Orion Welders LZR series, User Manual

Page 1: ...Orion Laser Welder User Manual Orion LZR ...

Page 2: ...sion Conditions 2 4 Risks for the Eyes and the Skin 2 5 Safety General Prescriptions Chapter 3 Seals 3 1 Labels 3 2 Labels Positioning Chapter 4 Technical Data 4 1 Laser Specifications 4 2 Other Data Chapter 5 Controls Description 5 1 Machine Controls 5 2 Joystick Controls 5 3 Display Touchscreen Controls Chapter 6 Installation 6 1 Internal Controls 6 2 Joystick Controls 6 3 Display Touch Screen Co...

Page 3: ...e the Cooling Water 7 4 How to Remove the Water 7 5 How to Refill the Cooling System Chapter 8 Error Messages and Troubleshooting 8 1 Other Anomalies Chapter 9 Safety Systems 9 1 Resonator Shutter 9 2 Microscope Shutter 9 3 Microscope Infrared Filter 9 4 Weld Chamber Infrared Filter 9 5 Leather Strips Protecting the Chamber Opening Chapter 10 Technical Assistance ...

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Page 5: ...e Orion we are committed to producing quality products and ensuring complete owner satisfaction If you require assistance after reading this manual please contact us with the information provided below Orion Welders a Subsidiary of Sunstone Engineering R D Corp 1693 American Way Suite 5 Payson UT 84651 Email sales orionwelders com Voice 801 658 0015 Fax 866 701 1209 NOTE The information contained ...

Page 6: ...com www OrionWelders com Caution Improper use of this equipment can result in harmful exposure to laser radiation Carefully follow all instructions and warnings included in this document CONTENT GUARANTEE The information included in this manual is subject to modifications without notice Sunstone Engi neering and Orion Welders will be not responsible for errors included in this document nor for any ...

Page 7: ...parts NOTE This equipment should only be used for its intended use and purpose It is not allowed to modify change or use any part of the equipment for any purposes other than the intended usage Sunstone Engineering and Orion Welders declines all responsibility for any non conformance use of the equip ment ...

Page 8: ...guarantee is void under the following circumstances The buyer fails to report to Sunstone Engineering any initial defects or issues due to shipping within seven days from the installation date The device or its parts have been used in a way different from that which it was intended to be used The device has been entrusted for repair to an unauthorized agent or company or the device or its pieces ha...

Page 9: ...ted with their face being eye level with the weld chamber This includes children whose standing height would be level with the weld chamber It is also recommended that the weld operator use adequate and approved working gloves when using the machine FIRE WARNING This symbol shows the danger of fire when working with flammable materials are processed When there is a danger of fire it is very important...

Page 10: ...ding gas used to weld can gradually change the air causing sickness or death Assure that the air in the room is safe to breathe Don t weld near any degreasing cleaning or vaporization areas The heat could react with the vapors to form very toxic and irritating gases Check that the metals do not have impurities that may produce fumes or gases during the weld process ELECTRIC WARNING This symbol sho...

Page 11: ... not rated for this machine Ensure that the cables are not near any heat sources Use the equipment only when in perfect conditions Immediately repair or change any damaged parts IMPORTANT WARNING This symbol shows the need to pay special attention to suggestions or warnings in cluded in this manual ...

Page 12: ...ect exposure of a laser beam can provoke irreversible damages to eyesight and vision To avoid permanent damage to the operator and others nearby it is necessary to follow some pre cautions Everyone in the near vicinity of the machine and who may be exposed to harmful levels of laser radia tion must be informed when the laser is active Due to the high power of the laser generated in this machine th...

Page 13: ... retina The wavelength of the LZR machines is 1064nm and therefore it will pass through unobstructed to the retina In regards to skin the absorption of the radiation will vary from one person to the next regardless of the wavelength Therefore seeing as the absorption may vary the exact and specific details are hard to state regarding the maximum tolerable exposure levels Picture 1 Eyeball The exten...

Page 14: ...ipment potentially consisting of certified protection glasses for the laser radiation 2 3 RADIATION VISION CONDITIONS The laser beam is highly collimated and intense as it is generated and leaves the internal resonator If this collimated beam were to pass through to a person s retina this focused beam of high dense power can be very dangerous Conversely if the beam becomes divergent and spreads out...

Page 15: ...TICAL DENSITY GREATER THAN 4 CAN SUFFICIENTLY PROTECT THE SIGHT FROM THE ACCIDENTAL VIEWING OF THE HARMFUL LASER RADIATION NOTE Always use certified eye protection 2 4 RISKS FOR THE EYES AND THE SKIN The cornea and the retina can be burned and damaged possibly irreversibly if exposed to an intense laser radiation regardless of duration Also exposure to a less intense laser radiation over a long du ...

Page 16: ...unctioning procedures Operators are aware of the dangers related to the exposure to radiation and the biological effects that could result from exposure to the skin and eyes Operators understand the need to use Individual Protection Devices IPDs ...

Page 17: ...cessing the internal parts of the equipment is allowed only to authorized personnel who are qualified trained and aware of the potential electric risks Sunstone Engineering denies all responsibility for any interventions on behalf of untrained personnel NOTE Access to the internal parts of the laser resonator is allowed only to authorized personnel who are qualified trained and aware of the optical ...

Page 18: ...ABELS Label Shape and type Sizes mm Laser N 1 Laser warning Side 22 Side 50 Laser N 2 Laser class information 104 x 52 52 x 26 Laser N 3 Radiation information 104 x 52 52 x 26 Laser N 4 Laser exposure information 56 x 40 ...

Page 19: ...RIC WARNING LABELS Label Shape and type Sizes mm Electric N 1 Electricity warning Side 22 Side 50 PRODUCT IDENTIFICATION LABEL This label shows the data about the manufacturer Ref A the electric specifications Ref B the gen erator power Ref C and the risk class of the laser machine Ref D A B C D ...

Page 20: ...g ways Picture 2 Outside laser warning labels Picture 3 Internal laser warning labels The Laser warning labels are placed on the backside of the machine in the following way Picture 4 Backside laser warning labels LASER N 3 LASER N 1 LASER N 6 LASER N 4 LASER N 2 LASER N 5 IDENTIFICATION LABEL ...

Page 21: ...0 1 100 Weld Length msec 0 5 20 Repetition Frequency Hz 0 5 30 Average Power W 75 Max Peak Power KW 7 Duty Cycle 80 Weld Spot Sizes mm 0 2 2 0 Maximum Argon Gas Pressure bar 1 5 Cooling Type Liquid Fuse 12 AT Weight lbs kg 100 45 Sizes in cm 20x35x22 50x90x56 4 2 OTHER DATA SPECIFICATIONS DESCRIPTION Work Environment Temperature C 17 35 Maximum Humidity during Operation 65 Noise Level dB A 70 Reco...

Page 22: ...nch Picture 5 Picture 5 Machine resting on table If using shielding gas connect it to the gas inlet connection Do not exceed 1 5 bar of pressure to the shielding gas connection The air inlet connection can be used to blow compressed air on welded pieces that may heat up during the welding process Picture 6 PROTECTION GAS AIR CONNECTION Picture 6 Protection gas connection and air connection NOTE Do...

Page 23: ...ck of the machine Picture 7 Picture 7 Power cable connection Connect the Interlock into the interlock port on the back of the machine Picture 8 Picture 8 Interlock Connect the foot pedal to the back of the machine Picture 9 Picture 9 Foot pedal INTERLOCK FOOT PEDAL ...

Page 24: ...es NOTE As a general practice to streamline the alignment of the crosshair the eyepiece with the crosshair should be placed in the right ocular tube 5 1 ADDING WATER NOTE During the first setup and installation extra steps are needed to get the machine functioning The next steps are only important during the initial setup or after changing the water in the machine Steps to install water correctly 1...

Page 25: ...nternal joystick down for 5 6 seconds until you hear the fans and the pump turn on This will force the air out of the system 8 After a minute turn the key and press start If an error message appears saying ERROR 02 TEST FLUX H20 then you will need to turn off the machine and repeat steps 6 and 7 9 If you do not see the ERROR 02 TEST FLUX H20 error your machine is ready to use The final step is to pl...

Page 26: ...s disengaged and not pushed in Picture 12 Picture 12 Emergency stop button Turn on the machine by flipping the switch on the back of the welder Picture 13 Picture 13 Power switch Insert the key and put it in the central position Picture 14 Picture 14 Switching on key ...

Page 27: ...S LASER ACTIVE Fig 6 NOTE Do not proceed with the installation if the display does not show as described above If you encounter any problems or errors consult chapter 8 of this docu ment or contact Sunstone Engineering At this point the operator will be able to Select the welding parameters and begin welding Load a previously saved setting and begin welding 5 3 WELDER SWITCHING OFF ATTENTION Befor...

Page 28: ...n to display the message LASER BLOCKED When the message appears then flip the power switch on the back of the machine to the off position Picture 16 Picture 17 Power switch ATTENTION When the welder is not being used ensure that the key is removed from the ma chine ...

Page 29: ...ture 18 Internal Controls Reference Description A Shield gas delivery nozzle B Compressed air delivery nozzle C LED brightness control 0 40 70 100 D Internal joystick control Fumes suction fan not pictured 6 2 JOYSTICK CONTROLS Picture 19 joystick controls ...

Page 30: ...parameter The Orion LZR laser welder has a touchscreen interface To make changes to the welder s parameters and settings can be achieved by tapping a button or moving a slider bar In addition to the touchscreen controls the welder also has a joystick inside the weld chamber When using the joystick the selected parameter will be outlined with an orange box By moving the joystick users can cycle thr...

Page 31: ... value given the selected power and time If changes are made to either the power or the time slide the frequency bar up to ensure that the welder is set to the maximum weld rate Spot Size The spot size bar is used to select the weld spot diameter The minimum setting is 0 2mm and the maximum setting is 2 0mm Gas Flow The gas flow bar is used to select the amount of time that protective shield gas ar...

Page 32: ...also cycle through the parameters and make adjustments using the joystick found inside the weld chamber The joystick selected parameter is highlighted with an orange box and text In addition to giving access to view and change parameters this screen also has a live video feed displayed on the screen Picture 21 Camera Tab Interface Power See Home Screen Time See Home Screen Spot See Home Screen Fre...

Page 33: ...he screen Auto Exposure can be turned on off Finally the white balance of the camera can be manually adjusted to enhance the picture lighting and quality Pressing Save will save any changes and exit back to the regular camera view Pressing Del will delete any changes and exit back to the regular camera view VIDEO SCREEN The video screen give the option to view pre loaded videos A list of available ...

Page 34: ...ead and refer ence when using the welder Picture 23 Manuals SETTINGS The Settings screen has multiple tabs with different contents The main settings screen displays the weld counter firmware version and welder model number The system status box is also visible on this page Picture 24 Settings Tab ...

Page 35: ...ment of the optional motorized pedestal stand option to turn on off the red aiming laser and other tempera ture and setting readouts Picture 25 Parameters SETTINGS MEMORY SET The Memory Set tab allows you to quickly load any saved setting by number rather than scrolling through one by one Picture 26 Memory Set ...

Page 36: ...AND TIME The date and time tab allows users to enter in the current date and time settings Picture 27 Date and Time SETTINGS CONTACT The contact tab displays all the contact details for Orion Welders Picture 28 Contact ...

Page 37: ...uniform weld beads around an object such as a ring or tube Contact Orion Welders with any questions re garding this option SETTINGS NETWORKING The networking tab can be used to connect the welder to a LAN which in turn can allow users to con trol the welder remotely To view and control the screen remotely users will need to download and install the VNC software available at www realvnc com Picture...

Page 38: ...sed to update the welder s software Picture 30 Software Management SETTINGS LANGUAGE The language tab can be used to change the language of the interface Available languages include English Spanish Italian German French Russian Turkish and Vietnamese Picture 31 Language ...

Page 39: ...en tinted viewing glass for viewing inside the weld chamber should ever break this must be replaced only with approved spare parts Regular glass or plastic cannot be used as these do not provide safety from the laser emission Do not ever remove the filter inserted in the microscope lens Do not ever insert large mirror like surfaces mirrors aluminum sheets chrome plated items into the weld chamber T...

Page 40: ...ly remove some of the protective filter material on the lens 5 Reinsert the lens into place and carefully reposition everything back into place Picture 32 Changing or replacing the protective lens ATTENTION It is recommended to keep this lens clean If it becomes dirty with metal deposits it is recommended to replace the lens There is possible that the metal slag de posits could heat up while the la...

Page 41: ...ations inside the weld chamber To set the cross alignment it is necessary to make slight adjustments to two allen screws inside the chamber Ref A and B below These screws require a 3 mm allen key Picture 33 Cross hair realignment Before making any adjustments make sure the stereomicroscope is firmly attached in place Ref C in Picture 19 below Also make sure that the eyepieces are set to the 0 posit...

Page 42: ...d A turn of the screw will re sult in a large change in the weld spot location Continue turning these screws until you are able to make the weld spot location fall in line with the crosshairs Picture 35 Turning Screws ATTENTION Always use small adjustments when aligning the crosshairs and ensure that the test piece you are welding on stays stationary inside the weld chamber DO NOT ever completely ...

Page 43: ...ng out Fig 3 7 5 HOW TO REFILL THE COOLING SYSTEM 1 Insert the plastic connection equipped with the machine Fig 1 to the female connector at the right bottom of the rear panel Fig 3 2 Remove the red plug in upper position Fig 3 3 Use the funnel equipped with the machine to refill the tank Fig 2 Fig 4 4 Continue to fill the machine until you see water coming out of the upper connector of the tank 5 P...

Page 44: ... back of the unit and push the Joystick down for 5 6 seconds to force start the water pump and clear any air in the system This process may need to be repeated 2 3 times C Contact Sunstone Engineering 03 Refrigerating Liquid High Temperature The refrigerating liquid has reached the temperature mark of 55 C Possible causes A High work cycle of the ma chines B Insufficient liquid inside the tank C Fau...

Page 45: ...acitor Voltage The capacitors are not charging A The generator is broken A Contact Sunstone Engineering 07 Blocked Optical Motor The motor that sets weld diameter doesn t move A Switch off the machine and switch on again In this way the machine will perform again the motor check If the error persists contact Sun stone Engineering 8 1 Other Anomalies PROBLEM RESOLUTION The machine switches on but is...

Page 46: ...n Check that the input pressure is not higher than 2 Bars Check the flux regulator insidethe weld chamber Verify that in gas tubing is not kinked or blocked I try to blow compressed air from the nozzle but no air comes out Verify that in gas tubing in not kinked or blocked Too low pressure The laser doesn t turn on Verify that the switch placed on the back is in ON position Verify that the emergenc...

Page 47: ...he generation of undesired laser radiation Functioning When the power switch is turned on and key is still not turned on the reso nator shutter is engaged When the key is turned on the shutter is disen gaged When the key turned off the shutter is engaged again 9 2 MICROSCOPE SHUTTER Description The microscope shutter is a liquid crystal filter LCD that dims completely when a regulated voltage is sup...

Page 48: ...s turned off while the weld puddle cools and solidifies The shutter will disengage allowing the operator to see through the mi croscope again 9 3 MICROSCOPE INFRARED FILTER Description This filter is an optical glass designed to filter laser radiation of 1064nm It has a slight gray color but is perfectly transparent It is placed inside the microscope Ref A Picture 35 Purpose The purpose of this filter ...

Page 49: ...tly transparent Operators should look through this window any time they need to view inside the weld chamber rather than looking through the leather strips Picture 37 Welding room infrared filter ATTENTION If this filter should ever break it is very important to get it replaced with a new filter To ensure safety use only original and approved spare parts from Sunstone Engineering B ...

Page 50: ...eld chamber and to shield the bright flash that occurs during welding To help retain shielding gas argon while welding and also allow the shield gas to dissipate after the welding is finished Functioning The leather strips prevent the laser light from leaving the chamber and at the same time helps improve the usage of shielding gas Picture 38 Leather strips coving the opening to the weld chamber ATT...

Page 51: ...s at SUNSTONE ENGINEERING AND ORION WELDERS 1693 American Way 5 Payson UT 84651 USA Phone 1 801 658 0015 Toll free USA 1 877 786 9353 Email sales sunstoneengineering com Orion Laser User Manual Go to http www orionwelders com resources orion laser resources for full video tutorials ...