Orion Welders LZR series User Manual
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Orion Welders LZR series User Manual

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Orion Laser Welder User Manual
Orion LZR

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Summary of Contents for Orion Welders LZR series

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

  • Page 2: Table Of Contents

    Table of Contents 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 3.2: Labels Positioning Chapter 4: Technical Data...
  • Page 3 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 Chapter 8: Error Messages and Troubleshooting 8.1: Other Anomalies Chapter 9: Safety Systems 9.1: Resonator Shutter...

  • Page 5: Introduction

    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.

  • Page 6: Use And Installation

    Sunstone Engi- neering and Orion Welders will be not responsible for errors included in this document nor for any incidental damages or consequences due to any erroneous interpretation of this manual.
  • Page 7 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: Contractual Guarantee/Warranty

    Sunstone Engineering and Orion Welders CONTRACTUAL GUARANTEE / WARRANTY Sunstone Engineering 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.

  • Page 9: Chapter 1: Symbols

    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 radia- tion.
  • Page 10 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;...
  • Page 11 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.

  • Page 12: Chapter 2: Safety

    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 them- selves or to the machine.

  • Page 13: 13 2.1: Laser Radiation Absorption

    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 radia- tion. 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...

  • Page 14: 14 2.3: Radiation Vision Conditions

    e extent of the damage depends on the quantity of absorbed radiation and on the power and inten- sity 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 clas- sified 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.

  • Page 15: 15 2.5: Safety General Prescriptions

    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 danger- ous 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.
  • Page 16 • 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)

  • Page 17: Chapter 3: Seals

    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 Engineering. NOTE Removing or breaking certain seals on this machine can have immediate and negative effects on the weld system.
  • Page 18 LASER WARNING LABELS: Label Shape and type Sizes (mm) Laser warning Laser N. 1 Side 22 Side 50 Laser class information Laser N. 2 104 x 52 52 x 26 Radiation information Laser N. 3 104 x 52 52 x 26 Laser exposure information Laser N.
  • Page 19 Laser technical data Laser N.5 104 x 25 Laser opening information Laser N.6 104 x 26 ELECTRIC WARNING LABELS Label Shape and type Sizes ( mm) Electricity warning Side 22 Electric N.1 Side 50 PRODUCT IDENTIFICATION LABEL is 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).

  • Page 20: Labels Positioning

    3.2: LABELS POSITIONING e Laser warning labels are placed on the machine in the following ways: LASER N.1 LASER N.3 Picture 2: Outside laser warning labels 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.2 LASER N.5...

  • Page 21: Chapter 4: Technical Data

    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 Average Energy Consumption KW Laser Crystal Type Nd:YAG Wavelength nm 1,064 Weld Energy joule 0.1-60 or 0.1-100 Weld Length msec 0.5-20 Repetition Frequency Hz...

  • Page 22: Chapter: 6 Installation

    Chapter 5: Installation Position the equipment on a strong and sturdy table or workbench that is able to support the weight of the machine (approximately 73 lbs or 33 Kg). Make sure that all four support legs of the laser are resting firmly on the table or workbench.
  • Page 23 Connect the power cable to the wall outlet and then to the back 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) INTERLOCK Picture 8: Interlock Connect the foot pedal to the back of the machine (Picture 9) FOOT PEDAL Picture 9: Foot pedal...
  • Page 24 ATTENTION: Use only the cables and equipment provided with the machine. Do not substitute or change any cables or plugs. If needed, contact Sunstone Engineering before making any changes Remove the eyepieces from the containers (Picture 10) and fasten them on the machine. Screw the screw using a 2.5mm allen key and plug the connector.
  • Page 25 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 (Fig 3). 6. Turn on the machine by flipping the switch on the back of the machine. Do not turn the key switch.
  • Page 26 5.2: FIRST SWITCHING ON Ensure that the emergency stop button is 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.
  • Page 27 AT THIS POINT ON THE GRAPHIC DISPLAY THE INITIAL SCREEN WILL APPEAR THAT WILL INVITE TO THE MACHINE SWITCHING ON WITH THE INDICATION “PRESS START “. AT THIS POINT PRESS “START” ON THE DISPLAY. Picture 15: Orion LZR touch screen interface When you have pressed “START”...
  • Page 28 Turn the key to the Locked position and wait for the screen 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 Chapter 6: Controls 6.1: INTERNAL CONTROLS Picture 18: Internal Controls Reference Description Shield gas delivery nozzle Compressed air delivery nozzle LED brightness control (0%, 40%, 70%, 100%) Internal joystick control Fumes suction fan (not pictured) 6.2: JOYSTICK CONTROLS Picture 19: joystick controls...

  • Page 30: Display Touch Screen Controls

    Reference Description Moving the joystick up will cycle ‘upwards’ through the differ- ent parameters. DOWN Moving the joystick down will cycle ‘downwards’ through the different parameters. LEFT Moving the joystick left will lower the value of the selected parameter. RIGHT Moving the joystick right will raise the value of the selected parameter.
  • Page 31 Weld Parameters Description Power e power bar is used to select the power of the weld. It is possible to lower the power as low as 0.1kW, or raise it as high as 5kW on the LZR100. (Max power is 3kW for the LZR60).

  • Page 32: Additional Interface Screens

    6.4: ADDITIONAL INTERFACE SCREENS CAMERA SCREEN e camera screen displays most of the same parameters found on the Home screen. Users can touch any parameter and use the “+” or “-“ button in the lower right corner to raise or lower the se- lected parameter (highlighted in blue text).
  • Page 33 Zoom Tapping this button will change the camera zoom from 1x to 2x to 4x and then back to 1x. Menu e menu button will replace the on screen weld parameters with certain parame- ters relating to the camera. ere are 4 blue buttons that will position the crosshairs on the screen.
  • Page 34 MANUALS e Manuals screen provides on-screen documentation and instructions for users to read and refer- ence when using the welder. Picture 23: 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.
  • Page 35 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 tempera- ture and setting readouts. Picture 25: 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.
  • Page 36 SETTINGS: DATE AND TIME e date and time tab allows users to enter in the current date and time settings. Picture 27: Date and Time SETTINGS: CONTACT e contact tab displays all the contact details for Orion Welders. Picture 28: Contact...
  • Page 37 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 re- garding this option.
  • Page 38 SETTINGS: SOFTWARE MANAGEMENT e software management tab can be used to update the welder’s software. Picture 30: 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 31: Language...
  • Page 39 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 there- fore 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 Engineering or an agent authorized by Sun-...
  • Page 40 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.
  • Page 41 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 mis- aligned, the beam may travel to unexpected locations inside the weld chamber.
  • Page 42 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.
  • Page 43 ATTENTION It is advisable to change the cooling water at least every two years, and in particu- lar before or after any periods of heavy usage. 7.4: HOW TO REMOVE THE WATER Insert the plastic connection equipped with the machine (Fig. 1) to the female connector at the right bottom of the rear panel.
  • Page 44 Chapter 8: Error Messages and Troubleshooting e table shows information regarding the various error and messages that may appear on the weld- ER.N° MESSAGE CAUSE REMEDY Error Simmer e laser lamp is not switching A. Check the fuse. B. Contact Sunstone Engineering Not Working e refrigerating liquid is not A.
  • Page 45 ER.N° MESSAGE CAUSE REMEDY High Electronic Tempera- e internal thermostat inside A. Let the machine rest for 15-20 minutes ture the power electronic has noticed and wait for the error to disappear. an high temperature: B. Blow some compressed air into the A.
  • Page 46 PROBLEM RESOLUTION e lights inside the welding chamber do not • Check the light adjustment knob inside the weld turn on. chamber and make sure it is not in the off posi- tion. (Ref. Fig 4) • Check the fuses. Smoke created from the weld rises towards •...
  • Page 47 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.
  • Page 48 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 fol- lowing steps: •...
  • Page 49 9.4: WELD CHAMBER 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.
  • Page 50 9.5: LEATHER STRIPS PROTECTING THE CHAMBER OPENING Description e opening to the weld chamber is covered with skirted leather strips. allows users to insert their hands and workpieces into the weld chamber, while still blocking the laser from escaping the weld chamber. (Picture 37) Purpose It is necessary to have this protection installed on the machine for two main reasons:...
  • Page 51 Chapter 10 Technical Assistance With any questions or issues please contact us 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/...

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