (both sides, one inlet and
one outlet) as shownbelow. Both gas and water pipes are φ 6mm.
2 Controller
2.1 Overall Wiring

Power supply of controller: one 24V power supply and one ±15V power supply are included in the
standard kit and they shall be connected as below
2 2 Wiring from HMI Panel to Controller

Connect HMI panel to controller by 24V power cable and signal cable as below.

2.2 Wiring from Laser to Controller

 Enable +: external enable input +. Enable -: external enable input GND. (generally PNP)
 PWM +: external PWM input +. PWM -: external PWM input GND. (Laser pulse width
modulation)
 DA+: external analog input +. DA -: AGND (laser power control)
 Fault +: fault output +. Fault -: fault output -. (to receive fault signal from laser)
 The exact wiring to laser shall be object to laser manufacturers.

2 .4 Wiring from Laser Processing Head to Controller

  DB15 connector of handheld laser welding head is to be plugged in controller as above.
 Single core cable as safety lock is to be connected between controller and alligator clamp.

2.5 Wiring from Power Supply to Controller

15V Power Supply 24V Power Supply

15V Power Supply to Controller 24V Power Supply to Controller

15V Power Supply

15V Power Supply Controller

V1 15v+

V2 15v-

Com gnd
24V Power Supply

24v power supply Controller

V+ 24v+

v- Gnd

Earthing Pe

Pe (pin 7 ) to be grounded

2. 6 Wiring from Gas Valve and Chiller to Controller

 Gas Valve ±: control switch of protection gas. The gas valve + (red line of solenoid valve in
the figure) is 24V + relayoutput. There is no need to use additional relay control. The gas
valve - (black line of solenoid valve in the figure)is 0V. The solenoid valve from customer gets
air inlet and air outlet. It must be clearly distinguished beforeconnecting the air pipe.

 Water Cooling Alarm ±: switch signals. If there is no water pressure alarm interface of chiller,
the positive andnegative interfaces can be directly shorted.

2.7 Wiring from Wire Feeder to Controller

 DC24V± Power Supply
Ss1 Wire Feeding +
SS2 Wire Feeding –
Wire feeding starts/stops when the power is on/off

3 Wire Feeder

3.1 Installation of Wire Feeder

The two 24V input wires of the wire feeder shall be connected to the 24V power supply or switching
power supplyof the laser welding machine (power supply power≥ 80W). The two signal wires SS1
and SS2 shall be connectedto the relevant positions on the handheld welding controller.

 Hang the welding wire reel on the reel shaft in the wire feeder.
Select the groove diameter of the wire feeding wheel. Loosen the tension regulator of the wire
feeding machine(as shown above) and pass the welding wire through the wire leading nozzle. Align it
with the groove of the wirefeeding wheel and tighten the tension regulator