LW300 - 400 Technical Manual

LW300 - 400 Technical Manual
USER’S MANUAL
REVISION E
990-538
May 2013
OPERATOR MANUAL
FOR THE
LW300A (E) / LW300AH (E) / LW400A (E)
( ML-2551A [CE] / ML-2552A [CE] / ML-2550A [CE] )
PULSED Nd:YAG LASER
Copyright © 2002-2013 Miyachi Unitek Corporation
The engineering designs, drawings and data contained herein are the proprietary work of MIYACHI
UNITEK CORPORATION and may not be reproduced, copied, exhibited or otherwise used without the
written authorization of the MIYACHI UNITEK CORPORATION.
Printed in the United States of America
Revision Record
Revision
EO
Date
Basis of Revision
A
19390
8/02
Production release
B
19670
3/03
Updated features and specifications.
C
40857
1/11
Corrections + MLE-118A use.
D
42307
2/13
Corrections and updates.
E
42509
5/13
Corrections and updates.
This manual covers the following models:
Miyachi Unitek Lasers Models
Miyachi Headquarters Models
CDRH Compliant
(U.S. usage)
CE Compliant
(European usage)
CDRH Compliant
(U.S. usage)
CE Compliant
(European usage)
LW300A
LW300AE
ML-2551A
ML-2551A-CE
LW300AH
LW300AHE
ML-2552A
ML-2552A-CE
LW400A
LW400AE
ML-2550A
ML-2550A-CE
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Contents
Page
Revision Record ......................................................................................................................................... ii
Contents
.............................................................................................................................................. iii
Contact Us .............................................................................................................................................. ix
CDRH Compliance Statement .................................................................................................................. ix
CE Declaration ............................................................................................................................................x
Safety Precautions ..................................................................................................................................... xi
Chapter 1. System Description
Section I: Features .................................................................................................................................. 1-1
Section II: System Components ............................................................................................................. 1-2
Front Panel ....................................................................................................................................... 1-2
Middle Panel .................................................................................................................................... 1-3
Top, Side, and Rear Panels .............................................................................................................. 1-5
Laser Oscillator................................................................................................................................. 1-6
MLE-115A Laser Controller (Control Panel) .................................................................................. 1-8
MLE-118A Laser Controller (Control Panel) .................................................................................. 1-9
Chapter 2. Installation and Setup
Section I: Planning ................................................................................................................................. 2-1
Physical Requirements ..................................................................................................................... 2-1
Power Requirements ........................................................................................................................ 2-1
Section II: Installation ............................................................................................................................ 2-2
Removing the Oscillator Hold-down Brackets ................................................................................ 2-2
Securing the Laser (CE and Non-CE Models) ................................................................................ 2-3
Supplying Power .............................................................................................................................. 2-4
Cooling Water System ..................................................................................................................... 2-5
Cooling Water Block Diagram ................................................................................................. 2-5
Connecting the Hose for Primary Cooling Water .................................................................... 2-6
Supplying the Secondary Cooling Water ................................................................................. 2-6
Handling Fiber Optic Cables ........................................................................................................... 2-7
Minimum Bend Radius for Specified Core Diameter .............................................................. 2-7
Optical Fiber Connection ......................................................................................................... 2-7
Connecting to Laser Beam Input Unit (Inside the Laser) ......................................................... 2-7
Connecting to Laser Beam Output Unit (Focus Head) ............................................................ 2-8
Connecting the Laser Controller Remotely (Optional) .................................................................... 2-9
Chapter 3. MLE-115A Programming Functions
Section I. LCD Control Screens ............................................................................................................. 3-1
About the LCD Screens ................................................................................................................... 3-1
Screen Content ................................................................................................................................. 3-2
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Page
Section II. How to Use LCD Screens .................................................................................................... 3-3
SCHEDULE Screen ......................................................................................................................... 3-3
FORM: FIX Function ............................................................................................................... 3-3
SCH # ............................................................................................................................... 3-3
FORM ............................................................................................................................... 3-3
PEAK ................................................................................................................................ 3-3
Estimated Laser Output Energy ................................................................................. 3-4
WATER ............................................................................................................................. 3-4
REPEAT SHOT ................................................................................................................ 3-4
SEAM WELD MODE Screen ........................................................................................... 3-4
POSITION ......................................................................................................................... 3-4
MAIN SHUTTER ............................................................................................................ 3-4
HV ..................................................................................................................................... 3-4
FORM : FIX Settings ....................................................................................................... 3-4
GRAPH ...................................................................................................................... 3-5
FORM: FLEX Function ........................................................................................................... 3-6
Point 1 through Point 20 .................................................................................................... 3-6
SEAM WELD Screen ...................................................................................................................... 3-7
No SHOT ENERGY ................................................................................................................. 3-7
ALL RESET ............................................................................................................................. 3-8
Status Screen .................................................................................................................................... 3-9
CONTROL DEVICE Mode ..................................................................................................... 3-9
RESET SELECT ...................................................................................................................... 3-9
PRESET .................................................................................................................................... 3-9
POSITION BLINK ................................................................................................................... 3-9
FIBER ..................................................................................................................................... 3-10
BEAM-1 to BEAM-4 ............................................................................................................. 3-10
Power Monitor Screen ................................................................................................................... 3-11
GRAPH ........................................................................................................................... 3-11
HIGH / LOW alarm limits ...................................................................................................... 3-11
REFERENCE SET and LAMP INPUT POWER .................................................................. 3-11
SHOT COUNT GOOD COUNT........................................................................................... 3-12
AVERAGE ............................................................................................................................. 3-12
ENERGY ................................................................................................................................ 3-12
Section III. Hidden Menu Screens ....................................................................................................... 3-13
Overview ........................................................................................................................................ 3-13
Initialization Screen ....................................................................................................................... 3-13
INITIALIZE ........................................................................................................................... 3-14
WATER .................................................................................................................................. 3-14
WATER TEMPERATURE ALARM SETTINGS L 25qC H 40qC ..................................... 3-14
A =20, B = 80, C = 50, D = 50 (Fan Speed Settings) ............................................................. 3-14
POSITION AUTO-OFF 60MIN ............................................................................................ 3-14
TEMP CONT WATER 30qC ................................................................................................. 3-14
NETWORK # 00-31 ............................................................................................................... 3-14
SOFTWARE SWITCH SETTINGS ...................................................................................... 3-15
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Maintenance Mode Screen ............................................................................................................ 3-17
MAINTENANCE MODE: OFF ............................................................................................. 3-17
DEIONIZE ............................................................................................................................. 3-17
ROM VERSION ..................................................................................................................... 3-17
ADJ ......................................................................................................................................... 3-17
ERROR RECORD .................................................................................................................. 3-18
CONTROL ............................................................................................................................. 3-18
DELIVERY SYSTEM ........................................................................................................... 3-19
PULSE WIDTH ...................................................................................................................... 3-19
CURRENT ............................................................................................................................. 3-19
PASSWORD MODE Screen ......................................................................................................... 3-20
Incorrect Password ................................................................................................................. 3-20
Correct Password .................................................................................................................... 3-21
Password-Protected Settings & Functions .............................................................................. 3-22
PRINT-OUT MODE Screen .......................................................................................................... 3-23
Printing the Welding Conditions in Each Schedule ............................................................... 3-23
Printing Out the Power Monitor Measurements ..................................................................... 3-23
Printing Out the Seam Weld Conditions ................................................................................ 3-23
Welding Condition Print-Out Examples – Schedule Screen .................................................. 3-24
Power Monitor Examples – Power Monitor Screen ............................................................... 3-25
Connecting the Serial Printer ......................................................................................................... 3-26
Chapter 4. MLE-118A Programming Functions
Section I. LCD Control Screens ............................................................................................................. 4-1
General Navigation .......................................................................................................................... 4-1
About the LCD Screens ................................................................................................................... 4-1
Screen Content ................................................................................................................................. 4-2
Section II. How to Use LCD Screens .................................................................................................... 4-3
Common to ALL Screens ................................................................................................................ 4-3
SCHEDULE: # ......................................................................................................................... 4-3
FORM ....................................................................................................................................... 4-3
PUMP ....................................................................................................................................... 4-3
WATER TEMP ........................................................................................................................ 4-3
HV ........................................................................................................................................... 4-3
MAIN SHUT ............................................................................................................................ 4-3
POSITION ................................................................................................................................ 4-4
TROUBLE RESET .................................................................................................................. 4-4
BEAM ....................................................................................................................................... 4-4
SCHED ..................................................................................................................................... 4-4
STATUS ................................................................................................................................... 4-4
MON ......................................................................................................................................... 4-4
SEAM ....................................................................................................................................... 4-4
PASSWD .................................................................................................................................. 4-4
PRINT ....................................................................................................................................... 4-4
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SCHEDULE Screen ......................................................................................................................... 4-5
FORM: FIX Function ............................................................................................................... 4-5
PEAK POWER ................................................................................................................ 4-5
REFERENCE VALUE ..................................................................................................... 4-6
SHOT ................................................................................................................................ 4-6
REPEAT ........................................................................................................................... 4-6
COOL ............................................................................................................................... 4-6
SEAM ............................................................................................................................... 4-6
FORM (Fix settings) ........................................................................................................ 4-6
FORM: FLEX Function ........................................................................................................... 4-7
PEAK POWER ................................................................................................................ 4-7
REFERENCE VALUE ..................................................................................................... 4-8
SHOT ................................................................................................................................ 4-8
REPEAT ........................................................................................................................... 4-8
RESET .............................................................................................................................. 4-8
SEAM ............................................................................................................................... 4-8
Point 01 though Point 20 (Flex settings) .......................................................................... 4-8
SEAM Function ............................................................................................................................... 4-9
SHOT [COUNT] .............................................................................................................. 4-9
POWER [%] ..................................................................................................................... 4-9
RESET ............................................................................................................................. 4-10
REPEAT .......................................................................................................................... 4-10
SHOT .............................................................................................................................. 4-10
and ........................................................................................................................... 4-10
Status Screen .................................................................................................................................. 4-11
POSITION BLINK ................................................................................................................. 4-11
CONTROL DEVICE Mode ................................................................................................... 4-11
DELIVERY SYSTEM ........................................................................................................... 4-12
FIBER ..................................................................................................................................... 4-12
RESET COUNT ..................................................................................................................... 4-13
DEIONIZE WATER RES ...................................................................................................... 4-13
PRESET COUNT ................................................................................................................... 4-13
ROM VERSION ..................................................................................................................... 4-13
Power Monitor Screen ................................................................................................................... 4-14
ENERGY ................................................................................................................................ 4-14
AVERAGE ............................................................................................................................. 4-14
HIGH / LOW alarm limits ...................................................................................................... 4-14
SHOT COUNT GOOD COUNT........................................................................................... 4-15
REFERENCE SET and LAMP INPUT POWER .................................................................. 4-15
GRAPH ................................................................................................................................... 4-15
PASSWORD MODE Screen ......................................................................................................... 4-16
Incorrect Password ................................................................................................................. 4-16
Password-Protected Settings & Functions .............................................................................. 4-17
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PRINT-OUT MODE Screen .......................................................................................................... 4-18
Printing the Welding Conditions in Each Schedule ............................................................... 4-18
Printing Out the Power Monitor Measurements ..................................................................... 4-18
Printing Out the Seam Weld Conditions ................................................................................ 4-18
Welding Condition Print-Out Examples – Schedule Screen .................................................. 4-19
Power Monitor Examples – Power Monitor Screen ............................................................... 4-20
Connecting the Serial Printer .................................................................................................. 4-20
Section III. Hidden Menu Screens ....................................................................................................... 4-21
Overview ........................................................................................................................................ 4-21
Initialization Screen ....................................................................................................................... 4-21
INITIALIZE ........................................................................................................................... 4-22
NETWORK # 00-31 ............................................................................................................... 4-22
WATER TEMPERATURE ALARM SETTINGS L 25qC H 40qC ...................................... 4-22
FAN SPEED SETTINGS ....................................................................................................... 4-22
MEMORY SWITCH .............................................................................................................. 4-22
POSITION AUTO OFF 60MIN ............................................................................................. 4-22
JOG BUZZER ........................................................................................................................ 4-22
MEMORY SWITCH SETTINGS screen ............................................................................... 4-23
BACK button .......................................................................................................................... 4-24
Maintenance Mode Screen ............................................................................................................ 4-25
MODE .................................................................................................................................... 4-25
CONTROL ............................................................................................................................. 4-26
DATE / TIME ......................................................................................................................... 4-26
ERROR RECORD .................................................................................................................. 4-26
CURRENT ............................................................................................................................. 4-26
PULSE WIDTH ...................................................................................................................... 4-26
FLOW ..................................................................................................................................... 4-26
Chapter 5. Operating Instructions
Section I. Welding Preparation .............................................................................................................. 5-1
Preparation ....................................................................................................................................... 5-1
General Operator Safety .................................................................................................................. 5-1
Starting the Laser ............................................................................................................................. 5-1
Section II. Welding using the MLE-115A ............................................................................................. 5-2
Prepare Processing Point and Set Weld Schedule (MLE-115A) ..................................................... 5-2
Welding Using the MLE-115A Laser Controller ............................................................................ 5-3
Shutdown using the MLE-115A Laser Controller ........................................................................... 5-3
Section III. Welding using the MLE-118A ............................................................................................ 5-4
Prepare Processing Point and Set Weld Schedule (MLE-118A) ..................................................... 5-4
Welding Using the MLE-118A Laser Controller ............................................................................ 5-5
Shutdown using the MLE-118A Laser Controller ........................................................................... 5-5
Section IV. Welding Using External I/O ............................................................................................... 5-6
Shutdown through External I/O ....................................................................................................... 5-6
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Chapter 6. Maintenance
Section I: Precautions ............................................................................................................................ 6-1
Section II. Troubleshooting ................................................................................................................... 6-2
Error Codes ...................................................................................................................................... 6-2
Error Codes and Corrective Actions ................................................................................................ 6-2
Section III. Routine Maintenance Schedule ........................................................................................... 6-8
Section IV: Maintenance Procedures...................................................................................................... 6-9
Overview .......................................................................................................................................... 6-9
Cleaning the Air Filter ............................................................................................................ 6-10
Cleaning Optical Parts – Removing Dirt, Dust, etc. from the Optics .................................... 6-10
Cleaning Optical Parts – Fogging and Staining ..................................................................... 6-11
Cleaning Optical Parts – Optical Fiber ................................................................................... 6-11
Power Supply - Replacing the Backup Battery ...................................................................... 6-12
Cooler Maintenance – Checking Water Level and Adding Water ......................................... 6-13
Cooler Maintenance – Draining the Primary Cooling Water ................................................. 6-14
Cooler Maintenance – Draining Secondary Cooling Water ................................................... 6-15
Cooler Maintenance – Draining the Cooling Water when the Laser is not used
for Long Periods of Time or when the Ambient Temperature is Below 0°C ................. 6-15
Cooler Maintenance – Replacing the Water Filter ................................................................. 6-17
Cooler Maintenance – Refilling and/or replacing Ion-Exchange Cartridge ........................... 6-17
Cooler Maintenance – Cleaning the Solenoid Valve Strainer ................................................ 6-19
Power Detector Adjustment ................................................................................................... 6-20
Replacing the Flashlamp ........................................................................................................ 6-22
Section V: Parts Lists ........................................................................................................................... 6-24
Accessories .................................................................................................................................... 6-24
Consumable Parts .......................................................................................................................... 6-24
Section VI: Repair Service ................................................................................................................... 6-25
Appendix A. Technical Specifications ............................................................................................... A-1
Appendix B. Electrical and Data Connections ..................................................................................B-1
Appendix C. System Timing ...............................................................................................................C-1
Appendix D. RS-485 External Communication Specifications ...................................................... D-1
Appendix E. Schedule Data Tables ....................................................................................................E-1
LW300A(H)/LW400A PULSED Nd:YAG LASER
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CONTACT US
Thank you for purchasing a Miyachi Unitek Pulsed Nd:YAG Laser. Upon receipt
of the laser, please thoroughly inspect it for shipping damage before you install it.
If there is any damage, contact the shipping company immediately to file a claim,
and notify Miyachi Unitek at:
Miyachi Unitek Corporation
1820 South Myrtle Ave.
Monrovia, California 91017-7135
Phone: (626) 303-5676
FAX: (626) 358-8048
E-mail: [email protected]
The contents of this manual are subject to change without notice. If you have any
questions, or find any errors or omissions in it, please contact us.
Miyachi Unitek is not responsible for any losses due to improper use of this
product.
CDRH COMPLIANCE STATEMENT
The Miyachi Unitek Corporation LW300A(E)/LW300AH(E)/LW400A(E) and
Miyachi Headquarters Corporation ML-2551A(-CE)/ML-2552A(-CE)/ML2550A(-CE) Nd:YAG Lasers are certified to be fully compliant with all
applicable standards and regulations as set forth by the United States of America’s
Health and Human Services (HHS), Food and Drug Administration (FDA),
Center for Devices and Radiological Health (CDRH), title 21 Code of Federal
Regulations (CFR) sections 1002, 1010, and 1040 for Class IV laser devices.
Reference CDRH Accession number is available upon request.
LW300A(H)/LW400A PULSED Nd:YAG LASER
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x
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SAFETY PRECAUTIONS
Before using this equipment, read the SAFETY
PRECAUTIONS carefully to understand the
correct usage of the equipment.
x
These precautions are given for safe
use of the Laser and for prevention of
injury to operators or others.
x
Be sure to read each of the
instructions, as they are all important
for safe operation.
x
The meaning of the words and
symbols are as follows:
DANGER
DO NOT TOUCH THE INSIDE OF THE LASER UNNECESSARILY.
High voltages are present inside the equipment cabinet. Do not touch the inside of
the Laser unnecessarily with the power turned ON.
NEVER DISASSEMBLE, REPAIR, OR MODIFY THE LASER.
These actions can cause electric shock and fire. Do not do anything other than the
maintenance described in the Operator Manual.
DO NOT LOOK AT OR TOUCH THE LASER BEAM.
Both direct laser beams and reflected laser beams are highly dangerous. If the
beam enters the eye directly, it can cause blindness.
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WARNING
Wear protective glasses.
Be sure to wear protective glasses while using the laser. Even with eye protection, you may
lose your sight if you look directly at the laser beam.
Do not expose your skin to the laser beam.
Your skin may be severely burned.
Do not touch any processed part during, or immediately after processing.
Welded parts are very hot.
Use only specified cables.
A cable with insufficient capacity or loose connections can cause electric shock or fire.
Do not use a damaged power cable, connecting cables, or plugs.
Do not step on, twist, or tense any power cable. The power cable and connecting cables
may be damaged which can cause electric shock, short circuit, or fire. If any part needs to be
repaired or replaced, consult Miyachi Unitek or your distributor.
Stop operation if any trouble occurs.
If you detect a burning smell, abnormal sounds, abnormal heat, smoke, etc. from the Laser,
turn the power OFF immediately to prevent fire or electric shock. Contact Miyachi Unitek or
your distributor for help.
Ground the Laser.
If the Laser is not grounded, you may get an electric shock when there is trouble or if
electricity leaks through the protective insulation.
Use a stopper plug.
Laser beams are dangerous to the human body. Prevent accidental leakage of the laser
beam by using a stopper (a heat-resistant, laser beam absorbing material).
People with pacemakers MUST stay away from the Laser.
When the Laser is operating, it generates a magnetic field, which adversely affects
pacemakers. People who use a pacemaker must not approach the Laser, or walk around
the laser shop while the Laser is operating, unless their medical doctor has deemed it safe to
do so.
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CAUTION
Keep water and water containers away from the Laser.
Water spilled on the Laser can cause a short circuit, electrical shock, or fire.
Use proper tools (wire strippers, pressure wire connectors, etc.) for terminations of the
connecting cables.
Do not nick the wire conductor. Doing so can cause a short circuit, electric shock, or fire.
Install the Laser on a firm, level surface.
Injury may result if the Laser falls over or drops from an uneven surface.
Keep combustible matter away from the Laser.
Laser spatter can ignite combustible materials. If you cannot remove all combustible materials,
cover them with a non-combustible material.
NEVER apply the laser beam to combustible materials.
To avoid the risk of fire, never apply the laser to flammable or combustible materials.
When operating the Laser, do not cover it with a blanket, cloth, etc.
Heat generated by the operating Laser may ignite a blanket or cover.
Do NOT use the Laser for purposes other than processing metal.
Use of the Laser on other materials, or in a manner other than specified may cause fire or
electrical shock.
Wear protective gear when operating the Laser.
Wear protective gear such as protective gloves, long-sleeved jacket, leather apron, etc. so that
Laser spatter will not burn the skin.
Keep a fire extinguisher nearby.
Make sure there is a fire extinguisher in or near the Laser shop in case of fire.
Regularly inspect and maintain the Laser.
Regular inspection and maintenance is essential for safe operation and long life of the Laser.
If you see any damage, make necessary repairs before operating the Laser.
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General Precautions
This Operator's Manual describes the Operation and Maintenance of the
LW300A(E)/300AH(E)/400A(E) and ML-2551A(-CE)/2552A(-CE)/2550A(CE) Nd:YAG Laser
Welders, and provides instructions relating to its SAFE use. Procedures described in this manual must
be performed as detailed by qualified and trained personnel.
x
Before attempting to use the laser, please read this instruction manual and the Laser Safety Manual
(Part Number 990-502) thoroughly for safety reasons and to effectively take advantage of the full
capabilities of the Laser Welder.
x
After reading this manual, retain it for future reference when any questions arise regarding the
proper and SAFE operation of the Nd:YAG Laser Welder.
Installation Precautions
x
Install the Laser securely on a firm and level surface.
x
LW300A(E)/300AH(E)/400A(E) and ML-2551A(-CE)/2552A(-CE)/2550A(-CE) Models: Use a
power supply of three-phase, 200/220/240 VAC +10%/-15% (50/60 Hz) having a capacity of at
least 50 A, or three-phase, 380/400 VAC r10% (50/60 Hz) having a capacity of at least 30A (CE
models).
NOTE: Depending on the manufacturing date, the 240VAC option may not be available.
x
Be sure to apply good grounding to the laser.
x
This manual does not cover adjustments made prior to start-up, as such adjustments are performed
by our engineers after the Laser is installed. For space requirements and power supplies, see
Appendix A, Technical Specifications.
x
Use the Laser in a place where the ambient temperature is between 41-95°F (5-35°C) and humidity
is 85% (non-condensing) or less and where there are no sudden temperature fluctuations.
x
Do not use the Laser in the following places:
Where there is considerable dirt, dust, mist, chemicals, fumes, moisture, or near a highfrequency noise source.
Where the Laser may be subjected to vibration or impact.
Where moisture may be condensed on the surface of the Laser.
Where atmosphere has a high concentration of CO2, NOx or SOx
(Air containing more than 0.1% CO2 may shorten the life of the ion-exchange resin).
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Installation Precautions (Continued)
x
If the outside of the Laser is stained, wipe it with a dry or slightly moistened cloth. If it is badly
stained, use a neutral detergent or alcohol to clean it. Do not use paint thinner, acetone, benzene,
etc. which can discolor or deform the parts.
x
Do not put screws, coins, etc. in the Laser, since they can cause a malfunction.
x
Operate the switches and buttons carefully by hand. If they are operated roughly or with the tip of a
screwdriver, a pen, etc. they can cause a malfunction.
x
Operate the switches and buttons one at a time. If two or more of them are operated
simultaneously, the Laser may develop trouble.
x
The outer panels and the covers are electrically connected to the main unit by connecting ground
cables. When the panels, covers and connecting cables are removed and installed again, make sure
that all these ground cables are put back into place correctly. Also, make sure that the cables do not
block the optical path of the oscillator or get caught between the outer panel and the frame.
Operation Precautions
When operating or servicing the Laser Welder unit, always wear Protective Goggles having an optical
density of at least 7+ at a wavelength of 1064 nanometers for the operation of the
LW300A(E)/300AH(E)/400A(E) and ML-2551A(-CE)/2552A(-CE)/2550A(-CE) Nd:YAG Laser
Welders.
Appoint a Laser Safety Officer. The Laser Safety Officer (LSO) must provide personnel with sufficient
training so that they can operate, maintain and service the Laser Welder safely. The LSO must take
charge of the key to the Key Switch to ensure that only qualified and authorized personnel operate the
Laser Welder.
Establish and control a dedicated Laser Operation Area. The Laser Safety Officer must isolate the Laser
Operation Area from other work areas and display signs warning that the Laser Operation Area is offlimits to unauthorized personnel.
Maintenance/Service Precautions
x
Do not modify the Laser Welder without prior written approval from Miyachi Unitek.
x
Before performing any maintenance on the Laser, read Chapter 6, Maintenance thoroughly. Use
the appropriate tools for terminating the connecting cables, being careful not to nick the wire
conductors.
x
Procedures other than those described in this manual or not performed as prescribed in this manual,
may expose personnel to electrical and/or laser radiation hazards.
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Cold Weather Precautions
x
Rapid temperature changes may cause dew condensation on the end faces of the Nd:YAG rod and
on other optical surfaces. This will attract dust and can cause damage to the optical surfaces. If this
occurs, see Chapter 6, Maintenance for corrective action.
x
If the temperature drops below 32°F (0°C), the water inside the Laser’s cooling system can freeze,
thus damaging the unit. Take special care to keep the ambient temperature above 32°F (0°C). If the
temperature is likely to drop below 32°F (0°C), drain the water in accordance to the procedure
described in Chapter 6, Maintenance.
Transporting Precautions
When transporting the Laser, observe the following precautions to prevent an accident to the worker and
damage to the Laser.
x
Package the Laser securely.
x
The worker must wear a helmet, safety shoes and gloves for safety. (Leather gloves are
recommended.)
x
When transporting the Laser, use a lift truck, crane, belt, etc., with a capacity of at least 1100
pounds (500 kg) of allowable load.
x
Retract the level adjuster fully when transporting the Laser.
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Lift Truck/Forklift Precautions
x
As shown below, adjust the distance between the lift truck forks to at least 22.0” (560mm).
Verify that the fork does not hit the level adjuster.
x
When transporting, belt the Laser to the lift truck and keep it horizontal.
When using a forklift, insert the forks fully until the points appear from under the Laser.
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Crane Precautions
x
When lifting the Laser, belt it between the
caster and level adjuster as shown in the
BELT HERE label.
x
Use two belts.
x
During transportation, keep the Laser
horizontal.
x
To prevent damaging the level adjusters,
make sure that the lifting belt is not
interfering with the level adjuster.
Using Cushions
x
When lifting with a belt, properly cushion
the Laser.
x
When craning the Laser, use cushions
(blanket, sponge, or rubber) between the
Laser and belts to prevent damaging the
Laser. Keep the Laser stable.
x
Verify that the distance (B) between the top
corner of the Laser and the crane hook is at
least 1.5 times the Laser width (A)
[including the protective cushions].
x
When the belt is not long enough as shown,
insert a board (plywood, laminated board,
or angle board) on the Laser to prevent
damage to the top surface of the Laser.
x
Do not belt the front door, as it may become
deformed and will not open/close properly.
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Shipping Precautions
x
Fix the Laser firmly using belts, cushions,
etc., to prevent an accidental fall or damage
due to vibration.
x
Retract the level adjuster fully when
freighting the Laser.
x
Insert a board and thick cushion between the
front door and wall to provide enough
clearance between the wall and the upper
front panel of the Laser.
x
Insert wood between the bottom of the Laser and floor to balance the Laser.
x
Belt and fix the laser using at least two planes of floor and wall. Be sure to use cushions
between the Laser and the belt(s) to prevent damaging the laser.
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CHAPTER 1
SYSTEM DESCRIPTION
Section I: Features
For the rest of this manual, the LW300A(E) / ML-2551A(-CE), LW300AH(E) / ML-2552A(-CE) and
LW400A(E) / ML-2550A(-CE) Laser will be referred to simply as the Laser. The Laser is a compact,
pulsed, Nd:YAG laser designed as a precision spot and seam welder. It incorporates the following
features in its design:
x
The Compact YAG Laser is equipped with laser power feedback control to operate with the same
performance shot after shot.
x
The Laser can handle a wide variety of workpieces. Up to 32 different weld schedule settings can
be programmed into the laser, each with its own unique weld characteristics.
x
High output repetition (500 pps max.) supports seam welding and high-speed processing.
x
The Laser controller is detachable from the main body of the Laser which allows remote control.
x
A variety of input and output signals allow the Laser to be connected to automated equipment.
x
The power monitor measures both the oscillation output energy (J) and its mean power (W). In
addition, an oscillation output energy comparator (upper-lower limit judgment) is provided for
quality control purposes.
x
For seam welding, the output can be set to fade-in at the start of a weld and fade-out at the end of a
weld, to smooth overlaps at both ends of the weld.
x
Use of high-precision optical fiber eliminates the optical axis adjustment usually needed every time
the fiber is removed and reinstalled.
Options
x
Optical fiber breakage/detatchment detection is available.
x
Multi-Workstation Interlock function is available.
x
The Laser can be operated by two different Laser Controller's; the MLE-115A (Black & Gray LCD
display) and the MLE-118A (Color LCD display).
x
The external communications function allows central control of all data, such as parameter settings
and monitored values for the Laser.
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CHAPTER 1: SYSTEM DESCRIPTION
Section II: System Components
Front Panel
1.
SHUTTER (1 to 4). Lights to indicate which
branch shutters (1-4) are open.
2.
POWER Lamp. Lights up when the MAIN
POWER switch is turned on, indicating that
power is ON.
3.
HIGH VOLTAGE Lamp. Indicates that high
voltage is present in the laser oscillator.
4.
READY Lamp. Lights up when the capacitor
bank is charged and the laser is ready to fire.
5.
MAIN SHUTTER Lamp. Stays on while the
main (resonator) shutters are open.
6.
CONTROL Key Switch. When MAIN POWER
is ON, turning this switch ON will make the
Laser operable. When shutting down the
Laser, turn this switch OFF and remove the
key. A designated safety supervisor should
keep the key.
7.
Laser Controller. Sets the weld schedules
and operates the Laser. Displays various data
on its Liquid Crystal Display (LCD). There
are two different Laser Controllers available
for this Laser model; the MLE-115A and
MLE-118A. The MLE-115A is shown in the
illustrations throughout this manual.
8.
MAIN POWER Switch. Switches power to
the Laser ON and OFF.
9.
Water Level Viewing Window. Allows the user to view the cooling water level in the cooling
water tank.
10. Front Door Handle. Press the button under the handle and the handle will pop out. Pull the
handle up to open the front door. After closing the door, put back the handle back into place and
the door will lock.
11. Front Door. Opens for access to the cooling water tank, power supply terminals, I/O
connections and the main circuit breaker.
12. EMERGENCY STOP Switch. Pressing this switch will stop the Laser immediately. This switch
has the same effect as turning the CONTROL switch to OFF. On CE models, activating the
EMERGENCY STOP Switch has the same effect as turning the MAIN POWER switch OFF, however
the Power Supply will remain ON. To reset this switch, turn it to RESET (clockwise).
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CHAPTER 1: SYSTEM DESCRIPTION
Middle Panel
1.
EXT. I/O (1), EXT. I/O (2), EXT. I/O (3), EXT. I/O (4) Connectors
(Refer to Appendix B: Electrical & Data Connections for detailed information).
x EXT I/O (1) and EXT I/O (2): Used for output signals (e.g. alarm signals, monitor judgment
signals) and input signals (e.g. start signal, schedule signals, etc.).
x EXT I/O (3): Used to input and output Emergency Stop signals.
x EXT I/O (4): Used to input and output redundant Emergency Stop and Remote Interlock
signals. This function works independently from EXT I/O(3) and the Remote Interlock
connectors and is available on CE models.
NOTE: Depending on the configuration and date of manufacture, the Dual E-Stop/Interlock
option may not be available.
2.
SIGNAL Connector. This BNC connector can be used to connect the Laser to an oscilloscope so
you can view the output waveform of each Laser output pulse.
NOTE: VOUT 1V/kW.
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CHAPTER 1: SYSTEM DESCRIPTION
3.
REMOTE INTERLOCK Connector. Used to connect the Laser to the Remote Interlock circuit for
safety. When disconnected (opened), the main (resonator) shutters close to prevent laser emission.
4.
RS-485 (2) Connector. For external communications (optional).
5.
RS-485 (1) Connector. For external communications (optional).
6.
Power Supply Terminals. If you open the front door, you will see the input terminals inside.
Connect the terminals to a 3-phase power supply of 200/220/240 VAC or 380/400 VAC for CE
models. To ensure safety and optimal operation, the laser must be properly grounded. A Neutral
connection is not required or used on this laser. However a PE (protective earth) Ground is provided
and MUST be used. It is important to note that the Neutral and PE Ground are NOT the same. DO
NOT connect the Neutral line to the PE terminal.
7.
Drains. For draining water from the secondary cooling water tank in order to prevent damage from
freezing conditions.
8.
Water Filter. Removes dirt and other contaminants from the secondary cooling water.
9.
Ion-exchange Resin (Deionizer). Used to deionize the secondary cooling water.
10. Water Level Label. Shows the proper level of the secondary cooling water.
11. Cooling Water Tank. Holds secondary cooling water used for cooling the Nd:YAG rod, flashlamp
and the electronics.
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CHAPTER 1: SYSTEM DESCRIPTION
Top, Side, and Rear Panels
1.
Head Covers A & B. Covers the laser oscillator.
2.
Flashlamp Access Cover. Open this cover when replacing the flashlamp.
3.
Optical Fiber Inlets. These inlets are on the top and rear of the Laser. Pass the optical fibers
through the grommets and connect them to the “Laser Beam Input Units” (see below).
4.
Cable Inlet. Pass the Fiber Breakage/detachment or Multi-Workstation Interlock wires through
these grommets (optional). Depending on the configuration, there may be connectors installed in
these locations.
5.
Rear Cover. Covers the Power Supply and Cooler on the rear of the Laser.
6.
Air Filter. Covers the air intake to prevent dust and dirt from getting into the Laser. The main
cooling fan for the electronic assemblies is behind this filter.
7.
Solenoid Valve Cover. Covers the solenoid valve used to control the flow-rate of the primary
cooling water.
8.
Cooling Water Outlet. For the primary cooling water. Connect to an external cooling unit (chiller).
9.
Cooling Water Inlet. For the primary cooling water. Connect to an external cooling unit (chiller).
10. Side Covers. Located on both sides of the Laser, they cover the Laser Power supplies and Cooler.
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CHAPTER 1: SYSTEM DESCRIPTION
Laser Oscillator
1.
Hold-down Brackets. The yellow hold-down brackets are used to lock the laser oscillator in place
to prevent any damage or dislocation during transportation. Be sure to remove both hold-down
brackets before starting operations.
2.
Branch Unit Cover. Do not remove this dust-proof cover except when installing and removing the
optical fiber.
3.
Timeshare Unit (Only for Time Shared configurations). When closed, laser light output is
reflected internally. Depending on the configuration, 0 to 3 timeshare shutters will be installed.
4.
Resonator Mirror Holder (PR). Holds the Partially Reflective resonator mirror. Light excited in
the Laser Chamber is amplified between the two resonator mirrors and output through this mirror as
a laser beam.
5.
Main (Resonator) Shutter # 1. When this shutter is closed, the laser beam will not be produced
even if the flashlamp is turned ON. This shutter opens and closes in unison with Main Sutter # 2.
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CHAPTER 1: SYSTEM DESCRIPTION
6.
Laser Resonator / Oscillator Chamber. Contains the flashlamp and the Nd:YAG rod. The
flashlamp lights up to excite the YAG rod and emit the laser beam.
7.
Guide Beam. Outputs a red, visible laser beam. This visible laser beam is used as a guide beam
for oscillation adjustment and incident beam adjustment. Additionally the guide beam can also be
used for positioning parts to be welded (since the Nd:YAG beam is invisible).
8.
Main (Resonator) Shutter # 2. When this shutter is closed, the laser beam will not be produced
even if the flashlamp is turned ON. This shutter opens and closes in unison with Main Sutter # 1.
9.
Resonator Mirror Holder (HR). Holds the Highly Reflective resonator mirror. Light excited in the
Laser Chamber is amplified between the two resonator mirrors and output as a laser beam.
10. Power Monitor Unit. Measures the resonator power and energy output of the YAG laser beam.
11. Guide Beam Steering Mirrors. Adjusts the guide beam (visible laser beam) so that this beam
passes down the center of the YAG laser beam optical path.
12. Laser Beam Input Unit (Up to 4). Connect the optical fiber to this unit. The Laser Beam Input
Unit focuses the laser beam emitted from the laser oscillator chamber into the optical fiber.
Depending on the configuration, 1 – 4 laser beam input units will be installed.
13. Branch Shutter (Up to 4). When closed, the laser light output is blocked for that output.
Depending on the configuration, 1 to 4 branch shutters will be installed.
14. Beamsplitter (Up to 4). Splits a laser beam into the number of deliveries and reflects them onto
each laser beam input unit. Depending on the configuration, 1 to 4 beamsplitters will be installed.
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CHAPTER 1: SYSTEM DESCRIPTION
MLE-115A - Laser Controller (Control Panel)
1.
Liquid Crystal Display. Displays data such as schedule settings and monitored data.
2.
Line Cable Connector. Connect the supplied line cable to the Laser for operation.
3.
EMERGENCY STOP Switch. Press the EMERGENCY STOP switch in an emergency and the
laser will stop immediately. This switch has the same function as the other EMERGENCY STOP
switch on the Laser. Only use this function in an emergency.
4.
MENU Key. Each time the MENU key is pressed, a different menu function will be displayed.
5.
LASER START/STOP Button with EMISSION INDICATOR. Pressing this button when the
READY lamp is on and the resonator shutters are open; will produce laser emission. If the Laser
is programmed for continuous mode operation, pressing this button once will start a continuous
output of programmed laser pulses. Pressing it again will stop laser emission (will not occur if
the Laser is set for EXT. I/O control). Emission indicator illuminates when the unit is able and
ready to fire the laser.
6.
ENTER Key. Stores numerical and changed settings in the Laser Controller. The Laser
Controller will not recognize set or changed data, unless the ENTER key is pressed. Once you
change any setting, be sure to press the ENTER key.
7.
ON(+)/OFF(-) Key. Use this key when you want to change the numerical value or switch an
ON/OFF setting of the selected item. Press ON (+) to increase the number; OFF (-) to decrease.
8.
CURSOR Key. Moves the cursor (
) up, down, left and right on the LCD screen.
9.
TROUBLE RESET Key. If trouble arises, an alarm will be activated. Eliminate the cause of
the trouble, then press this key to reset the alarm.
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CHAPTER 1: SYSTEM DESCRIPTION
MLE-118A - Laser Controller (Control Panel)
1.
LASER START/STOP Button with EMISSION INDICATOR. Pressing this button when the
READY lamp is on and the resonator shutters are open; will produce laser emission. If the Laser
is programmed for continuous mode operation, pressing this button once will start a continuous
output of programmed laser pulses. Pressing it again will stop laser emission (will not occur if
the Laser is set for EXT. I/O control). Emission indicator illuminates when the unit is able and
ready to fire the laser.
2.
Liquid Crystal Display. Displays data such as schedule settings and monitored data.
3.
Line Cable Connector. Connect the supplied line cable to the Laser for operation.
4.
EMERGENCY STOP Switch. Press the EMERGENCY STOP switch in an emergency and the
laser will stop immediately. This switch has the same function as the other EMERGENCY STOP
switch on the Laser. Use this function only in an emergency.
5.
ENCODE Function Switch. Used to control all functions of the Laser. Turn the ENCODE
button clockwise and counter-clockwise to scroll through the various menu screen functions.
Once you land on a field you want to change (highlighted in yellow), select the ENCODE button
by pressing it downward. Rotate the ENCODE button to change parameters, then select the
ENCODE button by pressing it downward to set the changed value. All menu navigation and
function selections are achieved using this button.
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CHAPTER 2
INSTALLATION AND SETUP
Section I: Planning
When planning for the installation of the Laser, assure that the following conditions are met:
Physical Requirements
x
The Laser should be placed in a dedicated laser operation area. The person responsible for the
area (the Laser Safety Officer) must isolate the laser operation area from other work areas and
display signs warning that the laser operation area is off limits to unauthorized personnel.
x
See Appendix A, Technical Specifications for specific weight and dimensional requirements.
x
The Laser should be placed on a firm, level floor that is free from vibration.
x
Do not operate the unit where there is considerable dirt, dust, oil mist, chemicals fumes,
moisture, or near a high-frequency noise source.
x
The ambient temperature should be between
41°F - 95°F (5°C - 35°C). The ability of the
internal cooling system to maintain the correct
operating temperature is inversely proportional
to the duty cycle. Refer to Appendix A,
Technical Specifications for details. The
humidity should be 85% or less (noncondensing). The area should have no sudden
temperature fluctuations.
Allow adequate clearance on all sides of the
Laser to allow for cooling, maintenance, and
servicing. (see figure to the right)
x
Power Requirements
x
LW300A/300AH/400A Models: Use a power supply of three-phase, 200/220/240 VAC +10%/15% (50/60 Hz) having a capacity of at least 50A. The Laser is shipped standard for 220VAC.
Consult with Miyachi Unitek if operating on 200VAC or 240VAC.
x
LW300AE/300AHE/400AE Models: Use a power supply of three-phase, 380/400 VAC r10%
(50/60 Hz) having a capacity of at least 30A. The Laser is shipped standard for 400VAC. Consult
with Miyachi Unitek if operating on 380VAC.
x
To ensure safety and optimal operation, the laser must be properly grounded. A Neutral connection
is not required or used on this laser. However a PE (protective earth) Ground is provided and
MUST be used. DO NOT connect the Neutral line to the PE terminal. Service should be from a
ground fault circuit breaker that is inverter high frequency surge-resistant.
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CHAPTER 2: GETTING STARTED
Section II: Installation
Removing the Oscillator Hold-down Brackets
Oscillator hold-down brackets are provided on the laser to protect the oscillator against vibration and
shock during transportation. These brackets should be removed before operation.
1.
Remove the Operation Panel holding screws on both sides of the Laser and tilt the panel
forward as shown.
2.
Remove all Head Cover holding screws, then pull both Head Covers up as shown to remove.
3.
Loosen the screws to disengage the hold-down brackets from the oscillator base. The oscillator
is supported with rubber legs to absorb slight vibrations. Do not subject the Laser to shock or
strong vibrations.
NOTE: When transporting the Laser after it has been installed, secure the oscillator with the hold-down
brackets as it was when shipped.
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CHAPTER 2: GETTING STARTED
Securing the Laser (CE and Non-CE Models)
Secure the Laser to floor (optional) using the supplied MUC # KC-1275C-3 Adjuster Pressure Plates.
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CHAPTER 2: GETTING STARTED
Supplying Power
To ensure safety and optimal operation, the laser must be properly grounded. A Neutral connection is
not required or used on this laser. However a PE (protective earth) Ground is provided and MUST be
used. DO NOT connect the Neutral line to the PE terminal. Service should be from a ground fault
circuit breaker that is inverter high frequency surge-resistant.
Open the front door and remove the terminal block cover to access the power supply input terminals.
Route the power cable through the bottom of the Laser and connect it to the power supply input
terminals, checking the color of the wires. The phases must be connected to the laser in a specific order.
If you get an E05: Phase Trouble error when first turning on the laser, simply reverse two of the phases.
Non-CE Models: The Laser is factory jumpered for 220VAC operation. Consult Miyachi Unitek if you
plan on operating the Laser at 200VAC or 240VAC.
NOTE: Depending on the manufacturing date, the 240VAC option may not be available.
CE Models: The Laser is factory jumpered for 400VAC operation. Consult Miyachi Unitek if you plan
on operating the Laser at 380VAC.
Power Cable Requirements
3-Phase Power Supply
Rated Voltage
Number of Cores
Cross Section
200/220/240 VAC
380/400 VAC
300 VAC
600 VAC
3
3
2
8 AWG (8mm )
9 AWG (6mm2)
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Cooling Water System
The Laser uses two isolated cooling water systems:
Primary Cooling Water
External: for cooling the Secondary cooling water.
Secondary Cooling Water
Internal: for cooling the flashlamp, Nd:YAG rod and electronics.
Cooling Water Block Diagram
Temperature is maintained by allowing the primary cooling water to cycle through the laser. Once the
secondary cooling water reaches a predefined high temperature set-point, the Solenoid Valve is
energized which allows the primary cooling water to flow through the Heat Exchanger. Once the
secondary cooling water reaches the low temperature set-point, the Solenoid Valve is turned off.
Connect the primary cooling water supply to the hose barbs on the rear panel of the laser.
Parameter
LW300A(H)(E)/400A(E)
ML-255xA(-CE)
3.36 ton
Minimum Cooling Capacity
10,150 kcal/hr
40,252 BTU/Hr
11.82kW (maximum)
Water Temperature Range
5°C ~ 35°C (41°F ~ 95°F)
Recommended Flow Rate
(at maximum output)
16 L/min (@ 30°C / 86°F)
Differential Pressure
14.2 psi ~ 42.6 psi (98 ~ 294kPa)
Maximum Pressure
42.6 psi (294kPa)
Water Inlet Diameter
15mm
25 L/min (@ 35°C / 95°F)
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CHAPTER 2: GETTING STARTED
Connecting the Hose for Primary Cooling Water
Connect the supplied 15mm braided hoses to the cooling water inlet and the outlet on the rear of the
Laser. Tighten the hoses using the supplied hose bands.
NOTE
Use city water or water for industrial use for the primary cooling water, with a
maximum pressure of 42.6 psi (294 kPa) and a differential pressure of 14.2 to 42.6 psi
(98GtoG294 kPa). The required flow rate will vary depending on cooling water
temperature. Refer to Appendix A for flow rate requirements.
Supplying the Secondary Cooling Water
CAUTION
Use ion-exchanged water or steam-distilled water for the secondary cooling water. Tap
water, water for industrial use, ground water, super pure water (16 M:/cm resistivity)
and water with ethyl glycol may cause corrosion or clogging, resulting in a failure.
1.
Remove the cover of the cooling water tank.
2.
Fill the tank with cooling water up to the line reading [HIGH] on the level gauge label, using
the supplied hand pump.
3.
After filling the tank, put the floating panel on top of the water.
4.
Fasten the cover back onto the cooling water tank. Once you have supplied the cooling water
and started the cooler, the water level may drop slightly. If so, add more cooling water. Make
sure that the floating panel is removed when adding the cooling water.
NOTES
x Only use the supplied hand pump for the secondary cooling water. To avoid
contamination, do not use it for any other purpose.
x
You can use the floating panel repeatedly until it starts cracking or breaking apart. If the
panel becomes stained, clean it using tap water and a soft sponge, then rinse it with ionexchanged water or steam-distilled water.
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CHAPTER 2: GETTING STARTED
Handling Fiber Optic Cables
Minimum Bend Radius for Specified Core Diameter
Optical fibers may be damaged and become unusable when they are bent beyond their minimum bend
radius, subjected to twisting or exposed to the shock of a strong impact.
Minimum Bend Radius
Core Diameter
(μm)
(Inches)
(mm)
200μm
7
175
300μm
7
175
400μm
7
175
600μm
10
255
800μm
12
305
1000μm
14
355
Dirt or dust on the end surfaces of an optical fiber can damage the fiber. The damaged surfaces of the
fibers can also cause contamination to adjacent lenses. To prevent contamination, do not remove the
protective rubber fiber end caps from either end of the optical fiber until it is necessary.
Optical Fiber Connection
The Laser uses high-precision optical fiber. Once the laser beam is adjusted, no further adjustment is
necessary, even if the optical fiber is removed and re-installed again.
NOTES
x Make sure that the end face of the optical fiber is free of stains and/or dust. If any dust or stains
are found, blow the end face clear using a camera lens air blower or wipe it off using lenscleaning paper. (See Chapter 6, Section IV: Maintenance Procedures, Cleaning the Optical
Fiber.) Use a fiber inspection tool (MUC # 4-60091-01) as necessary to verify the cleanliness.
x Do not over-tighten the ring on the fiber plug, hand-tighten only. The laser beam may become
misaligned if the plug is too tight.
Connecting to the Laser Beam Input Unit (Inside the Laser)
1.
Remove the Operation Panel holding screws on both sides of the Laser, then tilt the Operation
Panel forward.
2.
Remove all Head Cover holding screws , then pull both Head Covers up to remove.
3.
Remove the Branch Unit Cover.
4.
Pass the optical fiber with its protective rubber cap into the Laser through one of the optical
fiber inlets located on the top or rear of the Laser
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CHAPTER 2: GETTING STARTED
5.
Remove the protective cap from the end of the passed fiber and blow off any dust using an air
blower, then connect the fiber(s) to the laser beam input unit(s). Align the key of the fiber plug
with the groove of the input unit. Do not over-tighten the fiber plug, hand-tighten only.
6.
Re-attach the Branch Unit Cover and Head Covers, then return the Operation Panel to its
original position and tighten the holding screws.
Connecting to Laser Beam Output Unit (Focus Head)
Remove the protective cap from the end of the fiber and blow off any dust using an air blower, then
connect the fiber to the output unit (focus head). Align the key of the fiber plug with the groove of the
output unit (focus head). Do not over-tighten the fiber plug, hand-tighten only.
CAUTION: Be careful not to apply any shock to the optical fiber or bend it beyond its minimum
bending radius.
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Connecting the Laser Controller Remotely (Optional)
CAUTION
To prevent electrical shock, be sure to turn the power supply OFF
before connecting the cable.
If the Laser Controller is to be located away from the Laser, an extension controller cable must be used
in order to connect the Laser Controller to the Laser.
1.
Remove the Operation Panel holding
screws on both sides of the Laser and
tilt the Operation Panel forward.
2.
Remove the Controller cable, cable
clamp, and clamp screw (located in a
plastic bag behind the Operation Panel).
3.
Return the Operation Panel to its
original position and tighten the holding
screws.
4.
Remove the laser controller holding
screw.
5.
Pull the Laser Controller toward you to
take it out.
6.
Connect the Controller cable between
the Laser Controller and the Laser.
7.
Clamp the cable to the laser with the
cable clamp and clamp screw.
In the example shown, the MLE-115A
is shown for illustrative purposes. The
same procedure applies for the MLE118A Laser Controller.
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CHAPTER 3
MLE-115A PROGRAMMING FUNCTIONS
Section I. LCD Control Screens
About the LCD Screens
There are three main LCD screens used to control the Laser.
x Schedule Screen – used to set the parameters of your weld.
x Status Screen – used to control the output process.
x Power Monitor – used to display output weld information.
Each time the MENU key is pressed, the CONTROL screen will change as shown below. If the Laser is
fired while viewing the SCHEDULE screen, the POWER MONITOR screen will automatically appear after
the Laser has fired.
NOTE: if the characters or numbers are shaded, the values may be changed by the operator.
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CHAPTER 3: MLE-115A OPERATION
Screen Content
The content of each LCD screen differs based on the screen, however some parameters are common to
all screens. The content of each screen is outlined below.
CONTENTS
SCREEN
Individual Screen
Common to Each Screen
Schedule Number
[FORM] Output Mode (FIX or FLEX)
Graph Display (ON/OFF)
) Display (J)
Laser Energy (
Laser Output Peak Setting (kW)
Repeat Setting (PPS)
Slope Time Settings (ms)
Number of Shots Setting
[FLASH/Point] Laser Output Time Setting (ms)
[FLASH/Point] Laser Output Value Setting (%)
Slope Time Setting (ms)
[COOL 1/2] No Laser Output Time (ms)
Seam Weld Mode (ON/OFF)
(HV) High Voltage (ON/OFF)
STATUS
[STATUS] Laser Control Method
[BEAM] Branch Shutter Control (ON/OFF)
Shot Count Preset/Reset
Good Count Preset/Reset
Guide Beam Blinking Control (ON/OFF)
Optical Fiber Settings (SI/GI/mm)
Position Guide Beam (ON/OFF)
POWER
MONITOR
Schedule Number
Graph Display (ON/OFF)
Laser Output Energy (J)
Laser Output Average Power (W)
Total Shot Count
Good Shot Count
Laser Energy Upper/Lower Limit Setting (J)
Lamp Input Power Display (%)
Lamp Input Power Upper Limit Setting (%)
SCHEDULE
Main Shutter (ON/OFF)
Water Temperature ( qC )
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Section II. How to Use the LCD Screens
SCHEDULE Screen
The Laser is capable of processing two types of [FORM] outputs:
x [FIX] Output – Defines a laser output process over three time segments.
x [FLEX] Output – Defines a laser output process over twenty discrete points.
[FORM: FIX] Function
The majority of all laser processing can be
completed using the [FORM: FIX] output mode.
The Laser output can be defined over three time
segments, including a power ramp UP/DOWN
feature in segments 1 and 3 as shown on the
right.
1.
SCH # – Displays the schedule number selected on the SCHEDULE screen. A schedule is a
stored set of laser output parameters. Since different welds require different welding
parameters, each may be stored separately using different schedule numbers. The Laser is
capable of storing up to 32 schedules (SCH # 00 – 31).
2.
FORM – There are two options in the FORM field: FIX and FLEX. When the FORM field is
selected, you can choose the FORM option. This section describes the FIX output mode feature.
NOTE: If the [FORM] output mode is switched, all waveform setting values will be set to “0”.
3.
PEAK – Sets the reference value of the Peak Power laser output. The actual programmed laser
output is set as a percentage of this Peak Power value. The maximum Peak Power output
setting of the laser output varies depending on the model number of the laser.
Example: PEAK 4.00 kW x 50% = 2.0 kW
Note: If Initialization Switch SW1-6 is ON, the Maximum Peak Power 0.10kW (see pg 3-15).
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Model
LW300A (E) / ML-2551 A(-CE)
LW300AH (E) / ML-2552A (-CE)
LW400A(E) / ML-2550A(-CE)
Maximum Peak Setting
5.0 kW ( 10ms )
5.0 kW ( 4ms )
8.0 kW ( 10ms )
4.
– Displays estimated laser output energy in Joules ( J ) of the programmed waveform.
Though the Laser computes the output energy based on the programmed settings, due to optical
and electrical characteristics, its estimated value will differ slightly from the monitored
(measured) value. Use the estimated laser output energy as an approximation.
5.
WATER – Displays the temperature of the internal cooling water.
6.
REPEAT SHOT
REPEAT sets the number of laser pulses per second (PPS). The
setting can be changed between 0 and 500. When it is set to 0, the
REPEAT = 000PPS
SHOT = 0000
laser pulse is not repeated.
SHOT sets the number of times (shots) you want to output the laser beam consecutively. The
setting can be changed between 0 and 9999. When REPEAT > 0 and SHOT = 0, the Laser will
continue to output a laser beam until it receives a laser-stop signal.
7.
SEAM WELD MODE Screen
Field used to activate the SEAM weld function that is used to suppress the output waveform
over a predetermined amount of pulses. Options:
OFF:
Turns the fade-in/out seam weld function OFF.
ON:
Activates the fade-in/out function for seam welding.
SET:
Displays the SEAM weld setting screen.
8.
POSITION – When ON, a visible guide beam laser is displayed at each laser output to aid in
process alignment. When OFF is selected, the guide beam laser is turned off.
9.
MAIN SHUTTER – When ON is selected, the main shutters are opened and the Laser is ready
for oscillation. When OFF is selected, no laser output is possible.
10. HV – HV stands for HIGH VOLTAGE. If ON is selected, the high voltage is turned on and the
HIGH VOLTAGE lamp will light up. When OFF is selected, the high voltage is not supplied
and laser output is not possible.
11. FORM : FIX Settings – The FORM:FIX settings are used to
define the pulse shape of the Laser output over three
segments. The pulse shape is defined using the SLOPE,
FLASH 1 / 2 / 3, SLOPE, and COOL 1 / 2 parameters. FLASH
1 / 2 / 3 are used to define how long (ms) and how much
power (%) should be delivered to the output during that
particular time segment.
SLOPE
FLASH 1
FLASH 2
FLASH 3
SLOPE
00.5ms
01.5ms
01.5ms
03.0ms
01.0ms
100.0%
025.0%
050.0%
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Ê SLOPE
Sets the upslope (the laser beam is gradually intensified) within the time set for
FLASH1. Set FLASH1 first and then set Ê SLOPE. (Note: Ê SLOPE d FLASH1).
Ê SLOPE can also eliminate “overshoot” on the rising edge of the output pulse.
FLASH1
Sets the first segment laser output time and the first laser output value (%).
FLASH2
Sets the second segment laser output time and the second laser output value (%).
FLASH3
Sets the third segment laser output time and the third laser output value (%).
Ì SLOPE
Sets the downslope (the laser beam gradually weakens) within the time set for
FLASH 3. Make sure that Ì SLOPE is d FLASH3.
COOL 1
Sets value of time between FLASH1 - FLASH2 when there will be no laser output.
When set to 0, there will be no cooling period.
COOL 2
Sets value of time between FLASH2 - FLASH3 when there will be no laser output.
When set to 0, there will be no cooling period.
The range of the FLASH 1 / 2 / 3 parameters depend on the laser model.
Model
Ê SLOPE + FLASH1 + COOL1 + FLASH2 + COOL2 + FLASH3 + Ì SLOPE
LW300A(E) / ML-2551A(-CE)
0.1 t 99.9 ms and 0 – 200% value
LW300AH(E) / ML-2552A(-CE)
0.1 t 99.9 ms and 0 – 200% value
LW400A(E) / ML-2550A(-CE)
0.1 t 99.9 ms and 0 – 200% value
The maximum peak power output available for each laser model depends on the output pulse
width. See the graphs in Appendix A, Section III: Maximum Peak Power for more information.
12.
(Graph) – When ON is selected, a graphical representation of the programmed waveform
is displayed. The X-axis is expressed in ms, the Y-axis as a percentage (of peak power).
When the graph is displayed, it hides the REPEAT SHOT field on the right side of the screen.
To access the REPEAT SHOT field, turn the graph OFF.
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[FORM: FLEX] Settings
Occasionally, the need for a non-conventional waveform is needed. Any user-specified output may be
defined using the [FORM: FLEX] output mode. With FLEX mode, the Laser output can be defined over
twenty discrete points in time.
An example of a programmed FLEX waveform
is shown on the right. In this example the entire
waveform is 15mS long specified with 5 points.
Point 1
Point 2
Point 3
Point 4
Point 5
1.0mS
2.0mS
3.0mS
4.0mS
5.0mS
90.0%
70.0%
80.0%
65.0%
00.0%
All screen settings are the same as the [FORM: FIX] screen, with the exception of the waveform entry
values which are explained below:
Point01 through Point20
Sets the laser output time and laser output value (%) for each point to form a free (user-defined)
waveform. You can set up to 20 discrete points. The maximum setting for each point depends on the
laser. To scroll the Point display, use the and function icons to scroll through each point setting (01
through 20).
Laser Model
Point 1 to Point 20*
LW300A(E) / ML-2551A(-CE)
0.3 – 99.9 ms
0.1 ms t 99.9 ms and 0 – 200%
LW300AH(E) / ML-2552A(-CE)
0.3 – 99.9 ms
0.1 ms t 99.9 ms and 0 – 200%
LW400A(E) / ML-2550A(-CE)
0.3 – 99.9 ms
0.1 ms t 99.9 ms and 0 – 200%
* where:
Point Settings
0.3mS d Last Point Value d 99.9mS
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SEAM WELD Screen
The Seam function allows the laser to vary in strength at any point within a continuous stream of
laser pulses for both Fix and Flex waveforms. The most common method of this feature is to
gradually increase the laser output power at the beginning of a seam weld and gradually decrease the
laser power at the end of a seam weld to allow for a smooth overlap at the beginning and ending of a
continuous weld.
Below is an example of how the Seam Weld function operates. In the top example waveform, the
laser is generating a series of 10 programmed output weld pulses without the Seam Weld function.
In the bottom waveform, the laser is generating the same series of 10 programmed output weld pulses
with the Seam Weld function “active”. In this example waveform, the Seam Weld function is active
during the first and last 3 output pulses (Shot 1, Shot 2, Shot 3, Shot 8, Shot 9 and Shot 10).
The SEAM WELD MODE settings for this example are shown in the screen shot below. To enable the
Seam function for any given Schedule # (FIX or FLEX), the SEAM WELD MODE option (on either
Schedule Screen) must be ON and the REPEAT and SHOT 1.
2
1
1.
NO SHOT ENERGY
SHOT defines what shot number to apply the change in Energy %.
ENERGY sets the Laser output value of each Point (0 – 150%) as the % ratio of the Peak
Power specified on the SCHEDULE Screen. When the SEAM WELD MODE is set to ON, the
Energy % values on the SEAM WELD MODE screen over-ride the SCHEDULE screen values.
When the laser is firing a series of seam weld pulses, it sets the ENERGY % at the shot count
specified in SHOT field of the SEAM WELD MODE screen. The output ENERGY % varies
gradually (either increases or decreases depending on the next ENERGY % specified) until it
reaches the next specified shot count. This process repeats for each specified SHOT entry.
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You can program up to 20 discrete SHOT and ENERGY values from Number 01 to Number
20. Use the and function keys, to scroll through all input fields (SHOT01 through
SHOT20). Press the MENU key to return to the SCHEDULE screen.
2.
x
If there are more points specified on the SEAM WELD screen than the total number of
SHOTs specified on the SCHEDULE screen, the Laser will use all of the SEAM WELD
points specified up to the number of SHOTs specified on the SCHEDULE screen. The rest
of the SEAM WELD values (above the SHOT number) will be ignored.
x
If there are more SHOTs specified on the SCHEDULE screen than the total number of
points specified on the SEAM WELD screen, the Laser will use all of the SEAM WELD
point’s specified then use the settings specified at the last point for the remainder of the
shots.
ALL RESET – When ON is selected, all the settings from SHOT01 to SHOT20 will be cleared.
EXAMPLE: SEAM WELD MODE
In the example below, a simple rectangular output pulse (1kW x 2mS) is programmed in the
FORM: FIX SCHEDULE screen at a 10pps repetition rate and a total of 100 shots. The SEAM WELD
MODE screen is made active in order to vary the laser output power over the entire seam weld
process.
SCHEDULE [FORM:FIX] screen
SEAM WELD MODE screen
Note: The POINT06 values (not shown in screen above) are: SHOT = 0100 and POWER [%] = 20%.
When the above parameters are entered into the Laser, the Laser Output will have the following
response (where 100% output = 1.00kW):
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Status Screen
1.
CONTROL DEVICE Mode
Displays the currently selected control method;
EXTERNAL CONTROL, PANEL CONTROL or RS-485 CONTROL.
EXTERNAL
CONTROL
PANEL CONTROL
RS-485 CONTROL
2.
The Laser is controlled by a programmable controller or other similar device
connected to the EXT. I/O connectors.
The Laser is controlled by the Control Panel.
The Laser is controlled by a personal computer connected to the RS-485 (1)
or the RS-485 (2) connector. (optional)
RESET SELECT
Resets the TOTAL Shot Count and the GOOD Shot Count. Move the cursor to the counter you
want to reset, then press the ENTER key. The count will be set back to 000000000.
3.
PRESET
Sets the desired number of laser outputs for the total shot count and the good shot count. When
the count has reached the set number, the following messages will appear:
When the SHOT count has reached the set number.
When the GOOD count has reached the set number.
-!!! COUNT UP !!!
-!!! COUNT UP !!!
WATER 28qC
CHECK THE LAMPS !!
HV:OFF
SHOT
MAIN SHUTTER:OFF
123456789
POSITION:OFF
GOOD COUNT UP !!
HV:OFF
WATER 28qC
GOOD
MAIN SHUTTER:OFF
123456789
POSITION:OFF
Press the TROUBLE RESET key to return to the previous screen.
4.
POSITION BLINK
When selected ON, the guide beam laser will blink continuously. This feature can be helpful
when trying to align dark colored parts to be welded. When OFF is selected, the guide beam
laser will not blink.
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5.
FIBER
This function prevents excessive power from being applied to the optical fiber. Input the fiber
type (SI/GI) and the core diameter of the optical fiber being used. The maximum output power
for any given optical fiber is automatically computed and limited to prevent fiber damage.
Setting range of core diameter: I 0.2 to 1.0 mm for all Laser models.
x The factory default setting is SI 1.0 mm. When a beam expander and/or internal aperture
are used, set the fiber diameter to one setting larger.
x If the schedule settings for PEAK, FLASH (pulse width and power setting) and REPEAT do
not match the fiber type and core diameter, an E51: SET ERROR FIBER or E48: OVER RATE
FIBER warning will appear. In these cases change the input settings.
x If the end face surface of the optical fiber is stained, broken, damaged, or covered with
dust, a warning message will not necessarily appear on the screen. Be sure to put the cap
on the optical fiber when it is not in use or unprotected.
x If the end face of the optical fiber is broken, check the lenses on both the input and output
units for damage. If the lenses are stained, clean them with the method described in
Chapter 6, Maintenance.
x Do not remove the Laser Beam Input Unit unless absolutely necessary. Doing so will
require that the input unit be re-aligned to the laser beam.
6.
BEAM-1 to BEAM-4
Field used to display the installed branch shutters. Each BEAM field allows the operator to
open/close each installed branch shutter. When ON is selected for any branch shutter, the
branch shutter will open. A field must be turned ON in order to get a laser output on that
particular output branch. When OFF is selected, the branch shutter will close.
For example, if the laser is configured with a 3E output (3 energy-shared outputs), BEAM-1
through BEAM-3 must be turned ON in order to get an output on branch fibers 1, 2, and 3.
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Power Monitor Screen
Whenever the Laser is fired, the POWER MONITOR screen automatically displays the measured output.
1.
Graph
When ON is selected, a graphical representation of the measured output waveform is displayed.
The X-axis is displayed in ms, and the Y-axis displays the peak power of the output pulse.
When the graph is displayed, it hides the HIGH, LOW, LAMP INPUT PWR and the REFERENCE
SET fields. To access any of these fields, turn the graph OFF.
If the displayed waveform exhibits “overshoot”, try adding/increasing the upslope ( SLOPE)
time by 0.1 to 1.0ms in the SCHEDULE screen until the overshoot is eliminated.
2.
HIGH / LOW alarm limits
To aid in critical welding processes, a HIGH / LOW energy output
monitor is provided. Set the allowable energy range for the selected
schedule. If the measured output energy falls outside of this range, an
Error Code will display on the LCD screen and the Laser will stop
firing.
3.
HIGH
000.0J
LOW
000.0J
REFERENCE SET and LAMP INPUT POWER
REFERENCE SET is used to set the
WATER 28qC
LAMP INPUT POWER LIMIT !!
maximum input power to the flashlamp. If
the input power exceeds this limit, the
following screen will appear, indicating
that the flashlamp needs replacement.
CHECK THE LAMPS !!
(LAMP INPUT POWER 95%)
HV:OFF
MAIN SHUTTER:OFF
POSITION:OFF
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NOTE: If this display continues for more than 3 seconds, an OVERRATE alarm will also occur.
LAMP INPUT POWER
LAMP INPUT POWER displays the ratio of the flashlamp input power to the output capacity of
the Discharge Unit. A value of 100% means that the Discharge Unit is producing the maximum
amount of designed output power. As a flashlamp ages, it requires more power to flash. In
normal operation, Power Feedback automatically draws the power required from the Discharge
Unit to maintain a constant output, thereby compensating for an aging flashlamp.
The best way to use this feature is to set the REFERENCE SETTING to 95% ~ 98%. Then as the
flashlamp starts to age, it will require more power to maintain a constant output. Eventually the
LAMP INPUT POWER will reach the REFERENCE SETTING value and Lamp Input Power Limit
screen will appear. Once this alarm condition exists the operator can set the REFERENCE
SETTING value to 100% and schedule a flashlamp replacement to minimize production downtime.
4.
SHOT COUNT GOOD COUNT
SHOT COUNT displays the total number of times the laser
SHOT COUNT
was fired. The shot count can be reset to 000000000 on the
STATUS screen.
123456789
GOOD COUNT
123456789
GOOD COUNT displays the number of Good shots that were fired. A Good shot count means
that the measured output energy was within the acceptable range set by the HIGH / LOW alarm
limits. The good count can be reset to 000000000 on the STATUS screen.
5.
AVERAGE
Displays the total mean power in Watts (W) of the laser oscillator (averaged over one second).
Each time the laser is fired, its output is measured and displayed. In the case of high-repetition
outputs, the energy is displayed at periodic intervals. This is because the repetitions are faster
than the LCD refresh rate. The displayed average power will differ from the actual delivered
power at the workpiece. This difference varies based on the optical configuration of the
system.
6.
ENERGY
Displays the measured laser energy in Joules (J) of the laser oscillator. Each time the laser is
fired, its output is measured and displayed. In the case of high-repetition outputs, the energy is
displayed at periodic intervals. This is because the repetitions are faster than the LCD refresh
rate. The displayed energy will differ from the actual delivered energy at the workpiece. This
difference varies based on the optical configuration of the system.
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Section III. Hidden Menu Screens
Overview
There are five hidden screens in the Laser used to INITIALIZE, SETUP, and CONFIGURE the Laser.
CAUTION: These screens should only be used by trained personnel. If the parameters on these
screens are set incorrectly, the Laser may become inoperable.
Initialization Screen
The INITIALIZATION screen is primarily used for the RS-485 communication settings and maintenance
functions.
1.
Turn both the MAIN POWER switch and Keyswitch to the OFF position.
2.
Press and hold the MENU key while turning the MAIN POWER switch ON.
3.
Continue to hold the MENU key until the laser starts the self-check routine, then release the key.
4.
The INITIALIZATION screen will display automatically.
5.
After making changes, press the ENTER key to store the changes. Once all changes have been
made, recycle the power on the Laser in order to initialize the Laser with the new settings.
NOTE: Systems with the ME-1891 PCB will only display three software dipswitch settings.
To modify the LASER START and SCHEDULE signal accept times, see Appendix B, Electrical
and Data Connections, Section IV: Laser Accept Times.
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1.
INITIALIZE
Select ON to restore the laser factory default settings. When this option is selected ALL
schedule data will be erased. Record or save the Schedule Data before Initializing the Laser to
avoid having to re-create all Schedule data.
Example:
Use when the Main PCB is re-programmed or replaced, or after the back-up
battery on the Main PCB is replaced.
2.
WATER
Displays the temperature of the internal cooling water.
3.
WATER TEMPERATURE ALARM SETTINGS - L 25qC H 40qC
These fields are used to set the water temperature threshold upper and lower limits. If the
temperature exceeds either of these set limits, the Laser will not operate until the water
temperature returns to normal. The REF TEMP setting is the optimal temperature point. In order
to prevent poor performance, do not change these setting values.
4.
A =20, B = 80, C = 50, D = 50 (Fan Speed Settings)
CAUTION: These are factory set, do not change these values.
5.
POSITION AUTO-OFF 60MIN
These fields are used to control the position guide beam. These settings are used to
automatically turn the position guide beam OFF to extend the life of the diode in the event the
guide beam is accidentally left ON. This field is adjustable from 01 to 98 minutes.
If the time is set for 00MIN, the position guide beam will not light.
If the time is set for 99MIN, the position guide beam will not turn OFF.
NOTE: The factory default setting is 60MIN.
6.
TEMP CONT WATER 30qC
TEMP CONT is the water temperature control setting for the Laser. The laser will maintain this
set temperature. Do not change this value, as the efficiency of the Nd:YAG output is directly
proportional to the temperature setting.
NOTE: The factory default setting is 30qC.
7.
NETWORK # 00-31
This field is used to select the device (Laser) number for the optional RS-485 communications
function. When connecting multiple Lasers together, each Laser needs a unique NETWORK ID
number. The factory default setting for all lasers is 00.
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8.
SOFTWARE SWITCH SETTINGS
The software switches are part of the Initialization Screen and they are used to set-up specific
Laser functions. When shipped from the factory, all switches are set in the OFF position. If the
Laser is re-initialized (by selecting INITIALIZE: ON from the previous screen), all of these switch
settings will revert back to the factory setting (all OFF).
SW1
Position
Function
SW1-1
Automatic High Voltage startup
SW1-2
External control of the LASER
START/STOP switch in the
Panel Control Mode.
SW1-3
SW1-4
ON
Unit will not turn High Voltage
ON during start-up
Enables control of the
START/STOP signal on the
EXT I/O connector while in
Control Panel Mode.
Not Used
Laser will fire on any
START signal.
Laser will fire according
To the LASER ACCEPT
TIME setting.
Not Used
00.00J (x10)
Peak Power 0.10kW
0.05ms*
Maximum setting = 5mS
Not Used
000.0J (x1)
Maximum Peak Power
0.10ms (default)
Maximum Setting = 99.9mS
ON
7 bits
Without parity
Odd parity
1 stop bit
OFF
8 bits
With parity
Even parity
2 stop bits
Laser Accept Time Trigger
(firmware V50-11N )
SW1-5
SW1-6
Measurement Accuracy (Energy)
SW1-7
Time Setting Resolution
SW1-8
OFF
Unit will turn High Voltage
ON during start-up
Disables control of the
START/STOP signal on the
EXT I/O connector while in
Control Panel Mode.
SW2
Position
SW2-1
SW2-2
SW2-3
SW2-4
SW2-5
SW2-6
SW2-7
SW2-8
Function
External Communications
Communication Baud Rate (see Appendix D)
Not Used
Not Used
Communication Baud Rate
9,600 bps (default)
19,200 bps
38,400 bps
9,600 bps
SW2-5
OFF
OFF
ON
ON
SW2-6
OFF
ON
OFF
ON
Default settings: 9,600 bps, 8-bit, even parity with 2-Stop bits
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SW3
Position
SW3-1
SW3-2
SW3-3
SW3-4
SW3-5
Function
ON
Not Used
OFF
See table below
Laser Start/Accept Times
Not Used
Trigger Signal Enable
(firmware V00-02H)
SW3-6
SW3-7
SW3-8
Trigger Signal Output on
Ext. I/O(1) - Pin7
No Trigger Output
Not Used
Laser Accept Times
16mS (default)
8mS
4mS
1mS
0.1mS
SW3-4
OFF
OFF
OFF
OFF
ON
SW3-3
OFF
OFF
ON
ON
x
SW3-2
OFF
ON
OFF
ON
x
X – don't care
SW4 (see Appendix B, Section III for more information on Independent Control.
Switch
Position
SW4-1
SW4-2
SW4-3
SW4-4
SW4-5
SW4-6
SW4-7
SW4-8
Function
Branch Shutter 1 – When in Independent Control mode, turn ON if branch shutter is installed.
Branch Shutter 2 – When in Independent Control mode, turn ON if branch shutter is installed.
Branch Shutter 3 – When in Independent Control mode, turn ON if branch shutter is installed.
Branch Shutter 4 – When in Independent Control mode, turn ON if branch shutter is installed.
Not Used
SW5 (see Appendix B, Section III for more information on Independent Control.
Position
SW5-1
SW5-2
SW5-3
SW5-4
SW5-5
SW5-6
SW5-7
SW5-8
Function
Time-Share 1 – When in Independent Control mode, turn ON if time-share shutter 1 is installed.
Time-Share 2 – When in Independent Control mode, turn ON if time-share shutter 2 is installed.
Time-Share 3 – When in Independent Control mode, turn ON if time-share shutter 3 is installed.
Not Used
SW6 – Not Used.
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Maintenance Mode Screen
The Maintenance Mode Screen is used for maintenance functions such as, checking the status and
alignment of the laser. This screen is not typically used by the laser operator. For information on the
Maintenance Screen contents, please consult with the Miyachi Unitek Corporation.
CAUTION: An incorrect setting in this screen may make the Laser inoperable.
1.
On the Program Box, press the TROUBLE RESET and
MAINTENANCE MODE screen.
2.
To exit the MAINTENANCE MODE screen, press the MENU key.
1.
MAINTENANCE MODE: OFF
simultaneously to access
To aid in laser alignment, turn Maintenance Mode ON. While in Maintenance Mode, the
Program Box is the only way of controlling the laser. When Maintenance Mode is ON, all fields
in the Maintenance Mode screen become active.
2.
DEIONIZE
This field displays the resistivity of the internal de-ionized cooling water.
3.
ROM VERSION
This field displays the firmware revisions inside the Laser (Main CPU & Program Box). The
actual location and layout of this data may differ depending on the firmware revision of the
Program Box.
4.
ADJ
This field is for entering the current date and time (24-Hour clock). Date and time are not
needed for normal operation. These fields become important when using the PRINT mode. The
current date and time will be displayed. If you need to change either the date or time (24 hour
clock), move the cursor to the number you want to change and Press the ON (+) and OFF (-) keys
accordingly, followed by ENTER.
Format:
[ 'YR.MO.DAY HR:MIN ]
[ '10.02.09 14:05 ]
(February 09, 2010 at 2:05 p.m.)
Example:
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CHAPTER 3: MLE-115A OPERATION
5.
ERROR RECORD
This field is used to view the error log
when enabled. The error log will
display the last 50 errors with the most
recent error listed at the top of the list.
Use the ON/OFF key to access the
error log.
If the MESSAGE field is OFF, the error
log will display only the date and time
of the errors. If the MESSAGE field is
ON, the error log will display the
description of the actual error.
ERROR RECORD
MESSAGE:OFF
WATER 28qC
c 01
E49:
'01.06.20
13:20
02
E38:
'01.02.10
15:11
03
E14:
'01.01.08
19:08
04
E02:
'00.09.12
08:13
05
E11:
'00.02.28
02:55
d 06
E47:
'99.04.20
22:10
HV:ON MAIN SHUTTER:ON
POSITION:OFF
-ERROR RECORD
MESSAGE:ON
WATER 28qC
c 01
E49:SET ERROR (TOO SHORT)
02
E38:FIBER SENSOR 1 TROUBLE
03
E14:SIMMER TROUBLE
04
E02:HEAD COVER OPENED
05
E11:LOW TEMPERATURE OF COOLANT
d 06
E47:OVER RATE
HV:ON MAIN SHUTTER:ON
POSITION:OFF
To exit the Error log screen, press the MENU key to return back to the Maintenance mode
screen.
6.
CONTROL
This field is used to display the status of the feedback control system.
DISPLAY
FEEDBACK STATUS
LASER POWER
POWER FEEDBACK ENABLED (CLOSED LOOP)
CURRENT
POWER FEEDBACK DISABLED (OPEN LOOP)
When set to LASER POWER, the power feedback circuit is active. The Laser should always be
set to LASER POWER mode for normal operation.
CURRENT mode is used to supply a user-defined current through the flashlamp.
CURRENT mode should only be used during oscillator alignment by factory-trained personnel.
LW300A(H)/LW400A Nd:YAG LASER
3-18
990-538
CHAPTER 3: MLE-115A OPERATION
7.
DELIVERY SYSTEM
This field is used to display the lasers optical configuration. The output configuration is set by
a dipswitch on the Main PCB. See Appendix B, Section II, Energy-sharing and Time-sharing
for more information.
DISPLAY
SINGLE
2 ENERGY SHARE
3 ENERGY SHARE
4 ENERGY SHARE
2 WAY TIME SHARE
3 WAY TIME SHARE
4 WAY TIME SHARE
2 ENERGY 2 WAY TIME
INDEPENDENT CONTROL
8.
OPTICAL CONFIGURATION
Single (One) output
Two Energy-Shared Outputs
Three Energy-Shared Outputs
Four Energy-Shared Outputs
Two Time-Shared Outputs
Three Time-Shared Outputs
Four Time-Shared Outputs
Two Time-Shared Outputs with Two Energy Shares each
Independent Branch Control
PULSE WIDTH
This controls the output pulse width. Used only when LASER CONTROL is set to CURRENT
mode. This pulse width adjustment must only be performed by factory-trained personnel.
Range: 0.3mS d t d 5.0mS
9.
CURRENT
This is the flashlamp current setting. Used only when LASER CONTROL is set to CURRENT
mode. The flashlamp current adjustment must only be performed by factory-trained personnel.
Range: 70A d I d 300A
LW300A(H)/LW400A Nd:YAG LASER
990-538
3-19
CHAPTER 3: MLE-115A OPERATION
PASSWORD MODE Screen
The Password Mode screen is used to prevent unauthorized users from changing laser parameters. The
PASSWORD consists of a user-defined combination of four letters and/or numbers.
On the Program Box, press TROUBLE RESET and
simultaneously to access to the PASSWORD MODE
screen. To exit the PASSWORD MODE screen, press the MENU key.
NOTES:
x The CONTROL key switch must be turned ON.
x The initial (factory-set) password is REDS. You will need to enter this in order to gain access
to the password edit screen.
1
Use the
keys to place the
cursor over the first digit of the
password.
2
Use the ON (+) and OFF (-) - keys to
cycle through the list of numbers and
letters. The list starts with the numbers
HV:ON
MAIN SHUTTER:ON
POSITION:OFF
0 - 9 then goes through the alphabet
from A - Z. After Z, the list starts again with 0. You can use the ON (+) and OFF (-) keys to
scroll up or down through the list.
3
After selecting the number/letter you want, you must press ENTER to accept the number.
4
Use the
keys to move the cursor to the next digit and repeat steps 2 and 3 until you
have selected a password.
-PASSWORD MODE
PASSWORD:
[0000]
WATER 28qC
CHANGE VALUE:ON
CAUTION: Write the password down for future reference. The Laser is not capable of
displaying the set password. If a password is set and forgotten, the only way to gain access to
the laser is to remove the back-up battery from the Main PCB (with the Laser power in the OFF
position). Allow the on-board memory capacitor to fully discharge (up to 3 hours), then
initialize the laser as described above.
Incorrect Password
If the password is incorrect, *PASSWORD
MISMATCH* will display. You can return
to the first screen by pressing the
TROUBLE RESET key.
-PASSWORD MODE
PASSWORD:
[0000]
WATER 28qC
CHANGE VALUE:ON
********** PASSWORD MISMATCH**********
HV:ON
MAIN SHUTTER:ON
POSITION:OFF
LW300A(H)/LW400A Nd:YAG LASER
3-20
990-538
CHAPTER 3: MLE-115A OPERATION
Correct Password
If the password is correct, the screen on the
right will appear. The CHANGE VALUE:
field is used to lock out unauthorized users
and is used in conjunction with the NEW
PASSWORD 0000 field. When a password
is entered and CHANGE VALUE: is ON, any
user may change the laser parameters.
-PASSWORD MODE
PASSWORD:
[****]
NEW PASSWORD:
HV:ON
MAIN SHUTTER:ON
WATER 28qC
CHANGE VALUE:ON
[0000]
POSITION:OFF
If CHANGE VALUE: is OFF, all unauthorized users will be locked out from changing the laser
parameters.
If you input a new password into the NEW
PASSWORD 0000 field, the following
screen will appear:
-PASSWORD MODE
PASSWORD:
[****]
WATER 28qC
CHANGE VALUE:ON
NEW PASSWORD:
RE-WRITE
NEW PASSWORD:
HV:ON
Confirm the password in the RE-WRITE
PASSWORD: field.
If the NEW PASSWORD: and RE-WRITE
PASSWORD: fields match, the new
password is saved and you will return to
the first screen.
If the password entered into the RE-WRITE
PASSWORD: does not match the password
entered into the NEW PASSWORD: field,
the password will not be saved and
**PASSWORD MISMATCH** will appear.
You can return to screen with TROUBLE
RESET, or re-enter the password again.
MAIN SHUTTER:ON
-PASSWORD MODE
PASSWORD:
HV:ON
[0000]
MAIN SHUTTER:ON
-PASSWORD MODE
PASSWORD:
[*****]
[0000]
POSITION:OFF
WATER 28qC
CHANGE VALUE:ON
POSITION:OFF
WATER 28qC
[0000]
CHANGE VALUE:ON
NEW PASSWORD: [****]
RE-WRITE PASSWORD [0000]
********** PASSWORD MISMATCH**********
HV:ON
MAIN SHUTTER:ON
POSITION:OFF
NOTE: The settings/functions that will be password protected are shown in the table on the next
page.
LW300A(H)/LW400A Nd:YAG LASER
990-538
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CHAPTER 3: MLE-115A OPERATION
Password-Protected Settings & Functions
NETWORK No.
Upper Limit (HIGH) of ENERGY monitor
FLASH TIME in Maintenance Mode
Lower Limit (LOW) of ENERGY monitor
PEAK in Maintenance Mode
REFERENCE SET
BLINK: ON/OFF of Guide Beam (LD)
UP SLOPE TIME
AUTO POWER OFF: ON/OFF of Guide Beam (LD)
FLASH 1 TIME
ON Time of Guide Beam (LD)
FLASH 2 TIME
OFF Time of Guide Beam (LD)
FLASH 3 TIME
MEMORY SWITCH 1 on INITIALIZATION screen
DOWN SLOPE TIME
MEMORY SWITCH 2 on INITIALIZATION screen
COOL 1 TIME
MEMORY SWITCH 3 on INITIALIZATION screen
COOL 2 TIME
MEMORY SWITCH 4 on INITIALIZATION screen
FLASH 1 WATT
MEMORY SWITCH 5 on INITIALIZATION screen
FLASH 2 WATT
MEMORY SWITCH 6 on INITIALIZATION screen
FLASH 3 WATT
TOTAL SHOT COUNT RESET
FLASH TIME in point 1 to 20
GOOD SHOT COUNT RESET
FLASH WATT in point 1 to 20
FEEDBACK MODE: LASER POWER/CURRENT
Number of Shots 1 to 20 in SEAM MODE
FIBER FORM: SI/GI
Power Setting 1 to 20 in SEAM MODE
FIBER DIAMETER
TOTAL SHOT COUNT RESET
FIX/FLEX mode in Wave Shape Control
TOTAL GOOD COUNT RESET
Wave Shape Display ON/OFF PEAK POWER
REPEAT
LW300A(H)/LW400A Nd:YAG LASER
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990-538
CHAPTER 3: MLE-115A OPERATION
PRINT-OUT MODE Screen
You can print out and view the welding conditions of each schedule using the PRINTOUT MODE screen.
When activated, the conditions are sent to both RS-485 connectors for printout. The output print
protocol is designed for use with a serial printer. Best results are achieved using a Sanei Electric Inc.,
BL2-58SNWJC printer. Due to differences in printer protocols, the generated output may differ from the
examples shown on the following pages. The welding conditions are also displayed on the screen in the
event a printer is unavailable.
1
On the Program Box, Press TROUBLE
simultaneously to
access to the Printout Mode Screen.
To exit the Print-out Mode screen,
press the MENU key
RESET and
2
NOTE: The CONTROL key switch
must be turned ON.
-PRINTOUT MODE
SCH.#00
WATER 28qC
1: SCHEDULE
2: POWER MONITOR
3: SEAM WELD
HV:OFF
MAIN SHUTTER:OFF
POSITION:OFF
Printing the Welding Conditions of Each Schedule
1.
Position the CURSOR to SCH. #00 and input the SCHEDULE NUMBER you desire, then press the
ENTER key.
2.
Move the CURSOR to 1:SCHEDULE, then press the ENTER key.
3.
The schedule conditions will be sent to the printer.
Printing Out the Power Monitor Measurements
1.
In order to view the monitored measurements, the
must be selected ON.
field on the POWER MONITOR screen
2.
Fire the Laser and check the measured waveform graph on the Laser Controller display. If you
would like a print-out of this waveform graph, go to the Print-out Mode Screen.
3.
Move the CURSOR to 2:POWER MONITOR, then press the ENTER key.
4.
The monitored values will be sent to the printer.
NOTE: Each time the laser is fired, the monitored waveform data is updated.
Printing Out the Seam Weld Conditions
1.
Position the CURSOR to SCH. #00 and input the Schedule Number you desire, then press the
ENTER key.
2.
Move the CURSOR to 3:SEAM WELD, then press the ENTER key.
3.
The SEAM WELD conditions will be sent to the printer.
LW300A(H)/LW400A Nd:YAG LASER
990-538
3-23
CHAPTER 3: MLE-115A OPERATION
Welding Condition Print-Out Examples – Schedule Screen
Example FORM:FIX
Example FORM:FLEX
SCHEDULE
-SCH. #00 FORM:FIX
SCHEDULE
-SCH. #00 FORM:FLEX
PEAK POWER = 01.00kW
PEAK POWER = 02.00kW
U-SLOPE
FLASH 1
FLASH 2
FLASH 3
D-SLOPE
Point1
Point2
Point3
Point4
Point5
Point6
Point7
Point8
Point9
Point10
Point11
Point12
Point13
Point14
Point15
Point16
Point17
Point18
Point19
Point20
=
=
=
=
=
00.5ms
01.5ms 040.0%
03.0ms 080.0%
01.0ms 020.0%
00.3ms
REPEAT = 010PPS
SHOT
= 0430
ESTIMATED VALUE = 3.1J
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
00.4ms
00.8ms
01.1ms
01.4ms
01.8ms
02.1ms
02.5ms
02.9ms
03.4ms
03.7ms
04.0ms
04.5ms
04.8ms
05.1ms
06.1ms
06.7ms
06.8ms
07.2ms
08.8ms
10.0ms
032.2%
107.0%
084.1%
094.2%
072.3%
060.4%
036.0%
100.5%
060.0%
102.0%
042.1%
070.3%
062.0%
050.4%
013.0%
011.2%
008.7%
040.0%
012.1%
000.0%
REPEAT = 002PPS
SHOT
= 1120
ESTIMATED VALUE = 8.8J
LW300A(H)/LW400A Nd:YAG LASER
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990-538
CHAPTER 3: MLE-115A OPERATION
Power Monitor Examples – Power Monitor Screen
Example FORM:FIX
Example FORM:FLEX
POWERMONITOR
-SCH. #00
POWERMONITOR
-SCH. #01
ENERGY
ENERGY
3.1 J
AVERAGE
8.8 J
AVERAGE
30.3 J
HIGH = 04.00J
LOW = 00.00J
25.9 W
HIGH = 04.00J
LOW = 00.00J
LAMP INPUT PWR
REFERENCE SET
000%
120%
SHOT COUNT = 000000708
GOOD COUNT = 000000241
LAMP INPUT PWR
REFERENCE SET
000%
120%
SHOT COUNT = 000000713
GOOD COUNT = 000000246
LW300A(H)/LW400A Nd:YAG LASER
990-538
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CHAPTER 3: MLE-115A OPERATION
Connecting the Serial Printer
The serial printer (Sanei Electric Inc., BL2-58SNWJC or equivalent) can be connected to either RS-485
(1) or RS-485 (2).
LW300A(H)/LW400A Nd:YAG LASER
3-26
990-538
CHAPTER 4
MLE-118A PROGRAMMING FUNCTIONS
Section I. LCD Control Screens
General Navigation
All control functions of the Laser are controlled by the ENCODE button. Turn the ENCODE button
clockwise and counter-clockwise to scroll through the various menu screen functions. Once you land on
a field you want to change (highlighted in yellow), select the ENCODE button by pressing it downward.
Once selected, the field will (1) either turn green indicating that it can be changed, or (2) a pop-up
window will appear showing the options for this particular field. If a pop-up window appears, rotate the
ENCODE button until the option you want to change is highlighted in yellow, then press the ENCODE
button to select. If a pop-up window appears that you do not want to change, select the CANCEL option
to return to the previous screen.
About the LCD Screens
There are six main LCD menu screens used to control the Laser, listed vertically on the right side.
x Schedule Screen – used to set the parameters of your weld.
x Status Screen – used to control the output process.
x Monitor Screen – used to display output weld information.
x Seam Screen – used to set the parameters of your seam weld.
x Password Screen – used to password protect the saved settings in the Laser.
x Printout Screen – used to print-out schedule and monitor information.
When each of the Menu buttons is pressed, the selected Menu will display:
LW300A(H)/LW400A Nd:YAG LASER
990-538
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CHAPTER 4: MLE-118A OPERATION
Screen Content
The content of each LCD screen differs based on the menu screen; however some parameters/settings
are common to all screens. The content of each screen is outlined below.
CONTENTS
SCREEN
Individual Screen
SCHEDULE
STATUS
POWER
MONITOR
Laser Output Peak Setting (kW)
Repeat Setting (PPS)
Up-Slope Time Settings (ms)
Number of Shots Setting
[FLASH/Point] Laser Output Time Setting (ms)
[FLASH/Point] Laser Output Value Setting (%)
Down-Slope Time Setting (ms)
[COOL 1/2] No Laser Output Time (ms)
Seam Weld Mode (ON/OFF)
Reset Shot Count Preset/Reset
Reset Good Count Preset/Reset
Guide Beam Blinking Control (ON/OFF)
Optical Fiber Settings (SI/GI/mm)
Laser Output Energy (J)
Laser Output Average Power (W)
Total Shot Count
Good Shot Count
Laser Energy Upper/Lower Limit Setting (J)
Lamp Input Power Display (%)
Lamp Input Power Upper Limit Setting (%)
Common to Each Screen
Schedule #
Form: Fix or FLEX
Pump (ON/OFF)
Water Temperature ( qC )
(HV) High Voltage (ON/OFF)
Main Shut – Main Shutter (ON/OFF)
Position - Guide Beam (ON/OFF)
Trouble Reset
Beam - Branch Shutters (ON/OFF)
LW300A(H)/LW400A Nd:YAG LASER
4-2
990-538
CHAPTER 4: MLE-118A OPERATION
Section II. How to Use the LCD Screens
Common to All Screens
There are common functions that are displayed on each LCD screen, as described below:
1
2
3
4
10
11
12
13
14
15
5
6
7
8
9
1.
SCHEDULE # – Displays the schedule number selected on the SCHEDULE screen. A schedule is
a stored set of laser output parameters. Since different welds require different welding
parameters, each may be stored separately using different schedule numbers. The Laser is
capable of storing up to 32 schedules (SCH # 00 - 31).
2.
FORM – There are two options in the FORM field: FIX and FLEX. When the FORM field is
selected, a pop-up window will display, which will allow you to choose the FORM option.
Options: FIX / FLEX / CANCEL.
3.
PUMP – Displays the status of the internal water pump. When ON is displayed, it indicates that
the internal cooling water pump is operating.
4.
WATER TEMP – Displays the temperature of the secondary (internal) cooling water.
5.
HV – Field used to turn the HV (High Voltage) on/off. When ON the laser is capable of
producing an output. When selected a pop-up window will display, which will allow you to
turn the High Voltage ON and OFF.
Options: ON / OFF / CANCEL.
6.
MAIN SHUT – Field used to open (on) / close (off) the Main Shutters. When selected a pop-up
window will display, which will allow you to open/close the Main Shutters.
Options: ON / OFF / CANCEL.
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990-538
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CHAPTER 4: MLE-118A OPERATION
7.
POSITION – Field used to turn the visible Guide Beam on/off. When selected a pop-up window
will display, which will allow you to turn the Guide Beam on/off.
Options: ON / OFF / CANCEL.
8.
TROUBLE RESET – When an error occurs in the Laser, a Trouble Error Code will display on the
LCD screen. Correct the cause of the error and then select TROUBLE RESET to clear the error
and resume normal operation. If the source of the error is not cleared, the Trouble Error Code
will not reset. The Laser will not operate until all Errors have been cleared.
9.
BEAM – Field used to display the installed branch shutters. When selected a pop-up window
will display, which will allow you to open/close each installed branch shutter. When ON is
selected for any branch shutter, the branch shutter will open. A field must be turned ON in
order to get a laser output on that particular output branch. When OFF is selected, the branch
shutters will close.
For example, if the laser is configured with a 3E output (3 energy-shared outputs); SHUTTER-1
through SHUTTER-3 must be turned ON in order to get an output on branch fibers 1, 2, and 3.
Options:
SHUTTER 1: ON/OFF
SHUTTER 2: ON/OFF
SHUTTER 3: ON/OFF
SHUTTER 4: ON/OFF
CANCEL
10. SCHED – Field used to select the Schedule Screen.
11. STATUS – Field used to select the Status Screen.
12. MON – Field used to select the Power Monitor Screen.
13. SEAM – Field used to select the Seam Weld Screen.
14. PASSWD – Field used to select the Password Screen.
NOTE: The Password Screen is not visible from the Maintenance Mode Screen.
15. PRINT – Field used to select the Print-out Screen.
NOTE: The Print-out Screen is not visible from the Maintenance Mode Screen.
LW300A(H)/LW400A Nd:YAG LASER
4-4
990-538
CHAPTER 4: MLE-118A OPERATION
SCHEDULE Screen
The Laser is capable of processing two types of [FORM] outputs:
x [FIX] Output – Defines a laser output process over three time segments.
x [FLEX] Output – Defines a laser output process over twenty discrete points.
[FORM: FIX] Function
The majority of all laser processing can be completed using the
[FORM: FIX] output mode. The Laser output can be defined
over three time segments, including a power ramp UP/DOWN
feature in segments 1 and 3 as shown on the right.
1
2
7
6
5
1.
4
3
PEAK POWER – Sets the reference value of the peak laser output. The actual programmed laser
output is set as a percentage of this Peak Power value. The maximum Peak Power output setting
varies depending on the Laser Model. Example: PEAK 4.00 kW x 50% = 2.0 kW
Note: If Initialization Switch SW1-6 is ON, the Maximum Peak Power 0.10kW (see pg 4-23).
Model
LW300A(E) / ML-2551A(-CE)
LW300AH(E) / ML-2552A(-CE)
LW400A(E) / ML-2550A(-CE)
Maximum Peak Setting
5.0 kW ( 10ms )
5.0 kW ( 4ms )
8.0 kW ( 10ms )
LW300A(H)/LW400A Nd:YAG LASER
990-538
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CHAPTER 4: MLE-118A OPERATION
2.
REFERENCE VALUE – Displays the estimated laser output energy in Joules ( J ) of the
programmed waveform. Though the Laser computes the output energy based on the
programmed settings, due to optical and electrical characteristics, its estimated value will differ
slightly from the monitored (measured) value. Use the estimated laser output energy as an
approximation.
3.
SHOT – Sets the number of times (shots) you want to output the laser beam consecutively. The
setting can be changed between 0 and 9999. When REPEAT > 0 and SHOT = 0, the Laser will
continue to output a laser beam until it receives a laser-stop signal.
4.
REPEAT – Sets the number of laser pulses per second (PPS). The setting can be changed
between 0 and 500. When it is set to 0, the laser pulse is not repeated.
5.
COOL – Sets a value of time between FLASH1-FLASH2 and FLASH2-FLASH3 when there will be
no laser output. When selected a pop-up window will display, which will allow you to set the
COOL1 time (time between FLASH1-FLASH2) and COOL2 time (time between FLASH2-FLASH3).
6.
SEAM – Field used to activate the SEAM weld function that is used to suppress the output
waveform over a predetermined amount of time. Options:
OFF:
Turns the seam weld function OFF (disables SEAM weld function).
ON:
Activates the seam weld function (enables SEAM weld function).
CANCEL:
No change made.
7.
FORM (FIX Settings) – These settings are used to define the pulse shape of the Laser output over
three segments. The pulse shape is defined using the KSLOPE, FLASH 1 / 2 / 3 and vSLOPE
parameters. FLASH 1 / 2 / 3 are used to define how long (ms) and how much power (%) should
be delivered to the output during that particular time segment.
KSLOPE
Sets the upslope (the laser beam is gradually intensified) within the time set for
FLASH1. Set FLASH1 first and then set KSLOPE. (Note: KSLOPE d FLASH1).
KSLOPE can also eliminate “overshoot” on the rising edge of the output pulse.
FLASH1
Sets the first segment laser output time and the first laser output value (%).
FLASH2
Sets the second segment laser output time and the second laser output value (%).
FLASH3
Sets the third segment laser output time and the third laser output value (%).
vSLOPE
Sets the downslope (the laser beam gradually weakens) within the time set for
FLASH 3. Make sure that vSLOPE is d FLASH3.
The range of the FLASH 1 / 2 / 3 parameters depends on the laser model.
Model
LW300A(E) / ML-2551A(-CE)
LW300AH(E) / ML-2552A(-CE)
LW400A(E) / ML-2550A(-CE)
KSLOPE + FLASH1 + COOL1 + FLASH2 + COOL2 + FLASH3 + vSLOPE
0.1 t 99.9 ms and 0 – 200% value
0.1 t 99.9 ms and 0 – 200% value
0.1 t 99.9 ms and 0 – 200% value
The maximum peak power output available for each laser model depends on the output pulse
width. See the graphs in Appendix A, Section III, Maximum Peak Power for more information.
LW300A(H)/LW400A Nd:YAG LASER
4-6
990-538
CHAPTER 4: MLE-118A OPERATION
[FORM: FLEX] Function
Occasionally, the need for a non-conventional waveform is needed. Any user-specified output may
be defined using the [FORM: FLEX] output mode. With FLEX mode, the Laser output can be defined
over twenty discrete points in time.
An example of a programmed FLEX waveform
is shown on the right. In this example the entire
waveform is 15mS long specified with 5 points.
Point 1
Point 2
Point 3
Point 4
Point 5
1.0mS
2.0mS
3.0mS
4.0mS
5.0mS
90.0%
70.0%
80.0%
65.0%
00.0%
1
2
7
6
5
1.
4
3
PEAK POWER – Sets the reference value of the peak laser output. The actual programmed laser
output is set as a percentage of this Peak Power value. The maximum Peak Power output setting
varies depending on the Laser Model. Example: PEAK 4.00 kW x 50% = 2.0 kW
NOTE: If Initialization Switch SW1-6 is ON, the Maximum Peak Power 0.1 kW
(see page 4-23).
LW300A(H)/LW400A Nd:YAG LASER
990-538
4-7
CHAPTER 4: MLE-118A OPERATION
Laser Model
Maximum Peak Setting
LW300A(E) / ML-2551A(-CE)
5.0 kW ( 10ms )
LW300AH(E) / ML-2552A(-CE)
5.0 kW ( 4ms )
LW400A(E) / ML-2550A(-CE)
8.0 kW ( 10ms )
2.
REFERENCE VALUE – Displays the estimated laser output energy in Joules ( J ) of the
programmed waveform. Though the Laser computes the output energy based on the
programmed settings, due to optical and electrical characteristics, its estimated value will differ
slightly from the monitored (measured) value. Use the estimated laser output energy as an
approximation.
3.
SHOT – Sets the number of times (shots) you want to output the laser beam consecutively. The
setting can be changed between 0 and 9999. When REPEAT > 0 and SHOT = 0, the Laser will
continue to output a laser beam until it receives a laser-stop signal.
4.
REPEAT – Sets the number of laser pulses per second (PPS). The setting can be changed
between 0 and 500. When it is set to 0, the laser pulse is not repeated.
5.
RESET – When ON is selected, all the settings from SHOT01 to SHOT20 will be cleared.
6.
SEAM – Field used to activate the SEAM weld function that is used to suppress the output
waveform over a predetermined amount of time. Options:
OFF:
Turns the seam weld function OFF (disables SEAM weld function).
ON:
Activates the seam weld function (enables SEAM weld function).
CANCEL:
No change made.
7.
Point 1 through Point 20 – Sets the laser output time and laser output value (%) for each point to
form a free (user-defined) waveform. You can set up to 20 discrete points. The maximum
setting for each point depends on the laser. To scroll the Point display, use the and function
buttons to scroll through each point setting (01 through 20).
Laser Model
Point 1 to Point 20
Point Settings
LW300A(E) / ML-2551A(-CE)
0.3 – 99.9 ms
0.1 ms t 99.9 ms and 0 – 200%
LW300AH(E) / ML-2552A(-CE)
0.3 – 99.9 ms
0.1 ms t 99.9 ms and 0 – 200%
LW400A(E) / ML-2550A(-CE)
0.3 – 99.9 ms
0.1 ms t 99.9 ms and 0 – 200%
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Seam Function
The Seam function allows the laser to vary in strength at any point within a continuous stream of
laser pulses for both Fix and Flex waveforms. The most common method of this feature is to
gradually increase the laser output power at the beginning of a seam weld and gradually decrease the
laser power at the end of a seam weld to allow for a smooth overlap at the beginning and ending of a
continuous weld.
Below is an example of how the Seam Weld function operates. In the top example waveform, the
laser is generating a series of 10 programmed output weld pulses without the Seam Weld function.
In the bottom waveform, the laser is generating the same series of 10 programmed output weld pulses
with the Seam Weld function “active”. In this example waveform, the Seam Weld function is active
during the first and last 3 output pulses (Shot 1, Shot 2, Shot 3, Shot 8, Shot 9 and Shot 10).
The SEAM WELD MODE settings for this example are shown in the screen shot below. To enable the
SEAM function for any given Schedule # (FIX or FLEX), the SEAM option (on either Schedule Screen)
must be set to ON and the REPEAT and SHOT 1.
6
1
2
3
4
5
1.
SHOT [COUNT] – Sets the number of output pulses for Point01, Point02, etc.
2.
Power [%] – Sets the Laser output value of each Point (0 – 150%) as the ratio of the Peak Power
set on the SCHEDULE Screen. The % Energy values on the SEAM WELD MODE screen, override
the % Energy values on the SCHEDULE screen.
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CHAPTER 4: MLE-118A OPERATION
3.
RESET – When ON is selected, all the settings from Point01 to Point20 will be cleared.
4.
REPEAT – Sets the number of laser output pulses per second. This is the same function as
REPEAT on the SCHEDULE screen. When REPEAT > 0 and SHOT = 0, the laser will fire
continuously until the Laser Stop signal is activated. This is the same function as SHOT on the
SCHEDULE screen.
5.
SHOT – Sets the number of Laser outputs (0000 to 9999). When the laser output count reaches
the set value, the Laser stops. For example, when SHOT is set to 1, a single shot output is
performed.
6.
and
– Used to scroll through all points (Point01 through Point20).
EXAMPLE: SEAM WELD MODE
In the example below, a simple rectangular output pulse (1kW x 2mS) is programmed in the
FORM: FIX SCHEDULE screen at a 10pps repetition rate with a total of 100 shots. The SEAM
WELD MODE screen is turned ON in order to vary the laser output power over the weld process.
SCHEDULE [FORM:FIX] screen
SEAM WELD MODE screen
Note: The POINT06 values (not shown in screen above) are: SHOT = 0100 and POWER [%] = 20%.
When the above parameters are entered into the Laser, the Laser Output will have the following
response (where 100% output = 1.00kW):
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CHAPTER 4: MLE-118A OPERATION
Status Screen
1
6
2
3
4
7
5
8
1.
POSITION BLINK
When selected ON, the guide beam laser will blink continuously. This feature can be helpful
when trying to align dark colored parts to be welded. When OFF is selected, the guide beam
laser will not blink.
2.
CONTROL DEVICE Mode
Displays the currently selected control method;
EXTERNAL CONTROL, PANEL CONTROL or RS-485 CONTROL.
EXTERNAL CONTROL
The Laser is controlled by a programmable controller or other similar
device connected to the EXT. I/O connectors.
PANEL CONTROL
The Laser is controlled by the Control Panel (Program Box).
RS-485 CONTROL
The Laser is controlled by a personal computer connected to the RS-485
(1) or the RS-485 (2) connector (optional).
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CHAPTER 4: MLE-118A OPERATION
3.
DELIVERY SYSTEM
This field is used to display the lasers optical configuration. The output configuration is set by
a dipswitch on the Main PCB. See Appendix B, Section II, Energy-sharing and Time-sharing
for more information.
DISPLAY
SINGLE
2 ENERGY SHARE
3 ENERGY SHARE
4 ENERGY SHARE
2 WAY TIME SHARE
3 WAY TIME SHARE
4 WAY TIME SHARE
2 ENERGY 2 WAY TIME
INDEPENDENT CONTROL
4.
OPTICAL CONFIGURATION
Single (One) output
Two Energy-Shared Outputs
Three Energy-Shared Outputs
Four Energy-Shared Outputs
Two Time-Shared Outputs
Three Time-Shared Outputs
Four Time-Shared Outputs
Two Time-Shared Outputs with Two Energy-Shares each
Independent Branch Control
FIBER
This function prevents excessive power from being applied to the optical fiber. Input the fiber
type (SI/GI) and core diameter of the optical fiber being used. The maximum output power for
any given optical fiber is automatically computed and limited to prevent fiber damage.
Setting range of core diameter: I 0.2 to 1.0 mm for all Laser models.
x
x
x
x
x
The factory default setting is SI 1.0 mm.
If the schedule settings for PEAK, FLASH (pulse width and power setting) and REPEAT do
not match the fiber type and core diameter, an E51: SET ERROR FIBER or E48: OVER RATE
FIBER warning will appear. In these cases change the input settings.
If the end face surface of the optical fiber is stained, broken, damaged, or covered with
dust, a warning message will not necessarily appear on the screen. Be sure to put the cap
on the optical fiber when it is not in use.
If the end face of the optical fiber is broken, check the lenses on both the input and output
units for damage. If the lenses are stained, clean them with the method described in
Chapter 6, Maintenance.
Do not remove the Laser Beam Input Unit unless absolutely necessary. Doing so will
require that the input unit be re-aligned to the laser beam.
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CHAPTER 4: MLE-118A OPERATION
5.
RESET COUNT
Resets the TOTAL Shot Count and the GOOD Shot Count. Move the cursor to the counter you
want to reset, then select the ENCODE key. The count will be set back to 000000000.
6.
DEIONIZE WATER RES
This field displays the resistivity of the secondary cooling water supply.
7.
PRESET COUNT
Sets the desired number of laser outputs for the total shot count and the good shot count. When
the count has reached this set number, the following messages will appear:
When the SHOT count has reached the set number.
When the GOOD count has reached the set number.
Select TROUBLE RESET to return to the previous screen.
8.
ROM VERSION
This field displays the firmware revisions inside the Laser (Main CPU & Program Box). The
actual location and layout of this data may differ depending on the firmware revision of the
Program Box.
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CHAPTER 4: MLE-118A OPERATION
Power Monitor Screen
Whenever the Laser is fired, the POWER MONITOR screen automatically displays the measured output.
3
1
4
2
5
6
1.
ENERGY
Displays the measured laser energy in Joules (J) of the laser oscillator. Each time the laser is
fired, its output is measured and displayed. In the case of high-repetition outputs, the energy is
displayed at periodic intervals. This is because the repetitions are faster than the LCD refresh
rate. The displayed energy will differ from the actual delivered energy at the workpiece. This
difference varies based on the optical configuration of the system.
2.
AVERAGE
Displays the total mean power in Watts (W) of the laser oscillator (averaged over one second).
Each time the laser is fired, its output is measured and displayed. In the case of high-repetition
outputs, the energy is displayed at periodic intervals. This is because the repetitions are faster
than the LCD refresh rate. The displayed average power will differ from the actual delivered
power at the workpiece. This difference varies based on the optical configuration of the
system.
3.
HIGH / LOW alarm limits
To aid in critical welding processes, a HIGH / LOW energy output
monitor is provided. Set the allowable energy range for the selected
schedule. If the measured output energy falls outside of this range, an
Error Code will display on the LCD screen and the Laser will stop
firing.
HIGH
000.0J
LOW
000.0J
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CHAPTER 4: MLE-118A OPERATION
4.
SHOT COUNT GOOD COUNT
SHOT COUNT displays the total number of times the laser was
SHOT COUNT 123456789
fired. The shot count can be reset to 000000000 on the
STATUS screen.
GOOD COUNT 123456789
GOOD COUNT displays the number of Good shots that were fired. A Good shot count means
that the measured output energy was within the acceptable range set by the HIGH / LOW
alarm limits. The good count can be reset to 000000000 on the STATUS screen.
5.
REFERENCE SETTING and LAMP INPUT POWER
REFERENCE SETTING is used to set the
maximum input power to the flashlamp. If
the input power exceeds this limit, the
following screen will appear, indicating
that the flashlamp needs replacement.
NOTE: If this display continues for more
than 3 seconds, an OVERRATE alarm will
also occur.
LAMP INPUT POWER displays the ratio of the flashlamp input power to the output capacity of
the Discharge Unit. A value of 100% means that the Discharge Unit is producing the maximum
amount of designed output power. As a flashlamp ages, it requires more power to flash. In
normal operation, Power Feedback automatically draws the power required from the Discharge
Unit to maintain a constant output, thereby compensating for an aging flashlamp.
The best way to use this feature is to set the REFERENCE SETTING to 95% ~ 98%. Then as the
flashlamp starts to age, it will require more power to maintain a constant output. Eventually the
LAMP INPUT POWER will reach the REFERENCE SETTING value and Lamp Input Power Limit
screen will appear. Once this alarm condition exists the operator can set the REFERENCE
SETTING value to 100% and schedule a flashlamp replacement to minimize production downtime.
6.
GRAPH
This section of the Power Monitor screen will display the graphical representation of the
measured output pulse. The scale limits of the graph will automatically resize based on the
measured output pulse. Due to the resolution of this graph, it should only be used for
reference and not as an absolute measurement.
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CHAPTER 4: MLE-118A OPERATION
PASSWORD MODE Screen
The Password Mode screen is used to prevent unauthorized users from changing laser parameters. The
PASSWORD consists of a user-defined combination of four letters and/or numbers.
On the Program Box, rotate the ENCODE button to the PASSWD field, then select the ENCODE button.
To exit the PASSWORD MODE screen, select any other menu function.
NOTES:
x The initial (factory-set) password is REDS. You will need to enter this in order to gain access
to the password edit screen.
1.
To enter or change a password rotate
the ENCODE button to highlight the
VALUE CHANGE field, then select.
When ON, the password may be
changed.
2.
Rotate the ENCODE button until the
first password field position is
highlighted. Using the ENCODE
button, select the PASSWORD
characters from the tile set. Press the
ENCODE button to select.
3.
Repeat for password characters 2
through 4.
AC = Clear All Characters
BS = Backspace
4.
Select ENTER to check the validity of the entered Password.
CAUTION: If you change the password, write it down for future reference. The Laser is not
capable of displaying the set password. If a password is set and forgotten, the only way to gain
access to the laser is to remove the back-up battery from the Main PCB (with the Laser power
in the OFF position). Allow the on-board memory capacitor to fully discharge (up to 3 hours),
then initialize the laser as described later in this Chapter. All Schedule information will be lost
and the password will reset back to the factory default: REDS.
5.
If entering a new Password, you will be prompted to re-enter the Password again. If the
Passwords do not match, the new Password will not be saved.
Incorrect Password
If the password is incorrect;
WRONG PASSWORD, ENTER CORRECT ONE
will display. You can exit out of the Password screen by selecting
a different Menu option.
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CHAPTER 4: MLE-118A OPERATION
Password-Protected Settings & Functions
SCHEDULE number
UP SLOPE TIME
FORM: FIX/FLEX mode in Wave Shape Control
FLASH 1 TIME
PEAK POWER (output peak value)
COOL 1 TIME
REPEAT function
FLASH 2 TIME
SHOT (total # of laser outputs)
COOL 2 TIME
POINT 1 to 20 (time in mS and output %)
FLASH 3 TIME
FIBER TYPE: SI/GI
DOWN SLOPE TIME
FIBER CORE DIAMETER
POSITION BLINK: ON/OFF of Guide Beam (LD)
Upper Limit (HIGH) of ENERGY monitor
TOTAL SHOT COUNT RESET
Lower Limit (LOW) of ENERGY monitor
TOTAL GOOD COUNT RESET
REFERENCE SET
RESET SHOT COUNT
CONTROL (in Maintenance Mode)
PRESET SHOT COUNT
SHOT COUNT
CURRENT (in Maintenance Mode)
GOOD COUNT
PULSE WIDTH (in Maintenance Mode)
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CHAPTER 4: MLE-118A OPERATION
PRINTOUT MODE Screen
You can print out and view the welding conditions of each schedule using the PRINTOUT MODE screen.
When activated, the conditions are sent to both RS-485 connectors for printout. The output print
protocol is designed for use with a serial printer. Best results are achieved using a Sanei Electric Inc.,
BL2-58SNWJC printer. Due to differences in printer protocols, the generated output may differ from the
examples shown on the following pages. The welding conditions are also displayed on the screen in the
event a printer is unavailable.
1
On the Program Box, rotate the
ENCODE button to the PRINT field,
then select the ENCODE button.
2
Select the SCHEDULE # for the printout that you want and then select what
you want to print (SCHEDULE,
POWER MONITOR, SEAM WELD).
3
To exit the Print-out Mode screen,
rotate the ENCODE button and select
any other menu function.
NOTE: The CONTROL key switch
must be turned ON.
Printing the Welding Conditions of Each Schedule
1.
Verify the proper SCHEDULE # is selected.
2.
Rotate the ENCODE button to the SCHEDULE field and then select it.
3.
The schedule conditions for the selected SCHEDULE # will be sent to the printer.
Printing Out the Power Monitor Measurements
1.
Verify the proper SCHEDULE # is selected.
2.
Rotate the ENCODE button to the POWER MONITOR field and then select it.
3.
The set values and measured values from the Monitor Screen will be sent to the printer.
NOTE: Each time the laser is fired, the monitored waveform data is updated.
Printing Out the Seam Weld Conditions
1.
Verify the proper SCHEDULE # is selected.
2.
Rotate the ENCODE button to the SEAM WELD field and then select it.
3.
The set values on the SEAM screen will be sent to the printer.
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CHAPTER 4: MLE-118A OPERATION
Welding Condition Print-Out Examples – Schedule Screen
Example FORM:FLEX
Example FORM:FIX
SCHEDULE
-SCH. #00 FORM:FIX
SCHEDULE
-SCH. #00 FORM:FLEX
PEAK POWER = 01.00kW
PEAK POWER = 02.00kW
U-SLOPE
FLASH 1
FLASH 2
FLASH 3
D-SLOPE
Point1
Point2
Point3
Point4
Point5
Point6
Point7
Point8
Point9
Point10
Point11
Point12
Point13
Point14
Point15
Point16
Point17
Point18
Point19
Point20
=
=
=
=
=
00.5ms
01.5ms 040.0%
03.0ms 080.0%
01.0ms 020.0%
00.3ms
REPEAT = 010PPS
SHOT
= 0430
ESTIMATED VALUE = 3.1J
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
00.4ms
00.8ms
01.1ms
01.4ms
01.8ms
02.1ms
02.5ms
02.9ms
03.4ms
03.7ms
04.0ms
04.5ms
04.8ms
05.1ms
06.1ms
06.7ms
06.8ms
07.2ms
08.8ms
10.0ms
032.2%
107.0%
084.1%
094.2%
072.3%
060.4%
036.0%
100.5%
060.0%
102.0%
042.1%
070.3%
062.0%
050.4%
013.0%
011.2%
008.7%
040.0%
012.1%
000.0%
REPEAT = 002PPS
SHOT
= 1120
ESTIMATED VALUE = 8.8J
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CHAPTER 4: MLE-118A OPERATION
Power Monitor Examples – Power Monitor Screen
Example FORM:FIX
Example FORM:FLEX
POWERMONITOR
-SCH. #00
POWERMONITOR
-SCH. #01
ENERGY
ENERGY
3.1 J
AVERAGE
8.8 J
AVERAGE
30.3 J
HIGH = 04.00J
LOW = 00.00J
25.9 W
HIGH = 04.00J
LOW = 00.00J
LAMP INPUT PWR
REFERENCE SET
000%
120%
SHOT COUNT = 000000708
GOOD COUNT = 000000241
LAMP INPUT PWR
REFERENCE SET
000%
120%
SHOT COUNT = 000000713
GOOD COUNT = 000000246
Connecting the Serial Printer
The serial printer (Sanei Electric Inc., BL2-58SNWJC or equivalent) can be connected to either RS-485
(1) or RS-485 (2).
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CHAPTER 4: MLE-118A OPERATION
Section III. Hidden Menu Screens
Overview
There are two hidden screens in the Laser used to INITIALIZE, SETUP and CONFIGURE the Laser.
CAUTION: These screens should only be used by trained personnel. If the parameters on these
screens are set incorrectly, the Laser may become inoperable.
Initialization Screen
The INITIALIZATION screen is primarily used for the RS-485 communication settings and maintenance
functions.
1.
Turn both the MAIN POWER switch and Keyswitch to the OFF position.
2.
Press and hold the ENCODE button while turning the MAIN POWER switch ON.
3.
When the picture of the Laser is displayed, turn the ENCODE button CCW (counter-clockwise)
while continuously holding down the ENCODE button.
4.
Once the INITIALIZATION screen appears, release the ENCODE button.
5.
After making changes, turn the Laser power OFF then ON again in order to initialize the Laser
with the new settings.
1
2
5
6
3
4
8
9
7
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CHAPTER 4: MLE-118A OPERATION
1.
INITIALIZE
Select ON to restore the laser factory default settings. When this option is selected ALL
schedule data will be erased. Record or save the Schedule Data before Initializing the Laser to
avoid having to re-create all Schedule data
Example:
2.
Use when the Main PCB is re-programmed or replaced, or after the back-up
battery on the Main PCB is replaced.
NETWORK # 00-31
This field is used to select the device (Laser) number for the optional RS-485 communications
function. When connecting multiple Lasers together, each Laser needs a unique NETWORK ID
number. The factory default setting for all lasers is 00.
3.
WATER TEMPERATURE ALARM SETTINGS - L 25qC H 40qC
These fields are used to set the water temperature threshold upper and lower limits. If the
temperature exceeds either of these set limits, the Laser will not operate until the water
temperature returns to normal. The REF TEMP setting is the optimal temperature point. In order
to prevent poor performance, do not change these setting values.
4.
FAN SPEED SETTINGS
CAUTION: These are factory set, do not change these values.
5.
MEMORY SWITCH
When MEMORY SWITCH is selected, the Memory Switch Settings screen will display.
6.
POSITION AUTO-OFF 60MIN
These fields are used to control the position guide beam. These settings are used to
automatically turn the position guide beam OFF to extend the life of the diode in the event the
guide beam is accidentally left ON. This field is adjustable from 01 to 98 minutes.
If the time is set for 00MIN, the position guide beam will not light.
If the time is set for 99MIN, the position guide beam will not turn OFF.
NOTE: The factory default setting is 60MIN.
7.
JOG BUZZER
This function controls whether a sound is made when the ENCODE button is rotated.
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CHAPTER 4: MLE-118A OPERATION
8.
MEMORY SWITCH SETTINGS SCREEN
The software switches are part of the Initialization Screen and they are used to set-up specific
Laser functions. When shipped from the factory, all switches are set in the OFF position. If the
Laser is re-initialized (by selecting INITIALIZE: ON from the previous screen), all of these switch
settings will revert back to the factory settings (all OFF).
SW1
Position
Function
ON
OFF
SW1-1
Automatic High Voltage startup
Unit will not turn High
Voltage ON during start-up
Unit will turn High Voltage
ON during start-up
SW1-2
External control of the LASER
START/STOP switch in the
Panel Control Mode.
Enables control of the
START/STOP signal on the
EXT I/O connector while in
Control Panel Mode.
Disables control of the
START/STOP signal on the
EXT I/O connector while in
Control Panel Mode.
Not Used
SW1-3
SW1-4
Laser Accept Time Trigger
(firmware V50-11N )
Laser will fire on any
START signal.
Laser will fire according
To the LASER ACCEPT
TIME setting.
Not Used
SW1-5
SW1-6
Measurement Accuracy (Energy)
SW1-7
Time Setting Resolution
00.00J (x10)
000.0J (x1)
Peak Power 0.10kW
Maximum Peak Power
0.05mS steps
0.1mS steps
Maximum setting = 5mS
Maximum Setting = 99.9mS
Not Used
SW1-8
SW2
Position
ON
OFF
SW2-1
7 bits
8 bits
SW2-2
No parity
With parity
Odd parity
Even parity
1 stop bit
2 stop bits
SW2-3
SW2-4
Function
External Communications
SW2-5
Communication Baud Rate (see Appendix D)
SW2-6
SW2-7
Not Used
SW2-8
Not Used
Communication Baud Rate
SW2-5
SW2-6
9,600 bps (default)
OFF
OFF
19,200 bps
OFF
ON
38,400 bps
ON
OFF
9,600 bps
ON
ON
Default settings: 9,600 bps, 8-bit, even parity with 2-Stop bits
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CHAPTER 4: MLE-118A OPERATION
SW3
Position
SW3-1
SW3-2
SW3-3
SW3-4
SW3-5
Function
ON
Not Used
See table below
Laser Start/Accept Times
Trigger Signal Enable
(Firmware V00-02H)
SW3-6
OFF
Not Used
Trigger Signal Output
On Ext. I/O(1) - Pin 7
SW3-7
SW3-8
No Trigger Output
Not Used
Laser Accept Times
16mS (default)
8mS
4mS
1mS
0.1mS
SW3-4
OFF
OFF
OFF
OFF
ON
SW3-3
OFF
OFF
ON
ON
x
SW3-2
OFF
ON
OFF
ON
x
x – don’t care
SW4 (see Appendix B, Section III for more information on Independent Control.
Switch
Position
SW4-1
SW4-2
SW4-3
SW4-4
SW4-5
SW4-6
SW4-7
SW4-8
Function
Branch Shutter 1 – When in Independent Control mode, turn ON if branch shutter is installed.
Branch Shutter 2 – When in Independent Control mode, turn ON if branch shutter is installed.
Branch Shutter 3 – When in Independent Control mode, turn ON if branch shutter is installed.
Branch Shutter 4 – When in Independent Control mode, turn ON if branch shutter is installed.
Not Used
SW5 (see Appendix B, Section III for more information on Independent Control.
Position
SW5-1
SW5-2
SW5-3
SW5-4
SW5-5
SW5-6
SW5-7
SW5-8
Function
Time-Share 1 – When in Independent Control mode, turn ON if time-share shutter 1 is installed.
Time-Share 2 – When in Independent Control mode, turn ON if time-share shutter 2 is installed.
Time-Share 3 – When in Independent Control mode, turn ON if time-share shutter 3 is installed.
Not Used
SW6 – Not Used.
9.
BACK – This button returns to the Initialization Screen.
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CHAPTER 4: MLE-118A OPERATION
Maintenance Mode Screen
The Maintenance Mode Screen is used for maintenance functions such as, checking the status and
alignment of the laser. This screen is not typically used by the laser operator. For information on the
Maintenance Screen contents, please consult with the Miyachi Unitek Corporation.
CAUTION: An incorrect setting in this screen may make the Laser inoperable.
1.
Rotate the ENCODE button to the Passwd field.
2.
Press and hold the ENCODE button for 2 seconds (until you hear a faint beep).
3.
Rotate the ENCODE button to the Print field.
4.
Press and hold the ENCODE button for 2 more seconds, until the Maintenance Mode Screen
appears, then release the ENCODE button.
5.
To exit the Maintenance Mode screen, rotate the ENCODE button to any MENU key, then press
the ENCODE button.
NOTE: The CONTROL key switch must be turned ON.
5
1
6
2
7
3
4
1.
MODE
To aid in laser alignment, turn Maintenance Mode ON. While in Maintenance Mode, the
Program Box is the only way of controlling the laser. When Maintenance Mode is ON, all fields
in the Maintenance Mode screen become active.
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CHAPTER 4: MLE-118A OPERATION
2.
CONTROL
This field is used to display the status of the feedback control system.
DISPLAY
LASER POWER
CURRENT
FEEDBACK STATUS
POWER FEEDBACK ENABLED (CLOSED LOOP)
POWER FEEDBACK DISABLED (OPEN LOOP)
When set to LASER POWER, the power feedback circuit is active. The Laser should always be
set to LASER POWER mode for normal operation.
CURRENT mode is used to supply a user-defined current through the flashlamp.
CURRENT mode should only be used during oscillator alignment by factory-trained personnel.
3.
DATE / TIME
These fields are used for entering the current date and time (24-Hour clock). Date and time are
not needed for normal operation. These fields become important when using the PRINT mode
and ERROR RECORDS.
'
FORMAT:
EXAMPLE:
4.
YR
. MO .
HR
: MIN
' 10.02.09
14:05
=
DAY
February 9, 2010
2:05 p.m.
ERROR RECORD
This field is used to view the error log when enabled. The error log will display the last 50
errors with the most recent error listed at the top of the list.
5.
CURRENT
This is the flashlamp current setting. Used only when LASER CONTROL is set to CURRENT
mode. The flashlamp current adjustment must only be performed by factory-trained personnel.
Range: 70A d I d 300A
6.
PULSE WIDTH
This controls the output pulse width. Used only when LASER CONTROL is set to CURRENT
mode. This pulse width adjustment must only be performed by factory-trained personnel.
Range: 0.3mS d t d 5.0mS
7.
FLOW
The FLOW field displays the measured flow rate of the internal water pump. As the water filter
and de-ionized cartridge get clogged, the flow rate will drop.
LW300A(H)/LW400A Nd:YAG LASER
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990-538
CHAPTER 5:
OPERATING INSTRUCTIONS
Section I. Welding Preparation
Preparation
Before operating the Laser, you must be familiar with the following:
x The principles of laser welding and the use of programmed weld schedules.
x The location and function of Controls and Indicators (see Chapter 1, Description).
x How to select and use the Control functions for your specific welding applications. For
more information, see the Programming Functions described in Chapter 3 or Chapter 4.
Follow the section that applies to the Laser Controller you are using.
General Operator Safety
WARNING
To prevent eye injury, be sure to wear protective glasses for
Nd:YAG with an optical density of at least 7+ at a 1,064
nanometer wavelength.
x
To prevent blindness or eye injury, wear safety goggles at all times during welding.
x
Do not touch the welded parts immediately after the weld process, because the welded parts
can get very hot.
x
Be careful of moving parts. You can be injured by moving parts during the welding process.
x
Do not wear loose clothing or jewelry around moving parts. They may get caught and cause
injury.
Starting the Laser
1.
Turn the Laser MAIN POWER switch ON.
2.
When prompted, turn the keyswitch to the ON position. Once any of the operating screens
appear, the Laser is ready for welding.
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5-1
CHAPTER 5: OPERATING INSTRUCTIONS
Section II. Welding using the MLE-115A
Prepare Processing Point and Set Weld Schedule (MLE-115A)
1.
Turn the High Voltage OFF so the laser cannot emit.
(The high voltage is automatically initialized during power-up).
2.
Adjust the position of the laser beam output unit (focus head). Set the proper working
distance for each installed laser beam output unit (focus head).
3.
Navigate to the SCHEDULE screen using the MENU key.
4.
If a waveform is displayed on the right portion of screen, set the
the desired welding parameters.
field to OFF, then input
Example:
Sample Settings:
x
SCH to #05
x
Ì SLOPE to 01.0ms
FORM: FIX
x
Ê SLOPE to 00.6ms
x
REPEAT = 10pps
x
FLASH1 to 04.2ms
x
PEAK = 2.00kW
x
FLASH2 to 00.0ms
x
x
FLASH3 to 01.0ms
OUTPUT VALUE = 50%
( FLASH1 )
5.
Move the cursor to SCH # and change each number to SCH # 05 by pressing the ON(+)/OFF() keys, followed by ENTER.
6.
Move the cursor to PEAK and change each number to 02.00 kW by pressing the ON(+)/OFF(-)
keys, followed by ENTER.
7.
Move the cursor to FLASH1 and change the value of each number to 04.2 ms by pressing the
ON(+)/OFF(-) keys, followed by ENTER.
8.
Move the cursor to FLASH1 04.2 ms 000% and change each number to 050 % by pressing the
ON(+)/OFF(-) keys, followed by ENTER. (Note: 50% of 2.00 kW is a peak setting of 1.0 kW)
9.
Move cursor to Ê SLOPE and change the value of each number to 00.6 ms by pressing the
ON(+)/OFF(-) keys, followed by ENTER.
10. Move cursor to FLASH2 and change the value of each number to 00.0 ms by pressing the
ON(+)/OFF(-) keys, followed by ENTER.
11. Move cursor to FLASH3 and change the value of each number to 01.0 ms by pressing the
ON(+)/OFF(-) keys, followed by ENTER.
12. Move cursor to ÌSLOPE and change the value of each number to 01.0 ms by pressing the
ON(+)/OFF(-) keys, followed by ENTER.
13. Move cursor to REPEAT and change the value of each number to 010 pps by pressing the
ON(+)/OFF(-) keys, followed by ENTER.
If the programmed data in the above example were plotted over time, it would appear as follows:
LW300A(H)/LW400A Nd:YAG LASER
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990-538
CHAPTER 5: OPERATING INSTRUCTIONS
Welding Using the MLE-115A Laser Controller
1.
Verify that PANEL CONTROL is displayed on the STATUS screen.
2.
Turn the High Voltage ON. Move cursor to HV: OFF and select ON with ON(+) key to turn
on the high voltage, followed by ENTER. Once the READY light turns on, proceed to the
next step.
3.
Open the Shutters.
x Move cursor to MAIN SHUTTER: OFF and open the main shutter with ON(+) key,
followed by ENTER.
x Move the cursor to the BEAM-X you are using and open the branch shutter(s) for each
configured output, followed by ENTER. For example, in an Energy-Shared delivery
system, each output branch shutter needs to be opened.
x Select the SCHEDULE # on either the SCHEDULE screen or the POWER MONITOR
screen. (From the previous example, select SCH. #05.)
4.
Check the Processing Site.
x On the STATUS screen, select ON for POSITION (Guide beam), followed by ENTER.
x The guide beam will show the processing site with a red dot. This is the position for the
laser processing.
x If the processing site is dislocated, adjust by moving the output unit or workpiece.
Verify the working distance before proceeding.
5.
Perform Laser Processing.
x Press the LASER START/STOP button on the Laser Controller.
x Verify an output response on the POWER MONITOR screen.
Shutdown using the MLE-115A Laser Controller
1.
Turn OFF the high voltage and close all shutters using the methods described above.
2.
Turn the Control key switch to the OFF position.
3.
Turn off the main power switch.
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5-3
CHAPTER 5: OPERATING INSTRUCTIONS
Section III. Welding using the MLE-118A
Prepare Processing Point and Set Weld Schedule (MLE-118A)
1.
Turn the High Voltage OFF so the laser will cannot emit (The high voltage is automatically
initialized during power-up). Rotate the ENCODE button to highlight the HV field, select the
ENCODE button and rotate the ENCODE knob to highlight OFF, select the ENCODE button
once more to turn off the high voltage.
2.
Adjust the position of the laser beam output unit (focus head). Set the proper working
distance for each installed laser beam output unit (focus head).
3.
Using the ENCODE button and navigate to the SCHEDULE screen.
Example:
Sample Settings:
x
SCH to #05
x
Ì SLOPE to 01.0ms
FORM: FIX
x
Ê SLOPE to 00.6ms
x
REPEAT = 10pps
x
FLASH1 to 04.2ms
x
PEAK = 2.00kW
x
FLASH2 to 00.0ms
x
x
FLASH3 to 01.0ms
OUTPUT VALUE = 50%
( FLASH1 )
1.
Rotate the ENCODE button and highlight SCH #. Change each number to SCH #05 by
rotating and selecting the ENCODE button.
2.
Rotate the ENCODE button and highlight PEAK. Change each number to 02.00 kW by
rotating and selecting the ENCODE button.
3.
Rotate the ENCODE button and highlight FLASH1. Change the value of each number to 04.2
ms by rotating and selecting the ENCODE button.
4.
Rotate the ENCODE button and highlight FLASH1 04.2 ms 000%. Change each number to 050
% by rotating and selecting the ENCODE button.
(Note: 50% of 2.00 kW is a peak setting of 1.0 kW)
5.
Rotate the ENCODE button and highlight Ê SLOPE. Change the value of each number to
00.6 ms by rotating and selecting the ENCODE button.
6.
Rotate the ENCODE button and highlight FLASH2. Change the value of each number to 00.0
ms by rotating and selecting the ENCODE button.
7.
Rotate the ENCODE button and highlight FLASH3. Change the value of each number to 01.0
ms by rotating and selecting the ENCODE button.
8.
Rotate the ENCODE button and highlight ÌSLOPE. Change the value of each number to 01.0
ms by rotating and selecting the ENCODE button.
9.
Rotate the ENCODE button and highlight REPEAT. Change the value of each number to 010
pps by rotating and selecting the ENCODE button.
If the programmed data in the above example were plotted over time, it would appear as follows:
LW300A(H)/LW400A Nd:YAG LASER
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990-538
CHAPTER 5: OPERATING INSTRUCTIONS
Welding Using the MLE-118A Laser Controller
1.
Verify that PANEL CONTROL is displayed on the STATUS screen.
2.
Turn the High Voltage ON. Rotate the ENCODE button to the HV field and select the
ENCODE button. Rotate and select ON from the pop-up window.
3.
Open the Shutters.
x Use the ENCODE button to open to select (open) the MAIN and BEAM (branch shutters).
For example, in an Energy-Shared delivery system, each output branch shutter needs to
be opened.
x Select the SCHEDULE # (from the previous example, select SCH #05.)
4.
Check the Processing Site.
x Use the ENCODE button to select and turn the POSITION (Guide beam) to ON.
x The guide beam will show the processing site with a red dot. This is the position for the
laser processing.
x If the processing site is dislocated, adjust by moving the output unit or workpiece.
Verify the working distance before proceeding.
5.
Perform Laser Processing.
x Press the LASER START/STOP button on the Laser Controller.
x Verify an output response on the POWER MONITOR screen.
Shutdown using the MLE-118A Laser Controller
1.
Turn OFF the high voltage and close all shutters using the methods described above.
2.
Turn the Control key switch to the OFF position.
3.
Turn off the main power switch.
LW300A(H)/LW400A Nd:YAG LASER
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5-5
CHAPTER 5: OPERATING INSTRUCTIONS
Section IV. Welding Using External I/O
1.
Program the welding parameters using one of the methods described above (using the MLE115A or MLE-118A Program Box).
2.
Close the CONTROL CHANGEOVER signal on the EXT-I/O (1) Connector and verify that
EXTERNAL CONTROL is displayed on the STATUS Screen.
3.
Turn the High Voltage ON. Close the HV-ON/OFF signal on EXT. I/O (1).
4.
Open all Shutters.
x Close the MAIN SHUTTER signal on EXT. I/O (1).
x Close the BEAM SELECT(s) on all configured outputs (EXT. I/O (1) and EXT. I/O (2)).
5.
Check the Processing Site.
x Close the GUIDE BEAM signal on EXT-I/O (1).
x The guide beam will show the processing site with a red dot. This is the position for the
laser processing.
x If the processing site is dislocated, adjust by moving the output unit or workpiece.
Verify the working distance before proceeding
6.
Select SCHEDULE No. Input the Schedule Number on EXT. I/O (1) by combining input
signals; SCHEDULE 1, 2, 4, 8, and 16.
7.
Perform Laser Processing.
x Close the LASER START signal on EXT. I/O (1).
x Verify an output response on the POWER MONITOR screen.
NOTE: Refer to Appendix B, Electrical and Data Connections for connection details.
Shutdown through the External I/O
1.
Open all I/O connections by turning OFF the high voltage and closing all shutters using the
signals described above.
2.
Turn the Control key switch to the OFF position.
3.
Turn off the main power switch.
LW300A(H)/LW400A Nd:YAG LASER
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990-538
CHAPTER 6
MAINTENANCE
Section I: Precautions
WARNING: Before starting any maintenance, carefully read all instructions, Warnings, and Cautions
DANGER
To prevent eye injury, service personnel, or anyone who may be exposed to Nd:YAG
laser beams, must wear safety goggles having a minimum optical density of 7+ at a 1,064
nanometer wavelength.
x
Turn the power to the laser OFF and disconnect it from the A.C. source before performing any
maintenance work.
x
Do not modify the Laser without prior written approval from the Miyachi Unitek Corporation.
x
If the high voltage was ON, wait 5 minutes for the capacitors to discharge after turning the
power OFF before starting any work. The capacitors store a lethal amount of energy.
x
When turning power ON to check operation during any maintenance procedure:
ƒ
Make sure that everyone who may be exposed to the Nd: YAG laser beam during
maintenance, is wearing laser protective glasses.
ƒ
Never put more than one hand inside of the Laser at any time.
ƒ
When high voltage is turned ON, the Nd: YAG laser oscillator is enabled.
ƒ
Use extreme caution while performing any work on the laser.
x
To operate the laser without the top cover, release the safety interlock switches by pulling them
outward until they are locked in the bypass position. The Interlock bypass lamp (LED) will
light when the top cover safety interlock has been overridden.
x
Use the appropriate tools for terminating the connection cables, being careful not to nick the
wire conductors.
x
Keep the exterior of the Laser clean. Use a dry or slightly dampened cloth to clean. If heavily
soiled, use a cloth moistened with a mild detergent or alcohol. Do not use paint thinner,
benzene or acetone.
LW300A(H)/LW400A PULSED Nd: YAG LASER
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6-1
CHAPTER 6: USER MAINTENANCE
Section II. Troubleshooting
Error Codes
Any malfunction occurring in the unit is indicated on the control unit display, for example:
MLE-118A Error Code Screen
MLE-115A Error Code Screen
The LCD screen can display up to six faults at a time. The most recent error detected is listed first,
followed by previously detected error codes (in reverse chronological order). The Error Code Number
consists of E for “Error” and a 2-digit code which correspond to the specific problem. For example an
E03 signifies an Emergency Stop. Follow the troubleshooting instructions listed in the Error Codes and
Corrective Actions table below, correct the problem, then select Trouble Reset to clear the error.
Error Codes and Corrective Actions
The error codes listed below are the most probable causes for the displayed error. Eliminate each cause for the
associated error. If the error still exists, contact the Miyachi Unitek Corporation. If an error code number is not
listed, then it is either (1) not used or (2) reserved for factory testing.
Code
00
LCD Screen
Communication Line Error
HV
Alarm
Corrective Actions
–
–
A communication error exists between the Program Box and
the Laser CPU. Recycle power, then check for each of the
these possible causes:
– RF noise source near the laser (isolate laser).
– Bad/loose cable connection between the Program Box and
the Main PCB.
– Faulty Power Supply (+24V).
– Faulty Main PCB or Program Box.
– Incorrect transmission mode and setting.
– CPU needs to be initialized.
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CHAPTER 6: USER MAINTENANCE
Code
LCD Screen
HV
Alarm
Corrective Actions
01
Power Supply Cover Opened
OFF
ON
A side, rear or front panel is removed. Check to be sure all
laser panels are installed. If panels are removed, verify
Interlock switches are bypassed. Possible causes:
– Laser cover is loose or removed.
– Faulty Interlock Switch.
– Faulty Interlock PCB, power supply, or CPU.
02
Head Cover Opened
OFF
ON
The head cover or flashlamp access cover is removed. Check
to be sure all panels are installed. If panels are removed, verify
Interlock switches are bypassed. Possible causes:
– Laser cover is loose or removed.
– Faulty Interlock Switch.
– Faulty Interlock PCB, power supply, or CPU.
03
Emergency Stop
(non-CE models only)
OFF
ON
An Emergency Stop signal is present. Check condition of both
Emergency Stop switches on the Control Panel and the E-Stop
input on the Interface panel. (EXT I/O (3) and EXT I/O (4) ).
04
Coolant Low Level
OFF
ON
The quantity of secondary cooling water is low. Add Steamdistilled water to the water tank (to the level indicated on the
water level label). If the problem persists, look for leaks.
Possible causes:
– The water level is too low
– Leak in cooling system
– Faulty water level sensor
– Faulty heat Exchanger
– Faulty Interlock PCB.
05
Phase trouble
OFF
ON
The phase order of the input AC is incorrect. If this error
occurs, check the A.C. service for proper phasing (X, Y, Z, or
R, S, T) and exchange two of the phases. Possible causes:
– Incorrect A.C. power installation
– Faulty phase detection circuit.
06
Overheat of Pump
OFF
ON
The temperature of the water pump is excessive. Measure the
A.C. line voltage and verify the laser is set to run at this input
voltage. Possible causes:
– Laser not correctly tapped for the A.C. supply voltage.
– Faulty pump (usually accompanied with noise)
– Faulty temperature sensor
07
DSP Unit Missing
OFF
ON
The Laser Controller (Program Box) is not connected to the
Laser. This error appears when the Main PCB cannot
communicate with the Laser Controller. Verify connection.
Possible causes:
– Faulty Laser Controller (bad communication driver)
– Faulty Main CPU (bad communication driver)
08
Discharge Resistor
Temperature
OFF
ON
The temperature of the Discharge Resistor is high. Turn the
Laser off for 10 minutes and allow the heat in the discharge
resistor to dissipate. Possible causes:
– The High Voltage is cycled on and off too frequently.
– Faulty thermal switch.
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CHAPTER 6: USER MAINTENANCE
Code
LCD Screen
HV
Alarm
Corrective Actions
09
Oscillator Temperature
OFF
ON
A high temperature has been detected on the Oscillator base
plate. Turn the Laser off for 10 minutes and allow the heat to
dissipate. Possible causes:
– The Laser is fired repeatedly into a closed shutter.
– An optical component is overheated.
– High ambient temperature.
10
High Temperature of Coolant
OFF
ON
The secondary cooling water temperature is >104ºF (40ºC).
Verify temperature with a thermometer. Possible causes:
– Dirty air filters
– High ambient temperature
– Poor or no primary water (chiller) flow
– Stuck or plugged solenoid (regulator) valve
– Faulty temperature sensor
– Faulty Main PCB
11
Low Temperature of Coolant
OFF
ON
The secondary cooling water temperature is < 77ºF (25ºC).
Verify temperature with a thermometer. Allow at least 30
minutes for laser to warm up before troubleshooting. Possible
causes:
– Low ambient temperature
– Primary cooling water lines connected in reverse
– Solenoid valve incorrectly adjusted or faulty
– Faulty heat exchanger
– Improperly adjusted regulator
12
Low Flow Rate of Coolant
OFF
ON
Flow rate of the secondary cooling water is low. Possible
causes:
– Clogged Ion exchange filter or water filter
– Broken flashlamp (causing blockage in oscillator)
– Bad Flow Sensor
– Bad water pump
– Faulty Main PCB
13
Deionize Trouble
(****M:/cm)
OFF
ON
The Resistivity of the secondary cooling water is < 2M:.
Allow laser to run and verify resistivity increases over time.
Possible causes:
– Old Ion Exchange Resin
– Contaminated water
– Short circuit or leakage across sensor probes
– Faulty Main PCB
14
Simmer Trouble
OFF
ON
Flashlamp will not simmer (stay on). Possible causes:
– Faulty flashlamp
– Low AC voltage (change Transformer taps)
– Resistivity of secondary cooling water is low
– Faulty Trigger or Simmer PCB
15
Charge Trouble
OFF
ON
The Capacitor Bank is not charging in the allotted time or the
charge voltage is too high. Possible causes:
– AC voltage out of spec (change Transformer taps)
– Blown fuse in Charge Unit (due to faulty component)
– Faulty Charge Unit or Capacitor Bank.
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CHAPTER 6: USER MAINTENANCE
Code
LCD Screen
HV
Alarm
Corrective Actions
16
Capacitor Bank Alarm
OFF
ON
The capacitor bank charge voltage is not correct (undercharge,
overcharge, or no voltage). Possible causes:
– Cap Bank Balance circuit needs to be reset. If problem
persists, the Cap Bank is faulty.
– Blown fuse in Charge Unit (due to faulty component)
– Faulty Charge Unit or Capacitor Bank
18
Main Shutter Trouble
OFF
ON
Main Shutter position not detected or does not change position
within 20ms. Possible causes:
– External Interlock open during Power-Up Self Test
– Incorrect External I/O implementation
(do not send Laser Start while shutters are opening)
– If Laser is equipped with a Multi-Workstation Interlock
option, all branch shutters/workstation doors must be
closed prior to the Power-up Self Test
– Faulty Shutter, Interlock PCB, or Main PCB
19
20
21
22
Branch Shutter 1 Trouble
Branch Shutter 2 Trouble
Branch Shutter 3 Trouble
Branch Shutter 4 Trouble
OFF
OFF
OFF
OFF
ON
ON
ON
ON
Branch Shutter position not detected or does not change
position within 20ms. Possible causes:
– External Interlock open during Power-Up Self Test
– Incorrect External I/O implementation
(do not send Laser Start while Main Shutter is opening )
– Faulty Shutter, Interlock PCB, or Main PCB
27
No Current
OFF
ON
No/Low current detected in flashlamp. Possible causes:
– Broken flashlamp or faulty flashlamp cable
– Faulty Power Supply or Hall Sensor
28
Discharge Unit Over-current
OFF
ON
Excessive Current in Discharge Unit. Possible causes:
– Faulty Discharge Unit (due to bad IGBT)
– Short Circuit in Capacitor Bank Wiring
29
Discharge Unit Temperature
ON
ON
A high temperature has been detected in the Discharge Unit.
Possible causes:
– Low level of secondary cooling water
– Faulty cooling fan(s)
– Faulty temperature sensor
– Faulty Discharge Unit
30
Discharge Unit Overpower
OFF
ON
Flashlamp is drawing excessive power. Possible causes:
– Old flashlamp
– Improper beam alignment
– Faulty YAG rod
– Faulty Hall Sensor
31
Branch Unit Cover Opened
OFF
ON
The branch unit cover is removed. If panels are removed,
verify interlock micro-switches are defeated. Possible causes:
– Branch Unit cover is loose or removed
– Faulty Interlock Microswitch
– Faulty Interlock PCB
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6-5
CHAPTER 6: USER MAINTENANCE
Code
LCD Screen
HV
Alarm
Corrective Actions
32
Fiber Switch Trouble
(used on hard-wired fiber
interlock systems only)
OFF
ON
Optical Fiber connection not detected. The possible causes of
this error are:
– ME-1955 dipswitch set incorrectly
– Fiber Optic Cable is disconnected or faulty
– Incorrect wiring to the fiber connector
– Faulty focus head connection switch
33
E. Indicator Trouble
(Output Unit – Focus Head)
E. Indicator Trouble
(Program Unit)
OFF
ON
No current is detected through the Emission Indicator(s).
Verify the condition of the Emission lamps and replace as
necessary. Possible causes:
– Faulty Emission lamp in Start/Stop switch (E34)
– Faulty Emission lamp in Focus Head (E33)
– Faulty wiring
– ME-1955 dipswitch set incorrectly
–
ON
Back-up memory lithium battery is low. Possible causes:
– Low (or dead) battery (on Main PCB)
– Faulty Main PCB
OFF
OFF
OFF
OFF
ON
ON
ON
ON
IR not detected at focus head. Possible causes:
– Faulty IR sensor in focus heads
– Faulty wiring
– ME-1955 dipswitch set incorrectly
34
35
Battery Low
38
39
40
41
Fiber Sensor 1 Trouble
Fiber Sensor 2 Trouble
Fiber Sensor 3 Trouble
Fiber Sensor 4 Trouble
44
External Interlock Opened
–
ON
Safety Interlock circuit is open. Possible causes:
– Faulty remote Interlock connection
– External Interlock connector not connected to the laser
– Faulty Interlock PCB
45
Laser Start is not Ready
–
ON
A process error has been detected. Possible causes:
– Issuing a start command before branch shutters are fully
open (wait at least 20mS after sending shutter command)
– Issuing a start command before the laser is “ready"
– Faulty branch shutter
46
Power Monitor Temperature
–
ON
Power Monitor temperature is out of specification (45~46qC).
If this error occurs, the Power Monitor Assembly is faulty.
47
Overrate
–
ON
The programmed laser settings exceed the capacity of the
Laser. Error usually appears after the laser has fired. Possible
causes:
– Programmed energy/power too high
– Programmed pulse width is too long
– Repetition rate set too high
– Faulty Power Monitor
48
Fiber Overrate
–
ON
The programmed laser settings exceed the capacity of the
Fiber Optic Cable. Error usually appears after the laser has
fired. Possible causes:
– Programmed energy/power too high
– Programmed pulse width is too long
– Repetition rate set too high
– Faulty Power Monitor
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CHAPTER 6: USER MAINTENANCE
Code
LCD Screen
HV
Alarm
Corrective Actions
49
Setting Error
(duration too short)
–
ON
Pulse width setting 00.2ms. Error usually appears before the
laser has fired. Set pulse width to > 00.2ms.
50
Setting Error
(overlimit of Max Pwr)
–
ON
The programmed laser settings exceed the capacity of the
Laser. Error appears before the laser has fired. Once this error
is present, all laser settings will revert back to the settings
before the change. Lower the process settings.
51
Fiber Setting Error
–
ON
The programmed laser settings exceed the capacity of the
Optical Fiber. Error appears before the laser has fired. Once
this error is present, all laser settings will revert back to the
settings before the change. Lower the process settings.
52
Memory Trouble
–
ON
CPU memory trouble. Possible causes:
– CPU back-up battery is low on Main PCB
– Re-initialize Laser (all settings will be erased)
– Bad/loose connection on Main PCB
– Faulty Main PCB
53
Power Feedback Trouble
–
ON
Problem with laser power feedback system. Possible causes:
– Faulty Power Monitor
– Faulty Discharge Unit
– Faulty Main PCB
54
Deionize Caution
(****M:/cm)
–
–
Resistivity of secondary cooling water (2M: < Ur d 3M:) is
low. If this error does not clear after 50~60 minutes, replace
the Ion Exchange Resin. Possible causes:
– Old Ion Exchange Resin
– Short circuit across sensor probes
– Water leakage in sensor
– Faulty Main PCB
56
Overlimit of Laser Power
–
–
Output Energy exceeds “high” set point. Verify the ENERGY
HIGH value is correct.
57
Underlimit of Laser Power
–
–
Output Energy falls below the “low” set point. Verify the
ENERGY LOW value is correct.
59
60
61
Time-Share 1 Trouble
Time-Share 2 Trouble
Time-Share 3 Trouble
OFF
OFF
OFF
ON
ON
ON
Time-Share Shutter position not detected or does not change
position within specified time. Possible causes:
– External Interlock open during Power-Up Self Test
– Incorrect External I/O implementation
(do not send Laser Start while Main Shutter is opening )
– Faulty Time-share Shutter
– Faulty Interlock PCB
– Faulty Main Board
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CHAPTER 6: USER MAINTENANCE
Section III. Routine Maintenance Schedule
To ensure reliable and safe operation of the Laser, you should regularly perform routine inspection,
cleaning, and maintenance as indicated in the table below.
Frequency or Occasion
Action
Daily
Reference Paragraph
SemiAnnually
Other
Air Filter Procedures
•
Inspect air filter
Vacuum air filter
•
Clean air filter with detergent
As required when inspected
Cleaning the Air Filter
As required when inspected
Cleaning the Air Filter
As required
Cleaning the Air Filter
Cooling Water Procedures
As required when inspected
Checking Water Level
and Adding Water
Add cooling water
As required when inspected
Checking Water Level
and Adding Water
Partially drain secondary cooling
water
Replacement of ion
exchange resin or cartridge,
water filter replacement,
long-term storage; shipment
Draining the Secondary
Cooling Water
Inspect cooling water level
Completely drain primary and
secondary cooling water
•
•
Long periods of non-use,
possibility of freezing.
Draining Primary
Cooling Water
Draining Secondary
Cooling Water
Partially drain Primary Cooling
Water
Clean Solenoid Valve
Strainer
Draining the Primary
Cooling Water
Replace Ion exchange cartridge
When necessary
(Roughly every 3 years)
Refilling Ion Exchange
Resin and replacing IonExchanger
Replace ion-exchange resin
When necessary
(Roughly every 6 months)
Refilling Ion Exchange
Resin and replacing IonExchanger
Lithium Battery Procedure
Replace lithium battery (BIOS
program storage battery)
Every 30 months
(2-1/2 years)
Replacing Back-up
Battery
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CHAPTER 6: USER MAINTENANCE
Section IV: Maintenance Procedures
Overview
The maintenance procedures in this section are grouped based on their degree of difficulty to perform.
Procedure
Page
Easy
Cleaning the Air Filters ................................................................................................................. 6-10
Cleaning Optical Parts -- Removing Dirt, Dust, Etc. from Optics ................................................ 6-10
Cleaning Optical Parts -- Fogging and Staining ............................................................................ 6-11
Cleaning Optical Parts -- Optical Fiber ......................................................................................... 6-11
Replacing the Power Supply Backup Battery ................................................................................ 6-12
Cooler Maintenance -- Checking Water Level and Adding Water ............................................... 6-13
Cooler Maintenance -- Draining the Primary Cooling Water ....................................................... 6-14
Cooler Maintenance -- Draining Secondary Cooling Water ......................................................... 6-15
Cooler Maintenance -- Draining the Cooling Water when the Laser
Is Not Used for Long Periods of Time or Its Temperature Goes Below 0°C ........................ 6-15
Cooler Maintenance -- Replacing the Water Filter ........................................................................ 6-17
Cooler Maintenance -- Refilling and/or Replacing Ion Exchange Cartridge ................................ 6-17
Moderate
Cooler Maintenance – Cleaning the Solenoid Valve Strainer ....................................................... 6-19
Power Detector Adjustment ........................................................................................................... 6-20
Replacing the Flashlamp ................................................................................................................ 6-22
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CHAPTER 6: USER MAINTENANCE
Cleaning the Air Filter
Required Items
x Phillips screwdriver
1.
Remove the filter
retainer from the rear of
the Laser.
2.
Take out the filter and
wash it with tap water.
If the filter is badly
stained, use a neutral
detergent to clean it.
3.
Air-dry the filter
naturally and then install
the filter back into the
Laser.
Cleaning Optical Parts -- Removing Dirt, Dust, Etc. from Optics
Required Items
1.
Hold the optical part horizontally by
the sides.
2.
Blow off any dirt and dust using an air
blower.
3.
Check that no dirt or dust remains.
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CHAPTER 6: USER MAINTENANCE
Cleaning Optical Parts -- Fogging and Staining
1.
Hold the optical part horizontally by
the sides.
2.
Place a drop of acetone on the center
of the lens cleaning paper.
3.
Place the wet part of the cleaning
paper onto each optical part.
4.
Holding one end of the cleaning paper,
wipe each optical part by pulling the
cleaning paper across it at a constant speed from one side to the other. If there is an air gap
between the cleaning paper and optical part while being wiped or if any liquid acetone remains
at the trailing edge of the cleaning paper when wiping is completed, the optical part may not be
cleaned evenly.
5.
Check that no dirt or dust remains.
Cleaning Optical Parts -- Optical Fiber
1.
Remove the optical fiber from the
connector.
2.
Blow the dust off the end face of the
optical fiber with an air blower.
3.
If dust cannot be removed by
performing the step above, lightly
wipe it with lens cleaning paper. To
avoid scratching the end face, never
press the cleaning paper againat the
end face of the fiber.
4.
Check the end face for dust and stains.
NOTE: Use a fiber inspection tool (P/N 4-60091-01) to check the end face of the optical fiber
for flaws, dust, and burns.
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CHAPTER 6: USER MAINTENANCE
Power Supply -- Replacing the Backup Battery
NOTE: The service life of the backup lithium battery is about three years.
1.
Turn the MAIN POWER switch OFF.
2.
Wait for at least 5 minutes and then remove the right side cover.
3.
Remove the battery from the Control PC board (non-conductive tweezers can be used to
simplify the extraction process).
4.
Install a new battery, making sure the polarity is correct.
5.
Re-install the right side cover.
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CHAPTER 6: USER MAINTENANCE
Cooler Maintenance -- Checking Water Level and Adding Water
The water level should be checked each day before operation.
NOTE: If the water level is low, add water. If you need to add water daily, check for leaks.
Required Items
x PH-10 hand pump
x Latex Gloves (powder free)
x Eye Protection
x Steam-distilled Water (as required)
1.
Open the Front Door of the Laser.
2.
Inspect the water level inside the
Cooling Water Tank. The water level
should be between the HIGH and LOW
line of the water level label.
3.
Remove the tank cover.
4.
Remove the floating panel (keep the
panel clean).
5.
Add steam-distilled water using the
hand pump until the water is at the
HIGH line of the water level label. If
this is an initial filling, or a lot of water
is needed, the level may again drop
after the unit has been running a few
minutes. Recheck the level and add
additional water as necessary.
6.
Replace the floating panel.
7.
Replace the cover on the cooling water tank.
8.
Close the front door.
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CHAPTER 6: USER MAINTENANCE
Cooler Maintenance -- Draining the Primary Cooling Water
Drain the water when marked with a “•” on the following occasions:
Maintenance work
Draining
Replacing Ion-Exchange resin refill
Not necessary
Replacing Ion-Exchange Cartridge
Not necessary
Replacing water filter
Not necessary
Replacing secondary cooling water
Not necessary
Shift and transportation
•
Long period of non-use
•
Required Items
x Clean bucket or similar container
x Flat-blade screwdriver
1.
Disconnect the two externally
connected hoses to drain the water. If
you splash water on the equipment,
wipe it off with a clean cloth.
2.
Open the solenoid valve cover on the
back of the Laser and pull out the
solenoid valve.
3.
Open the solenoid valve. Push and turn
screw A shown at right to the “Open”
(horizontal) position with a flat-blade
screwdriver.
4.
Remove the valve plug (B).
5.
Blow clean compressed air (42 psi or
294 kPa maximum) into the pipes to
drain the water.
6.
Return the valve plug B. Return screw
A to “Normal” position (vertical).
7.
Return the solenoid valve cover.
8.
Connect a small piece of hose between
the cooling water inlet and outlet and
secure each end with a hose band as
shown to keep dirt out of the laser.
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CHAPTER 6: USER MAINTENANCE
Cooler Maintenance -- Draining Secondary Cooling Water
Drain the water when marked with a “•” on the following occasions:
Maintenance work
Secondary cooling water
Replacing Ion-Exchange resin refill
Replacing Ion-Exchange Cartridge
Replacing water filter
Replacing secondary cooling water*
Shift and transportation
Long period of non-use
•
•
•
•
•
•
* Replace secondary cooling water once every 6 months.
Required Items
x PH-10 hand pump
x Clean container, such as a bucket
x Latex Gloves (powder-free)
1.
Open the front door.
2.
Open the cover of the cooling water tank
and remove the floating panel. (keep the
floating panel clean)
3.
Pump the water out of the cooling tank
using a hand pump.
4.
Return the floating panel in the tank.
Return and secure the tank cover.
Cooler Maintenance – Draining the Cooling Water when Laser Is Not Used
for Long Periods of Time or when the Ambient Temperature is Below 0°C
1.
Remove the Left Side panel.
2.
Drain the Primary Cooling Water (see
Draining the Primary Cooling Water).
3.
Drain the Secondary Cooling Water (see
Draining the Secondary Cooling Water).
4.
Remove the flashlamp access cover and
the top cover of the laser chamber.
5.
Allow the water in the chamber to drain into the cooling water tank.
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CHAPTER 6: USER MAINTENANCE
6.
Return and secure the top cover of the laser chamber and the flashlamp access cover in
reverse order.
7.
Place a pan under the Drain Plugs under the front of the Laser.
8.
Open both drain plugs to drain remaining water from secondary cooling water tank. When
removing the plug, press the release ring evenly and pull the plug straight toward you. If
you do not press the ring hard enough, the plug may not come out or the adapter and plug
may be damaged, which can cause a water leak.
9.
Disconnect the tube at location A (noted above) and blow clean compressed air (42psi or
294kPa maximum pressure) into the pipes to force the excess water out.
10. After draining all the water, return the drain plugs and tubes.
11. Return and secure the left side cover.
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CHAPTER 6: USER MAINTENANCE
Cooler Maintenance – Replacing the Water Filter
Required items
x PH-10 hand pump
x Clean container, such as a bucket
x
Latex Gloves (powder-free)
Secondary Cooling Water (or steam-distilled water)
x
NOTE: Replace the water filter and secondary cooling water every 6 months.
1.
Remove the cover of the cooling water tank.
2.
Remove the floating panel (keep the panel clean).
3.
Pump the water out of the tank using the hand
pump.
4.
Pull the water filter up and out. (The water filter is
pressed into the bottom of the cooling water tank.)
Depending on the date of manufacture, the water
filter may be in a slightly different location.
5.
Insert a new water filter and then supply the
secondary cooling water with the hand pump, until
it reaches the HIGH line on the water level label.
6.
Return the floating panel in the tank. Return and
secure the tank cover.
Cooler Maintenance – Refilling and/or replacing Ion Exchange Cartridge
x
The Laser uses an economical ion-exchange cartridge. You can use it repeatedly by refilling its
contents, i.e., ion-exchange resin. Service life of the cartridge housing is about 3 years.
x
Our high performance Ion-Exchange Resin is exclusively blended, so that it purifies more
effectively than conventional resin and has a longer service life.
TIPS
x Life expectancy of the ion-exchange resin is approximately 6 months. Generally it’s best to
replace the ion-exchange resin before the old resin becomes non-effective.
x If the ion-exchange resin is exposed to air, it will deteriorate. When opening the bag, put the
resin into the cartridge immediately and put back the cartridge into cooling water tank.
x Do not expose ion-exchange resin to direct sunlight; keep it in a cool place but do not freeze it.
x When replacing the Ion-Exchange Cartridge, use the proper replacement tool. Do not overtighten, or damage to the threads will occur.
x You can use the floating panel repeatedly. As the floating panel is made of polyethylene foam,
dispose according to all relevant regulations.
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CHAPTER 6: USER MAINTENANCE
Required items
x Ion-exchange replacement tool
x Secondary cooling water
x PH-10 hand pump
x Ion-exchange resin refill
x Phillips screwdriver
x
Latex Gloves (powder free)
x
Clean container, such as a bucket.
1.
Remove the cover of the cooling water tank and take
out the floating panel. (Keep it clean).
2.
Use a hand pump to remove water from the cooling
water tank.
3.
Turn the ion-exchange cartridge in the tank to the
left (CCW) with the replacement tool to remove it.
The ion-exchange cartridge screws into the base of
the cooling water tank. Depending on the date of
manufacture, the ion-exchange cartridge may be in a
slightly different location
4.
Remove the four screws (M4x16mm, stainless steel)
from the cap of the cartridge and pull up on the cap.
5.
Discard the used resin. Dispose the used resin in a
plastic trash can.
6.
Put the resin refill into the cartridge taking care not to spill it.
7.
Wipe off the excess resin on the edge of the cartridge. Reinstall the cap, and screw it down.
8.
Insert the ion-exchange resin cartridge into the cooling water tank and turn it to the right (CW)
with the replacement tool to tighten. Do not over-tighten.
9.
Supply the secondary cooling water, with the hand pump, until it reaches the HIGH line on the
water level label.
10. Return the floating panel in the cooling water tank. Return and secure the cooling water tank
cover.
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CHAPTER 6: USER MAINTENANCE
Cooler Maintenance – Cleaning the Solenoid Valve Strainer
CAUTION
The Laser may overheat if the solenoid valve is clogged with dirt or the flow rate of
the primary cooling water is lowered. Supply clean tap water or water for industrial
use as the primary cooling water. Clean the solenoid valve once a year.
Required Items
x Brush
x 10mm and 17mm wrenches
x Philips screwdriver
x Clean container (such as a bucket)
1.
Turn off the primary cooling water, disconnect
the hoses from the cooling water inlets, and drain
the water (see Draining the Primary Cooling
Water).
2.
Open the solenoid valve cover on the back of the
Laser and pull out the solenoid valve assembly.
3.
Remove the four fastening screws on the top of
the solenoid valve.
4.
Remove the upper portion of the solenoid valve,
and then slowly pull out the spring and
diaphragm (assembly is under spring tension).
5.
Take the strainer out of the solenoid valve, and
carefully clean the net.
6.
Return the strainer and install the diaphragm,
spring, and upper portion of the solenoid valve.
7.
Secure them with the four fastening screws.
8.
If the net or the small hole at the bolt end of the
solenoid valve is clogged, the valve will not
close, causing the primary cooling water to keep
flowing. Check and clean periodically.
9.
Return the disconnected primary cooling water
hoses and secure them with a hose band.
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CHAPTER 6: USER MAINTENANCE
Power Detector Adjustment
The power detector is used to measure the output power/energy of the laser. The measured
power/energy is displayed on the Laser Controller each time the laser is fired. This laser is equipped
with a real-time power feedback system. The power detector is used as the primary feedback device for
output control. The procedure below describes how to adjust the power detector. This procedure should
be performed every six months for application critical processes, or once a year for normal use.
WARNING: Only authorized personnel should perform the following procedure. Nd: YAG safety
goggles with a minimum optical density of 7+ at 1064nm wavelength must be worn at all times during
this procedure.
Required Items:
x Phillips screwdriver
x Potentiometer adjustment tool
x DMM (digital multi-meter)
x Beam Expander
x External IR Power Detector + Meter
x Nd: YAG glasses.
Remove the Head and Branch Unit covers.
1.
Remove the Head and Branch
Unit covers and disable all
Interlock Switches.
2.
Locate the ME-1906 Power
Detector PCB and remove the
plastic cover (4 screws) that
protects the ME-1906 PCB.
3.
Connect a DMM on the ME1906 PCB; (+) to TP6 (SIG) and
(-) to TP1 (GND).
4.
Place a beam expander and IR
Power Meter somewhere in the
optical beam path after the
corner mirror (as shown on the
right). The purpose of the beam
expander is to decrease the
energy density on the face of the
IR Detector. If any optical
components are removed, it will
be necessary to re-align the
Laser after this procedure.
Proceed with caution.
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CHAPTER 6: USER MAINTENANCE
5.
Turn the Laser ON. Once the SCHEDULE screen appears, turn the High Voltage (HV) OFF.
6.
Adjust VR2 (OFFSET) on the ME-1906 PCB for a reading of 0.01 to 0.03 volts on the DMM.
7.
Turn the High Voltage (HV) ON and allow the Laser to reach the READY state.
8.
Open the Main Shutters.
9.
Put the Laser in to MAINTENANCE mode (see Chapter 3, Section III for details using the MLE115A Controller, or Chapter 4, Section III for details using the MLE-118A Controller).
10. Navigate to the CONTROL field and change the mode to CURRENT.
11. Exit the MAINTENACE mode and navigate to the SCHEDULE screen.
12. Enter the operating parameters according to the table below:
Laser Model
Peak Power (A)
Power (%)
Pulse Width
Ideal Output Energy
LW300A
300A
100%
10mS
40J
LW300AH
138A
100%
10mS
10J
LW400A
400A
100%
10mS
60J
13. Turn the Guide Beam ON momentarily to verify all light is hitting the center of the IR Power
Detector in a wide pattern ( 50% coverage is recommended). If necessary, re-position the
beam expander or IR Power Detector.
14. Fire the Laser and increase or decrease the Peak Power (A) until the Ideal Output Energy
(defined in the table above) is measured by the IR Power Meter.
15. Adjust VR1 on the ME-1906 Power Detector PCB until the measured energy on the Laser LCD
screen equals the measured value on the IR Power Meter.
NOTE: turning VR1 clockwise decreases the LCD energy value, likewise turning VR1
counter-clockwise increases the LCD energy value).
16. If VR1 is adjusted, repeat steps 6 – 16 until no further adjustments are necessary.
17. Get back into the MAINTENANCE mode screen and set the CONTROL method back to LASER
POWER.
18. Remove the Beam Expander and IR Power Detector.
19. Remove the DMM and reinstall the ME-1906 plastic protective cover.
20. If any optical components were removed during this process, re-align the Laser.
21. Re-install the Branch Unit and Head covers back on to the Laser.
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CHAPTER 6: USER MAINTENANCE
Replacing the Flashlamp
DANGER
To avoid electrical shock, turn the laser power to the OFF position and wait for at least 5
minutes when replacing the flashlamp,.
CAUTION
x Place the removed top cover, reflector, and the other parts on a clean cloth to protect them
from oil and dust. Do not scratch the inside surface of the reflector (reflector panel) or a
reduced laser output may occur.
x When replacing the flashlamp, do not reverse the polarity of the flashlamp. If you do, the
lifetime of the flashlamp will be significantly reduced.
x Do not touch or scratch the glass portions of the flashlamp or flowtube with bare hands. If
they are scratched or oil from the hands is deposited on the flashlamp, it may break during
operation.
x Before turning the power ON, check that the eight mounting bolts on the top cover of the
laser chamber are tightened securely. Do not overtighten the bolts or damage will occur to
the sealing o-ring.
x Check for leaks after replacing the flashlamp during the first power-up sequence.
Required Items
x Ballpoint hexdriver: 2.5 mm, 5 mm
x Phillips screwdriver
x Alcohol
x Flashlamp (new)
x Powder-free latex gloves (Must be worn for the entire procedure.)
1.
Turn the Laser power OFF. If high voltage
was on, wait for at least five minutes before
starting this procedure.
2.
Remove the flashlamp access cover.
3.
Loosen the bolts on the laser chamber and
remove the top cover, store in a clean area.
4.
Remove the reflector by slowly lifting up
on the top portion of the reflector, store in a
clean area. Do not damage the inner
surface of the reflector.
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CHAPTER 6: USER MAINTENANCE
5.
Loosen the bolts at both ends of the
flashlamp.
6.
Using two hands, hold both ends of the
flowtube (glass tube) and lift it up
together with the flashlamp.
7.
Place the flashlamp on a clean lint-free
cloth.
8.
Carefully pull the flashlamp out of the
flowtube. Straighten the flashlamp
leads as necessary.
9.
Clean the new flashlamp with alcohol and pass the cleaned flashlamp through the flowtube.
10. Carefully place the flashlamp so that it’s "+" aligns with the "+" in the chamber. Make sure
that the flashlamp is securely placed inside the guide groove of the chamber.
11. Center the flowtube inside the chamber.
12. Secure the flashlamp tightly with the bolts.
13. Carefully replace the top portion of the reflector.
14. Install the top cover on the chamber and tighten the bolts.
NOTE: Make sure that the O-ring between the top cover and chamber is pressed evenly.
16. Pull up on the end of the flashlamp access cover interlock switches to bypass them, then turn on
the power.
17. Turn the CONTROL key switch ON.
18. Verify that there are no water leaks and the Laser operates normally, then turn the power OFF.
NOTE: If you detect a leak, turn the CONTROL key switch and the MAIN SWITCH OFF
immediately. Wait for 5 minutes, then wipe off the leaking water and fix the cause of leak.
20. Install the flashlamp access cover.
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CHAPTER 6: USER MAINTENANCE
Section V: Parts Lists
Accessories
Name
EXT. I/O (1) connector (37 pin male)
37 pin D-sub Backshell
EXT. I/O (2) connector (25 pin male)
EXT. I/O (4) connector (25 pin female)
25 pin D-sub Backshell
EXT. I/O (3) E-STOP connector (9 pin male)
9 pin D-sub Backshell
RS-485 connector (1) or (2)
REMOTE INTERLOCK connector
Fiber interlock connector
Ion-exchange resin replacing tool
YAG laser-protective glasses
Ball point hex screwdriver 2.5mm
Ball point hex screwdriver 3mm
Ball point hex screwdriver 4mm
Water feed hand pump
Operation manual
Fiber Scope
Part Number
250-409
250-537
250-479
250-480
250-536
250-193
250-535
451-052
451-035
520-139
451-082
475-118
770-035
770-036
770-037
PH-10
990-538
FOS-04
Consumable Parts
Name
Flashlamp (MLD-0861), LW300A(H)/400A
Flow tube, Flashlamp, LW300A(H)/400A
Flow tube, YAG rod, LW300A(H)/400A
Ion-exchange resin refill
Ion-exchange cartridge
Ion-exchange resin cartridge kit
(With one bag of ion-exchange resin)
Cooling water (Distilled water)
Water filter
Floating Panel
Lithium battery
Fan Filter
Part Number
435-138
Z-01981-002
Z-01981-001
318-026
318-025
318-027
900-241
318-019
Z-01463-001
145-014
HR1320TX350X250
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CHAPTER 6: USER MAINTENANCE
Section VI: Repair Service
Repair Service
If you have problems with your Laser that you cannot resolve, please contact our laser service
department at the address, phone number, or e-mail address listed in CONTACT US in the front of this
manual.
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