THEO MA1 Series User Manual

Handheld laser welding machines

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USER GUIDE

THEO MA1 Series | Handheld Laser Welding Machines

REVISION: V1.2

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Page 1 USER GUIDE THEO MA1 Series | Handheld Laser Welding Machines REVISION: V1.2 ©COPYRIGHT2024 THEO LASER INC Page 1 of 125...
Page 2: Disclaimer
Disclaimer THEO strives to ensure that the information in this User Guide is accurate and reliable. However, no warranty or representation, expressed or implied, is made regarding the content of this document. This includes, without limitation, any implied warranty of merchantability or fitness for a particular purpose, whether used alone or in combination with other devices, equipment, materials, or processes.
Page 3: Copyright Notice
THEO, Maxphotonics, and the THEO and Maxphotonics logo are registered trademarks of Maxphotonics Co., Ltd. Their use is governed by trademark law. THEO does not grant any rights to patents or other intellectual property mentioned in this document.
Page 4: Preliminary Note
82205 Gilching, Germany Website: http://theo.inc This guide is intended for all owners and operators of THEO equipment, as well as individuals working near the product during operation. Usage of this product is restricted to fully trained professional and non-professional welding operators.
Page 5: Preface
Preface Thank you for choosing THEO's handheld laser welding products. This User Guide has been created to assist you in using and maintaining the laser effectively. While we have made every effort to ensure the accuracy of the information in this document, occasional oversights may occur. We appreciate your understanding and welcome any suggestions for improvement.
Page 6: Invitation To Theo Academy
THEO Academy is an online learning platform designed to provide operators with essential training on the safe use and maintenance of THEO laser welding equipment. It offers a range of video tutorials and instructional materials covering topics such as laser safety, machine setup, and operational best practices.
Page 7: Table Of Contents
DISCLAIMER ..............................2 COPYRIGHT NOTICE ............................3 PRELIMINARY NOTE ............................4 PREFACE ................................5 INVITATION TO THEO ACADEMY ........................6 Online Laser Welding Safety and Training......................... 6 TABLE OF CONTENT ............................7 CHAPTER 1 PRODUCT INFORMATION ......................10 CHAPTER 2 GENERAL SAFETY INFORMATION....................11 1 - Safe Usage of Handheld Laser Welding Machines ....................
Page 8 1. Features ................................. 41 Key Features: ......................................41 Applications:......................................41 2. Module Configuration ............................42 3. Laser Model overview and Safety Features ......................43 4. Certificate of Assurance ............................44 5. Front and Back Panel Description of Laser Welding Machine ................45 5.1.
Page 9 Parameters Library:................................110 Customize: ......................................112 (4) Setting interface ................................115 HHW Settings: ..................................... 115 Laser Setting: ....................................... 118 (5) System Information ...............................121 MACHINE INFORMATION:................................121 COMPANY PROFILE ............................123 Introduction ................................123 About THEO ..................................123 About Maxphotonics ................................124 Page 9 of 125...
Page 10: Chapter 1 Product Information
Introducing the MA1 Series: High-Efficiency, High-Reliability, Maintenance-Free High-Power Lasers from THEO The MA1 series by THEO offers a high-performance, efficient, and reliable range of lasers designed for a variety of applications. Utilizing phase transition heat dissipation technology, these lasers feature a wavelength range of 1070 nm to 1090 nm, with an approximate wall plug efficiency of 30%.
Page 11: Chapter 2 General Safety Information
OD rating of 6 or higher before operating a handheld laser welding machine. Always follow proper safety protocols to minimize the risk of injury. For more detailed information and training on laser welding safety, please visit THEO Academy (https://academy.theo.inc), where you can access comprehensive resources on safe laser operation and best practices.
Page 12 IMPORTANT • Always avoid looking directly at the fiber output connector and ensure that you are wearing appropriate protective eyewear while using the laser to prevent potential eye injuries. • Refrain from opening the laser device as there are no parts or accessories intended for user access inside.
Page 13: 2-Safety Conventions
2-Safety Conventions As shown in the following table, all safety warning signs (not limited to those affixed to the laser body) during the operation of the handheld laser welding machine include: SAFETY SIGNS NAME DESCRIPTION Warning: Text marked with electrical warning symbol Electrical hazard indicates potential personal danger.
Page 14 The symbol indicates that personnel must wear Wear protective gloves laser - and heat-resistant protective gloves. The symbol indicates that personnel must wear Wear protective clothing protective sleeves and outerwear against laser exposure and heat. The symbol indicates that personnel must put on the helmet against laser and heat.
Page 15: 3-Laser Protection Measures
THEO provides these names for convenience only, without endorsing or recommending any specific supplier, product, or service. Furthermore, THEO assumes no responsibility for the advice, products, or services provided by these suppliers. Page 15 of 125...
Page 16: 4-Welding Feature Safety
For all personnel in the laser-controlled area, THEO recommends wearing personal protective equipment, including IR safety glasses and helmet shield devices, to protect the eyes from any reflected or scattered laser beam as well as welding strong light, ultraviolet light and heat and sparks.
Page 17: Cylinder Safety Measures
(3) Use a respirator in confined spaces or other situations where it may be required. (4) Conduct regular air monitoring to determine the level of noxious fumes in the welding area. 5. Cylinder Safety Measures A gas cylinder poses a risk of explosion if it is damaged or situated close to the welding zone. To ensure safety, place shielding gas cylinders in a secure location where they are not susceptible to impact or damage, and maintain distance from sources of heat, sparks, or flames.
Page 18: Important Safety Notice For Outbound Security Indicators
6. Important Safety Notice for outbound Security Indicators: IMPORTANT: • It is crucial to be aware that when the power supply (PS) is activated, the laser is in a hazardous state. Every necessary precaution must be taken to prevent accidental exposure to direct and reflected beams. Both diffuse and specular reflections can lead to severe retinal or corneal damage, potentially causing permanent eye damage.
Page 19 WARNING • . Never attempt to perform service on the laser power supply or torch optics past the protective window. If required, contact THEO technical support for service. Unauthorized alterations to this product will void the warranty. WARNING •...
Page 20: Secondary Radiation Hazard
8. Secondary radiation hazard During the welding process, both visible and invisible light radiation are generated. The interaction between the high-power laser beam and the target material being welded can result in the production of ultraviolet (UV) light and plasmas that emit "blue light." This radiation can lead to various health issues, such as conjunctivitis, photochemical damage to the retina, and sunburn-like reactions on the skin.
Page 21: Precautionary Measures For Welding Protection And Minimizing Risks In Welding Processes
9. Precautionary Measures for Welding Protection and Minimizing Risks in Welding Processes WARNING • To safeguard your eyes from harmful conditions during welding, it is crucial to wear appropriate personal protective equipment! Employing a combination of a mask, gloves, welding helmet, and laser safety glasses can effectively mitigate most process and environment related hazards while welding.
Page 22: Dangers Of Reflected Beam In Welding Process
WARNING • While welding, be mindful of potential hazards and take the appropriate precautions. Ensure that all combustible and flammable materials are kept at a safe distance from the welding area, as heat and sparks produced during welding may result in fires or explosions. Limit laser welding operations to designated areas free of combustible materials.
Page 23: Hazard Of Welding Smoke
To ensure safety and proper shielding gas coverage, equipment operators are advised to use only the round-tipped nozzle tips. For the part number of THEO nozzle tip kit. Refer to the table in Figure 6-1. Replacement nozzle tips can be purchased as needed.
Page 24 WARNING: BEWARE OF THE DANGERS OF INHALING WELDING SMOKE! • Welding "smoke" contains a mixture of fine particles and gases that are created during the welding process. This smoke originates from the materials being welded, filler materials, shielding gases, coatings, paints, chemical reactions, and air pollutants.
Page 25: Cylinder Safety
12. Cylinder safety WARNING • Be cautious that gas cylinders may explode if damaged or located close to the welding zone. It is crucial to protect and position them in a secure area, away from potential hazards such as impact damages, heat, sparks, or flames.
Page 26: Optical Safety
13. Optical Safety WARNING • Please be cautious of the following optical safety measures: The laser output is transmitted through a window. Ensure that these windows are clean free of damage. Any dust on the head assembly may cause damage to both the window and the laser. Any variations in laser power (the ability to produce and/or maintain a weld pool) should warrant an inspection of the protective window.
Page 27 WARNING • While operating a laser, NEVER look directly into the output port. • Ensure that the laser and all associated optical components are not placed at eye level. • Refrain from utilizing lasers in dimly lit surroundings. • No matter what, some type of solid light proof enclosure must surround the laser welding area during operations.
Page 28: Equipment And Solvents
14. Equipment and solvents WARNING • Please note that the photosensitive components within the equipment, including the camera, photomultiplier tube, and photodiode, may suffer damage from laser exposure. Understanding proper tool positioning and how laser reflections work will allow operators to avoid potentially damaging the unit while performing ordinary welding applications.
Page 29: Electrical Safety
15. Electrical safety WARNING • Ensure that all electrical and welding gas connections are properly connected and secured the appropriate hardware before powering on the unit. The input voltage to the laser can be lethal, and all cables, connectors, and equipment enclosures should be treated as hazardous.
Page 30: Environmental Safety
Many byproducts of laser processing can be toxic and pose additional safety risks. It is crucial to remove these fumes from the workspace using an extraction system. • For general information about laser products, please visit the THEO official website. Page 30 of 125...
Page 31: Reference Standard
In compliance with EU and national standards and requirements, lasers must be categorized based on their output power and wavelength. • All MA1 series laser products fall under Class 4 classification, as per EN 60825-1, Chapter 8. Page 31 of 125...
Page 32: General Safety Instructions
WARNING • The output laser intensity of THEO handheld laser welding machine can weld metal, burn skin, clothing, and paint, and ignite volatile substances like alcohol, gasoline, and ether. During operation and use, make sure to isolate flammable items around the handheld laser welding machine.
Page 33: Optical Handling Precautions
(7) Operate the equipment strictly according to the instructions provided in this document; otherwise, the protective devices and performance of the equipment may be compromised, and any and all warranties will be voided. THEO will not be held responsible for any damages or injuries incurred by unapproved use of this machine.
Page 34 • Exercise caution around any heat or molten metal fumes that may be generated during the operation of the handheld laser welding machine. WARNING • Select appropriate safety protection equipment based on the laser output power and wavelength requirements. • Never look down into the aperture of the gun, and always wear IR rated safety glasses when the machine is powered on.
Page 35: Electrical Operating Guidelines For The Handheld Laser Welding Machine
4. Electrical operating Guidelines for the Handheld Laser Welding Machine THEO strongly advises you to carefully read the following operating instructions before using the handheld laser welding machine: (1) Ensure that the machine's electrical ground cable is securely fastened to the machine and work surface;...
Page 36: Operating Environment Requirements For Handheld Laser Welding Machines
The corresponding operators need to go through certain assessment and training and be familiar with and master the general safety regulations of laser operation. While not required by law, THEO encourages all end users of our handheld laser tools to attend and complete a Laser Safety Officer (LSO) certification course.
Page 37 NOTICE: • Handle the equipment with care to prevent accidental damage. • Periodically clean the filter at the bottom of the laser to remove dust debris from the air inlet. Page 37 of 125...
Page 38: 7-Additional Safety Information
7-Additional Safety Information For more information on laser safety and corresponding jurisdictional standards where applicable please refer to the following resources: Laser Institute of America (LIA) 13501 Ingenuity Drive, Suite 128 Orlando, Florida 32826 Phone: 407 380 1553, Fax: 407 380 5588 Toll Free: 1 800 34 LASER American National Standards Institute ANSI Z136.1, American National Standard for the Safe Use of Lasers (Available through LIA) International Electro-technical Commission IEC 60825-1, Edition 1.2...
Page 39: Important Safety Information
8 - Important Safety Information 1. LASER RADIATION Laser exposure can lead to severe retinal or corneal damage, resulting in permanent eye damage and potential skin damage. Adhere to safety protocols to avoid accidental exposure to invisible direct or reflected beams. operate the system within the designated laser control area only. 2.
Page 40 All users within the laser control area must read the entire user guide and completebasic laser safety and unit operation training before use. Keep your head away from smoke during welding, and always use a fume extraction system to remove vapors, particles, and harmful debris from the welding area.
Page 41: Chapter 3 Product Description
Chapter 3 Product Description 1. Features The hand-held laser welding machine offers a highly integrated and efficient solution for various applications. This compact and user-friendly device combines the laser, welding torch, and control system to deliver outstanding performance compared to traditional hand-held welding equipment. KEY FEATURES: (1) Highly integrated and compact design (2) Excellent ergonomics for ease of use...
Page 42: Module Configuration
2. Module Configuration THEO offers multiple configuration options for tailored solutions. Detailed information about each mode can be found in Chapter 6 "Usage Guide" of this manual. Page 42 of 125...
Page 43: Laser Model Overview And Safety Features
3. Laser Model overview and Safety Features MODEL MODEL CODING RULES MA1-XX In d ic a te s the pe ne tr a tio n c ap a ci ty of THEO Handheld Laser Welding: X.Xmm for stainless steel Product Functional Safety Electrical safety...
Page 44: Certificate Of Assurance
THEO after-sales team. As you unbox this product, please handle it with care to prevent any damage or cracking to the fiber optic cables.
Page 45: Front And Back Panel Description Of Laser Welding Machine
5. Front and Back Panel Description of Laser Welding Machine 5.1. Front Panel Description: (Left: MA1-35; Right: MA1-45&MA1-65) FRONT PANEL NAME DESCRIPTION ACTIVE/ALARM Normal working status (Green light) abnormal alarm status indicator (Red light) Standby, no laser output status (red and green lights flash alternately) Emergency stop switch Emergency stop equipment work Key switch...
Page 46: Back Panel Description: (Left: Ma1-35; Right: Ma1-45&Ma1-65)
5.1. Back Panel Description: (Left: MA1-35; Right: MA1-45&MA1-65) REAR PANEL NAME DESCRIPTION ON/OFF 200-240VAC AC power switch EX-CTRL External control interface (For Safety & Cobot) RS232 Welding platform RS2 3 2 interface POWER 200-240VAC AC power input FEEDER Wire feeder interface GAS_IN Protective gas inlet port Page 46 of 125...
Page 47 Page 47 of 125...
Page 48: Rs232 Interface Description
The laser welding machine's external control port utilizes an RS232 interface (DB9) and an EX-CTRL interface (DB25), with the following interface descriptions: 5.2. RS232 Interface Description PIN# DESCRIPTION RxD Serial data input TxD Serial data output Page 48 of 125...
Page 49: Ex-Ctrl Description (Security Interface) (Db25)
5.3. EX-CTRL Description (Security interface) (DB25) (Note: Bold font is the basic function, the other functions are optional for the Cobot) PIN # SIGNAL NAME TYPE FUNCTIONALITY EX-CTRL+ External Start (Optional Function) External control Laser Emission ON/OFF; when voltage is high ( 2 4 V) , Laser Emission is ON.
Page 50: Torch Instructions
6. Torch Instructions DESCRIPTION Laser Trigger Button Contact Tip Extension Tube Protective Window Subassembly Focus Lens Status Indicator Feed Wire Switch The welding head's indicator light displays various working states. A successful communication between the welding head and the laser, coupled with a normal functioning of the equipment, results in a yellow indicator light.
Page 51 MA1 Welding Torch (Optics) Page 51 of 125...
Page 52: Precautions For Welding Gun Angle
NOTICE: • Please pay attention to the following when using the welding head: The welding head serves as the point of contact during welding operations. Ensure that the contact tip of the welding gun or, for wire assist processes, the end of the filler fire with guide beam visibly centered on the wire is in direct contact with the workpiece to establish a proper interlock feedback loop before proceeding with any welding operations.
Page 53 (2) As shown in the diagram, when welding, multiple reflections should be taken into consideration, and proper safety precautions should be taken. Page 53 of 125...
Page 54: Welding Torch Indicator Light Description
(3) As shown in the diagram, during welding, improper welding gun angles should be avoided to prevent damage to the gun head. WELDING TORCH INDICATOR LIGHT DESCRIPTION INDICATOR COLOR ILLUSTRATE Yellow blinking Standby Mode – ready to fire (weld) Green solid Process beam firing (unit is welding) Fault State –...
Page 55: Chapter 4 Specification
Chapter 4 Specification 1. Optics Characteristic Parameters CHARACTERISTICS TEST CONDITIONS MIN. NOM. MAX. UNIT Operation mode CW/Modulated Polarization Random 1000 1200 The ambient output 100% CW temperature 1400 1500 is 26℃/79 deg F Power Tunability 1080 Central wavelength 100% CW Electro-optical efficiency 10-100% Linear fitting Spectral bandwidth...
Page 56 5.6 meters/18.4 feet MA1-45&MA1-65 Bending radius of 200m optical fiber armored m/ 7.9 cable Output form QCS integrated with the torch Continuous light output Light 120S, stop 6S time (S) Page 56 of 125...
Page 57: General Characteristic Parameters
2. General Characteristic Parameters CHARACTERISTICS TEST CONDITIONS MIN. NOM. MAX. UNIT Operating Voltage 100% output/MA1-35 Input Power 100% output/MA1-45 100% output/MA1-65 operating Ambient ℃ Temperature Operating Ambient Relative Humidity Laser cooling method Phase change heat dissipation Cooling method of tip Nitrogen and argon cooling ℃...
Page 58: Structural Layout
3. Structural Layout MA1-35 LASER THREE VIEWS. (UNIT: MM) Page 58 of 125...
Page 59: Ma1-45 & Ma1-65 Laser Three Views. (Unit: Mm)
MA1-45 & MA1-65 LASER THREE VIEWS. (UNIT: MM) Page 59 of 125...
Page 60: Chapter 5 Disassembly Guide
4. Be particularly careful when unpacking software packages. To minimize the risk of equipment damage, THEO strongly recommends reviewing these instructions in their entirety. 2. Delivery And Transportation The carrier's information and details should be prominently displayed on the shipping package, although it should be noted that this information may not always be accurate.
Page 61 1) Lift the box 2) Takeout the welding head and accessories CAUTION: • Do not use cable accessories to lift or move equipment. Page 61 of 125...
Page 62: Chapter 6 Operation Guide
N=0VAC, and PE=ground. Verify that the wiring is correct before operating the machine, and never neglect the PE connection. For enhanced safety, THEO strongly recommends connecting a 32A circuit breaker (air switch) in series between the power supply and the laser. Ideally, position the power supply near the device's power supply unit for easy disconnection.
Page 63: Electrostatic Grounding Process
3. Electrostatic Grounding Process It is essential to ensure a secure and reliable connection between the laser housing's grounding nut and the ground using a grounding wire, in order to prevent any potential damage to the laser due to static electricity. As illustrated in the wiring diagram: Attach one end of the grounding wire to the ground stud.
Page 64: Securely Lock The Connection
4. Securely Lock the Connection Ensure a Secure Connection Before Activating the Laser Prior to switching on the laser, it is crucial to attach the safety lock to the loop interface of the laser device. During laser preparation, fasten the other end of the safety lock (alligator clip) onto the workpiece or immediate work surface.
Page 65: Device Connection Diagram
Device Connection Diagram Page 65 of 125...
Page 66: Wire Feeder Instructions And Installation Guide
6. Wire Feeder Instructions and Installation Guide Introducing the THEO Welding Wire Feeding System, launched in 2022. This innovative system features our independently researched and developed control system and provides users with convenient filler-assisted welding options across all processes. The versatile multifunctional wire feeder is fully compatible with THEO’...
Page 67: Specifications And Characteristics Of The Wire Feeder
3. Specifications and Characteristics of the Wire Feeder: Size: 580mm×360mm×244.5mm FEATURES: (1) The device offers laser coupling, a dual driving force mechanism, a closed-circuit board design, and a robust cold rolled plate shell for enhanced efficiency and durability. (2) Supports wire feeding/drawing speeds ranging from 2 to 100mm/s, offering both continuous and pulse wire feeding options, allowing for the aesthetically pleasing, tacked- coin appearance of TIG welding beads.
Page 68: General Definition Of Circuit Connection
4. General definition of circuit connection CONNECTION DEFINITION 1 ，2 pins Connect to power +24V 3 pins Signal input/low level is active 4 pins Connect to the power GND 5 pins Shell PE 6 pins Enter RX for the serial port 7 pins Serial port output TX Page 68 of 125...
Page 69: External Wiring Method For Wire Feeder
5. External wiring method for wire feeder 6. Installing Wire Spool and Wire Feed Wheel Page 69 of 125...
Page 70 1. As illustrated in the figure, remove the fixing nut from the rotary wire feeding platform, place the welding wire spool onto the platform, and securely fasten the fixing nut back onto the platform. 2. Refer to the figure demonstrating the assembly of the wire feeding wheel. Lower the two red handles, remove the fixing screws of the two wire feeding wheels, and take out the wheel to be replaced.
Page 71: Installation Of Wire Feeding Tube
7. Installation of Wire Feeding Tube 1.INTERFACE OF WIRE FEEDER 1. Connect the communication wire of the wire feeder (left side) as shown in the above diagram (with the red point of the wire plug aligned to the upward direction of the parent). Connect the other end to the wire feeding interface of the MA1 unit.
Page 72: Wire Feeder And Torch Connection
8. Wire Feeder and Torch Connection Comprehensive Assembly Diagram (1) Secure the wire feed tube Insert the wire guide tube into the push-in connector Wire Feed Tube Assembly Page 72 of 125...
Page 73: Adjust The Wire Feed Frame Position
(2) Attach the wire feeder Assemble the wire feeder securely to ensure proper functioning (3) ADJUST THE WIRE FEED FRAME POSITION First, determine the length of the welding gun barrel to establish the welding focal point. Then, adjust the wire feed tip to align with the center of the wire groove in the contact tip. Lastly, adjust the length of the wire feeding tube so that the wire feed nozzle is close to the welding copper nozzle.
Page 74: Wire Feed Frame And Hand Welding Connection
9. Wire Feed Frame and Hand Welding Connection 1. Power Button: This button signifies the power control for the wire feeder. When activated, a red light will illuminate, indicating that the wire feeder is powered on. 2. Manual Wire Feeding Button: This button is used to toggle manual wire feed, typically during daily troubleshooting or maintenance procedures.
Page 75: Maintenance And Troubleshooting Of Wire Feeders
10. Maintenance and Troubleshooting of Wire Feeders 1. CHECK REGULARLY: Regular Inspections: Before using the wire feeder, ensure to examine the following components for any damages: (1) Control cables and their connectors (2) Linked MA1 Power supply and functionality of the wire feeding button (3) Switch locking mechanism 11.
Page 76: Selecting The Appropriate Wire Feeder And Welding Tip
Selecting the Appropriate Wire Feeder and Welding Tip: When it comes to wire-assisted welding, it's essential to choose a contact tip with a proper wire slot to ensure accurate welding wire position and smooth wire feeding. Page 76 of 125...
Page 77 WIRE FEED NOZZLE 0.8-1.6MM Wire feed speed may be adjusted under Wire Feeder Settings in the Advanced Options menu of the MA1 UI. Ensure wire feeder mechanisms are configured and aligned properly whenever changing filler wires or if there are inconsistencies in wire feed rate. Page 77 of 125...
Page 78: Startup Steps For Laser Operation
12. Startup Steps for Laser operation WARNING • Ensure all electrical connections (including protective gas and grounding) have been adequately connected before usage. It is recommended to tighten and secure all connectors with screws whenever possible. • NEVER look at the laser outlet during operation. Always wear appropriate safety gear such as protective laser safety eyewear, soundproof earplugs if necessary, and masks before operating the laser.
Page 79 (10) Perform a dry run with the visible guide beam before firing the process laser. This is a good opportunity to visualize your own approach to welding the joint and adjust wobble width to match joint width if necessary. Press and hold the torch trigger to fire the process beam.
Page 80: Welding Process Parameters
13. Welding Process Parameters HHW WELDING PROCESS PARAMETER TABLE Wobbl Wobble Power Welding Thickness Defocus Gas Flow Material Frequency Performance Form (mm) (mm) (L/min (mm) (Hz) Stitch 60~80 -1~1 15~20 Penetration Carbon Steel Stitch 60~80 -1~1 15~20 Penetration (Q235B) Stitch 100%/D2 1.5-2 50~70...
Page 81 The welding form is splicing welding, welding head ratio of 60:120,800 W laser fiber core Remark diameter of 20 microns. Shielding gas: steels - nitrogen (purity 99.99%), other materials - argon (purity 99.99%); The power percentage is 10-100%, the wobble width is 0-4mm (2-3mm is recommended), the wobble frequency is 0-220hz (40-80hz is recommended for manual welding, and the gas flow rate is 15- 20L/min 25 - 40 CFH).
Page 82 HANDHELD LASER WELDING PROCESS PARAMETER TABLE - WIRE FEEDING ER5356 12~18 40~80 1~-1 15~20 Aluminum 0.8-1.0 Penetration Aluminum alloy alloy ER5356 (Al6061) 12~15 100%/D2 40~80 1~-3 15~20 Aluminum Penetration alloy Remark The welding form is splicing welding, welding head ratio of 66:120,800 W laser fiber core diameter of 20 microns.
Page 83: How To Use The Fish Scale Function
14. How To Use the Fish Scale Function METHOD 1: ENABLE THE FISH SCALE PATTERN ON THE HOME PAGE The fish scale pattern has built-in default parameters, so you don't need to set them. Simply turn on the switch: 1. Firing time: 150ms 2.
Page 84 Note: When using the pulse mode for the wire feeder, set the laser light output to continuous mode. Page 84 of 125...
Page 85: Product Accessory Inspection And Cleaning Guide
THEO warranty. • Please wear powder-free gloves or finger cots when cleaning the product in a dust-free environment. THEO is not responsible for tip damage due to improper operation or incorrect cleaning procedures. • When cleaning, the concentration of alcohol should be equal to or greater than 99.5%.
Page 86: Cleaning Steps Follow These Procedures To Clean And Maintain The Laser Welding Machine
2. CLEANING STEPS FOLLOW THESE PROCEDURES TO CLEAN AND MAINTAIN THE LASER WELDING MACHINE. Page 86 of 125...
Page 87: Protective Windows
PROTECTIVE WINDOWS The most common wear item to fail is the protective window in the torch. Regularly inspect the protective window and ensure its’ cleanliness and integrity. Laser welding with a dusty or damaged protective window may cause damage to the welding torch hardware and optics and degrade welding quality.
Page 88 • Position the cotton swab on the dust location on the lens • Gently wipe the dust with the swab, moving it towards the edge of the lens, and discard the swab after use. • Gently wipe the front of the lens with a clean cotton swab or clean cloth dipped in alcohol. •...
Page 89: Replace Focus Lens Instruction
Replace Focus Lens Instruction First, prepare 1 piece of new focusing lens, alcohol, cotton swabs, lint-free cloth, finger cots, patterned paper, and a Phillips screwdriver. 1. Prepare the tools. 2. Remove the nut above the protective lens. 3. Install the removed nut into the upper hole of the focusing lens drawer. 4.
Page 90 5. Slowly pull out the nut from the focusing lens drawer 6. After pulling out the focusing lens, place the drawer aside 7. Cut a suitable amount of patterned paper to seal the gun body of the focusing lens to prevent dust from entering.
Page 91 10. Remove the old focusing lens to be replaced. 11. Install the new focusing lens, ensuring that the convex side of the lens faces downward. 12. After installing the plug seal, gently press with your finger to secure it in place. 13.
Page 92 15.Tighten the two screws with a Phillips screwdriver to secure it. 14.Install the cleaned focusing lens drawer back into the gun body. 16. The focusing lens replacement is complete. Page 92 of 125...
Page 93: Chapter 7 Service And Maintenance
If the product is beyond the warranty period or outside the warranty scope, customers will be responsible for any repair costs. CHANGE: THEO reserves the right to modify the design or structure of our products, and the information is subject to change without notice. Page 93 of 125...
Page 94: Service Statements
For further inquiries, please contact the Customer Service Department. Our technical support team will verify and address your concerns. If the problem remains unresolved, you may need to return the product to THEO for further troubleshooting. Page 94 of 125...
Page 95: Chapter 8 Warranty Statement
Warranty Statement 1. General Provisions THEO Lasers Inc and Maxphotonics Co., Ltd. provides a warranty for any defects in its products resulting from materials and manufacturing processes during the warranty period agreed upon in the contract. We ensure that our products meet the relevant quality and specification requirements outlined in the documentation under normal usage conditions.
Page 96 IMPORTANT NOTICES: • Purchasers must report any product defects to THEO within 31 days of discovery to be eligible for warranty coverage. • THEO does not authorize any third party to repair or replace parts, equipment, or other THEO products.
Page 97: Chapter 9 Operation Gui Description
Chapter 9 Operation GUI Description The machine features a 7-inch touchscreen that is connected to the host via the UART interface. This connection enables equipment control and status monitoring functionalities. 1. Startup safety instructions Upon first use, a detailed safety notice page will be displayed. It is important to carefully read and understand the safety notice.
Page 98: Operation Interface
2. Operation Interface The operation interface offers two modes: Basic mode and Expert mode. (1) Basic mode operating in Basic mode is straightforward. Simply select the appropriate material, plate thickness, and welding mode. Then, click Laser Enable button. If all components of the machine are functioning correctly, you can begin welding.
Page 99 When in Basic mode, click Laser Enable button. A pop-up window will appear, indicating that the laser has been activated and protective gear must be worn. Please ensure safety precautions and click confirm to officially start the device. Page 99 of 125...
Page 100: Expert Mode
(2) Expert mode The expert mode operation interface enables advanced welding settings and detailed configurations. Expert mode consists of four sub-interfaces: Home, Status, Warning, and Details. HOME Here, you can set the Wobble Width, Laser Power, and Wobble Frequency. Tapping the input box in the middle of the dial will display a numeric keypad, allowing you to enter the desired values.
Page 101 FUNCTIONAL FUNCTIONAL REMARK CLASSIFICATION 1 . When power is ≥ 9 0 % , D + can be opened; 1-2gear adjustable, D mode (only for the same power under the maximum power of 2 gear MA1-35) 2. When power is 11% ≤ power ≤ 49%, D- can be opened and -1 and -2 gears are adjustable Wire feed Wire feed can be enabled or disabled.
Page 102: Status
STATUS This interface displays the current gas pressure and optics temperature. It also provides information about the machine's working status, giving you real-time updates on its performance. FUNCTIONAL FUNCTIONAL REMARK CLASSIFICATION The numerical Gas pressure Indicates the current guard gas pressure. state The lens Indicates the current gun optics temperature.
Page 103: Warning
FUNCTIONAL FUNCTIONAL REMARK CLASSIFICATION Green: The gun switch is down. Gray: The gun switch is not Torch Switch down WARNING In this interface, you can view any alarm information generated by the machine. It alerts you to any issues or potential problems that may require attention or troubleshooting. FUNCTIONAL FUNCTIONAL REMARK...
Page 104 FUNCTIONAL FUNCTIONAL REMARK CLASSIFICATION When the environment around the machine reaches the set low temperature alarm value, the low temperature alarm will light temperature Laser emergencies stop alarm, please check E-Stop whether press the emergency stop switch, confirm the correct contact after-sales treatment. The pressure of the protective gas is not normal.
Page 105: Details
FUNCTIONAL FUNCTIONAL REMARK CLASSIFICATION Torch PD Voltage V- Forward PD V-Backward PD DETAILS: This interface provides a comprehensive display of the detailed parameters currently set in Expert mode. It allows you to view and modify these parameters according to your specific requirements. NOTE: •...
Page 106 In editable mode, you can make changes to the parameters. After editing, click the "Save" button to save the changes. The edited document will be stored in the parameter customize library for future reference. To access the wire feeding parameter setting interface, click the "Wire Feeding Setting" button. This will allow you to modify the wire feeding parameters as needed.
Page 107 NOTE: • Modifying the wire feeding parameter settings requires a successful connection between the machine and the wire feeder. This connection is necessary to complete the parameter modification process. Page 107 of 125...
Page 108: Specifications
FUNCTIONAL FUNCTIONAL REMARK CLASSIFICATION SPECIFICATIONS The light mode includes three kinds: continuous, shooting and pulse. Continuous: output laser continuously. Shooting: a single laser output. Pattern Light Mode Pulse: output pulse laser continuously according to the duty Adjustment cycle. orange: Wire feeding is synchronized with laser. Wire Feed White: Wire feeding is not performed in mode.
Page 109 FUNCTIONAL FUNCTIONAL REMARK CLASSIFICATION SPECIFICATIONS Set wire CW: continuous wire feeding feeding Pulse: Intermittent wire feeding according to the set pulse parameters period Set the wire feed speed (this function only works with its Wire feed speed own wire feed head) Withdraw Speed Set the pumping speed;...
Page 110: Parameters Library
The process parameters interface consists of two sub-interfaces: Parameters Library and Customize. Parameters Library: This section provides four pages where you can store up to 32 welding process parameter sets (recipes).. This feature allows you to easily switch between parameter sets to accommodate various welding applications.
Page 111 When in editable mode, you can click on any blank space within the interface. This will allow you to make changes to the parameters as needed. once you have made the desired modifications, click 'Save' in the pop-up prompt box. If you wish to modify the name of the parameter document, click on the blank space within the name box.
Page 112: Customize
FUNCTIONAL FUNCTIONAL REMARK CLASSIFICATION SPECIFICATIONS The process library surface comes with 32 sets of process Process parameters, so that customers can use them in different Parameters or So Pages situations. Click any parameter document to enter the parameter detail interface, where the specific parameters of the parameter document are Parameter displayed.
Page 113 To enter edit mode and make changes to the parameters, click on any blank space within the interface. This will enable both reading and writing capabilities for the parameters. After making the desired modifications, click 'Save' in the pop-up prompt box. If you wish to modify the name of the parameter document, click on the blank space within the name box.
Page 114 If the storage for parameters is already full, modifying a file and clicking 'Save As' will prompt a pop-up box. At this point, you can change the existing name to "EMPTY" to clear that particular process entry. Page 114 of 125...
Page 115: Setting Interface
(4) Setting interface To access the setting interface, first click on the "Config" interface. A pop-up box will appear, prompting you to enter the login password. 1. The Config Interface is displayed only after entering the password successfully. 2. In case of a password input error, the box will display the message: "Login password error, please check and try again!"...
Page 116 FUNCTIONAL FUNCTIONAL NOTE CLASSIFICATION SPECIFICATIONS The user can customize the full power correction of external control. The parameter can be set Power from 1 to 4095. Note: Clicking the Restore Factory Settings Calibration button cannot reset this data. The user can customize the full wobble profile in conjunction with the galvanometer.
Page 117 FUNCTIONAL FUNCTIONAL NOTE CLASSIFICATION SPECIFICATIONS Target output Displays the target output voltage of the machine in the current voltage state. Click factory reset, the machine reset data, restore to Factory Reset other factory Settings data Page 117 of 125...
Page 118: Laser Setting
LASER SETTING: This screen contains a series of Settings for reference points and alarm points. Page 118 of 125...
Page 119 FUNCTIONAL FUNCTIONAL NOTE CLASSIFICATION SPECIFICATIONS Users can customize the overcurrent reference voltage. The overVolt value ranges from 0.00V to 5.00V. Note: Clicking Factory Reset button cannot reset this data. Permitted The user can customize the number of continuous optical lock, Backward the parameter can be set range: 1-20;...
Page 120 FUNCTIONAL FUNCTIONAL NOTE CLASSIFICATION SPECIFICATIONS The user can customize the temperature alarm value of the pump source plate, and the parameter can be set within the range of 0-100℃; This value is followed by an Enable button. Pump board Temp When this item is enabled, the button is on.
Page 121: System Information
(5) System Information There is an information interface called the System Information interface. This interface consists of two sections: Machine Information and Normal Information. MACHINE INFORMATION: The Machine Information section primarily displays important details about the machine, such as its version information and business-related data.
Page 122 FUNCTIONAL FUNCTIONAL NOTE CLASSIFICATION SPECIFICATIONS Model The machine model HW Version Hardware version number of the machine MCU Version Machine firmware version number Torch S/N Head serial number (unique number for each head) Mainboard S/N Machine Serial number (unique number of each host) Complete machine version number Laser Version Machine...
Page 123: Company Profile
Introduction About THEO Theo Laser Inc. is at the forefront of transforming the welding industry with cutting-edge laser technology, built on a foundation of innovation, quality, and safety. We are committed to empowering professionals by enhancing their craftsmanship and productivity, while minimizing the barriers to entry in advanced welding techniques.
Page 124: About Maxphotonics
• Production Scalability: With an annual capacity exceeding 200,000 units, Maxphotonics is equipped to meet growing market demands. Maxphotonics provides Theo with a robust foundation for manufacturing, development, and service excellence. Headquartered in Shenzhen, China, Maxphotonics maintains a strong global presence, enabling rapid responses to customer needs and close collaboration with industrial partners.
Page 125 Quality and Certifications Maxphotonics is committed to delivering world-class quality products and services. With stringent quality control procedures, the company has achieved certifications such as ISO 9001, CE, and RoHS, reflecting its dedication to international quality standards. Research and Development (R&D) Maxphotonics continuously invests in R&D to drive technological advancements and product innovation.

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