BW101-GS SERIES

2KW Handheld Laser Processing Head (Single Galvo Type)- User Manual
 BW101-GS SERIES 2KW Handheld Laser Processing Head-User Manual

Thank you for choosing our product!

This manual describes the installation and commissioning of laser head in details so that you can

use this product quickly. You can consult us directly for more details.

Due to the continuous updating of product functions, the product you receive may differ from the

introduction in this manual in some aspects.

We reserve all rights in this document including the issued patents and other registered

commercial ownership related to this document. It is strictly prohibited to use this document in an

improper way especially to copy and disseminate it to third parties.

If you find any errors in this document, please inform us as soon as possible. The data contained in

this manual is only used to describe the product and shall not be regarded as a statement of

security interest.

For the benefit of our customers, we will constantly try to ensure that the products we develop

comply with the latest technology.

RayTools AG

Email: [email protected]

Website: www.raytools.ch

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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

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may not be fully protected by the ground wire due to function fault. These parts may have low

voltage. When installing electrical equipment, please pay attention to taking anti electric shock

measures 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 IEC

60825-1.

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.

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 BW101-GS SERIES 2KW Handheld Laser Processing Head -User Manual

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

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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.

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⚫ 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 be

sealed with textured paper to prevent dust.

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⚫ 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 textured

paper 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 can
work normally.

⚫ Check whether the copper nozzle is blocked and whether it is conductive between copper nozzle and safety lock
before daily use. If it is blocked and the welding slag cannot be removed, replace the copper nozzle. If the
conductivity 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 shown
below. Both gas and water pipes are φ 6mm.

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2 Controller

2.1 Overall Wiring

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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

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2.2 Wiring from HMI Panel to Controller

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

2.3 Wiring from Laser to Controller

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⚫ 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

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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

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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 + relay

output. 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 before

connecting the air pipe.

⚫ Water Cooling Alarm ±: switch signals. If there is no water pressure alarm interface of chiller, the positive and

negative interfaces can be directly shorted.

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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

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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 supply

of the laser welding machine (power supply power ≥ 80W). The two signal wires SS1 and SS2 shall be connected

to the relevant positions on the handheld welding controller.

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⚫ 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 wire

feeding wheel and tighten the tension regulator.

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⚫ Assemble the wire feeding mechanism and lead the wire out of it by pressing “Manual Feeding”. Fix the wire

feeding mechanism onto the wire feeder and tighten it by bolt.

⚫ Adjust the tension of tension regulator to enable the stable wire feeding. Deliver the wire to wire feeding nozzle

by manual feeding.

3.2 Operation of Wire Feeder

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3.2.1 Button and Indicators

⚫ Set: function switching. Related parameters could be modified by “+” and “-”.

⚫ Run: press this key to confirm when the setting is completed.

⚫ Manual Feeding: press and hold the key to feed wire continuously untill it is released.

⚫ Manual Pumpback: press and hold the key to pull back wire continuously until it is released.

⚫ Simulation Run: press and hold the key to feed wire continuously as per set parameter. It will pull back wire

continuously as per set parameter if it is released.

⚫ Feeding Speed: it lights up when it is selected. The wire feeding speed can be adjusted by "+" "-" key when it is on.

⚫ Delay Feeding: it lights up when it is selected. The wire feeding delay can be adjusted by "+" "-" key when it is on.

⚫ Filling Distance: it lights up when it is selected. The wire filling distance can be adjusted by "+" "-" key when it is on.

⚫ Pumpback Distance: it lights up when it is selected. The pumpback distance can be adjusted by "+" "-" key when it

is on.

⚫ Running: it glitters under normal working and continuously on under setting.

⚫ Setting: it glitters under setting status.

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⚫ Display Screen: to show parameters while setting and show wire feeding speed while running.

3.2.2 Parameter Setting

Data Range Unit Recommended Value

Delay Feeding 0-999 ms 002

Feeding Speed 0-99.9 mm/s 015

Filling Distance 0-999 mm 07.0

Pumpback Distance 0-99.9 mm 09.0

⚫ Remarks: After the parameter is changed, the last shutdown data is still defaulted when it is restarted. It can

help customer resume the last job quickly. If you want to restore the factory setting after the parameter is

changed, you can press the "+" - "key for 3 seconds at the same time. After 3 seconds, the screen displays" 888

", which means that the factory setting is restored.

3.2.3 Technical Data

Model RT-HWS-DM80A

P/N 3150140008

Voltage DC24V（≥80W）

Phase Single phase

Motor DC PM

Rotation 1200rpm

Wire Size 0.8/1.0/1.2/1.6mm

Feeding Speed 0.1-18M/min

Size 440*250*580MM

Weight 15kg

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3.3 Troubleshooting of Wire Feeder

S/N Faults Reason Solution

24V power cable breaks Change power cable
1 Power LED not ON
Power switch fails Change power switch
Poor welding / disconnection of internal Replace the plug and check the
wire inside switch plug of welding head connecting wire
Wire feeding motor fails Replace the wire feeding motor
Out of wire Replace the welding wire disc
Motor plug loose on motion card Replug
Wire feeding fails by Welding wire knotted Loosen the tension regulator and
2 operating welding rewind the wire
head Wire feeding tube knotted Straighten out the wire feeding tube
The welding wire is blocked at the outlet of Adjust the wire guide tube to align
the wire feeder with the outlet of the wire feeder
Wire feeding tube blocked Replace the wire feeding tube
Insufficient tension Loosen the welding wire disc brake
Control board fails Replace the control board
The welding wire is knotted in the welding Remove the knotted part and rewind
wire reel the wire
Mismatch or wear of wire feeding tube Replace wire feeding tube
Improper wire feeding reel Replace wire feeding reel
Incorrect tension by tension regulator Modify the tension
Unstable wire
Wire feeding motor fails Replace thr wire feeding motor
3 feeding speed and
Drive card fails Replace drive card
poor wire feeding
Jam of wire feeding tube eplace or clean the wire feeding tube
The bending angle of wire feeding tube is Put the wire feedign tube straight as
less than 30 degrees much as possible
Deformation of wire feeding tube after Replace the wire feeding tube
extrusion

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3.4 Daily Maintenance of Wire Feeder

3.4.1 Daily Maintenance

⚫ When not in use, the wire feeder should be shut down and placed in a cool, dry place away from dust.

⚫ Do not put other objects on the wire feeder to avoid damage.

⚫ Before installing a new welding wire reel, blow inside of feeding tube with compressed air to remove the

impurities in the wire feeding tube.

⚫ The wire guide tube shall be kept smooth without extrusion, deformation and folding.

⚫ Regularly clean the dust in the machine and check the smooth rotation and noise of the motor.

3.4.2 Cautions

Operation Environment

⚫ This machine is for indoor use and its protection grade is IP2X. Do not use it where water drops and raindrops are

available.

⚫ Please use it at ambient temperature of - 10 ℃ to 40 ℃.

⚫ Do not locate it on the table with strong vibration or great impact.

Use Attention

⚫ When installing the welding wire disc or inserting the welding wire into the wire guide tube, do not wear gloves to

avoid winding accidents caused by the rotation of rotating parts.

⚫ Please confirm the weight of the welding wire reel. The weight of the welding wire shall not be greater than 20kg.

Otherwise the wire reel may fall off.

⚫ During welding, please close the right side plate otherwise electric shock or winding accident may occur due to

the rotation.

⚫ Before welding, please confirm whether the disc shaft end cover is tightened otherwise the welding wire disc may

fall off due to the inclination of the welding wire disc.

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3.5 Supplementary Regulation of Auto Wire Feeding

⚫ Turn on the wire feeding on HMI panel.

⚫ Adjust the power to 0W.

⚫ Press and hold the trigger button of head, adjust the wire feeding speed at low speed (feeding speed 015-025).

According to the tightness of wire feeding, turn the two adjustable rotation sleeves of tension regulator until the

wire disc rotates at a uniform speed (it must be ensured that the wire feeding tube is smooth without bending).

⚫ Wire feeding speed and other parameters are to be manually regulated as per process performance.

4 Connection of Wire Feeding Mechanism to Laser Processing Head

① M2.5*5 screw is used to fix the wire feeding connecting block onto the handheld processing head.

② Tighten the wire feeding adapter block with M4 * 12 screw. Control the wire feeding angle by adjusting the angle

of the adapter block.

③ The feeding distance can be adjusted by loosening the screw.

④ Lock the wire feeding hose with M5 * 4 jacking screw.

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⚫ Disassemble the wire feeding nozzle.

⚫ Press the manual feeding button on the panel to deliver wire out.

⚫ Pass the welding wire through the wire feeding nozzle and reinstall the wire feeding nozzle back to the wire

feeding assembly.

⚫ Fix the wire feeding assembly on the laser head.

⚫ Adjust the wire feeding angle to align the laser beam with the welding wire.

1. Welding wire on installed wire reel shall not be knotted otherwise the wire must be straightened out.

2. Determine the welding focus, align the welding wire center with laser wobbling center and lock all screws.

5 HMI

5.1 Home

⚫ : entry of multifunction “Weld/Cut/WeldSeam Clean/Remote Clean”.

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⚫ Laser Power: laser output power from 0 to 2000W.

⚫ Pattern: SpotWeld or Line Wobble Weld.

⚫ Laser Freq: number of laser pulses emitted by the laser per second.

⚫ Wobble Freq: 0-200Hz.

⚫ PWM: the ratio of pulse duration to pulse cycle, 0-100%.

⚫ Wobble Size: to adjust the line spot width 0-5mm while wobble welding.

⚫ Laser: turn on/off laser.

⚫ Wire Feeding: turn on/off wire feeding.

⚫ ScaleWeld: turn on when spot-welding is required.

⚫ Gas-Manual: continuous gas blow for independent test.

⚫ Process No: 16 processes in total including full parameters could be saved for various applications.

⚫ Safety Lock: show status of safety lock. Green indicates conduction and grey indicates non-conduction.

⚫ Setting: enter submenu of basic setting or galvo setting to modify parameters.

⚫ Process: enter submenu of process to modify parameters or select process for running.

⚫ Monitoring: show red if alert occurs. Enter the submenu to check I/O status and faults.

⚫ : lock HMI in order to prevent other people from touching the screen by mistake in case of beam off or beam

on when the operator is welding or debugging. It is used to secure the safety of the operator. HMI could be locked

or unlocked by clicking the lock mark.

⚫ : language selection.

5.2 Setting
5.2.1 Basic Setting

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⚫ Gas in Advance: gas blow duration from laser on to beam shooting.

⚫ Gas Delay: gas blow duration after laser off.

⚫ Beam Off Delay: laser shooting duration after laser off. It is used to weld off welding wires.

⚫ On Power: starting power of ascent process. It is to be adjusted as per ascent duration.

⚫ Off Power: ending power of descent process. It is to be adjusted as per descent duration.

⚫ Ascent: duration from on power to set power after beam on.

⚫ Descent: duration from set power to off power after beam off.

⚫ Max Power: set as per the rating power of exact laser. The limit of max power is 2000W.

⚫ Alarm Signal: PNP 24V effective.

⚫ NozzleBreak Duration: duration of beam shooting when the nozzle temporarily is not in contact with workpiece.

The beam will be off if the non-contact duration is longer than NozzleBreak Duration.

⚫ ScaleWeld Duration: adjust the beam shooting duration as per spot welding application.

⚫ ScaleWeld Interval: beam off interval while spot welding.

5.2.2 Galvo Setting

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⚫ Wobble: turn on/off wobble function of red beam. It is only used for commissioning of red beam.

⚫ Pattern: line or spot.

⚫ Wobble Size: 0-5mm of line range.

⚫ Wobble Freq: 0-200Hz adjustable as per process.

⚫ X Center Offset: center alignment. Beam alignment is basically to be done before ex-works and a further slight

adjustment to align with welding wire center could be done if it is required for wire feeding. Nonsense adjustment

is prohibited.

⚫ X Magn: it is to be debugged before ex-works and a further slight adjustment could be done if it is required.

Nonsense adjustment is prohibited.

5.3 Process

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⚫ : to switch between wire feeding and non-wire feeding.

⚫ Process No: running process number. Each process parameter could be modified and saved.

⚫ Import: to import selected process number for operation.

⚫ Shutdown-save: to save modified process by clicking this button.

⚫ Restore: restore the default process by clicking this button.

5.4 Monitoring

⚫ I0.0 WeldingHead Switch: trigger button status of head.

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⚫ I0.3 Safety Lock: indicate if head is in contact with workpiece. Laser shooting is allowed when in contact.

⚫ I3.0 Galvo IO: input status.

⚫ Q0.2 LaserEnable: output status of laser enable signal.

⚫ Q0.4 Gas Valve: output status of gas valve.

⚫ Q1.1 Wire Feeding: feeding signal of wire feeder.

⚫ Laser: green-normal, red-abnormal.

⚫ Chiller: green-normal, red-abnormal.

⚫ HMI Panel-LaserCard Comm: communication status from HMI panel to laser control card. green-normal, red-

abnormal.

⚫ HMI Panel-GalvoCard Comm: communication status from HMI panel to galvo motion card. green-normal, red-

abnormal.

5.5 Function Switch

⚫ Enter the multifunction switch page by clicking the logo in “Home” page.

⚫ Weld: show assembly replacement diagram. Nozzle option could be selected by clicking “next”.

⚫ Cut: show assembly replacement diagram.

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⚫ WeldSeam Clean: show assembly replacement diagram.

⚫ Remote Clean: show assembly replacement diagram.

⚫ Function Switch: select required function and click “Function Switch” to enter sub-interface of selected function.

⚫ MFR Setting: 1-key recovery of default factory setting. It will clean all customized parameters. Keep caution.

⚫ About: show hardware version like HMI panel, laser control card and galvo motion card.

5.6 About

Each generation of products from us has corresponding supporting versions for control and traceability. This will

correspond to the versions of HMI panel, laser control card and galvo motion card. Version upgrade shall be subject to

our confirmation.

6 Auxiliary Function

6.1 Cut
6.1.1 Configuration

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⚫ Handheld laser cutting is one of 4-in-1 function.

⚫ Remove wire feeding mechanism & welding nozzle and mount the cutting nozzle to extension tube.

⚫ Select CUT function and modify process parameters as per process requirements.

6.1.2 Function and Feature

Function:

The laser beam shoots on the surface of the workpiece to make the workpiece reach the melting or boiling point. At

the same time, the high-pressure gas coaxial with the beam blows away the molten or gasified metal. With the

movement of the relative position between the beam and the workpiece, the material will finally form a slit, so as to

achieve the purpose of cutting. Hand held cutting is commonly used in sheet metal cutting, hardware, electrical

appliances, sheet metal manufacturing and other industries.

Feature:

Friendly, flexible and easy operation.

6.1.3 Software Setting

Home:

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⚫ Laser Power: laser output power from 0 to 2000W.

⚫ Laser Freq: number of laser pulses emitted by the laser per second.

⚫ PWM: the ratio of pulse duration to pulse cycle, 0-100%.

⚫ Laser: turn on/off laser.

⚫ Gas-Manual: continuous gas blow for independent test.

⚫ Process No: 16 processes in total including full parameters could be saved for various applications.

⚫ Safety Lock: show status of safety lock. Green indicates conduction and grey indicates non-conduction.

⚫ Setting: enter submenu of basic setting or galvo setting to modify parameters.

⚫ Process: enter submenu of process to modify parameters or select process for running.

⚫ Monitoring: show red if alert occurs. Enter the submenu to check I/O status and faults.

⚫ : lock HMI in order to prevent other people from touching the screen by mistake in case of beam off or beam

on when the operator is cutting or debugging. It is used to secure the safety of the operator. HMI could be locked

or unlocked by clicking the lock mark.

Basic Setting

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⚫ Gas in Advance: gas blow duration from laser on to beam shooting.

⚫ Gas Delay: gas blow duration after laser off.

⚫ Beam Off Delay: laser shooting duration after laser off. It is used to melt possible adhesion or burr.

⚫ Max Power: set as per the rating power of exact laser. The limit of max power is 2000W.

⚫ Alarm Signal: PNP 24V effective.

⚫ NozzleBreak Duration: duration of beam shooting when the nozzle temporarily is not in contact with workpiece.

The beam will be off if the non-contact duration is longer than NozzleBreak Duration.

Galvo Setting

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⚫ X Center Offset: center alignment. Beam alignment is basically to be done before ex-works and a further slight

adjustment to align with cutting object center could be done if it is required for cutting. Nonsense adjustment is

prohibited.

⚫ X Magn: it is to be debugged before ex-works and a further slight adjustment could be done if it is required.

Nonsense adjustment is prohibited.

6.2 WeldSeam Clean

6.2.1 Configuration

⚫ Handheld weld seam laser cleaning is one of 4-in-1 function.

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⚫ Remove wire feeding mechanism, welding nozzle and extension tube.

⚫ Mount the clean tube.

⚫ Select WELD SEAM CLEAN function and modify process parameters as per process requirements.

6.2.2 Function and Feature

Function

⚫ Remove the paint and coatings of metal or glass.

⚫ Fast removing of rust and various oxides.

⚫ Remove grease, resin, glue, dust, stains and production residues.

⚫ Remove paint, rust and oil before welding or bonding and treatment of oxides and residues after welding.

⚫ Mold cleaning such as tire mold, electronic mold and food mold.

⚫ Oxide treatment, paint removal and rust removal in the production or maintenance of aerospace weapons and

ships.

Feature

⚫ Low power, small scan range, flexible and friendly operation.

6.2.3 Software Setting

Home:

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⚫ Laser Power: laser output power from 0 to 2000W.

⚫ Laser Freq: number of laser pulses emitted by the laser per second.

⚫ Wobble Freq: 0-150Hz.

⚫ PWM: the ratio of pulse duration to pulse cycle, 0-100%.

⚫ Clean Width: to adjust the line spot width 0-10mm while cleaning.

⚫ Laser: turn on/off laser.

⚫ Gas-Manual: continuous gas blow for independent test.

⚫ Process No: 16 processes in total including full parameters could be saved for various applications.

⚫ Safety Lock: show status of safety lock. Green indicates conduction and grey indicates non-conduction.

⚫ Setting: enter submenu of basic setting or galvo setting to modify parameters.

⚫ Process: enter submenu of process to modify parameters or select process for running.

⚫ Monitoring: show red if alert occurs. Enter the submenu to check I/O status and faults.

⚫ : lock HMI in order to prevent other people from touching the screen by mistake in case of beam off or beam

on when the operator is cleaning or debugging. It is used to secure the safety of the operator. HMI could be locked

or unlocked by clicking the lock mark.

Basic Setting
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⚫ Gas in Advance: gas blow duration from laser on to beam shooting.

⚫ Gas Delay: gas blow duration after laser off.

⚫ Max Power: set as per the rating power of exact laser. The limit of max power is 2000W.

⚫ Alarm Signal: PNP 24V effective.

⚫ NozzleBreak Duration: duration of beam shooting when the nozzle temporarily is not in contact with workpiece.

The beam will be off if the non-contact duration is longer than NozzleBreak Duration.

Galvo Setting

⚫ Wobble: turn on/off wobble function of red beam. It is only used for commissioning of red beam.
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⚫ Pattern: only line available for cleaning.

⚫ Wobble Size: 0-10mm of line range.

⚫ Wobble Freq: 0-150Hz adjustable as per process.

⚫ X Center Offset: center alignment. Beam alignment is basically to be done before ex-works and a further slight

adjustment to align with cleaning objects could be done if it is required for cleaning. Nonsense adjustment is

prohibited.

⚫ X Magn: it is to be debugged before ex-works and a further slight adjustment could be done if it is required.

Nonsense adjustment is prohibited.

6.3 Remote Clean

6.3.1 Configuration

6.3.2 Function and Feature

Function

⚫ Remove the paint and coatings of metal or glass.

⚫ Fast removing of rust and various oxides.

⚫ Remove grease, resin, glue, dust, stains and production residues.

⚫ Remove paint, rust and oil before welding or bonding and treatment of oxides and residues after welding.
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⚫ Mold cleaning such as tire mold, electronic mold and food mold.

⚫ Oxide treatment, paint removal and rust removal in the production or maintenance of aerospace weapons and

ships.

Feature

⚫ Low power, medium scan range, non-contact with workpiece, flexible and friendly operation.

6.3.3 Software Setting

Home:

⚫ Laser Power: laser output power from 0 to 2000W.

⚫ Laser Freq: number of laser pulses emitted by the laser per second.

⚫ Wobble Freq: 0-100Hz.

⚫ PWM: the ratio of pulse duration to pulse cycle, 0-100%.

⚫ Clean Width: to adjust the line spot width 0-80mm while cleaning.

⚫ Laser: turn on/off laser.

⚫ Gas-Manual: continuous gas blow for independent test.

⚫ Process No: 16 processes in total including full parameters could be saved for various applications.

⚫ Setting: enter submenu of basic setting or galvo setting to modify parameters.

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⚫ Process: enter submenu of process to modify parameters or select process for running.

⚫ Monitoring: show red if alert occurs. Enter the submenu to check I/O status and faults.

⚫ : lock HMI in order to prevent other people from touching the screen by mistake in case of beam off or beam

on when the operator is cleaning or debugging. It is used to secure the safety of the operator. HMI could be locked

or unlocked by clicking the lock mark.

Basic Setting

⚫ Gas in Advance: gas blow duration from laser on to beam shooting.

⚫ Gas Delay: gas blow duration after laser off.

⚫ Max Power: set as per the rating power of exact laser. The limit of max power is 2000W.

⚫ Alarm Signal: PNP 24V effective.

⚫ Safety Lock Interval: the beam shooting will be triggered when the trigger button of head is pressed twice. Single

pressing will not trigger beam shooting as safety protection. The interval between 2-time pressing is safety lock

interval. The beam shooting will not be triggered if it is more than interval.

Galvo Setting

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⚫ Wobble: turn on/off wobble function of red beam. It is only used for commissioning of red beam.

⚫ Wobble Size: 0-80mm of line range.

⚫ Wobble Freq: 0-100Hz adjustable as per process.

⚫ X Center Offset: center alignment. Beam alignment is basically to be done before ex-works and a further slight

adjustment to align with cleaning objects could be done if it is required for cleaning. Nonsense adjustment is

prohibited.

⚫ X Magn: it is to be debugged before ex-works and a further slight adjustment could be done if it is required.

Nonsense adjustment is prohibited.

7 Option Table of Welding Nozzle and Wire Feeding Nozzle

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8 Troubleshooting Table

Faults Conclusion Solution

Communication alarm of
Wiring Check wiring and restart in 2 mins.
HMI panel

1. Restart.
Beam shooting not coming
Laser alarm 2. Check wiring.
out
3. Check if laser is encrypted.

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4. Check QBH for firm lock status if fiber interface interlock is under

alarm.

5. Replace QBH if alarm stays intermittently or continuously.

1. If the red beam indication is normal, wobble in red beam to see

whether it is centered.

NO laser 2. If it can wobble normally, check the process parameter setting.

alarm 3. Check whether the beam is locked or the focus is wrong.

4. Check if optics contamination occurs in head or laser can work

independently.

Wiring Check wiring as per Clause 3. Independent power supply is suggested.

Wire feeder not working
Installation Check installation from wire feeder to wire feeding mechanism.

9 Reference Table of Welding Process

Welding Process (with wire feeding)

Laser CW fiber laser Power 2000W CL: 60mm/FL: 150mm

Fiber Core 50μM Gas N2/Ar Gas 20L/min Gas Purity ≧99.99

Flow

MATL Thickness Power PWM Frequency Focus Wobble Wobble Feeding Melting

Width Frequency Speed/Wire Dia. Depth

SS (by SS 1.0MM 600W 100% 1000HZ -1.5 2.0MM 80HZ 14mm/s, 0.8mm 1.0MM

wire) 1.5MM 800W 100% 1000HZ -2 2.0MM 80HZ 14mm/s, 1.0mm 1.5MM

2.0MM 1000W 100% 1000HZ -2 2.0MM 70HZ 12mm/s, 1.0mm 2.0MM

3.0MM 1500W 100% 1000HZ -2 2.5MM 60HZ 10mm/s, 1.2mm 2.5MM

4.0MM 2000W 100% 1000HZ -3 3.0MM 50HZ 6mm/s, 1.6mm 3.0MM

AL-5 series 1.0MM 600W 100% 1000HZ 0 2.0MM 70HZ 14mm/s, 1.0mm 1.0MM

(by 2.0MM 1000W 100% 1000HZ 0 2.5MM 70HZ 12mm/s, 1.2mm 2.0MM
Aluminum 3.0MM 1500W 100% 1000HZ -1 2.5MM 60HZ 10mm/s, 1.2mm 2.5MM

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magnesium 4.0MM 2000W 100% 1000HZ -2 3.0MM 60HZ 10mm/s, 1.6mm 3.0MM

wire)

MS (by SS 1.0MM 600W 100% 1000HZ +2 2.0MM 80HZ 14mm/s, 0.8mm 1.0MM

wire) 2.0MM 1000W 100% 1000HZ +2 2.0MM 80HZ 14mm/s, 1.0mm 2.0MM

3.0MM 1500W 100% 1000HZ +2 2.5MM 60HZ 10mm/s, 1.2mm 2.5MM

4.0MM 2000W 100% 1000HZ +2 3.0MM 50HZ 10mm/s, 1.6mm 3.0MM

Welding Process (without wire feeding)

Laser CW fiber laser Power 2000W CL: 60mm/FL: 150mm

Fiber Core 50μM Gas N2/Ar Gas Flow 20L/min Gas Purity ≧99.99

MATL Thickness Power PWM Frequency Focus Wobble Wobble Feeding Melting

Width Frequency Speed Depth

SS 1.0MM 500W 100% 1000HZ 0 1.5MM 100HZ 16mm/s 1.0MM

1.5MM 700W 100% 1000HZ 0 1.8MM 100HZ 16mm/s 1.5MM

2.0MM 1000W 100% 1000HZ 0 2.0MM 100HZ 14mm/s 2.0MM

2.5MM 1200W 100% 1000HZ 0 2.0MM 80HZ 14mm/s 2.5MM

3.0MM 1500W 100% 1000HZ -1.5 2.5MM 60HZ 14mm/s 3.0MM

4.0MM 2000W 100% 1000HZ -2 3.0MM 60HZ 10mm/s 3.5MM

AL-5 series 1.0MM 500W 100% 1000HZ 0 1.5MM 100HZ 16mm/s 1.0MM

2.0MM 1000W 100% 1000HZ 0 1.8MM 100HZ 16mm/s 2.0MM

3.0MM 1500W 100% 1000HZ -1 2.0MM 70HZ 14mm/s 2.5MM

4.0MM 2000W 100% 1000HZ -2 2.0MM 70HZ 14mm/s 3.0MM

MS 1.0MM 500W 100% 1000HZ 0 1.5MM 100HZ 16mm/s 1.0MM

2.0MM 1000W 100% 1000HZ 0 2.0MM 100HZ 16mm/s 2.0MM

3.0MM 1500W 100% 1000HZ +1.5 2.0MM 80HZ 14mm/s 2.5MM

4.0MM 2000W 100% 1000HZ +2 2.0MM 50HZ 12mm/s 3.0MM

Remark: the parameters above are only for reference due to difference of power density and beam quality from various brand lasers.

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