Miller OptX 2kW Owner's Manual
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Miller OptX 2kW Owner's Manual

Handheld laser welding and cleaning system
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OM-296747A
2024-0
Processes
Laser Welding
Description
OWNER'S MANUAL
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Summary of Contents for Miller OptX 2kW

  • Page 1 OM-296747A 2024-0 Processes Laser Welding Description OWNER’S MANUAL For product information, Owner’s Manual translations, and more, visit www.MillerWelds.com...

  • Page 3: Important Safety Information

    The combination of appropriate laser safety glasses and laser welding helmet will provide sufficient protection against eye damage. OptX Miller recommends to use appropriate laser safety glasses in combination with Miller helmet. OptX If any PPE becomes damaged or compromised while using the...

  • Page 4: Important Safety Information (Cont.)

    Everyone in Laser Controlled Area* Must Read and Observe All users must review the Owner’s Manual in its entirety and be fully trained before using the OptX 2kW System Reflected Beam Hazard Highly reflective metals such as aluminum, stainless steel, copper and copper alloys can cause reflection of the laser energy away from the target weld site to the laser source or surrounding area and can present a hazard.

  • Page 5: Legal Notices

    Further, Miller does not assume responsibility for use of the information contained in this document or for any infringement of patents or other rights of third parties that may result from its use. Miller shall not be liable for errors in or omissions from this document or for any incidental, consequential, indirect or special damages, including without limitation, lost profits, lost production costs or similar damages, in connection with the furnishing, performance or use of this material.

  • Page 6: Preface

    Ensure you read and understand this guide in its entirety and familiarize yourself with the operating and maintenance instructions before you use the product. Miller strongly recommends that all operators of the product read and pay particular attention to all safety information contained herein prior to oper- ating the product.
  • Page 7 Preface In the European Union: • IEC 60825-1:2014 - Safety of Laser Products - Part 1: Equipment classification and requirements. IEC 60825-4 - Safety of Laser Products - Part 4: Laser Guards Standards can be found through the IEC webstore at: https://www.iec.ch/homepage •...
  • Page 8 Preface This Page is Intentionally Blank. OM-296747A | 4/15/24...

  • Page 9: Table Of Contents

    Table of Contents Table of Contents Important Safety Information ............. . . 3 Important Safety Information (cont.) .
  • Page 10 Table of Contents 2.7.2. Humidity ................53 2.7.3.
  • Page 11 Table of Contents 7.1.1. Fiber Interlock ..............101 7.1.2.
  • Page 12 Table of Contents 10. Troubleshooting ..............153 A.

  • Page 13: List Of Figures

    List of Figures List of Figures Figure 1 Laser Safety Banner Label - Primary Laser ......... . 35 Figure 2 Laser Safety Banner Label - Guide Laser .
  • Page 14 List of Figures Figure 44 Local Area Connection Properties Window ........130 Figure 45 Internet Protocol Version 4 Properties Window .

  • Page 15: List Of Tables

    List of Tables List of Tables Table 1 Signal Words Used in this Owner’s Manual ..........24 Table 2 Safety Symbols Used in this Owner’s Manual .
  • Page 16 List of Tables This Page is Intentionally Blank. OM-296747A | 4/15/24...

  • Page 17: Overview

    In addition, the OptX system can weld an extended range of material thicknesses as well as reflective materials. The Miller fiber laser welding system has been designed and tested with safety in mind. By following this Owner’s Manual and applying sound laser safety practices, it can be a safe and reliable device.

  • Page 18: Non-Intended Use (Foreseeable Misuse)

    9. Use of this product by any individual in residential area. 10. Welding on containers that contain flammable, combustible or unknown materials. Target Groups This manual for the product OptX has been created by Miller for the operating and maintenance personnel of the product owner. OM-296747A | 4/15/24...

  • Page 19: Personnel Qualifications

    The maintenance personnel are trained in the maintenance of the product by Miller or another responsible Miller subsidiary or authorized to carry out the maintenance work, insofar as this is not carried out by employees of Miller. The following tasks are performed by the maintenance personnel:...

  • Page 20: Overview Task / Qualification

    Overview • Assembly and installation – Setting up the Laser Controlled Area – Set up and install the product – Run lines and fibers to the product – Connect the product (the power supply must be connected by an electrician) –...

  • Page 21: Certification

    A.2 [▶163] Connect/Disconnect Fiber Output A.3 [▶167] Output Termination Cleaning Procedure Certification Miller certifies that this instrument has been thoroughly tested and inspected. It was found to meet published specifications prior to shipping. Models Covered Miller system models covered by this document include: •...
  • Page 22 Overview This Page is Intentionally Blank. OM-296747A | 4/15/24...

  • Page 23: Safety And Compliance Information

    There are no user serviceable parts, equipment or assemblies associated with this product, except as indicated in Section A [▶157]. All internal service and maintenance should only be performed by qualified Miller personnel, except as noted in Section A [▶157].

  • Page 24: Table 1 Signal Words Used In This Owner's Manual

    Safety and Compliance Information The table below lists the signal words used in this manual. ▼Table 1. Signal Words Used in this Owner’s Manual Signal Word Explanation • This signal word indicates an immediate DANGER danger. If this danger is not avoided, this will lead to death or severe injuries.

  • Page 25: Table 2 Safety Symbols Used In This Owner's Manual

    Safety and Compliance Information ▼Table 2. Safety Symbols Used in this Owner’s Manual Symbols Explanation Symbols Explanation WARNING HAZARD SYMBOLS: MANDATORY SYMBOLS: ELECTRICAL HAZARD NOTICE SYMBOL Indicates presence of dangerous voltages Symbol is used in conjunction with the NOTICE that can be of sufficient magnitude to signal word.
  • Page 26 Safety and Compliance Information ▼Table 2. Safety Symbols Used in this Owner’s Manual (Continued) Symbols Explanation Symbols Explanation WARNING HAZARD SYMBOLS: MANDATORY SYMBOLS: DIRECT BEAM POINTING IS PROHIBITED WEAR PROTECTIVE CLOTHING Symbol illustration shows the handheld Symbol indicates that personnel must wear laser torch being pointed towards person’s laser and heat-resistant protective head.

  • Page 27: Laser Safety Information

    Safety and Compliance Information Laser Safety Information 2.2.1 Key Control The keyswitch, on the front panel of the device, limits access to the laser device and can prevent an unauthorized user from turning the laser device on. In order for the laser to operate, the key must be inserted into the keyswitch and turned to the 1 (ON) position (refer to section 3.2 [▶63]).

  • Page 28: Laser Classification

    Safety and Compliance Information 2.2.3 Laser Classification Governmental standards require that all lasers be classified according to their output power or energy and the laser wavelength. This device is classified as a high power laser instrument with laser classification for each laser type identified in Table 3 [▶28].

  • Page 29: Laser Safety Eyewear And Welding Helmet

    Safety and Compliance Information DANGER Class 4 invisible laser radiation. Eye and skin hazards. This level of light can cause severe damage to the eyes and skin.  Due to these risks a qualified laser safety officer should be present to ensure a safe working environment.
  • Page 30 IMPORTANT  Miller is providing one pair of laser safety glasses and one carbon fiber welding helmet with the unit. This safety equipment must be worn while operating the device, as well as by any individuals in the vicinity of this device while in operation.

  • Page 31: Laser And Heat Resistant Clothing Ppe

    Rockwell Laser Industries https://rli.com Miller provides the names of these providers solely as a convenience and does not endorse or recommend any of them, or their products or services. Miller assumes no liability for their recommendations, products or services.

  • Page 32: Laser Technical Data And Safety Hazard Calculations

    Jutec https://jutec.com Miller provides the names of these providers solely as a convenience and does not endorse or recommend any of them, or their products or services. Miller assumes no liability for their recommendations, products or services. This list is not necessarily complete.

  • Page 33: Table 7 Laser Safety Terms And Definitions

    Safety and Compliance Information ▼Table 7. Laser Safety Terms and Definitions Laser Safety Terms Definitions for Laser Safety Terms Maximum Permissible The MPE is the irradiance or radiant exposure that can Exposure (MPE) be incident upon the eye (or the skin) without causing injury or adverse biological changes in the eye or skin.

  • Page 34: Table 8 Laser Safety Hazard Calculations

    Safety and Compliance Information Laser safety hazard calculated values are specified in the table below. ▼Table 8. Laser Safety Hazard Calculations OptX 2kW Laser Safety Hazard Calculations Nominal Ocular Hazard Distance (NOHD) Skin NHZ Eye Nominal Hazard Zone (NHZ) EYE HAZARD CALCULATIONS...

  • Page 35: Device Safety Label Locations

    The safety label banner which is affixed on the device, provides information on the laser radiation hazards that are present in your particular device. The Miller safety label and the information listed on the safety label will vary based on the output power(s), wavelength(s), and other performance characteristics. It is important to review the labels affixed to the product for specific information about your laser device.

  • Page 36: Table 9 Safety Label Description And Location

    FREQUENCY: 50/60 Hz FULL LOAD CURRENT: 32 A MAXIMUM BREAKER SIZE: 40 A DESCRIPTION: LASER WELDER OptX 2kW LOT NUMBER: OX2R32403012U MANUFACTURE DATE: MARCH 2024 C.O.O.: Rear panel of the device. (Products Made in the US) - See Figure 3 [▶...
  • Page 37 Safety and Compliance Information ▼Table 9. Safety Label Description and Location (Continued) 6. Primary Laser - Class 4 Information Label Identifies the output power, peak power, pulse duration, pulse repetition rate and wavelength range for the primary fiber laser used for material processing. Located on rear panel of the device. This label is specified in English, French and Spanish.
  • Page 38 Safety and Compliance Information ▼Table 9. Safety Label Description and Location (Continued) 11. Protective Conductor 12. Safety Label - QR Code 13. Patent List Label Terminal This symbol is specifically reserved for the PROTECTIVE CONDUCTOR Scan QR code to access online TERMINAL and no other.

  • Page 39: Figure 3 Label Placement - Device Panels And Torch

    Safety and Compliance Information ▼Figure 3. Label Placement — Device Panels and Torch ⑬ ① ⑩ ⑤ ④ ⑦ ⑥ ⑧ ⑪ ③ ② ⏚ ⑭ ⑫ ④ ④ ⑨ ⑨ Item Designation Item Designation Item Designation Identification Plate Label Laser Radiation Hazard Label Aperture Label (Laser Torch) Primary Laser...

  • Page 40: Regulatory Compliance

     Always keep the labels in good condition so they remain legible.  Never remove any of the labeling affixed onto the product.  If any label is damaged, illegible or missing, contact Miller Service (refer to section B.1 [▶171]) for replacement.

  • Page 41: Class A Digital Device

    Safety and Compliance Information ▼Table 10. Compliance Standards Listing (Continued) Standard Title / Description Electrical Safety: EN/ISO 61010-1 Safety Requirements for Electrical Equipment for Measurement, Control, and Laboratory Use - Part 1: General Requirements (EU) Laser Safety: IEC 60825-1 (EU) Safety of Laser Products - Part 1: Equipment Classification and Requirements CDRH 21 CFR 1040.10 Code of Federal Regulations (CFR) - Title 21.

  • Page 42: Important Operation Safety Information

    Safety and Compliance Information Important Operation Safety Information 2.4.1 Secondary Radiation Hazard WARNING Visible and invisible light radiation produced during device operation The interaction between high power laser beams and target materials being welded can create plasmas that produce UV emissions and “blue light” which can cause conjunctivitis, photochemical damage to the retina and/or sunburn-like reaction to the skin.

  • Page 43: Skin Hazard

    Safety and Compliance Information 2.4.3 Skin Hazard WARNING Welding and cleaning process - UV radiation Damage to skin from exposure to UV-radiation produced during the welding (or cleaning) process.  PPE must be worn during equipment operation.  Required PPE includes: (1) welding helmet over specified laser safety glasses, (2) laser and heat resistant gloves, (3) laser and heat resistant clothing, and (4) laser and heat resistant apron.

  • Page 44: Fire Hazard

    Safety and Compliance Information 2.4.4 Fire Hazard DANGER Laser can ignite solvents, gases, combustible materials Laser light can ignite volatile substances such as alcohol, gasoline, ether and other solvents and flammable gases (e.g. MAPP gas) causing a fire or explosion. ...

  • Page 45: Reflected Beam Hazard During Welding

    IMPORTANT For safety reasons, Miller recommends that OptX device operators only use Miller nozzle tips. The part number for the Miller Nozzle Tip Kit is specified in the Accessories Table 14 [▶61]. Replacement nozzle tips are available for purchase. 3. Proper nozzle installation - See sections 7.3.2 [▶109] and 7.3.3 [▶109].

  • Page 46: Table 11 Welding And Cleaning Nozzle Selection Chart

    Safety and Compliance Information • Compared to other models, the cleaning nozzles are sized differently due to optical differences within the torch. Therefore, users with multiple model types should not mix and match the cleaning nozzles. OptX models must use the OptX cleaning nozzles.

  • Page 47: Figure 4 Torch Angle, Reflections And Viewing Position

    Safety and Compliance Information ▼Figure 4. Torch Angle, Reflections and Viewing Position Lower power density radiation scattered from the process zone can travel Always maintain viewing position at certain distances. Within the Ocular Hazard Distance, the scattered radiation least 20 inches (500 mm) from the can be dangerous to the eyes.

  • Page 48: Process By-Products And Fume Hazards

    Safety and Compliance Information 2.4.6 Process By-Products and Fume Hazards When a laser beam reacts with any material, it can generate vapors, fumes, sparks and particulate debris. By-products from the laser process are often toxic and can pose additional safety hazards. WARNING Welding process fumes and particles Damage to body tissues or organs from exposure to fumes and other by-products...

  • Page 49: Gas Cylinder Safety

    Safety and Compliance Information NOTICE Risk assessment for welding fumes, particles, and dust It is the responsibility of the system owner to ensure proper disposal of waste debris and other by-products. Any extraction system must comply with local and health and safety regulations. System owner minimum requirement before starting the laser process is to: ...

  • Page 50: General Safety Instructions

    This can also damage the equipment and increase the risk of injuries due to laser irradiation.  Only connect the fiber to an Miller approved and supplied torch.  Do not plug in other devices to the laser welder head connections on the rear panel other than the cable and head provided.

  • Page 51: Optical Safety

    Safety and Compliance Information • Provide suitable barriers to secure a laser safe work area and to prevent the beam from escaping the area. Any barriers used in the LCA should be made of a laser- safe material that can withstand direct and diffusely scattered beams. In EU: please refer to EN 60825-4.

  • Page 52: Electrical Safety

    Lethal danger from direct or indirect contact with live parts.  There are no operator serviceable parts inside. Refer all servicing to qualified Miller personnel.  To prevent electrical shock, do not remove covers.  Any tampering with the product voids the warranty.

  • Page 53: Emitted Noise Level During Use

    The laser device is air-cooled. Operation at higher temperatures will accelerate aging, increase threshold current and lower slope efficiency. If the device is overheated, do not use it and call Miller Service for assistance. The device will turn emission off automatically and generate an alarm when the temperature of the laser exceeds 55°C.

  • Page 54: Recycling And Disposal

    Safety and Compliance Information 2.7.4 Recycling and Disposal NOTICE WEEE directive for environmentally safe disposal Incorrect disposal leads to environmental contamination and pollution.  Electronic devices have to be disposed according to the regional directives on waste electrical and electronic equipment (WEEE) such as directive 2012/19/EU. ...

  • Page 55: Laser Training Resources

    Laser Safety Certification (LSC) https://www.lasersafetycertification.com/ Kentek Corporation https://www.kenteklaserstore.com/lightweld-class-4-laser- safety?utm_source=pd https://lasersafetyu.kentek.com/product/laser-safety-training-classroom/laser- safety-officer-online-course Miller provides this information solely for convenience. Miller does not endorse any organization, products or services, and assumes no liability for their products or ser- vices. OM-296747A | 4/15/24...

  • Page 56: Optx Device Operation Training Resources

    4. Laser Welding Basics 5. Your First Weld 6. Program Modes and Control Adjustments 7. Computer Control for Customized Settings 8. OptX Maintenance Procedures For specific questions concerning OptX device operation, contact Miller Support at email: PWSService@millerwelds.com. OM-296747A | 4/15/24...

  • Page 57: Additional Resources

    Safety and Compliance Information 2.8.4 Additional Resources ▼Table 13. Applicable Standards Resources Organization Website / Contact Information For United States: Laser Institute of America (LIA) Laser Institute of America 13501 Ingenuity Drive, Suite 128, Orlando, Florida 32826 Phone: 407.380.1553, Fax: 407.380.5588 Toll Free: 1-800-34-LASER Email: lia@laserinstitute.org https://www.lia.org...
  • Page 58 (VDI) https://www.vdi.de/richtlinien IMPORTANT  Miller recommends that the user of this product investigate any local, state or federal requirements as well as facility or building requirements that might apply to installing or using a laser or laser device.  Ensure that the standard you are using which include, but may not be limited to ANSI, IEC, and OSHA are current.

  • Page 59: Additional Product Specific Safety Features

    [▶ 60]). IMPORTANT To receive the 4-digit activation code, users must first complete the Miller Laser Safety Training webinar. Activation code is provided upon successful completion of training webinar. When the system arrives there will be a removable label over the keyswitch. Scan the QR code to access the activation portal.

  • Page 60: Figure 6 Unit Locked On First Power Up

    Safety and Compliance Information ▼Figure 6. Unit Locked on First Power Up 1. Turn Laser Power knob to set activation code 2. Press and hold both mode buttons until mode display starts flashing then release Unit is Locked Webpage interface is locked OM-296747A | 4/15/24...

  • Page 61: Laser Welder Device Description

    Laser Welder Device Description 3 Laser Welder Device Description Accessories The following accessories are included with your Laser Welder Device, as indicated in Table 14 [▶61]. ▼Table 14. List of Available Accessories Items Part Number Note STANDARD ACCESSORIES OptX Handheld Laser Welding and OM-296747 This document Cleaning System Owner’s Manual...
  • Page 62 Cart (assembly required) used to hold weld unit, wire feeder and gas tank Lens, Focus Assy, OptX 2kW 296267 Focus lens assembly Tool, Focus Lens Installation, OptX 2kW 296263 Focus lens assembly installation tool Switch, Door Interlock, 2NC, 32’ Length 301804 Door Interlock Switch and Cable - Quantity 1 is included with welding unit.

  • Page 63: Weld Unit Front View

    Laser Welder Device Description Weld Unit Front View Refer to Table 15 [▶63] for a description of all these features and connections. ▼Table 15. Weld Unit Front Panel Features Item Feature Description ③ ⑦ ④ ⑤ ② ⑥ ① Keyswitch •...
  • Page 64 Laser Welder Device Description ▼Table 15. Weld Unit Front Panel Features (Continued) Item Feature Description Wobble Frequency • Manually adjust the Wobble Frequency (frequency of sinusoid) by turning the rotary Display with Control control knob. Knob (Hz) Wobble Length • Manually adjust the Wobble Length (line length) by turning the rotary control knob.

  • Page 65: Weld Unit Rear View

    Laser Welder Device Description Weld Unit Rear View Refer to Table 16 [▶65] for a description of the rear panel features and connec- tions. ▼Table 16. Weld Unit Rear Panel Features Item Feature Description ④ ⑤ ⑥ ① ⑦ ② ⑧...
  • Page 66 Laser Welder Device Description ▼Table 16. Weld Unit Rear Panel Features (Continued) Item Feature Description Ethernet Port Standard 10/100 Ethernet Communication Port. Ethernet connection to customer host computer. RJ-45 Connector. Use shielded Ethernet Cable. Access web page interface for welder status troubleshooting, recipe creation/management, and IP configuration.

  • Page 67: Hand Laser Torch

    Laser Welder Device Description Hand Laser Torch Refer to Table 17 [▶67] for a description of the torch features and connections. ▼Table 17. Torch Feature Descriptions Item Feature Description ⑤ ⑥ ④ ③ ⑦ ② ① ⑩ ⑪ ⑧ ⑨ Trigger 1 - Start Gas Press and hold Trigger 1 to begin shielding gas flow.
  • Page 68 Laser Welder Device Description ▼Table 17. Torch Feature Descriptions (Continued) Item Feature Description • Solid Green - while Trigger 1 is pressed and no Green Status errors are present. Indicator Light • Blinking Green - once all the interlocks are fully satisfied.

  • Page 69: Torch Protective Accessories

    Laser Welder Device Description 3.4.1 Torch Protective Accessories To prevent damage to the torch, please use the protective cover and cradle. When the device is not in use, place the torch in the cradle as shown in the figure below. ▼Figure 7.

  • Page 70: Layout And Dimensions

    Laser Welder Device Description Layout and Dimensions Welder unit dimensions are indicated in the figure below. See Figure 10 [▶ 71] for the unit's center of gravity location. ▼Figure 9. Device Layout and Dimensions Units: mm [inch] OM-296747A | 4/15/24...

  • Page 71: Figure 10 Center Of Gravity

    Laser Welder Device Description ▼Figure 10. Center of Gravity Units: mm [inch] 251.4mm 251.4mm [9.90in] [9.90in] 166.7mm 346.1mm [6.56in] [13.63in] Torch dimensions are indicated in the drawing below. ▼Figure 11. Torch Layout and Dimensions Units: mm OM-296747A | 4/15/24...

  • Page 72: Fiber Cable Output Connection

    Laser Welder Device Description Fiber Cable Output Connection IMPORTANT The OptX-series welder system will arrive with the fiber cable already inserted and connected to the torch. Should it become necessary to disconnect and reconnect the fiber (e.g. need to replace torch), refer to Maintenance Appendix section A.2 [▶163].

  • Page 73: Delivery And Transport

    Special care is recommended when unpacking. To minimize the risk of damage to the unit, Miller recommends that you unpack the unit using the instructions provided in section 4.2 [▶75]. IMPORTANT ...

  • Page 74: Table 18 Shipping Container Impact Indicators And Labeling

    Delivery and Transport ▼Table 18. Shipping Container Impact Indicators and Labeling NORMAL SHIPPING CONDITION CRATE WAS MISHANDLED • Red indicates shock and rough handling. • Blue beads in arrow tip indicates container was mishandled or tipped. DELICATE / HANDLE WITH CARE MONITORED SHIPMENT •...

  • Page 75: Unpacking From Shipping Container

    Check all items in the crate against this list. IMPORTANT  Contact Miller immediately if any of the items are missing or if any damage to the unit is evident. If any damage to the unit is evident or suspected, do not attempt to install or operate the laser device in any case.

  • Page 76: Transport To Installation Location

    Delivery and Transport ▼Figure 13. Domestic Shipments - Collapsible Crate Transport to Installation Location NOTICE Umbilical cable handling Severe laser damage will occur if optical fiber cable, routed through the umbilical, is mishandled (extreme bending, pulling or impact).  Do not bend the yellow optical fiber cable to a radius less than 50 mm minimum bending radius.

  • Page 77: Installing Welding Device

    Installing Welding Device 5 Installing Welding Device Precautions Personnel Qualifications: Maintenance Personnel and Electrician (see section 1.4 [▶19]). NOTICE Incorrect voltage and wiring can damage the welder system. Ensure the voltage and wiring is correct prior to turning ON the power. ...

  • Page 78: Air Flow And Installation Clearances

    Installing Welding Device Air Flow and Installation Clearances The laser welder unit is air cooled. In choosing the location to install the unit, make sure to leave approximately a 4 inch (10 cm) clearance above and to the left and right of the unit.

  • Page 79: Connect Welding Gas

    Installing Welding Device Connect Welding Gas IMPORTANT Pressure regulator selection A single-stage pressure regulator with 50 psi maximum output is recommended for use with the OptX system. A flow regulator is not recommended as it may not provide sufficient gas pressure to the system. Welding Gas specifications and connection to the back of the unit are specified in Table 19 [▶79].

  • Page 80: Customer Interface Connections

    ▼Table 20. 12-pin Interface Connection and Pinout Table Signal Name Type Notes CABLE MATING CONNECTOR MOUNTED ON REAR PANEL (Miller Part Number: 296264) Phoenix Mating Connector 1754898 Phoenix Terminal Block 1777170 12 position Terminal Block Plug, Female 12 Position Terminal Block Header, Male Sockets 0.200”...

  • Page 81: Figure 18 12-Pin Interface Output Pin Pairs (5-6, 7-8 And 9-10)

    Installing Welding Device ▼Table 20. 12-pin Interface Connection and Pinout Table (Continued) Signal Name Type Notes Power Supply Contact Output is normally open. The 5-6 Enabled+ Closure contacts close when the power supply on the laser driver is enabled Power Supply or told to be enabled.

  • Page 82: Connect Electrical Power

    Installing Welding Device Connect Electrical Power Personnel Qualifications: Electrician (see section 1.4 [▶19]). Please refer to the laser welder’s PRODUCT SPECIFICATION for power requirements. An AC line cord with pigtail is provided with your laser welder. ▼Table 21. Wiring AC Line Input Characteristic Specification Input AC Voltage...

  • Page 83: Figure 19 Wiring The Ac Line Cord Pigtail To The Disconnect Device

    Installing Welding Device DANGER Exposed electrical components. Danger to life due to electrical shock.  Installation exclusively by qualified personnel that are knowledgeable in electri- cal safety practices. Refer to Figure 19 [▶ 83]. 1. Input Power Conductors. 2. Disconnect Device. The switch is shown in the OFF position. 3.

  • Page 84: Connections To External Circuits

    Installing Welding Device 5.7.2 Connections to External Circuits Except for Mains connection, the external connections between this product and other external devices are PELV (Protected Extra Low Voltage) as defined by IEC 61140. Non-Mains outputs of other devices connected to this product should also be PELV or SELV (Safety Extra Low Voltage).

  • Page 85: Door Switch Entry Interlock Example

    Allen-Bradley Door Switch Example Case Actuator Safety Magnet Switch ▼Table 22. Door Switch to OptX Connector Wiring for Allen-Bradley Example Case Miller Part #: 301804 OptX Device 12-pin Connector Door Switch Wire 1 - Blue Pin-1 (External Interlock A+) 4 - Red...

  • Page 86: Mounting The Door Switch

    Installing Welding Device ▼Figure 21. Interconnection example for the door interlock integration in the OptX device safety logic 12-pin connector Safety Actuator position Switch Magnet Door OptX NOTE**: Safety switch incorporating 2 separate circuits and 4 contacts The OptX device has redundant interlock circuits. The OptX device requires these interlock circuits be closed for the laser to operate (contact pairs 1-2 and 3-4, refer to Table 20 [▶80].

  • Page 87: Figure 23 Mounting Alignment Of Door Switch Sensor And Actuator

    Installing Welding Device IMPORTANT  Maintain 5 mm (0.2 in) clearance from ferrous surroundings.  After installation and commissioning, the actuator, switch and switch mounting screws should be coated with tamper-evident varnish or similar compound.  Do not use anaerobic adhesive. ...

  • Page 88: Testing Door Entry Safety Interlocks

     All persons must wear PPE prior to testing that the external safety interlocks are wired correctly.  Required PPE includes: (1) Miller laser safety glasses, (2) welding helmet with appropriate filters and face shield, and (3) laser and heat-resistant protective gloves and clothing.

  • Page 89: Figure 24 Door Interlock Closed - Safety Interlock Is Satisfied

    Installing Welding Device ▼Figure 24. Door Interlock Closed - Safety Interlock is Satisfied Interlock LED Indicator is lit green when: (1) External Safety Interlocks Closed (e.g. Door to Laser Controlled Area is closed); (2) Work Sense clamp is connected; (3) Torch Trigger 1 Control is Pressed;...

  • Page 90: System Startup

    Installing Welding Device System Startup WARNING  All electrical connections must be connected prior to applying power to the unit.  Where applicable, all connections must be secured with screws to ensure proper functionality. WARNING  Ensure you wear all PPE gear while operating this product. These include spec- ified laser safety glasses, welding helmet with face shield, laser and heat-resis- tant gloves, clothes, apron.

  • Page 91: System Shutdown

    Installing Welding Device IMPORTANT Device IP address setting  The IP address of the device is only shown when the unit first turns ON after the AC line cord is plugged into an outlet. The IP address of the device will show sequentially in the Wobble Frequency 3 digit display (e.g.
  • Page 92 Installing Welding Device IMPORTANT Turning keyswitch to 0 (OFF) position turns off the main DC power supply. The front panel displays and indicators are turned off. The laser cannot be turned on without the key inserted and turned to 1 (ON). 4.

  • Page 93: Operating Front Panel Controls

    Operating Front Panel Controls 6 Operating Front Panel Controls Rotary Control Knobs There are 3 rotary control knobs on the front panel. • Laser Power - refer to section 6.1.1 [▶93]. Wobble Frequency - refer to section 6.1.2 [▶93]. • •...

  • Page 94: Wobble Length Rotary Control Knob

    Operating Front Panel Controls • If the program display starts to blink it indicates that one or more parameters have changed compared to the saved settings for that program. You are no longer using the preset settings (or settings from user created program). •...

  • Page 95: Table 24 Program Mode Button Functions

    Operating Front Panel Controls • Preset Programs are pre-programmed recipes from the factory. The program identification number will be a letter followed by a number. (e.g. A0, A1, A2, C0, C1, C2, etc). • The Preset Program letter options can be: A, C, E, F, H, J, L, P, U, and Y. ▼Table 24.

  • Page 96: Device Front Panel Setup Mode

    Operating Front Panel Controls Device Front Panel Setup Mode Setting the program mode to Y0 (refer to Process Mode Chart that came with the device) puts the welder device into “Front Panel Setup Mode”. This allows a user to set eight global device parameters using the front panel control knobs instead of the welder web page and therefore does not require a PC connected to the welder device.

  • Page 97: Table 25 Y0 Setup State Program Mode

    Operating Front Panel Controls ▼Table 25. Y0 Setup State Program Mode Code # Parameter Front Panel Explanation Displays User Must First Set Program Mode to Y0 Wobble Offset Sets wobble offset (to center output beam when using wire feeder). 1. Turn Wobble Length knob to Code 0. 2.
  • Page 98 Operating Front Panel Controls ▼Table 25. Y0 Setup State Program Mode (Continued) Code # Parameter Front Panel Explanation Displays User Must First Set Program Mode to Y0 Warning Group 1 Displays first group of 3 Warning states. 1. Turn Wobble Length knob to Code 7. 2.
  • Page 99 Operating Front Panel Controls ▼Table 25. Y0 Setup State Program Mode (Continued) Code # Parameter Front Panel Explanation Displays User Must First Set Program Mode to Y0 Interlock Group 2 Displays second group of 3 Interlock states. 1. Turn Wobble Length knob to Code 10. 2.
  • Page 100 Operating Front Panel Controls ▼Table 25. Y0 Setup State Program Mode (Continued) Code # Parameter Front Panel Explanation Displays User Must First Set Program Mode to Y0 Maintenance Reset This will clear the maintenance time warning and reset the timer for the maintenance interval. Refer to section 9.10 [▶145].

  • Page 101: Operating Laser Welder

    This can also damage the device.  Only connect the fiber to a Miller approved and supplied torch.  Do not plug in other devices to the laser welder head connections on the rear panel other than the cable and torch provided.

  • Page 102: Torch Nozzle And Work Sense Clamp Interlock

    Operating Laser Welder 7.1.3 Torch Nozzle and Work Sense Clamp Interlock This safety loop ensures the laser only fires when the torch nozzle is electrically connected (touching) to the workpiece. The operator must clamp the workpiece to the jack stud terminal on the rear panel of the unit. Whenever the nozzle of the torch touches the workpiece the nozzle interlock loop will be closed and satisfied.

  • Page 103: Plasma Detection

    Operating Laser Welder The location of the Thermal Fuse is indicated in Figure 32 [▶ 103] (item 1). ▼Figure 32. Torch Thermal Fuse and Plasma Sensor ① ② ② ① Item Designation Item Designation Thermal Fuse Plasma Sensor 7.1.6 Plasma Detection The handheld torch includes a photo sensor to monitor plasma (the bright visible light created during welding).

  • Page 104: Gas Pressure Monitoring

    Operating Laser Welder 7.1.7 Gas Pressure Monitoring The availability of shielding gas is monitored by requiring a minimum gas pressure that activates a sensor. When there is less than approximately 10 psi (0.7 bar) pressure present, the laser will not turn on. The green gas LED indicator on the front panel will not be lit when there is insufficient pressure.

  • Page 105: Warning And Status Lights

    Operating Laser Welder In case of an emergency, press the red E-Stop button on the front panel. When the E-Stop Button is triggered (pressed) the following occurs: • The E-Stop function opens an interlock in the safety circuitry of the device. •...

  • Page 106: Integrated Beam Wobble Function

    Operating Laser Welder Integrated Beam Wobble Function The OptX device’s “beam wobble” functionality creates a wider weld seam which improves the quality and aesthetics of the weld joint. The integrated wobble device optics deflect the laser beam and sweep it linearly back and forth along the cross- axis relative to the on-axis welding direction motion.

  • Page 107: Torch Nozzle Tip And Tube

    Operating Laser Welder Torch Nozzle Tip and Tube Personnel Qualifications: Advanced Operating Personnel (see section 1.4 [▶19]). 7.3.1 Nozzle Tip Types There are six types of nozzle tips available for welding (Figure [▶ 108]). Proper selection of the nozzle tip is required for safety and to also achieve the optimum welding results.

  • Page 108: Table 26 Welding And Cleaning Nozzle Selection Chart

    Operating Laser Welder ▼Table 26. Welding and Cleaning Nozzle Selection Chart WELDING AND CLEANING NOZZLE SELECTION WELDING NOZZLE KIT (#301832) CLEANING NOZZLE KIT (#301833) Nozzle, OptX, Welding, Conical Nozzle, OptX, Cleaning, Outside Corner #301811 #301819 Nozzle, OptX, Welding, 1-Point Nozzle, OptX, Cleaning, 1-Point #301812 #301820 Nozzle, OptX, Welding, 2-Point 6mm...

  • Page 109: Installing Nozzle Tip For Welding

    Operating Laser Welder 7.3.2 Installing Nozzle Tip for Welding IMPORTANT Prior to changing the nozzle tip, shutdown the unit using the keyswitch (refer to section 5.10 [▶91]). The following applies for all models. The nozzle tip will thread onto the torch’s extension tube.

  • Page 110: Table 27 Changing And/Or Adjusting The Torch Nozzle

    Operating Laser Welder ▼Table 27. Changing and/or Adjusting the Torch Nozzle Welding Nozzle Tip Cleaning Nozzle 1. Loosen nut to unlock nozzle. 1. Loosen nut to unlock nozzle. 2. Pull out the nozzle and insert the new 2. Pull out the nozzle and insert the new nozzle.

  • Page 111: Table 28 Examples Of Correct Nozzle Placement And Orientation

    Operating Laser Welder ▼Table 28. Examples of Correct Nozzle Placement and Orientation Welding Nozzle Tips Cleaning Nozzles 1-point welding nozzle tip positioned 1-point cleaning nozzle is shown here. over the seam is shown here. Red arrow indicates cleaning direction on-axis. 2-point welding nozzle tip positioned 2-point cleaning nozzle is shown here.

  • Page 112: Quick Start Welding Using Preset Programs

    Operating Laser Welder Quick Start Welding Using Preset Programs Personnel Qualifications: Operating Personnel (refer to section 1.4 [▶19]). DANGER Eye hazards during OptX device operation Risk of permanent eye damage and vision impairment from invisible reflected and scattered Class 4 laser radiation. Also risk of eye damage as a result of exposure to UV light, welding bright light, heat and sparks produced during the material processing.
  • Page 113 Operating Laser Welder 6. Ensure the Work Sense clamp is connected to either the parts, or the electri- cally conductive welding table on which the parts are placed. 7. Press Trigger 1 on the torch to turn on the shielding gas. Wait for a few seconds to clear the gas line.
  • Page 114 Operating Laser Welder IMPORTANT For Wire Welding:  When wire welding, the travel speed is determined by the feed rate of the wire feeder. Do not push or pull the welding head while welding. The wire feeder will push the welding head down the joint automatically. By adjusting the wire feeder speed or power you can change the depth of the weld.

  • Page 115: Quick Start Cleaning Using Preset Programs

    Operating Laser Welder Quick Start Cleaning Using Preset Programs This section is only applicable when operating in laser cleaning mode. Personnel Qualifications: Operating Personnel (refer to section 1.4 [▶19]). DANGER Eye hazards during OptX device operation Risk of permanent eye damage and vision impairment from invisible reflected and scattered Class 4 laser radiation.
  • Page 116 Operating Laser Welder NOTICE Using incorrect nozzle results in torch damage Damage to torch if beam wobble length is set to value greater than 5 mm while using a welding nozzle tip.  For cleaning width 5 to 15 mm, one of the cleaning nozzles MUST be installed on the torch.

  • Page 117: Figure 37 Optx System Operator Performing Laser Cleaning

    Operating Laser Welder ▼Figure 37. OptX System Operator Performing Laser Cleaning NOT CLEANED LASER CLEANED IMPORTANT For Cleaning:  Laser cleaning is done with a pulling motion at constant as possible travel speed.  Practice the motion before pressing Trigger 2. Do not break contact with the part. If the nozzle tip is lifted up off the part at any time, while Trigger 2 is pressed, the laser will automatically turn OFF.
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  • Page 119: Program Recipes And Parameters

    A laminated copy of the mode chart for your device is provided with the unit. If that sheet is lost, a copy of the mode chart may also be downloaded from the Miller Product Support webpage (refer to section B [▶171]).

  • Page 120: Tack Mode Parameters - Tack Welding

    The device will allow users to set a minimum power of 0 W. However, the minimum allowable power for laser processing is 200 W. Pulse waveform shapes 1-10 are created by the user and 11-20 are preset by Miller. Above parameter settings need to be configured to operate in “PULSED” mode.

  • Page 121: Hpp Mode Parameters - Reflective Materials

    The device will allow users to set a minimum power of 0 W. However, the minimum allowable power for laser processing is 300 W. Pulse waveform shapes 1-10 are created by the user and 11-20 are preset by Miller. Above parameters settings need to be configured to operate in “HPP” mode. The min and max allowable settings are specified.

  • Page 122: Clean Mode Parameters

    0 and 35 s. On the web page it is con- trolled in ms (finer resolution). Pulse waveform shapes 1-10 are created by the user and 11-20 are preset by Miller. Above parameters settings need to be configured to operate in “ADV STITCH”...

  • Page 123: Front Panel Knob Adjustments

    Program Recipes and Parameters Parameter definitions are specified in the glossary of terms in section 8.4 [▶125]. Front Panel Knob Adjustments IMPORTANT  As different User or Preset Program Modes are selected, the front panel rotary knob adjustment parameters will change. The Laser Power control knob will remain the same for all program recipes.

  • Page 124: Table 29 Front Panel Knob Adjustment Range Vs Recipe Setting

    Program Recipes and Parameters ▼Table 29. Front Panel Knob Adjustment Range vs Recipe Setting Laser Mode Parameter Adjusted by Knob Parameter Adjusted by Knob Wobble Frequency Wobble Length PRESET MODE Wobble Frequency Wobble Length Adjustment Range: +/- 90 Adjustment Range: +/- 9 Stitch Laser On Time Laser Off Time...

  • Page 125: Glossary Of Program Parameter Terms

    For pulsed modes, selects the pulse shape waveform to use for the pulse. Wave number 1-10 is allocated for user to create. Wave number 11-20 is Miller Preset. 15 Stitch Count For “Stitch Mode”, determines the number of pulses to generate before turning emission OFF.
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  • Page 127: Computer Connection To Device

    Computer Connection to Device 9 Computer Connection to Device To access the welder unit’s webpage interface, users must first connect their PC to the welder unit’s Ethernet port with the supplied Ethernet cable. ▼Figure 39. Connect Ethernet Cable from Laser Device to Host PC Ethernet Connection ⏚...

  • Page 128: Pc Ethernet Configuration - Windows 10 Os

    Computer Connection to Device 9.1.1 PC Ethernet Configuration - WINDOWS 10 OS 1. Open Windows Start Menu. Scroll down and expand the folder Windows System. Select Control Panel. See Figure 40 [▶ 128]. ▼Figure 40. Windows Start Menu 2. The Control Panel window opens. Select Network and Sharing Center from list See Figure 41 [▶...

  • Page 129: Figure 42 Network & Sharing Center Window

    Computer Connection to Device ➤ In the active networks list, click on the Local Area Connection correspond- ing to your network interface or USB-Ethernet adapter (it might be labeled as “Unidentified network”). In this example it is Ethernet 2. See Figure 42 [▶...

  • Page 130: Figure 44 Local Area Connection Properties Window

    Computer Connection to Device ▼Figure 44. Local Area Connection Properties Window 6. Select Use the following IP address. Fill out entries and click OK - see Figure [▶ 130]. ➤ IP address - 10.0.0.1 (for example)*** ➤ Subnet Mask - 255.255.255.0 ➤...

  • Page 131: Webpage Interface

    Support - Opens the Product Support page. Software and firmware revision information is located here (see section 9.6 [▶139]). • Login/Logout - This login is intended to be used by Miller personnel to access factory device settings. OM-296747A | 4/15/24...

  • Page 132: Laser Welder Page

    Computer Connection to Device Laser Welder Page To access the Laser Welder page, click on the Welder tab. The Welder page enables the user to perform similar and/or equivalent functions as what is done via the device front panel controls. Refer to Figure 48 [▶...

  • Page 133: Welder Status Indicator Pane

    Computer Connection to Device ▼Figure 49. Laser Welder Page - Preset Program Recipe 9.4.1 Welder Status Indicator Pane The Welder Status panel is a graphical representation of the unit’s front panel indicators and will enable users to troubleshoot which particular status or alarm bits are causing the error or warning.
  • Page 134 Computer Connection to Device ▼Table 31. Welder Status Indicator Pane Features (Continued) ITEM Feature Description Warning • The main Warning indicator will be lit yellow when there is a warning. If there are no warnings, it will not be lit (gray). •...

  • Page 135: User Mode Program Recipe Setup

    Computer Connection to Device ▼Table 31. Welder Status Indicator Pane Features (Continued) ITEM Feature Description Clear Alarms Button • Click button to clear alarms. This will perform a similar function as clearing the alarm using the Trigger 1 control on the torch as long as the condition that caused the error in the first place was resolved.

  • Page 136: Table 32 Effects Of Power Compensation Setting

    Computer Connection to Device ▼Table 32. Effects of Power Compensation Setting Example Power Power Power used at the Power used at the Setpoint in Recipe Compensation center of the weld edges of the weld Setting 1000 W 0% (Default) 1000 W 1000 W 1000 W 1000 W...
  • Page 137 Computer Connection to Device ▼Table 33. User Mode Recipe Configuration for Each Laser Mode (Continued) Laser Mode User Mode Recipe Configuration STITCH CLEAN ADV STITCH OM-296747A | 4/15/24...

  • Page 138: Preset Mode Program Recipe Setup

    Computer Connection to Device 9.4.3 Preset Mode Program Recipe Setup ▼Figure 51. Preset Mode Recipe Configuration per Laser Mode CW MODE Network Settings Page To access the Network Settings webpage, click on the Settings tab. The Network Settings page enables the user to view or change the TCP/IP settings for the device. See Figure 52 [▶...

  • Page 139: Product Support Page

    Downloads folder. The name of the downloaded file will be: dict_values_download_serialnumber.bin. Should you experience technical issues with your device, please provide your Miller support representative: (1) a screen shot of this page, (2) the downloaded binary file.

  • Page 140: Buzzer Setup - Advanced Settings

    Computer Connection to Device Buzzer Setup - Advanced Settings For instructions on accessing the device webpage refer to section 9.3 [▶131]. 1. Click the + button on the bottom right of the main user webpage to expand the Advanced Settings section of the webpage. 2.

  • Page 141: User Program Data - Advanced Settings

    Computer Connection to Device User Program Data - Advanced Settings 9.8.1 Creating User Program Data File The user is allowed to upload their own program data to the device. User must first create their program table using a standard CSV (comma separated values) file.

  • Page 142: Pulse Shape Generation - Advanced Settings

    Computer Connection to Device ▼Figure 54. Advanced Feature - Uploading User Program Data ① ② ④ ③ Pulse Shape Generation - Advanced Settings Users can generate up to ten unique pulse shapes that can be selected by the pulse wave number (programs using PULSED, HPP or ADV STITCH laser mode). Each pulse shape consists of six points - four unique points, plus the starting point, and the ending point.

  • Page 143: Creating Pulse Shape Files

    Computer Connection to Device When a different pulse shape is requested the CPU reads the points of the selected shape. It then converts the point units from percentages to proportional values of time period (x-axis) and laser power (y-axis). Once the points are converted the rest of the pulse shape can be derived by interpolating between each point.

  • Page 144: Figure 57 Advanced Feature - Uploading Example User Pulse Wave Shapes

    Computer Connection to Device 1. Click the + button on the bottom right of the page to expand the Advanced Settings section of the webpage. 2. Go to Pulse Shape File section under Advanced Settings, press the Choose file button to upload your created shape file. Follow the on screen prompts and dialogs to select your pulse shape file.

  • Page 145: Configure Misc. Settings - Advanced Settings

    Computer Connection to Device 9.10 Configure Misc. Settings - Advanced Settings For instructions on accessing the device webpage refer to section 9.3 [▶131]. 1. Click the + button on the bottom right of the main user webpage to expand the Advanced Settings section of the webpage. 2.
  • Page 146 Computer Connection to Device ➤ The range of the purge time setting is 0 to 998 seconds, with a default value of 60 seconds. Setting the purge time to 999 will keep purge gas on infinitely (replicating legacy operation from older firmware). 5.

  • Page 147: Reseller Setting Lock Unit - Advanced Settings

    ➤ User will be asked to input the 4 digit activation code and then click Set Lock button to confirm the lock. This is the code that was provided to user after successful completion of the Miller safety webinar. Once locked the unit cannot be used and must be unlocked again. Refer to section 2.10 [▶59].

  • Page 148: Locking Device Front Panel Controls

    Computer Connection to Device 9.12 Locking Device Front Panel Controls For instructions on accessing the device webpage refer to section 9.3 [▶131]. 1. Click the + button on the bottom right of the main user webpage to expand the Advanced Settings section of the webpage. 2.

  • Page 149: Test Settings - Advanced Settings

    Computer Connection to Device 9.13 Test Settings - Advanced Settings Test Mode is used by advanced users for testing and calibration purposes. Special tools, meter and/or fixtures are required. Contact Miller Customer Support for more information on using this mode. DANGER Class 4 invisible radiation during Test Mode.
  • Page 150 Computer Connection to Device ➤ Banner at the top of the webpage will indicate that laser device is operating in Test Mode. 3. Operator must press the Trigger 1 switch followed by Trigger 2 switch to turn the emission on. After one emission cycle, Test Mode is automatically disabled.

  • Page 151: Enabling The Cobot Option

    2. Go to Test Settings section under Advanced Settings and click the Cobot Enabled button. ➤ The user will be prompted to input the Miller provided key. ➤ If successful, the background color of this button will change to orange.
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  • Page 153: Troubleshooting

    3. Reboot Using Keyswitch: A small subset of these alarms can only be cleared by rebooting the unit. If the condition that caused it was not resolved, the alarm is likely to occur again. If this is the case, contact Miller Service for assistance.
  • Page 154 Fuse 1 allowable threshold (there is too much power in the external fiber). This is a critical error that must be addressed. Contact Miller for assistance. Er07 Fiber Second Internal fiber fuse photodiode Trigger 1 Control or “Clear Alarms”...
  • Page 155 Troubleshooting ▼Table 35. Welder Status Alarms Bit Table (Continued) Code Type of Description How to Clear Error? Alarm Er11 Interlock Malfunctioning Interlock Safety Loop. Power off and on the unit with the Malfunction Monitors key signals, remote start and keyswitch, E-Stop or AC power cord. “all safe”...
  • Page 156 Troubleshooting ▼Table 35. Welder Status Alarms Bit Table (Continued) Code Type of Description How to Clear Error? Alarm Er22 Trigger 1 While emission was ON, the Trigger 1 Trigger 1 Control or “Clear Alarms” Shutdown interlock opened which resulted in the laser being shutdown (e.g.During welding the operator released the Trigger 1 gas control on the torch).

  • Page 157: Maintenance

    Maintenance A Maintenance WARNING ELECTRIC SHOCK can kill Touching live electrical parts can cause fatal shocks or severe burns. The input power circuit and machine internal circuits are also live when power is on. Incorrectly installed or improperly grounded equipment is a hazard. WARNING Invisible class 4 laser radiation when the OptX device is energized Risk of permanent skin or eye damage and vision impairment from invisible direct,...

  • Page 158: Protective Window Replacement

    This can damage the torch. This will also alter the specifications and performance of the device.  For safe and reliable operation only use an Miller supplied protective window. Only the Miller protective window will have the correct specifications and coating specifically designed to work with the laser inside the device.

  • Page 159: Figure 58 Disengaging Window/Nozzle Assembly

    Maintenance ▼Figure 58. Disengaging Window/Nozzle Assembly 5. Flip open the cap to access the protective window underneath. Users should inspect the new protective window for contamination prior to installing it. Use CDA to blow any dust or debris off the new protective window. Replace the protective window and securely close cap (Figure 59 [▶...

  • Page 160: Focus Lens Replacement

    Maintenance ▼Figure 61. Reattach window/nozzle assembly - Align Balls with Circular Cutouts Align Ball with Groove ➤ Turn nut as shown to lock assembly in place (Figure 62 [▶ 160]). ▼Figure 62. Reattach window/nozzle assembly - Turn Nut to Lock Assembly End of Procedure A.1.2 Focus Lens Replacement 1.

  • Page 161: Wearing Of Safety-Related Components

    Maintenance ▼Figure 64. Lens Cell Replacement - Pull out damaged Lens Cell and Replace ③ ④ 5. Align the red dots on the nozzle assembly with the red dot on the head. See Figure 65 [▶ 161]. 6. Push the nozzle assembly over the ball bearings and twist to lock in place. See Figure 65 [▶...

  • Page 162: Replacing The Torch

    Contact local Miller Service to have the torch returned for switch replacement or exchanged (refer to section B.1 [▶171]). The replacement of the torch switches is only to be performed by Miller service personnel. A.1.4 Replacing the Torch Personnel Qualifications: Maintenance Personnel (see section 1.4 [▶19]).

  • Page 163: Connect/Disconnect Fiber Output

    Maintenance 11. Re-install the netted sheathing that was removed from the umbilical cable in step 3. 12. Turn on gas supply. 13. Power up the welding system. ▼Figure 66. Disconnecting Torch ② ① Item Designation Item Designation Electrical Connection Gas Tubing Connection A.2 Connect/Disconnect Fiber Output Personnel Qualifications: Maintenance Personnel (see section 1.4 [▶19]).

  • Page 164: Disconnect Fiber Output

    Maintenance NOTICE Fiber cable terminator contamination The quartz block is very delicate and must stay perfectly clean. Any contamination will result in serious damage to the fiber cable. See section 3.6 [▶72].  Always wear clean nitrile gloves when disconnecting fiber from torch. ...

  • Page 165: Figure 69 Pulling Out Fiber Connector From Torch

    Maintenance ▼Figure 69. Pulling out fiber connector from torch 5. Leave protective cap installed over quartz block. Install storage sleeve. Never touch the protective cap window or quartz block optical surfaces. These surfaces must remain clean. 6. Close the welding head with a protective cap. ▼Figure 70.

  • Page 166: Connecting Fiber Cable To Torch

    Maintenance A.2.3 Connecting Fiber Cable to Torch IMPORTANT Must read and follow precautions in section A.2.1 [▶163] before beginning this procedure. 1. Remove power from the device. 2. Before reconnecting the fiber to the torch, the technician must first perform the cleaning procedure (section A.3 [▶167]) on the fiber output quartz block.

  • Page 167: Output Termination Cleaning Procedure

    NOTICE  The use of a dirty or improperly cleaned output fiber termination can lead to serious damage to the unit. Miller is not responsible for any damages due to contaminated output fiber termination. Custom fiber terminations may require a different procedure.

  • Page 168: Cleaning The Quartz Block (Generic Procedure)

    Maintenance ▼Figure 71. Recommended Cleaning Supplies (not included) A.3.2 Cleaning the Quartz Block (Generic Procedure) IMPORTANT It is imperative that you wear powder free rubber gloves during this cleaning procedure. Perform the following procedure to clean the fiber output termination: 1.

  • Page 169: Figure 72 Isopropanol On Lens Tissue

    Maintenance ▼Figure 72. Isopropanol on lens tissue ▼Figure 73. Lateral wipe across surface IMPORTANT Do not let the areas where your fingers have touched the tissue come into contact with the surface being cleaned. 8. Re-inspect the surface 9. Repeat step 7 with Acetone if it is still contaminated. 10.
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  • Page 171: Service And Support

    Email: PWSService@millerwelds.com If you cannot resolve the issues by using this Owner’s Manual or over the telephone with our technical support group, you might need to return the product to Miller. Refer to section C.1 [▶175] for more details. B.1.1 Accessing Product Support Webpage Scanning the QR code specified on the yellow safety label on the front of the unit will take you to the “OptX Safety Information”...

  • Page 172: Remote Troubleshooting With Teamviewer

    Owner’s Manual and Process Mode Chart. B.1.2 Remote Troubleshooting with TeamViewer Should remote troubleshooting with the Miller Customer Service department be needed: 1. Connect a PC via Ethernet to the welder as described in section 9.1 [▶127]: Computer Connection to Device.

  • Page 173: Figure 77 Teamviewer License Agreement Dialog

    Service and Support ▼Figure 77. TeamViewer License Agreement Dialog 6. A pop-up window will appear. Supply the generated ID and Password to the Miller support team (see Figure 78 [▶ 173]). ▼Figure 78. Teamviewer Connection ID and Password OM-296747A | 4/15/24...
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  • Page 175: Product Returns

    3. All requests for repair or replacement under this warranty must be made to Miller within 30 days after discovery of the defect (but not later than 7 days after warranty expiration). 4. All products returned to Miller but which meet applicable specifications, not defectively manufactured or used not in accordance with this Owners Manual, will result in the Buyer being charged Miller’s standard examination charge.
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  • Page 177: Glossary

    Glossary D Glossary SI UNIT PREFIX USED (e.g. cm for centimeter) T = tera (10 k = kilo d = deci (10 µ = micro (10 f = femto (10 G = giga (10 h = hecto (10 c = centi (10 n = nano (10 M = mega (10 da = deca (10...
  • Page 178 Glossary European Union is a political and Personal Protective Equipment economic union of 27 member states that are located primarily in Europe. European Norm Quartz Block Head Foreseeable Exposure Limit Quasi-Continuous wave (operating mode) High Peak Power (laser operating mode) Root mean square or quadratic mean International Electrotechnical Transmission control protocol...

  • Page 179: Index

    Index Index Accessories List Ethernet ....... … 61 Advanced Settings Connection .
  • Page 180 Index Tip Selection Label Locations ....... … 107 ......… 35 Laser Controlled Area Door Interlocks .
  • Page 181 Index Web Page Interface Laser Welder Page ......… 132 Main Access Page ......… 131 Network Settings Page .
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  • Page 183 Effective January 1, 2024 (Equipment with a serial number preface of NE or newer) This limited warranty supersedes all previous Miller warranties and is exclusive with no other guarantees or warranties expressed or implied. • RFCS Foot Controls (Except RFCS-RJ45)

  • Page 184: Owner's Record

    Appleton, WI 54914 USA tact your distributor and/or equipment manu- facturer’s Transportation Department. International Headquarters–USA USA Phone: 920-735-4505 USA & Canada FAX: 920-735-4134 International FAX: 920-735-4125 For International Locations Visit www.MillerWelds.com ORIGINAL INSTRUCTIONS – PRINTED IN USA © Miller Electric Mfg. LLC 2024-0...

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