Orion Laser Welder User Manual
Orion Combo 200
Table of Contents
5
6
8
9
12
17
Introduction
Use and Installation
Contractual Guarantee/Warranty
Chapter 1: Symbols
Chapter 2: Safety
2.1: Laser Radiation Absorption
2.2: Classification and Dangerousness
2.3: Radiation Vision Conditions
2.4: Risks for the Eyes and the Skin
2.5: Safety General Prescriptions
Chapter 3: Seals
3.1: Labels
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1
22
28
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 Controls
6.4: Additional Interface Screens
2
35
Chapter 7: Maintenance
7.1: Clean or Replace the Protection Lens
7.2: Realigning the Cross hairs
7.3: Periodically Change the Cooling Water
7.4: How to Remove the Water
7.5: How to Refill the Cooling System
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43
46
48
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
QUICK LASER PARAMETERS
Chapter 10: Quick Setup
10.1: COMBO 200 QUICK SETUP
10.2: LASER WELDER SAFTY BASICS
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4
Orion Welders
LZR User Manual
INTRODUCTION:
ank You for Choosing Orion Welders and congratulations on your purchase!
You are now the proud owner of an Orion Laser Welder. is manual was designed to help you set up
the welder and begin welding. Please read and follow all safety precautions before proceeding with
the welding process.
Sunstone Engineering is the parent company of Orion Welders. At Sunstone & 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: +1.801.658.0015
Fax: 866.701.1209
NOTE: e information contained in this manual is subject to change as improvements are made to
our products. Visit www.orionwelders.com or www.sunstonewelders.com for the latest version of
this document.
5
ORION LZR LASER WELDERS
USE AND INSTALLATION
IMPORTANT
Carefully follow the content of this manual, pay attention to the information and warnings for
the installation, use, and the maintenance of this machine. Any repairs or services should only be
performed by a qualified technician. With any questions or needed assistance, please contact
Sunstone/Orion Welders.
Sunstone / Orion Welders
1693 American Way #5
Payson, UT, USA 84651
+1.801.658.0015
www.sunstonewelders.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
e information included in this manual is subject to modifications without notice. Sunstone Welders
and Orion Welders will not be responsible for errors included in this document nor for any incidental
damages or consequences due to any erroneous interpretation of this manual.
INTENDED USAGE
e Orion LZR laser welding machines are designed for making small-sized welds on metal parts.
NOTE
is 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 / Orion Welders declines all responsibility for any non-conformance use of the equipment.
6
7
Sunstone / Orion Welders
CONTRACTUAL GUARANTEE / WARRANTY
Sunstone Welders guarantees this product will be free of any defects for the duration of two years
from the date of purchase. e warranty covers all components excluding the following: the LED
lamps found in the weld chamber, fuses, protection glass, fire lens and all consumable material.
Sunstone Welders will, at its discretion, chose to repair or replace any defective part during the 2 year
warranty period. If an issue should arise during the 2 year warranty, Sunstone Welders will be responsible for any costs associated with the repair or replacement on any components, excluding any shipping costs. Any damaged and replaced parts will become property of Sunstone Welders. Any replaced
or repaired parts will also be covered under this guarantee until the 2 year term is expired.
e guarantee is void under the following circumstances:
• e buyer fails to report to Sunstone Welders any initial defects or issues due to shipping within
seven days of recieving the product.
• e device or its parts have been used in a way different from that which it was intended to be
used.
• e device has been entrusted for repair to an unauthorized agent or company, or the device or its
pieces have had some modifications not authorized by Sunstone Welders.
• e recommendations and procedures regarding the use and the maintenance of the machine
found in this manual have not been respected and followed.
• e warranty seals and stickers on the machine have been removed or broken without authorization from Sunstone Welders.
Any other defects or damages caused by normal wear and tear are also excluded from the warranty.
If there is a defect during the warranty period, Sunstone Welders will take action to completely resolve
the problem in accordance with this guarantee.
8
Chapter 1: Symbols
GENERIC WARNING:
is symbol indicates a need to carefully read and follow instructions found here to
ensure proper use and maintenance of the equipment.
LASER WARNING:
is symbol shows the danger of being exposed to visible and invisible laser radiation. is symbol can be included also on the machine in corresponding areas of risk to
exposure. If you see this symbol:
• Don’t ever introduce mirrors or reflecting objects in the welding chamber while
the machine is in use.
• Check the weld chamber exclusively through the green-tinted viewing glass
found on the front of the machine.
• Don’t ever remove the leather strip curtains that cover the opening to the weld
chamber.
When using the machine, ensure that no one is seated with their face being eye-level
with the weld chamber. is 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:
is symbol shows the danger of fire when working with flammable materials are
processed. When there is a danger of fire, it is very important to follow the instructions
provided from the manufacturer during the installation of the machine.
Don’t weld near flammable materials.
Remove all flammable materials from nearby the welder. If this is not possible, carefully cover all flammable material with fireproof material.
Also, it is recommended to keep fire extinguishers in the vicinity of this machine.
EXPLOSION WARNING:
is symbol shows that the gas contained in the cylinders is under pressure and can
consequently explode if the cylinders aren’t handled with the necessary cautions.
9
Protect any cylinder from excessive heat and mechanical stresses.
Install the cylinders in a vertical position and position them with a fixed support chain
or with a proper cylinder case to avoid falls or knocks.
Maintain the cylinders far away from the welding place and from any electric circuits.
Use only regulation cylinders, pressure reducers, pipes and joints approved for the
specific use; maintain them in good conditions together with the connected parts.
GAS AND FUMES WARNING:
e welding processes produce fumes and gas, which can be harmful and dangerous
if inhaled.
Do not breathe any welding fumes.
Don’t cover the grids and vents placed on the machine.
Carefully read the supplied instructions regarding the different types of metals, cleaning substances and shielding gases.
When possible, dedicate a room for the use of this machine. If the room is small, use
it only if well ventilated. e shielding 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. e 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:
is symbol shows dangerous voltages associated to the laser which may have sufficient power to cause electric risk. is symbol can also be found on the machine.
Touching electric parts under voltage can cause fatal damages or serious burns. e
electric circuits are always under voltage when the machine is switched on. Incorrect
installation and/or inappropriate wiring and grounding of the machine is dangerous.
Don’t touch electric parts under voltage.
Remove the power plug from the machine before installing or performing any maintenance to the machine.
Ensure that the power cord is correctly connected to both the wall plug and to the back
of the machine- according to this manual and any local standards and rules.
10
Switch off the machine when not in use.
Do not use any power cables that are damaged or that are 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:
is symbol shows the need to pay special attention to suggestions or warnings included in this manual.
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Chapter 2: Safety
is chapter discusses matters relating to the safety of the individuals using this machine.
When used properly, this laser welding machine is safe and reliable. It is necessary, however, that the
operator is informed about the precautionary standards so as to avoid possible damages to themselves or to the machine.
LASER RADIATION
Laser radiation is an electromagnetic emission with micrometric wavelengths that are placed in the
far infrared (CO2 laser), in the near infrared (laser at Nd-YAG, Nd-YVO4), in the visible (laser He: Ne or
Argon), or in the ultraviolet (excimer laser) ranges. Laser radiation produced from the LZR machines
is invisible and therefore can be very dangerous, especially dangerous to eyes and skin.
NOTE
Direct 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 precautions.
Everyone in the near vicinity of the machine and who may be exposed to harmful levels of laser radiation, must be informed when the laser is active.
Due to the high power of the laser generated in this machine, there is a potential that the laser may
reflect off of welded pieces. If this happens, the reflected light can be potentially dangerous for the
eyes and the skin. As stated previously, the laser generated in the LZR welder is invisible, and therefore it is not easy to identify if the laser is reflecting off the piece, nor is it easy to know where the
laser may be travelling once reflected.
NOTE
It is crucial to be protected from the reflected light beams, because they can be
sufficiently intense to create permanent damages to the eyes or to the skin
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NOTE
e laser generated here is a class IV. e risks associated with class IV lasers
include not only the risk of direct or reflected radiation, but also of diffused radiation. ese lasers can present a remarkable risk for the skin and eyes, as well as a
fire risk when working near flammable materials
2.1: LASER RADIATION ABSORPTION
e human tissue absorbs electromagnetic radiation in different ways, depending on the wavelength
of the radiation. Eyes and skin accept some wavelengths, while refracting others. Specifically relating to the eye, the cornea and the lens both allow lasers within the 400-1400nm wavelengths to pass
through and reach the retina. e 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. erefore, seeing as the absorption may vary, the exact and specific details are hard
to state regarding the maximum tolerable exposure levels.
Picture 1: Eyeball
e extent of damages due to radiation absorption depends on the wavelength. e short wavelengths (ultraviolet UV-C 180-280nm, UV-B 180-280nm, UV-A 315-400nm) generally provoke and
cause photochemistry effects: cataract or opacification of the lens in the eye, blackening or reddening
for the skin. Major wavelengths (infrared: IR-a 780-1400nm IR-c 3000-10 E6nm) generally provoke
thermal effects: retinal detachment and photocoagulation for the eye, burning for the skin.
13
e extent of the damage depends on the quantity of absorbed radiation and on the power and intensity of the radiation source.
2.2: CLASSIFICATION AND DANGEROUSNESS
Laser classifications are based on the laser’s ability to cause damage to people. All lasers are classified according to their output, from Class 1, which describes lasers which are of such low power that
they represent no hazard at all, to Class 4 lasers which are always hazardous.
e LZR lasers belong to the class IV and can produce risks, not only from direct or reflected radiation,
but also from diffused radiation. For these reasons users must take all precautions to assure that
safety guidelines are established and followed. In addition, the operator must be informed of the risks
deriving from the exposure to laser radiation, and he/she must be provided with the proper personal
protective equipment, potentially consisting of certified protection glasses for the laser radiation.
2.3: RADIATION VISION CONDITIONS
e 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, then the
beam is much less dense and therefore less dangerous. Below are some different scenarios related
to viewing the laser beam.
DIRECT VIEW OF A LASER BEAM
is type of exposure is the most dangerous and can occur through the opening to the weld
chamber, or if the optics have been removed.
DIRECT VIEW OF A REFLECTED LASER BEAM
is can happen anytime the laser beam reflects off a reflective surface. A reflected beam
can be equally dangerous as a direct view of a laser beam.
DIRECT VIEW OF A LASER BEAM EXITING A FIBER OPTIC
is can happen anytime the optical fiber is connected to the resonator. e beam can be
dangerous even if viewed from considerably far away.
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DIRECT VIEW OF A LASER BEAM AFTER FOCUSING OPTICS
is can happen if the beam is not absorbed at the end of its path. is beam can be dangerous even if viewed over considerable distances. Filters and protective glasses can guarantee
the safety for short exposures, on the condition that they are well dimensioned and certified
to be safe for the relating wavelength.
VIEWING A DIFFUSED LASER BEAM AFTER FOCUSING THE OPTICS
is happens when using this machine. Viewing the diffused beam is not dangerous over a
short period of time, and viewing through a filter and lenses can guarantee safety, even during long exposures..
THE NOMINAL OCULAR HAZARD DISTANCES NOHD FOR THE LZR LASERS IS LESS THAN 15M FOR
DIRECT OR SPECULAR REFLECTED RADIATION, AND LESS THAN 0.5M FOR THE DIFFUSED REFLEC
TION. ONLY A SUITABLE WELD LENS WITH OPTICAL 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
e 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 duration, can result in similar dangerous and possibly irreversible outcomes. is danger is completely
realistic in any case of direct vision of any laser beam.
Skin can also burn, if submitted to the focused direct radiation. In addition to focused direct exposure,
exposure to ultraviolet radiation over time can also cause negative consequences to skin.
2.5: SAFETY GENERAL PRESCRIPTIONS
We recommend developing a Standard Operating Procedure (SOP) to follow when operating and servicing the machine. A written copy of this procedure should be easily accessible to any operator using
the machine. Training and review of the process over time is recommended as well to ensure:
15
• Operators are familiar with the system functioning 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)
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Chapter 3: Seals
ere are various seals in and on the LZR machines. ese seals must not be, for any reason, broken
or removed without authorization from Sunstone / Orion Welders.
NOTE
Removing or breaking certain seals on this machine can have immediate and
negative effects on the weld system.
ATTENTION
e manufacturer denies all responsibility for the nonconformance use of this
machine.
It is prohibited to start the equipment before the machine is declared in conformance with the actual directives.
NOTE
Opening the laser and accessing the internal parts of the equipment is allowed
only to authorized personnel who are qualified, trained, and aware of the potential
electric risks.
Sunstone / Orion Welders 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 risks.
Sunstone / Orion Welders denies all responsibility for any interventions on behalf
of untrained personnel.
3.1: SAFETY LABELS
e labels and the stickers are applied on the equipment in conformance with both the FDA and European safety rules. ey must not be removed or damaged. For possible changes you can contact
Sunstone / Orion Welders.
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LASER WARNING LABELS:
Label Shape and type Sizes (mm)
Laser warning
Laser N. 1
Laser N. 2
Laser N. 3
Side 22
Side 50
Laser class information
104 x 52
52 x 26
Radiation information
104 x 52
52 x 26
Laser exposure information
Laser N. 4
18
56 x 40
Laser technical data
Laser N.5
Laser opening information
Laser N.6
ELECTRIC WARNING LABELS
Label Shape and type Sizes ( mm)
104 x 25
104 x 26
Electricity warning
Electric N.1
PRODUCT IDENTIFICATION LABEL
B
C D
Side 22
Side 50
A
is label shows the data about the manufacturer (Ref A), the electric specifications (Ref B), the generator power (Ref C) and the risk class of the laser machine (Ref D).
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3.2: LABELS POSITIONING
e Laser warning labels are placed on the machine in the following ways:
LASER N.5
LASER N.2
Picture 2: Outside laser warning labels
LASER N.1
LASER N.6
Picture 3: Internal laser warning labels
e Laser warning labels are placed on the backside of the machine in the following way:
LASER N.4
LASER N.3
Picture 4: Backside laser warning labels
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Chapter 4: Technical Data
4.1: LASER SPECIFICATIONS
SPECIFICATIONS DESCRIPTION
Electric Input VAC 110V or 230V
Electric Power Phase Single Phase
Electric Frequency Hz 50-60 Hz
Average Energy Consumption W 100 W
Laser Crystal Type Nd:YAG
Wavelength nm 1064 nm
Weld Energy joule 0.5-200 J
Weld Length msec 0.5-20 msec
Repetition Frequency Hz 0.5-30 Hz
Peak Power KW 12 KW
Duty Cycle 80%
Weld Spot Sizes mm 0.9-1.8 mm
Maximum Argon Gas Pressure bar 1.5 bar
Cooling Type Liquid
Fuse 25 AT
Weight lbs (kg) 77 lbs (45 kg)
Sizes - L x W x H- in (cm) 30x21x22 (50x90x56)
4.2: OTHER DATA
SPECIFICATIONS DESCRIPTION
Work Environment Temperature °F (C) 17-35
Maximum Humidity during Operation % 65
Noise Level dB(A) <70
Recommended Argon Purity % 99.8-99.996
Shield Gas (Argon) Consumption l/min 2-4 con 1.5 bar
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Chapter 5: Installation
Position the Combo 200 power supply in a strong and sturdy area that is able to support the weight
of the machine (approximately 73 lbs or 33 Kg). Make sure that all four support wheels of the laser are
resting firmly on the floor. Lock the wheels once the power supply is in the desired location.
Picture 5: Machine resting on floor
If using shielding gas, connect it to the gas inlet connection. Do not exceed 1.5 bar of pressure to the
shielding gas connection. (Picture 6).
PROTECTION GAS
Picture 6: Protection gas connection and air connection
NOTE
Do not exceed 1.5bar of pressure to the shielding gas connection.
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Connect the power cable to the back of the machine then to AC power. (Picture 7)
Picture 7: Power cable connection
Connect the foot pedal to the back of the machine (Picture 8)
FOOT PEDAL
Picture 8: Foot pedal
ATTENTION:
Use only the cables and equipment provided with the machine. Do not substitute
or change any cables or plugs. If needed, contact Sunstone / Orion Welders before making any changes
Remove the eyepieces from their containers and fasten them to the microscope on the articulating
arm. Finger tighten the set screw to hold them in place.
For steps on aligning the crosshairs, see chapter 7.3.
Picture 9: Eyepieces Mounted on Ocular tubes
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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 initial setup and installation, extra steps are needed to get the machine
functioning. e next steps are only important during the initial setup, or after
changing the water in the machine.
Steps to install water correctly:
1. Insert the plastic connection equipped with the machine (Fig. 1) to the female connector at the
bottom of the rear panel. (Fig.3)
2. Remove the red plug from the upper connector tube. (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 (Fig.4).
5. Remove the plastic connection from the female connector (Fig.1), but do not replace the red
plug. To minimize the amount of spilled water, place you thumb over the open end of the
tube while removing it from the connector. (Fig 3).
6. Turn on the machine by flipping the switch on the back of the machine. Do not turn the key
switch.
7. Push the internal joystick down for 5-6 seconds, until you hear the fans and the pump turn
on. is 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. e
final step is to plug the upper connector with the red plug (Fig.2, Fig.4).
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UPPER CONNECTOR PLUG
FEMALE CONNECTOR
FIG. 3 FIG.4
5.2: FIRST SWITCHING ON
FIG. 1
FIG. 2
Ensure that the emergency stop button is disengaged and not pushed in. (Picture 10)
Picture 10: Emergency stop button
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Turn the switch on the left side of the machine to the on position (Picture 11)
Picture 11: Power switch
Insert the key and put it in the central position. (Picture 12)
Picture 12: Switching on key
After turning the key, a “start” button should appear. Pressing start will allow you to adjust parameters and make welds.
Picture 13: Combo 200 touch screen interface
26
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 document, or contact Sunstone / Orion Welders.
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:
Before flipping the power switch, make sure to always turn the key to the locked
position. is will allow the microprocessor to drain the internal capacitors.
Turn the key to the Locked position and wait for the screen to display the message: “LASER
BLOCKED.”
Picture 14: Power switch
When the message appears, then tirn the power switch on the left of the machine to the off position.
27
ATTENTION:
When the welder is not being used, ensure that the key is removed from the machine.
Chapter 6: Controls
e 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 through the
parameters and also make changes to the selected parameter.
6.1: DISPLAY TOUCH SCREEN CONTROLS
Picture 17: Display Touch screen
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Weld Parameters Description
Power e power bar is used to select the power of the weld.
Time e time bar is used to select the duration of the weld.
Frequency e frequency bar is used to select the rate at which the welds are made. Select-
ing “0” will cause the welder to weld only when the foot pedal is initially pressed.
Each subsequent foot pedal press will cause a weld. With a setting as low as 0.5
Hz or as high as 30 Hz, the welder will continue to weld at that rate per second for
as long as the foot pedal is pressed. To stop the welds, simply lift your foot off
the pedal. In some cases, the slider bar may automatically adjust to a lower value
that what is selected. is may occur when either the power and/or time value is
too large to handle a high repetition rate. e frequency will automatically adjust
to the highest possible 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 e spot size bar is used to select the weld spot diameter. e minimum setting
is 0.2mm and the maximum setting is 2.0mm.
Gas Flow e gas flow bar is used to select the amount of time that protective shield gas
(argon) is allowed to flow after the last weld is made. A value of “0” will deactivate the gas flow. If the value is set between 00 (min) and 00 (max).
Waveform ere are 6 different waveforms to choose from. Each waveform has slightly
different characteristics. e available waveforms are: Normal (Square), Slope+
(Upslope), Slope- (Downslope), BRD (both up and down slope), Pulse (2 square
welds), and FDC (2 square welds, one at 50% power). e most common waveforms are Normal, Slope+, and Slope-.
Memory is box shows the currently selected saved settings. Pressing the “+” and “-“
buttons below the memory number will cycle through the saved settings. It is
possible to name each saved setting, and the saved name will be displayed in the
box to the right of the memory boxes.
Memory Box is box will display instructions, status conditions, system settings, warnings,
and error messages.
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MANUALS
e Manuals screen provides on-screen documentation and instructions for users to read and reference when using the welder.
Picture 15: Manuals
SETTINGS
e Settings screen has multiple tabs with different contents. e main settings screen displays the
weld counter, firmware version, and welder model number. e system status box is also visible on
this page.
Picture 16: Settings Tab
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SETTINGS: PARAMETERS
e parameters tab displays various parameters including: the standby time, up/down movement of
the optional motorized pedestal stand, option to turn on/off the red aiming laser, and other temperature and setting readouts.
Picture 17: Parameters
SETTINGS: MEMORY SET
e Memory Set tab allows you to quickly load any saved setting by number rather than scrolling
through one by one.
Picture 18: Memory Set
31
SETTINGS: DATE AND TIME
e date and time tab allows users to enter in the current date and time settings.
Picture 19: Date and Time
SETTINGS: CONTACT
e contact tab displays all the contact details for Orion Welders.
Picture 20: Contact
32
SETTINGS: ENGINE CONTROL
e engine control tab can be used when the welder is equipped with optional accessories designed
for automated welding. For example, a rotary ring clamp can be purchased and used to make uniform
weld beads around an object such as a ring or tube. Contact Orion Welders with any questions regarding this option.
SETTINGS: NETWORKING
e networking tab can be used to connect the welder to a LAN, which in turn can allow users to control 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 21: Networking
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SETTINGS: SOFTWARE MANAGEMENT
e software management tab can be used to update the welder’s software.
Picture 22: Software Management
SETTINGS: LANGUAGE
e 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 23: Language
34
Chapter 7: Maintenance
ATTENTION
Do not ever open the laser case and panels. Even if the machine is switched off,
there are some internal parts that may still be subject to live voltage, and therefore there may be the possibility of electric shock.
ATTENTION
Any required maintenance on the laser’s optic rail and trajectory path, must be
performed EXCLUSIVELY by Sunstone / Orion Welders or an agent authorized by
Sunstone / Orion Welders.
In order to keep the machine in a safe and optimal working condition, ensure that the following safety
measures are followed:
• Change the leather protection strips that cover the entrance to the weld chamber if there are ever
any signs of wear or damage.
• If the green-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. ese mirror-like surfaces could cause dangerous reflections of the laser
beam inside the weld chamber.
The following maintenance items can be performed by the user since they do
not create any risk of personal injury.
7.1: CLEAN OR REPLACE THE PROTECTION LENS
Over time, the protective glass lens may become dirty, and can cause a reduction in amount of weld
energy that gets delivered. If the lens does become dirty or contaminated with metal slag, it will need
to be cleaned and/or possibly replaced.
35
Periodically check the lens of the microscope that is found inside the weld chamber. is special glass
is treated with an anti-glare of 1064 nm. e lens is held in place with two screws at the bottom of the
optic assembly.
To change or clean the protective lens:
1. Unscrew the two screws (Ref. A and B) seen in the picture below.
2. Disconnect the housing unit (Ref. C) from the optic assembly and remove the lens.
3. Clean the surface with a soft and non-abrasive cloth.
4. Do not try to scrape off the metal slag that may be deposited on the lens. is could potentially remove some of the protective filter material on the lens.
5. Reinsert the lens into place and carefully reposition everything back into place.
B
A
C
Picture 24: 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. ere is possible that the metal slag deposits could heat up while the laser is in use, and the lens could crack or break due
to the heat.
7.2: REALIGNING THE CROSSHAIRS
e welding crosshairs must be aligned correctly in order to be able to make accurate and precise
welds. e crosshairs can become out of alignment anytime the welder is moved or lifted. Also, any
impact to the microscope could also affect the crosshair alignment.
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Aligning or realigning the cross hair is a simple process that any user can perform.
ATTENTION
Make sure that your hands and other objects are free and clear of the path of
the laser beam when testing the crosshair alignment. If the crosshairs are misaligned, the beam may travel to unexpected locations 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). ese screws require a 3 mm allen key.
SCREW A
SCREW B
Picture 25: Cross hair realignment
Before making any adjustments, make sure the stereomicroscope is firmly attached in place. Also,
make sure that the eyepieces are set to the ‘0’ position before making any alignment changes.
Picture 26: Fastening of the Stereomicroscope
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e easiest way to align the cross hairs is to place a flat metal piece inside the chamber so that it is
in focus through the microscope. en perform low-powered welds one at a time to see where the
laser is being directed onto the metal piece.
Screw A (below) adjusts the vertical (up/down) positioning of the laser. Turning the screw in a clockwise direction will raise the weld spot location. Screw B adjusts the horizontal (left/right) positioning.
Turning the screw in a clockwise direction will move the weld spot location to the right. Only adjust
one screw at a time. Also, typically only small adjustments are needed. A ¼ turn of the screw will result 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.
SCREW A
UP/DOWN
SCREW B
LEFT/RIGHT
CLOCKWISE = RIGHT
Picture 27: 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 unscrew either of these adjustment screws.
7.3: PERIODICALLY CHANGE THE COOLING WATER
CLOCKWISE = UP
It is necessary to periodically change the internal refrigerating liquid (distilled water or demineralized
water). e purpose in changing the water is to avoid the formation of micro alga inside the cooling
system that could reduce or block the thermal exchange efficiency.
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ATTENTION
It is advisable to change the cooling water at least every two years, and in particular before or after any periods of heavy usage.
7.4: HOW TO REMOVE THE WATER
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 and let the water going out. (Fig.3)
7.5: HOW TO REFILL THE COOLING SYSTEM - (use de-ionized water)
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. Plug the upper connector with the red plug and remove the plastic connection from the female
connector.
FIG. 1
FIG. 2
RED PLUG
UPPER CONNECTOR
FEMALE CONNECTOR
FIG. 3 FIG.4
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Chapter 8: Error Messages and Troubleshooting
e table shows information regarding the various error and messages that may appear on the welder.
ER.N° MESSAGE CAUSE REMEDY
01 Error Simmer e laser lamp is not switching
A. Check the fuse.
02 Not Working
Refrigerating Liquid
(Error 02 Test Flux H20)
03 Refrigerating Liquid High
on.
e refrigerating liquid is not
flowing inside the cooling pipes.
A. e pump is not working.
B. e water is dirty and needs
to be changed.
e refrigerating liquid has
B. Contact
A. Make sure there is water in the machine,
and that the water level is full. is might
be a good opportunity to change the
water.
B. Before turning the key switch, remove
the red plug on the 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. is process may need
to be repeated 2-3 times.
C. Contact Sunstone / Orion Welders.
A. With the machine turned on, wait 15 min
Sunstone / Orion Welders
Temperature
reached the temperature mark
of 55°C. Possible causes:
A. High work cycle of the ma-
chines.
B. Insufficient liquid inside the
tank.
C. Faulty or not working cooling
fans.
D. Too much dust or dirt on the
heat pump.
until the error disappears.
B. Make sure there is water in the machine.
Add water if needed.
C. Make sure the fans are working. If not,
contact Sunstone Engineering.
D. Blow some compressed air into the
machine to try and remove any dust or dirt
that may have settled inside. Do not, how-
ever, open the case without first contact-
ing Sunstone Engineering.
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ER.N° MESSAGE CAUSE REMEDY
04 High Electronic Tempera-
e internal thermostat inside
A. Let the machine rest for 15-20 minutes
ture
the power electronic has noticed
an high temperature:
A. High work cycle.
B. Dust or dirt left on the cooling
fans.
C. Non-working cooling fans.
and wait for the error to disappear.
B. Blow some compressed air into the
machine to remove any dust or dirt that
may have settled inside.
C. Contact Sunstone Engineering.
05 Relay Input e machine doesn’t weld. A. Check the connection to the
power supply.
B. Change the power supply.
06 Low Capacitor Voltage e capacitors are not
A. Contact Sunstone Engineering
charging.
A. e generator is broken.
07 Blocked Optical Motor e motor that sets weld
diameter doesn’t move.
A. Switch off the machine and switch
on again. In this way the machine
8.1: Other Anomalies
PROBLEM RESOLUTION
e machine switches on but is not in the
START position
e display shows the parameters but the
laser doesn’t shoot.
e microscope shutter closes, but no weld
is made.
• Verify the key position inside the weld chamber.
• Check that the foot pedal is connect to the machine.
• e power and time settings are too low.
• MS5 zoom drum is not in the correct position.
• Dirty position glass. (see Chapter 7)
will perform again the motor check.
If the error persists contact Sunstone Engineering.
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PROBLEM RESOLUTION
e lights inside the welding chamber do not
turn on.
Smoke created from the weld rises towards
the microscope and impairs vision of the
workpiece.
e shielding gas doesn’t flow when the
pedal is pushed.
I try to blow compressed air from the nozzle,
but no air comes out.
• Check the light adjustment knob inside the weld
chamber and make sure it is not in the off position. (Ref. Fig 4)
• Check the fuses.
• e filter on the internal fan of the welding chamber is too dirty.
• e fan is not working; check the fuse.
• Check the home screen to verify the gas flow is
turned on.
• 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.
• Verify that in gas tubing in not kinked or blocked.
• Too low pressure.
e laser doesn’t turn on. • Verify that the switch placed on the back is in ON
position.
• Verify that the emergency stop switch is released.
• Check the fuses.
• Verify the welder is plugged in to an active power
source.
When replacing fuses, ensure that the replacement fuse is of the same rating and same type. It is
always recommended to have a fuse installed when using this machine.
Contact Sunstone Engineering with any questions.
42
Chapter 9: Safety Systems
is laser welder is equipped with a high number of safety system checks to avoid any radiation leaks
from the machine.
Here follow the list of these systems and their functioning description:
1. Resonator shutter
2. Microscope shutter
3. Microscope infrared filter
4. Welding room infrared filter
5. Weld chamber opening (leather strip curtain)
9.1: RESONATOR SHUTTER
Description is device is formed from a small flag controlled by an electromagnet and
it is placed inside the laser resonator. e shutter disconnects the laser
inside the resonator when the welder is in STAND-BY mode.
Purpose e purpose of this device is to prevent the 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 disengaged. When the key turned off, the shutter is engaged again.
9.2: MICROSCOPE SHUTTER
Description e microscope shutter is a liquid crystal filter (LCD) that dims completely when
a regulated voltage is supplied. It is placed between the 45° mirror and the focus
lens of the microscope. e shutter obstructs the operator’s vision through the
microscope at the precise moment that the laser weld is initiated.
Purpose e purpose of this device is to prevent the operator from exposure to the
visible radiation light flash that may result from the weld being formed. is is
second of three safety systems in place that are working each and every time a
weld is made.
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Functioning is shutter is normally in an opened state and is independent from the previ-
ously mentioned resonator shutter. is allows the microscope to be used at
any moment.
After the key has been turned to ‘start’, the shutter will engage under the following steps:
• e foot pedal is pressed.
• e microprocessor responds by engaging the shutter.
• e microprocessor turns on the laser lamp.
• e shutter remains engaged as the lamp is on, and then also remains
engaged for a short time after the lamp is turned off while the weld puddle
cools and solidifies.
• e shutter will disengage allowing the operator to see through the microscope again.
9.3: MICROSCOPE INFRARED FILTER
Description is 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 e purpose of this filter is to preserve the operator eyes from leaks, and to
completely ensure that all laser light is blocked from passing through the microscope.
Functioning Being opaque to the wavelength of 1064nm prevents any possibility of laser light
passing through the microscope.
A
Picture 28: Microscope infrared filter
44
9.4: WELD INFRARED FILTER
Description is filter is an optical glass designed to filter laser radiation of 1064nm (Ref.
B Picture 36). It has a slight green tint but is perfectly transparent. Operators
should look through this window any time they need to view inside the weld
chamber, rather than looking through the leather strips.
B
Picture 29: 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.
45
LASER WELDING PARAMETERS
QUICK LASER PARAMETERS
POWER SPOT TIME m/s FREQUENCY WAVE
Yellow Gold thin
Yellow Gold wire
Yellow Gold smoothing
White Gold thin
2.0 0.2 2.0 5.0 SLO+
2.4 0.4 2.4 6.5 SLO+
3.6 0.7 3.6 6.5 SLO+
1.5 0.2 1.6 6.5 SLO-
White Gold wire
White Gold smoothing
Rose Gold thin
Rose Gold wire
Rose Gold smoothing
1.7 0.4 1.7 6.5 SLO-
2.3 0.8 2.1 6.5 SLO-
1.6 0.2 1.9 5 SLO+
1.8 0.3 2.2 5 SLO+
3.2 0.6 3.1 6.5 SLO+
Silver thin
Silver wire
Silver smoothing
Platinum thin
Platinum wire
3.7 0.3 3.7 5 NORM
4.2 0.3 4.2 5 NORM
4.5 0.4 4.5 4 NORM
1.8 0.4 0.8 5 NORM
1.8 0.5 1 1.6 NORM
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Platinum smoothing
2.2 0.8 1.8 1.9 NORM
Stainless steel thin
Stainless wire
Stainless steel
smoothing
Titanium thin
Titanium wire
Titanium smoothing
Palladium thin
Palladium wire
Palladium smoothing
1 0.3 1 6 NORM
1.2 0.5 1.2 7 NORM
1.8 0.7 1.8 7 NORM
1.8 0.7 1.8 7 NORM
1 0.2 0.2 2.5 NORM
1.0 0.2 0.2 2.5 NORM
1.6 0.2 1.3 5.0 NORM
1.8 0.5 1.6 6.5 NORM
2.4 0.7 1.8 8 NORM
Nickel Silver thin
Nickel Silver wire
Nickel Silver smoothing
1.6 0.7 1.4 5 NORM
1.4 0. 1.4 7.0 NORM
1. 0.9 1.9 8 NORM
47
Chapter 10: Quick Setup
10.1: COMBO 200 QUICK SETUP
1. Remove the the Combo 200 power supply and place it in a safe and secure location. Be sure to lock the wheels once it is in your desired location.
2. With the help of another person, remove the articulating arm and place it
in a desired location on your tabletop. Once it is in the desired location have
the other person trace the holes that are on the bottom of the articulating
arm base.
3. Move the articulating arm and drill the traced holes out of your table.
4. Run the hardware through the holes in the bottom of the articulating
arm and then lower them into the holes in your table. Secure the Combo
200 articulating arm to the table. *Be sure that it is close enough to the
power supply to connect the necessary system cables.
5. Connect the green laser cable to the port on the back of the laser head
at the top of the articulating arm.
1. Connect the opposite end of the green cable to the port on the back
of the power supply.
48
6.Connect the black laser cable to the port on the back of the laser head at
the top of the articulating arm.
1. Connect the opposite end of the black cable (which has two separate connectors) to the ports on the back of the power supply.
7. Connect the blue air cable to the air port on the back of the laser head at
the top of the articulating arm.
1. Connect the opposite end of the blue air cable to the air port on the
back of the power supply.
8. Connect the foot pedal cable to the foot pedal port on the back of the
power supply.
9. Connect the female end of the power cable to the back of the power
supply.
10. Connect the male end of the power cable to AC power.
49
11. If using shielding gas, connect the gas tube into the gas port on the
back of the power supply.
12. Fill the water (follow water filling instructions, section 7.5 manual).
De-ionized water should be used.
13. Turn the welder power switch on the back of the welder clockwise to
turn on the welder.
14. Insert the key on the front of the power supply and turn it clockwise to
allow the welder to function.
15. Setup the microscope eyepieces.
16. Touch start on the touch screen user interface.
17. Set the welding parameters.
18. Look through the microscope eyepieces and bring your workpiece into
focus. (See ch 5 for eyepiece setup)
19. Line up the crosshairs on your workpiece where you want to weld.
20. Step on the foot pedal or press the thumb switch on the left hand grip
to initiate a weld.
50
10.2: LASER WELDER SAFTY BASICS
1) If laser is not used in a room of its own (with all windows covered), make sure laser operating area
is completely surrounded by walls of non-see-through material of some type.
2) Operator of laser must be looking through the microscope eye pieces for safety.
3) Anyone inside the laser operating area (while laser is in use) must be wearing laser safe approved protective goggles (one pair included with new laser welder purchase…contact Sunstone for
purchase of more sets of laser safe eye protection).
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