lwi iv flexx - vision lasertechnik · type: lwi 4 flexx version: open workstation laser class 4 we...

O p e r a t i n g I n s t r u c t i o n s

LWI IV Flexx

Version 07.08.2006

Operating Instructions Vision Laser LWI IV Page 1

Content 1.0 Important information.................................................................................................- 3 -

1.1 Manufacturer..........................................................................................................- 3 -

1.2 Target audience.....................................................................................................- 3 -

1.3 Importance of reading ............................................................................................- 3 -

1.4 If you have a problem ............................................................................................- 3 -

1.5 This manual ...........................................................................................................- 3 -

1.5.1 Validity.............................................................................................................- 3 -

1.5.2 Content............................................................................................................- 3 -

1.5.3 Location...........................................................................................................- 3 -

2.0 Safety ........................................................................................................................- 4 -

2.1 General safety advice ............................................................................................- 4 -

2.2 Safety signs ...........................................................................................................- 6 -

2.2.1 Meaning and location of the safety signs.........................................................- 6 -

3.0 Product specification .................................................................................................- 7 -

3.1 Type label ..............................................................................................................- 7 -

3.2 Intended use ..........................................................................................................- 7 -

3.3 Limit specification...................................................................................................- 7 -

3.4 Declaration of conformity .......................................................................................- 8 -

3.5 Technical data........................................................................................................- 9 -

4.0 Arrangement and functions of all parts ....................................................................- 10 -

4.1 Laser head...........................................................................................................- 10 -

4.1.1 The Stereo microscope .................................................................................- 10 -

4.1.2 The display 1 .................................................................................................- 10 -

4.1.3 The shielding gas outlet, illumination and focussing lens ..............................- 11 -

4.2 Supply unit ...........................................................................................................- 11 -

4.2.1 Front with display 2 .......................................................................................- 12 -

4.2.2 The back side panel ......................................................................................- 12 -

4.3 The standard foot paddle .....................................................................................- 13 -

4.4 The multi functional foot paddle (option) ..............................................................- 13 -

5.0 Installation ...............................................................................................................- 14 -

5.1 Installation site .....................................................................................................- 14 -

5.2 Electrical connections and external interlock .......................................................- 14 -

6.0 Operation.................................................................................................................- 14 -


6.1 Adjusting the microscope.....................................................................................- 14 -

6.2 The shielding gas nozzle .....................................................................................- 15 -

6.3 Setting the laser parameters................................................................................- 15 -

6.3.1 Display 1........................................................................................................- 16 -

6.3.2 Display 2........................................................................................................- 18 -

6.3.3 Classic-Mode / PULSFILL-Mode / PWM-Mode .............................................- 18 -

6.4 Storing parameters ..............................................................................................- 20 -

7.0 Welding ...................................................................................................................- 20 -

8.0 Service, maintenance and troubleshooting..............................................................- 21 -

8.1 Regular service....................................................................................................- 21 -

8.2 Maintenance ........................................................................................................- 21 -

8.2.1 Changing the flash lamp................................................................................- 22 -

8.2.3 Changing the protection glass .......................................................................- 24 -

8.2.4 Changing and refill the cooling water ............................................................- 24 -

8.3 Adjust the welding spot congruence with the cross hair.......................................- 24 -

8.4 Error messages and trouble shooting ..................................................................- 25 -

9.0 Appendix .................................................................................................................- 26 -


1.0 Important information

1.1 Manufacturer

Vision GmbH Phone: +49 5108 – 6446-0

Lügensteinweg 27 Fax: +49 5108 – 6446-11

D-30890 Göxe, Germany e-mail: [email protected]

1.2 Target audience

This Manual is for the technically qualified user of the Vision Laser Welder LWI IV who has been or going to be trained by Vision or by one of Visions authorized dealers in the professional and safe operation of the device.

1.3 Importance of reading

For safety reasons, the operator of the Laser welder is required to read this manual thoroughly before starting work with the machine. Please read the chapter 2.0 Safety! If you have any doubts or queries, please ask ether your local Vision dealer or Vision GmbH directly.

1.4 If you have a problem

If you come across a problem which cannot be solved by using this manual, please ask your authorized Vision dealer. A team of qualified staff will help you. If you contact Vision or an authorized Vision dealer it is necessary to give a precise and detailed description of the problem. Do not try to repair the laser without supervision of Vision or your authorized Vision dealer.

Warning! High Voltage inside the Laser and inside the supply unit!

Do not open any cover of the laser or its supply unit without supervision of Vision or one of Visions authorized dealer.

1.5 This manual

1.5.1 Validity

This Manual is valid for the following Product:

Model: Vision Welding Laser LWI IV

Year: 2005

1.5.2 Content

This Manual contains information for the set up, operation and maintenance of the laser welder. It should help you to operate the laser safely, efficiently and within its intended use.

1.5.3 Location

Please keep the Manual at the machine. It has to be in reach of the operator at all times.

mailto:[email protected]


2.0 Safety

2.1 General safety advice

The laser produces an intense, highly directional beam of light. If directed, reflected, or focused upon an object, laser light will be partially absorbed, raising the temperature of the surface and/or the interior of the object, potentially causing an alteration or deformation of the material. These properties which have been applied to laser surgery and materials processing can also cause tissue damage. The LWI IV is a class 4 device. There are a variety of laser safety standards in different countries. In the USA for example the most important and most often quoted is the American National Standards Institute's Z136 series of laser safety standards.

ANSI Z136.1 specifies that any facility using Class 3b or Class 4 lasers or laser systems should designate a Laser Safety Officer (LSO) to oversee safety for all operational, maintenance, and servicing situations. This person should have the authority and responsibility to monitor and enforce the control of laser hazards. This person is also responsible for the evaluation of laser hazards and the establishment of appropriate control measures.

This machine has left Vision in perfect condition. It has been tested thoroughly; it was designed and built according to national and international safety regulations. If misused or used by unqualified persons, the laser is dangerous and can cause serious injuries to any person at or near the Laser. The Laser light is invisible! Although you can’t see the light it is very dangerous for the eye. All persons working in the same room as the laser welder must wear specified safety goggles.

The laser welder LWI IV is classified as a tool for manual work. The work piece can be placed manually under the microscope and either moved by hand or by the joystick if integrated into the Vision Workstation. There is a risk of the skin being burned by laser radiation. If the skin is touched by a laser pulse it can be painful but it is not especially dangerous. The burn will be limited to a very small area. Please take all necessary precautions against any skin damage and if necessary do consult a doctor. The welding process produces heat at the work piece! The longer you work on one piece the hotter it will get, be careful when handling and allow time for it to cool down. The laser light can be reflected by jewellery, watches, etc. Please remove all metal from your hands before you start working.

During the welding process fume, smoke and other harmful gases are produced in large quantities. To prevent injury and or poisoning of the operator and people working near you, you must use a fume extractor with a filter to keep the air in your plant free of any harmful smoke. Be aware that the extractor must be sufficient for hot fumes, sparks and melted metal. There is a high risk of the filter starting to burn even after you have stopped working and left the plant.


Summary of the most important safety advices:

Ø Read this manual and ensure that you understand this manual.

Ø Ensure that laser operators are properly trained on laser and eye safety.

Ø Never wear rings, watches or bracelets when operating the laser to avoid unwanted

reflections.

Ø Name a Laser Safety Officer and ensure that you comply with your national safety

regulations. Contact the responsible authorities for further advice.

Ø Wear protective eyewear adapted to the power and wavelength of the laser !

Remember, the temporary discomfort of wearing protective eyewear outweighs the

discomfort from permanent eye damage. All persons near the laser must wear certified

protective eyewear at all times during laser operation.

Ø Position the work piece with care. Make sure that your hands have a fixed position

before you start pulsing the laser.

Ø Keep you fingers out of the viewing area of the microscope; especially the centre of

the cross hair which is the focus point and therefore the area with the highest

energy.

Ø Do not keep any explosive or inflammable material near the laser.

Ø Always use a fume extractor that is certified for extracting welding fume.

Ø Restrict access to laser-trained personnel only. Keep the key for the laser in a

separate place and entrust one person with responsibility for the laser

Ø Post a sign outside the laser room to indicate the use of a laser

Ø Install a key switch, interlock circuit feature or a warning light outside the laser room


2.2 Safety signs

2.2.1 Meaning and location of the safety signs

A. Warning of Laser Radiation

To be found on the front of the Laser Head under the Microscope

B. Warning of Laser Aperture

To be found on the front of the Laser Head under the Microscope

C. Warning of Invisible Laser Radiation and Laser Classification

To be found on the left of the Laser Head under the Microscope

Invisible laser radiation

Avoid eye or skin exposure

To direct or scattered radiation

Laser class 4

Pic.2: Laser head side face

Pic.1: Laser head front view


Hersteller: Vision GmbH

Typ: LWI IV

400 V 50 Hz 3N; max. 16 A

Laserklasse 4

SN.: LWI IV XX.XX-VXXX-YY

Pic.4: Type label

D. Technical Data

To be found on the back of the Supply unit. Shows the maximum laser values of:

Average Power Po [Watt]

Pulse Energy PP [Joule]

Pulse duration t [Milliseconds]

Pulse repetition frequency F [Hertz]

Wavelength of the laser light λ [Nanometre]

3.0 Product specification

3.1 Type label

The type label is located on the back of the supply unit. It carries the following information:

Manufacturer: Vision GmbH

Model: LWI IV

Supply Voltage: 400 Volt, 50Hz

3 Phases & Neutral,

16 Ampere

Laser class: 4

Serial Number: LWI IV

3.2 Intended use

The laser welder LWI IV can either be used for manual welding, or can be integrated into an automated process within a production line. It is a complete work station for daily use in general welding applications. It was built to weld nearly all metals and metal alloys at high quality. The welding process can be controlled by watching the work piece through the microscope. The laser is triggered by pressing the footswitch. The supply unit has 4 wheels with 2 brakes and the front wheels. The laser head must be fixed.

3.3 Limit specification

Ambient air temperature: 15 - 250C

Air humidity: ≤ 75 %

Po = max. 150 W PP = max. 80 J t = 0,1 – 20 ms F = max. 20 Hz λ = 1064 nm Norm EN 60825-1 : 1994

Pic.3: Back side panel


3.4 Declaration of conformity

We herewith declare that the device described below conforms to the relevant requirements of the applicable EU Directives. Any modification to the device will lead to this declaration losing its validity.

Device: Laser welding machine

Type: LWI 4 Flexx

Version: open workstation laser class 4

We have complied with the following EU Directives and standards:

EU EMC Directives:

EN 50082-1: 1997 Interference resistance generic specification, Part 1: Residential and commercial areas

EN 50083-1: 1992 Interference emission generic specification for residential, business and industrial areas and small businesses

EU Machinery Directive:

EN 60204-1: 1993 Electrical equipment of machines, Part 1: general requirements

EU Low Voltage Directive:

EN 60950: 2001 Safety of information technology devices

EU Laser Safety Directive:

EN 60825-1: 1994 Safety of laser devices

This machine needs additional protection against laser radiation to protect skin and eyes of the user.

Manufacturer: Vision GmbH Lasertechnik

für Forschung und Industrie

Lügensteinweg 27

D 30890 Göxe

Goexe, November 1th, 2004

Dirk Haussmann

General Manager


3.5 Technical data

Beam source: Nd:YAG

Pump source: Flash-lamp

Wavelength: 1064 nm

Operating mode: pulsed laser system

Max. Average output: 120 W (200 W)

Max. Power 80 Joules: (100 J option)

Max. Peak power: 10 kW

Spot diameter*: 200 µm – 2.5 mm, motor-powered adjustable

Focal length (standard): 190 mm (90, 120, 300 on request)

Power adjustment: via voltage or PWM feature

Pulse length: 0.5 – 20 ms

Pulse frequency: Single pulse up to 20 Hz

Pulse fill mode: 10 – 100 %

PWM: 1 – 100 %

Energy meter: integrated

Microscope: Leica Top with 20 x eyepieces**

Cooling: 120 W enclosed water/air heat exchangers

200 W Water/water heat exchanger with

temperature controlled flow control

Supply voltage: 120 W model: 380 Volt, 3-phase, 50/60 Hz, 4 KW

200 W model: 380 Volt, 3-phase, 50/60Hz, 8 KW

Interface: CAN & RS232

* The spot size is directly related to the focal length of the lens used. The adjustable range of the spot diameter lies in the 50 μm to 2.5 mm range, depending on the configuration of the system.

** The magnification of the optical system depends on the combination of eyepieces and lenses. Standard magnification is 20. Magnifications of 10x to 100x are possible.


4.0 Arrangement and functions of all parts

The Laser welder consists of the laser head and the supply unit. The following chapters give a detailed description of all parts, their function and the information necessary to operate and maintain the laser welder.

4.1 Laser head

The laser head consists of the following parts:

1. The resonator with all optical components where the actual laser beam is produced and formed with the telescope to adjust the diameter of the focal spot.

2. The bending 45 degree mirror to reflect the laser beam to the work piece

3. The focusing lens to focus the laser beam on the work piece

4. The stereo microscope to view the welding process

5. Two lamps for the Illumination of the welding area

6. Adjustable shielding gas outlet

7. Display 2 to view and set the parameters

4.1.1 The Stereo microscope

The stereo microscope allows you to view the welding process. Since it is stereo, you have a three dimensional image of the process. The Microscope consists of the base and the two adjustable eye pieces. The adjustment procedure is described in Chapter 6.1

4.1.2 The display 2

The display 2 above the microscope with its keypad allows you to view and change all welding parameters directly on the laser head.

Pic.5 The Display2 - Laser head


4.1.3 The shielding gas outlet, illumination and focussing lens

• Illumination – Two halogen lamps for a bright picture of the welding area without shadowing effects

• Focussing lens – point of laser radiation outlet! With special glass held by a knurled screw to protect the sensitive optic against welding spatter, fume and dirt.

• Shielding gas outlet – adjust the outlet pointing towards welding paddle to create oxygen free atmosphere around the welding zone

4.2 Supply unit

The supply unit has four wheels. The front wheels are equipped with brakes. It can be quickly repositioned and fixed with the brakes. For stability of the unit use both brakes when you have reached the final position. There are no serviceable parts inside the supply unit. Do not open the supply unit without supervision of an authorized technician! Do not try to repair, maintain or service without consulting an authorized Vision technician. The supply unit contains the following parts:

1. Power supply for the flash lamp in the resonator

2. Water to Air Cooling system with blower, heat exchanger, particle filter, flow meter and water container for distilled (purified) water only.

3. Micro Controller with the software to control all functions of the laser

4. Electric distribution board with fuses to produce, switch and control all voltages

Pic.6: Laser head - view from below


4.2.1 Front with display 1

All laser parameters can be seen and set on the front display 1. On the right of the display 1 is the emergency stop switch. In case of an emergency press the red button, and the system stops immediately. After the emergency switch is pressed unlock by turning it. The emergency switch must not be used to turn the laser on and off, it is for emergency use only!

The key switch is used to switch the laser on and off. Turn it right to start the laser. Ensure the keys are entrusted to authorized persons only!

• Display with Keypads

• Emergency Stop Switch

• Key switch

4.2.2 The back side panel

1. Footswitch – Connect the standard foot pedal here

2. Remote – A CAN - interface

3. External Interlock – A door switch can be connected here

4. 240 V AC / max. 400 VA - Additional socket, can be switched by the software, a fume extractor can be connected here for example

5. Fuse 2A for the external socket

6. Main Switch

7. Remote Foot Switch – Connect the Multi-Functional-Pedal here

8. RS-232 interface – A serial port

9. GAS 1 - First Shielding Gas inlet

10. GAS 2 - Secondary Gas inlet (optional)

1 2 3 4 5 6

7 8

9

10

Pic.8: Back side panel

Pic.7 The Display 1 – Supply unit


4.3 The standard foot paddle

If working manually, the Laser is triggered by a two stage foot paddle. The first stage opens the shielding gas outlet to create the welding atmosphere. Continue to press the foot paddle down and the laser starts pulsing.

4.4 The multi functional foot paddle (option)

This paddle allows you to change the welding parameter without taking the hands of the welding process.

1 Voltage [V] Tilt up or down ↕, Voltage increase or decrease in 5 Volt steps

2 Pulse duration [ms] Tilt up or down ↕, the pulse duration increase or decrease in 0,5 ms steps

3 - Spot Diameter [μ] press to reduce the spot diameter in 50 μm steps

4 + Spot Diameter [μm] press to increase the spot diameter in 50 μm steps

5 Two stage foot paddle the first stage starts the shielding Gas, the second stage starts the laser pulsing

+ + 1 ↕ 2 ↕ - -

3 4 5

Pic.9 Multifunctional Foot Paddle


400

V

400

V

400

V

240V

240V

240V

L1 (R)

L2 (S)

L3 (T)

N (MP)PE (Ground)

5.0 Installation

The installation of the laser welder has to be carried out by an authorized Vision technician.

5.1 Installation site

The installation site has to be clean and dust free. The laser has to stand on an even ground with the wheel brakes locked. It must be installed in a separate room with the door switch connected to the external interlock. Leave a space of 150 mm minimum between the heat exchanger on the back of the supply unit and the wall allowing the blower to operate. The room temperature during downtime of the system must not drop below 50C and should never exceed 450C. The Laser must not be placed near to any source of great electro-magnetic disturbance or heat such as induction furnaces or other such comparable devices. The electronics of the laser may be interfered by those machines and cause temporary or permanent malfunctions.

5.2 Electrical connections and external interlock

Connect the laser to a separate electric circuit with fuse box. The mains must be stable and protected against over voltage.

• 3 X 400 Volt AC (L1, L2, L3)

• Neutral & Ground (N, PE)

• 50-60 Hz

• 16 Ampere

To connect the external interlock to the door switch remove the dummy plug from the external interlock and connect it with the breaker contact of the door switch using a two line cable with a 0,75 mm2 diameter wire minimum.

6.0 Operation

6.1 Adjusting the microscope

Before you start working it is essential that the microscope is well adjusted to your eyes. Every operator has different eye sight. The focus level of the operator and the focus level of the laser must be the same; otherwise the set spot diameter is not equal to the spot diameter on the work piece so that a different user will have different welding results although both setting the same focus diameter on the same machine. A wrongly adjusted microscope also results in the operator’s eye becoming rapidly exhausted since the eye tries to focus all the time. The Picture 11 shows the correlation between laser spot diameter and focus level. To change the spot diameter the cone shaped laser beam is moved up or down. The cross section with the focus level determents the spot diameter.

Pic.10 Connection Diagram


For this reason it is important that every user works in the same focus level.

Foca

l Length

Cone Shaped Focused Laser Beam

Spot Diameter

Microscope Focus Level= Working Level

Adjusting the microscope:

o Adjust the eye base until you see a single circular field o Loosen the set screws on both eye pieces o Turn the eye piece with the cross hair (usually on the right) until the cross hair is in

focus and tighten the set screw o Move a flat object under the microscope up and down until it is focused in the

adjusted eye piece. o Fix the object in that position o Turn the other eye piece until the object is focused and tighten the set screw o Each operator should make a note of his personal dioptric settings for a quick

adjustment in the future

6.2 The shielding gas nozzle

The shielding gas protects the molten weld pool from exposure to the atmosphere and hinders oxidation. For most welding materials like steel, stainless steel or titanium argon is used as a shielding gas. Argon is heavier than air, which means that it blankets the weld zone, so lower flow rates are needed. The flow rate has to be set on the flow meter of your gas bottle. By pressing the footswitch to the first stage an electromagnetic valve inside the supply unit opens up and the gas starts flowing. Adjust the blue segments of the nozzle so that the gas is precisely delivered to the welding zone.

6.3 Setting the laser parameters

The laser parameters determine the whole welding process. Please read chapter 7 on

Pic.11 Spot size & focus level


how to find the right parameter set. The main laser parameters can be changed on both displays. Some settings can only be done on Display 1 or Display 2. The following Laser parameters are important:

• The Voltage [Volt] to which the capacitors in the power supply are charged, value between 160V and 450 Volt. Together with the pulse width it defines the energy of the single pulse

• The pulse width [milliseconds] is the time of the single pulse length, value between 0.5 and 20 ms. Together with the voltage it defines the energy of the single pulse

• The Spot diameter [μm] of the focused laser spot. It defines the density of the energy (Joule / mm2) Read Chapter 6.1 Values between 0.2 and 2.0 mm

• The Pulsfill is another option to manipulate the energy of the pulse. Value from 10 to 100 % For more information please read chapter 6.5

• The Frequency [Hertz, pulse/s] is the repetition rate of the pulses. Together with the energy of the single pulse it defines the average power (Watt) of the system

6.3.1 Display 2

The display 2 on the laser head allows you to view all parameters. To the left and to the right are keys to change the parameters and make certain settings. Use the arrow keys to move the curser to the parameter you want to change.

• To change the parameter use the plus and minus keys.

• To change the mode move the curser to the mode position in row 4 and press the plus or minus key. If “single” is set only one pulse is released even if triggering continues. If “continue” is set the pulses are generated in the frequency set in row 3

• To activate/deactivate the shielding gas move the curser to GAS1 and press the plus or minus key to check or uncheck.

• To activate/deactivate the optional secondary shielding gas move the curser to GAS2 and use the plus or minus key to check or uncheck

• To switch between classic and PULSFILL mode move the curser to CLMD and use plus or minus to check and unchecked. Read chapter 6.3.3 to learn more about the PULSFILL function

Arrow key up

Arrow key down

Plus key

Minus key

Set key

Pic.11 Display 2


The Display 2 shows the following Data:

Row 1

Row 2

Row 3

Row 4

Row 5

Row 6

Row 1: U: Voltage [Volt] Pw: Pulse width [millisecond]

Row 2: E: Energy single shot [Joule] Pf: Pulse fill [%]

Row 3: S: Spot diameter [μm] f: Frequency [Hertz, pulse/s]

Row 4: mode: single / continuous

Row 5: GAS1: Shielding Gas on/off GAS2: Optional secondary shielding gas outlet

CLMD: Classic Mode / PWM mode

Row 6: Material No.: Stored Set of Parameter

Pic.12 Content display2


6.3.2 Display 1

The operation of the display 1 on the supply unit is the same as on the Laser head. It does not allow you to change from Classic mode to PWM mode and to turn the GAS1/GAS2 on or off. In Row 7 a gas delay can be set. After the laser has stopped pulsing the gas continue to flow for the set time.

Row 1 Row 2 Row 3 Row 4 Row 5 Row 6 Row 7

Row 1: Voltage [Volt]

Row 2: Pulsewidth [millisecond] Pf: Pulse fill [%]

Row 3: Pulsfill

Row 4: Spotsize [μm]

Row 5: Frequency [Hertz, pulse/s]

Row 6: Energy single shot [Joule]

Row 7: Gasdelay [s]

6.3.3 Classic-Mode / PULSFILL-Mode / PWM-Mode

The energy of a single laser pulse is determined by:

- the Voltage to witch the capacitor bank in the power supply is charged

- the duration of the pulse

The PULSFILL- and PWM- Mode offer another option to change the pulse energy.

PWM-Mode:

Uncheck CLMD (Classic Mode) in Row 5 on Display 2 to change into the PWM Mode. PWM stands for Pulse Width Modulation. On display 2 in row 2 Pw changes to PWM. The Voltage in row 1 on Display 1 & 2 is now fixed at the power supplies optimal operating point and can not be changed anymore. To alter the Energy of the single pulse the PWM value in display 1 can be changed from 1% to 100%.

Instead of changing the voltage of the capacitor bank in the power supply and therefore the height (and Energy) of the pulse, the pulse itself is split into very small segments which are turned on and of in percentage ratio that is set.

Arrow key up

Arrow key down

Plus key

Minus key

SET / MENU key

Pic.13 Display1


tt

PWM 10%

t

tt

90 % OFF

10 % ON

PWM 30%

70 % OFF

30 % ON

PWM 60%

40 % OFF

60 % ON

PWM 10%

Picture 14 shows a part of a pulse at different PWM settings. At 10% each fraction is turned on for 10 % and off for the remaining 90%. The overall energy is reduced by 90 %. By increasing the PWM Value the “on – periods” get longer and the “off - periods” shorter.

PULSEFILL-Mode

Picture 15 shows a 4 ms pulse. The pulse is divided into four one millisecond long segments. Since PULSFILL is set to 100% the segment is complete for the whole millisecond. The pulse width is not modulated. The modulation can be seen in Picture 16 where PULSFILL is set to 70%. Here, 70% of the segment is on and 30% is off. The segment is repeated 4 times. The overall energy in the 4 ms pulse is reduced by 30%.

T= 4 ms

100%100% 100% 100%

t

ON ON ON ONPULSFILL

100%

1 ms

Pic.15 PULSFILL at 100%

Pic.14 PWM at 10, 30 and 60%


Pic.18: Display2 – Storing Step 2

T= 4 ms

70%

30%

70%

30%

t1 ms

ON ON ON ON

OFF OFF OFF OFF

PULSFILL70%

6.4 Storing parameters

The controller can store up to 50 complete parameter sets with a short description

1. To store the actual setting press the set key on display 1

2. Press the set key to store the aktual parameter or any other key to leave the menue.

3. Press the number 1 key on the left and use the arrow keys to select a number

4. Press the number 2 key to add a 20 letter long description. Use the arrow key to move the curser to the desired position. Use the +/- key to alter the letter or symbol

5. Press the set key to store the parameter set

6. To recall the parameter set move the cursor to row 6 and use the +/- key to select the number of the desired parameter set

7.0 Welding

Each welding task is different and finding the right laser parameters is essential for the result. There are an enormous number of different materials, circumstances, requirements and general set-ups that needs to be considered to achieve the perfect welding result. This manual does not contain any information on certain parameter sets for certain welding tasks simply because there are to many. For a successful laser welding the parameters needs to be found step by step. A general rule for finding the right parameter is to start with low parameters and increase them slowly. Use the following parameter set to start:

• U = 250 Volt (CLMD checked)

• Pw = 4 ms

• Mode = single

• S = 800 μm

Pic.16: PULSFILL at 70%

Pic.17: Display2 – Storing Step 1


Release a pulse and observe the result through the microscope. Increase and decrease Voltage, Pulse-Width and Spot Diameter in small steps to observe the effects on the work piece

Most welding applications require a shielding gas atmosphere. To produce a clean, bright and shiny wed seam adjust the shielding gas outlet so that it points towards the welding area. Set the flow rate at the gas supply so that a constant shielding gas blanked around the welding area is produced.

8.0 Service, maintenance and troubleshooting

All maintenance and service work must be complying with the following accident prevention regulations:

• V B G 93, VBG 4 (Germany)

• ANSI Z 136.1-1993 (USA)

8.1 Regular service

To ensure the long lasting and perfect functioning of your laser welder we strongly recommend a regular service which should be carried out by an authorized technician. Ask your Vision dealer for the nearest service station.

8.2 Maintenance

Any replacement of consumables and maintenance work has to be carried out by trained personal only. The laser has to be switched off and unplugged from the mains. The following parts are consumables and need to be changed after a certain period of operation.

• the flash lamp - if broken or the laser power decrease

• the protection glass - if broken or dirty

• the deionised (purified) cooling water - once a year


Pic.19 Remove screw 1 & 2

Pic.20 Open the brass nut

Pic.21 Remove lamp

8.2.1 Changing the flash lamp

The flash lamp is subject to an aging process and has to be changed after a certain time. The lifetime of the flash lamp depends on the stress it is exposed to. A high energy welding in the top laser parameter region will lead to a shorter lifetime and vice versa.

Careful!

The changing must be carried out by a trained person only. There are highly sensitive electronic and optical parts inside the resonator. Especially the mirrors on both ends of the lamp are aligned with high precision and are sensitive against any mechanical impact. The lamp is under pressure and may explode. Wear protective goggles during the changing procedure. All operations should be exercised with caution. The laser must be disconnected from the mains! Vision does not take responsibility for any brakeage if the lamp was changed in an unprofessional manner. If you are not trained do not change the lamp and call for a qualified technician.

Changing procedure:

1. Turn the laser on the main switch off and disconnect from the mains. Wait 30 minutes minimum to allow the power supply to discharge completely

2. Remove the blue cover on the end of the laser head and slide the two round cover segments back until there is free access to the lamp (Pic. 19)

3. Loose screw 1 & 2 and remove the black and red lamp cables from the terminal

4. Use a 9 mm spanner to open and remove the two brass nuts 3 & 4 that holds the lamp in position (Pic.20)

5. Pull the lamp out in the direction of the red cable (Pic.21). Put the red cable through the hole (red circle)

6. Continue to pull the lamp out until the lamp can be taken out completely (Pic. 22). Be aware of the O-ring seal inside. It might be pushed out with the Lamp and needs to be relocated.

7. Insert the brass nuts again and screw them back in so that the o-ring for the lamp is held in its place

8. Insert the new lamp carefully. Do not touch the glass body of the lamp. Move the lamp until the middle position is reached.

1 2

3 4


Pic.22 Lamp ready to be removed

9. Tighten the brass nuts carefully.

10. Put the cables tips back in the terminal and tighten screw 1 & 2

11. Start the laser and watch carefully for 30 minutes to test for any water leakage at the brass nuts or lamp cable

12. Turn the Laser off and disconnect from the mains. Replace the cover and start the laser

Warning! High Voltage and Laser Radiation!

Do not touch anything inside as long as the laser is switched on. Do not trigger the laser as long as the cover is open.


Pic.23 Water Container with particle filter

+

-

-

+- +

+-

Pic.24 Adjusting screws Laser Head

8.2.3 Changing the protection glass

Unscrew the aluminium knurled screw on the focusing lens. Replace the glass without touching it. Do not replace with regular glass and only use new parts!

8.2.4 Changing and refill the cooling water

The cooling water needs to be changed once a year. Remove the cover on the supply unit and unscrew the black lid of the water container. The cables connected to the lid can be twisted but must be handled with care. Use a small pump to remove the water.

Lid with Cables

Particle Filter

Water level line No. 5

Water Container inside the Supply Unit

Pump

Use de-ionized (purified) water only!

Any other water will cause

significant damage to the system!

Refill until the water level has reach line No. 5 on the container. Add more water after turning the system on if necessary. Pre-twist the black lid anti-clockwise three turns before screwing it back on the container.

8.3 Adjust the welding spot congruence with the cross hair

The welding spot can easily be adjusted to hit the centre of the cross hair in the microscope. Use a 2,5 mm Allen-Key in the two holes on the front of the laser head to move the welding spot up/down and left/right. Set the laser parameter to U = 170Volt, Pw = 3ms, S = 300μm, F = 2Hz. Look through the microscope and turn the screws while pulsing until the spot has reached the centre. Picture 24 shows the directions in which the welding spot is moving.


8.4 Error messages and trouble shooting

The following messages can be displayed. Please follow the recommended action.

Message Meaning Reason / Action Return from

Interlock

Test at

Start

Test while

running

1 Check main emergency switch Emergency switch pressed Unlock Emergency Switch if safe

Yes No Yes

2 Check external interlock External Interlock active Interlock is not closed Yes No Yes

3 Water level is low Not enough water in the water container

Refill purified water / Check for leakage Yes No No

4 Lamp not ignited No Simmer (60s after Start) Lampe, Power supply,/ Change lamp, / Call Service No Yes Yes

5 Lamp broken Simmer stop > 500ms during operation)

Lampe, Power supply,/ Change lamp / Call Service No No Yes

6 Terminal 1 not ready Display Controller in the supply unit is not working Call Service Yes Yes Yes

7 Terminal 2 not ready Terminal Laser is not working Call Service Yes Yes Yes

8 Integrator 1 not ready Integrator PCB (Measuring the Laser Energy) is not ready

s. Terminal 2 not ready / Call Service Yes Yes Yes

9 Stepper 1 not ready Stepper PCB (controls the focus motor)

s. Terminal 2 not ready / Call Service Yes Yes Yes

10 Temp is too high Water temperature is to high Thermo sensor measures more then 550C / keep the machine running for cool down

Yes Yes Yes

11 Waterflow low, checkfilter (Step1) Water flow lower then (Step1) Check Pump / Filter Yes Yes No

12 Waterflow low, checkfilter (Step2) Water flow low (Step2) Check Pump / Filter / Flow switch

No Yes Yes

13 Water flow is too high Flow sensor is not working Sensor / Master controller board / Call Service

No No Yes

14 Beamshutter defect, does not open Mechanical. Shutter does not open

Integrator PCB / Shutter / Limit switch / Call Service

No No Yes

15 Beamshutter defect, does not close Mechanical. Shutter does not close

Integrator PCB / Shutter / Limit switch / Call Service

No No Yes

16 Temperature Fuse Water temperature is to high Thermo fuse / turn laser off and wait until cool down

Yes No Yes

17 Power S. Temp. High. Power Supply temperature is too high

Wait until cool down Yes No Yes

18 Soft Interlock Internal additional Interlock Jumper (IN14,'reserve1') / Call Service

Yes No Yes

19 Unknown Interlock 3 Bit-Combination Interlock unknown

Call Service Yes No Yes

20 Phase (1) (2) (3) missed! Phases missing Fuse, Relay, Mains / Call Service

Yes Yes No


9.0 Appendix

lwi iv flexx - vision lasertechnik · type: lwi 4 flexx version: open workstation laser class 4 we...

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