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Orion Combo 200 User Manual

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Orion Laser Welder User Manual
Orion Combo 200

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Summary of Contents for Orion Combo 200

  • Page 1 Orion Laser Welder User Manual Orion Combo 200...

  • 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 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...

  • Page 5: Introduction

    Thank You for Choosing Orion Welders and congratulations on your purchase! You are now the proud owner of an Orion Laser Welder. This 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.

  • Page 6: Use And Installation

    The 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.

  • Page 8: Contractual Guarantee/Warranty

    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. The 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: This symbol indicates a need to carefully read and follow instructions found here to ensure proper use and maintenance of the equipment. LASER WARNING: This 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 This 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: Laser Radiation Absorption

    NOTE The laser generated here is a class IV. The risks associated with class IV lasers include not only the risk of direct or reflected radiation, but also of diffused radia- tion. These 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 The human tissue absorbs electromagnetic radiation in different ways, depending on the wavelength...

  • Page 14: Classification And Dangerousness

    The 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: Risks For The Eyes And The Skin

    DIRECT VIEW OF A LASER BEAM AFTER FOCUSING OPTICS This can happen if the beam is not absorbed at the end of its path. This 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

    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.

  • Page 18: Labels

    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 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).

  • Page 20: Labels Positioning

    3.2: LABELS POSITIONING The Laser warning labels are placed on the machine in the following ways: LASER N.1 LASER N.5 LASER N.2 Picture 2: Outside laser warning labels LASER N.6 Picture 3: Internal laser warning labels The 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...

  • 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 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...

  • Page 22: Chapter: 6 Installation

    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.
  • Page 23 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 be- fore making any changes Remove the eyepieces from their containers and fasten them to the microscope on the articulating arm.
  • Page 24 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.
  • Page 25 FIG. 1 FIG. 2 UPPER CONNECTOR PLUG FEMALE CONNECTOR FIG. 3 FIG.4 5.2: FIRST SWITCHING ON Ensure that the emergency stop button is disengaged and not pushed in. (Picture 10) Picture 10: Emergency stop button...
  • Page 26 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 param- eters and make welds. Picture 13: Combo 200 touch screen interface...
  • Page 27 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 / Orion Welders. At this point the operator will be able to: •...

  • Page 28: Display Touch Screen Controls

    Chapter 6: Controls 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.
  • Page 29 Weld Parameters Description Power The power bar is used to select the power of the weld. Time The time bar is used to select the duration of the weld. Frequency The frequency bar is used to select the rate at which the welds are made. Select- ing “0”...
  • Page 30 MANUALS The Manuals screen provides on-screen documentation and instructions for users to read and refer- ence when using the welder. Picture 15: 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.
  • Page 31 SETTINGS: PARAMETERS The 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 17: 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.
  • Page 32 SETTINGS: DATE AND TIME The date and time tab allows users to enter in the current date and time settings. Picture 19: Date and Time SETTINGS: CONTACT The contact tab displays all the contact details for Orion Welders. Picture 20: Contact...
  • Page 33 The 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 re- garding this option.
  • Page 34 SETTINGS: SOFTWARE MANAGEMENT The software management tab can be used to update the welder’s software. Picture 22: 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 23: Language...
  • Page 35 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: •...
  • Page 36 Periodically check the lens of the microscope that is found inside the weld chamber. This special glass is treated with an anti-glare of 1064 nm. The lens is held in place with two screws at the bottom of the optic assembly. To change or clean the protective lens: 1.
  • Page 37 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 38 The 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. Then 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 39 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 40 This process may need to be repeated 2-3 times. C. Contact Sunstone / Orion Welders. Refrigerating Liquid High The refrigerating liquid has A. With the machine turned on, wait 15 min...
  • Page 41 ER.N° MESSAGE CAUSE REMEDY High Electronic Tempera- The 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 42 PROBLEM RESOLUTION The 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 43 Chapter 9: Safety Systems This 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 44 Functioning This shutter is normally in an opened state and is independent from the previ- ously mentioned resonator shutter. This 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 45 9.4: WELD INFRARED FILTER Description This 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 46 QUICK LASER PARAMETERS LASER WELDING PARAMETERS POWER SPOT TIME m/s FREQUENCY WAVE Yellow Gold thin SLO+ Yellow Gold wire SLO+ Yellow Gold smoothing SLO+ White Gold thin SLO- White Gold wire SLO- White Gold smoothing SLO- Rose Gold thin SLO+ Rose Gold wire SLO+ Rose Gold smoothing...
  • Page 47 Platinum smoothing NORM Stainless steel thin NORM Stainless wire NORM Stainless steel NORM smoothing Titanium thin NORM Titanium wire NORM Titanium smoothing NORM Palladium thin NORM Palladium wire NORM Palladium smoothing NORM Nickel Silver thin NORM Nickel Silver wire NORM Nickel Silver smoothing NORM...
  • Page 48 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 se- cure location. Be sure to lock the wheels once it is in your desired location.
  • Page 49 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 sepa- rate connectors) to the ports on the back of the power supply. 7.
  • Page 50 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.
  • Page 51 10.2: LASER WELDER SAFTY BASICS 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. Operator of laser must be looking through the microscope eye pieces for safety. Anyone inside the laser operating area (while laser is in use) must be wearing laser safe ap- proved 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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