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WARPP ROCI WELD 1500 Operation And Maintanance Manual

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OPERATION & MAINTANANCE MANUAL
MODEL – ROCI WELD - 1500
LASER WELDING SYSTEM
WARPP ENGINEERS PVT.LTD.
Survey No. 36, House No. 15/3, Unique Industrial Estate
Dhumal Nagar Vasai (East) Dist. Palghar (Maharashtra) INDIA
PIN -401208
Tel: 8551817744 / 8551819944 / 8551817868 - 69 / 8551812002
Customer Care Tel: 8080808734
Email:
service@warpp.co.in
Website:
www.warpp.co.in

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  • Page 1 OPERATION & MAINTANANCE MANUAL MODEL – ROCI WELD - 1500 LASER WELDING SYSTEM WARPP ENGINEERS PVT.LTD. Survey No. 36, House No. 15/3, Unique Industrial Estate Dhumal Nagar Vasai (East) Dist. Palghar (Maharashtra) INDIA PIN -401208 Tel: 8551817744 / 8551819944 / 8551817868 - 69 / 8551812002...
  • Page 2 The machine has been carefully inspected both mechanically and electrically before it left the factory. The machine should be initially inspected upon receipt, if any damage which may have occurred in transit inform “WARPP ENGINEERS PVT.LTD. OR It’s Dealer immediately. Check for the accessories supplied against those listed in packing slip.
  • Page 3 INDEX 1. Safety Precautions 2. Product Features 3. Technical Specification 4. Installation 5. Controls 6. Parameters & its operational meaning 7. How to operate the machine 8. Trouble Shooting 9. Maintenance 10. Spare Part List 11. Chiller...

  • Page 4: Safety Precautions

    Safety Precautions General safety precaution: • Strictly comply with the rules and procedures defined in this manual to avoid accidents and equipment malfunctions. • Follow proper rules for connecting to the power supply and selecting the working area. • Do not allow non-operators to enter the working area under any circumstances.
  • Page 5 Preventing from fire, explosion, and container break accidents: • Do not store flammable materials in the working area, as hot spatter and welds can easily start a fire. • Rigidly connect cables to the workpiece to ensure good conductivity and prevent fires caused by resistance heat.
  • Page 6 Noise Prevention The corresponding measures shall be specified or explained and observed to ⚫ prevent personnel from being harmed by noise when the cutting air pressure is high. Storage and Transportation Observe the storage temperature range as per the technical data. ⚫...
  • Page 7 Air Inlet and Outlet There should be over 1.5m left between the air outlet of chiller and the obstacle, and over 1m left between the air inlet on the side of chiller and the obstacle, as shown below. Cooling Water •...

  • Page 8: Product Features

    1.2. Check before operation. (1) whether the connection of pipeline is correct, without bubbling and water leakage. (2) whether the water outlet is closed. (3) check the water tank level. (4) confirm that the electric circuit of the device is correctly connected. (5) check whether the device is grounded.

  • Page 9: Installation

    Installation • Place the machine in the room where there is no straight sunlight, no rain, less dust, low humidity and temperature range of 0° - 50°C. • The gradient of ground must not be more than 15°. • Connect Input supply to the machine. Supply voltage must be in the range of 230V ±...
  • Page 10 Fig. 5.3: wire feeding adapter block 3. Tighten the wire feeding fixing block with M4 * 3 screw. The feeding distance can be adjusted by stretching out and drawing back the feeding tube, as shown in figure 5.4. wire feeding fixing Fig.
  • Page 11 Fig. 5.5 4.2. Handheld Laser Welding Head Structure of the Handheld Welding Head Please replace the following accessories in a clean place to avoid dust. 4.2.1. QBH Connection 1. The structure of QBH interface on the handheld welding head is shown below Fig.
  • Page 12 2. Remove the dust cover of optical fiber and check whether the protective cap of fiber crystal head is locked. Clean the optical fiber head with a dust-free cotton swab and absolute ethanol to ensure that the optical fiber section is clean and dust-free, as shown in fig. 4.2. Fig.
  • Page 13 4.2.4. Daily Inspection • Check whether the cover glass is polluted before daily use and replace it if necessary. • Check whether the QBH connector is loose before daily use and ensure that the lock does not shake before it can work normally. •...
  • Page 14 4.3. Wire Feeder 4.3.1. Installation of Wire Feeder The two 24V input wires of the wire feeder shall be connected to the 24V power supply or switching power supply of the laser welding machine (power supply power ≥ 80W). The two signal wires SS1 and SS2 shall be connected to the relevant positions on the handheld welding controller, as shown in figure 5.2.
  • Page 15 Fig. 5.3 Fig. 5.4 Select the groove diameter of the wire feeding wheel. Loosen the ⚫ tension regulator of the wire feeding machine (as shown below) and pass the welding wire through the wire leading nozzle. Align it with the groove of the wire feeding wheel and tighten the tension regulator.
  • Page 16 Fig. 5.9 Adjust the tension regulator to enable the stable wire feeding. ⚫ Deliver the wire to wire feeding nozzle by manual feeding. 5. Controls 5.1. Front View:...
  • Page 17 Button and Indicator: HMI: Human Machine Interface. ⚫ Main Power: turn on clockwise and turn off anticlockwise. ⚫ Chiller: to power on chiller. Self-lock button. Power on chiller by pressing ⚫ and power off chiller by re-pressing. Laser: to power on laser. Self-lock button. Power on laser by pressing and ⚫...
  • Page 18 5.2. Back View: Button and Indicator: • Power Supply of Wire Feeder: power supply to and control of the wire feeder. • Power of wire feeder: supplies to the wire feeder. • MCB: for protection and manual switching. • Power: AC 230V single phase power supply from mains. •...
  • Page 19 6. Parameters & its operational meaning 6.1. Operation of Wire Feeder Fig. 5.10 switch functions. Relevant parameters could be modified by rotating stepless knob, which can also change feeding speed in feeding status. rotate to modify parameters when relevant indicator lights up. press to start wire feeding and release to stop wire feeding.
  • Page 20 lights up when power on. lights up when the wire feeder fails. switch function button to display relevant parameters. (display feeding speed in working status) 6.1.1. Parameter Setting Item Range Unit Recommended Value Delay Feeding 0-500 Feeding Speed 5-100 mm/s Retract Speed mm/s Retract Distance...
  • Page 21 6.2. Chiller 6.2.1. Sequence Of Operation For Liquid Chillers ITEMS ACTIONS REMARKS Step 1 a) Check all electrical connections are tight. Initial b) Check the supply voltage is within b) Shall be within checks permissible limits. c) Check the entire refrigerant & liquid circuit valves are open.
  • Page 22 6.2.2. Temperature Controller Setting MAIN FUNCTIONS : HOW TO SEE THE SETPOINT 1. Push and immediately release the SET key : the display will show the Set Point value. HOW TO CHANGE THE SETPOINT 1. Push the SET key for more than 2 seconds to change the set point value.
  • Page 23 6.2.3. Standard Controls 1. [HP] high pressure This is a manual reset type pressure controlled electromechanical device used as a safety cutout against high discharge pressure of the refrigerant. The reset button is located on the hp/lp switch. [LP] low pressure This is an automatic reset type pressure controlled electromechanical device used as safety cutout against low suction pressure.
  • Page 24 8. Water level low In chillers with in-built tank the float switch aids in maintaining an optimum level in the tank. The whole system comes to a halt as the water level goes low and an indication on the reset push button is generated on the panel. As the water level is made up &...
  • Page 25 6.3. Daily Maintenance of Wire Feeder 6.3.1. Daily Maintenance: • When not in use, the wire feeder should be shut down and placed in a cool, dry place away from dust. • Do not put other objects on the wire feeder to avoid damage. •...
  • Page 26 6.4. Supplementary Regulation of Auto Wire Feeding Turn on the wire feeding on HMI panel. ⚫ Adjust the power to 0W. ⚫ Press and hold the trigger button of head, adjust the wire feeding speed ⚫ at low speed (feeding speed 015-025). According to the tightness of wire feeding, turn the two adjustable rotation sleeves of tension regulator until the wire disc rotates at a uniform speed (it must be ensured that the wire feeding tube is...
  • Page 27 7. How to operate the machine 7.1. Initial Power On The first use of the new machine can be carried out according to the following steps: 1. Open the package and check whether the machine is intact and whether the accessories are complete.
  • Page 28 working conditions, do not start and shut down frequently. 7. Check the water level of the water tank . After the new machine is started, the air in the water pipe is drained, and the water level in the water tank will drop slightly.
  • Page 29 7.2. 7.2.1. Home (RAYTOOLS LOGO): entry of multi-function switching. The details of options are illustrated below. Laser Power: laser output power from 0 to 1500W. ⚫ Pattern: Spot Weld or Line Wobble Weld. ⚫ Laser Freq: number of laser pulses emitted by the laser per second. ⚫...
  • Page 30 7.2.2. Setting 7.2.2.1. Basic Setting Gas in Advance: gas blow duration from laser on to beam shooting. ⚫ Gas Delay: gas blow duration after laser off. ⚫ Beam Off Delay: laser shooting duration after laser off. It is used to weld ⚫...
  • Page 31 7.2.2.2. Galvo Setting Wobble: turn on/off wobble function of red beam. It is only used for ⚫ commissioning of red beam. Pattern: line or spot. ⚫ Wobble Size: 0-5mm of adjustable line range. ⚫ Wobble Freq: 0-200Hz adjustable as per process. ⚫...
  • Page 32 7.3. Process • to switch between wire feeding and non-wire feeding. • Process No: running process number. Each process parameter could be modified and saved. • Import: importing selected process number for operation. • Shutdown-save: to save modified process by clicking this button. •...
  • Page 33 I0.3 Safety Lock: indicate if head is in contact with workpiece. Laser ⚫ shooting is allowed when in contact. I3.0 Galvo IO: input status. ⚫ Q0.2 Laser Enable: output status of laser enable signal. ⚫ Q0.4 Gas Valve: output status of gas valve. ⚫...
  • Page 34 ⚫ About: show hardware version like HMI panel, laser control card and galvo motion card. 7.6. About Each generation of products from us has corresponding supporting versions for control and traceability. This will correspond to versions of HMI panel, laser control card and galvo motion card. Version upgrade shall be subject to our confirmation.
  • Page 35 7.7. Multi-function 7.7.1. Cutting 7.7.1.1. Configuration ▪ Handheld laser cutting is one of 3-in-1 function, as shown in the figure 8.1. ▪ Remove wire feeding mechanism & welding nozzle and mount the cutting nozzle to extension tube. ▪ Screw the nozzle into its holder as the direction shown in the figure. ▪...
  • Page 36 7.7.1.3. Software Setting 1. Home Laser Power: laser output power from 0 to 1500W. ▪ Laser Freq: number of laser pulses emitted by the laser per second. ▪ PWM: the ratio of pulse duration to pulse cycle, 0-100%. ▪ Laser: turn on/off laser. Turn on before use and keep closing when it is not ▪...
  • Page 37 2. Basic Setting Gas in Advance: gas blow duration from laser on to beam shooting. ⚫ Gas Delay: gas blow duration after laser off. ⚫ Beam Off Delay: laser shooting duration after laser off. It is used to melt ⚫ possible adhesion or burr.
  • Page 38 3. Galvo Setting X Center Offset: center alignment. Beam alignment is basically to ⚫ be done before ex-works and a further slight adjustment to align with cutting object center could be done if it is required for cutting. Random adjustment is prohibited. X Magn: it is to be debugged before ex-works and a further slight ⚫...
  • Page 39 7.7.2. Weld Seam Clean 7.7.2.1. Configuration Handheld weld seam laser cleaning is one of 4-in-1 function. ⚫ Remove wire feeding mechanism, welding nozzle and extension tube. ⚫ Mount the clean tube. Screw in and tightly lock the clean tube as the ⚫...
  • Page 40 7.7.2.3. Software Setting • Home • Laser Power: laser output power from 0 to 2000W. • Laser Freq: number of laser pulses emitted by the laser per second. • PWM: the ratio of pulse duration to pulse cycle, 0-100%. • Wobble Freq: 0-150Hz. •...
  • Page 41 • Basic Setting • Gas in Advance: gas blow duration from laser on to beam shooting. • Gas Delay: gas blow duration after laser off. • Max Power: set as per the rating power of exact laser. The limit of max power is 1500W.
  • Page 42 • Galvo Setting ▪ Wobble: turn on/off wobble function of red beam. It is only used for commissioning of red beam. ▪ Pattern: only line available for cleaning. ▪ Wobble Size: 0-10mm of line range. ▪ Wobble Freq: 0-150Hz adjustable as per process. ▪...
  • Page 43 7.7.3. Remote Clean - optional 7.7.3.1. Configuration Handheld remote cleaning for this handheld head matching function, as shown in figure 8.3, please in a clean environment, with inner hexagon spanner fixed together two of the focal lens drawer round head screws removed, carefully remove the focus lens, drawer again careful remote cleaning lenses drawer, immediately remove the mouth clamp components, according to the direction of graphic change cleaning tube, then according to the direction of rotation lock...
  • Page 44 7.7.3.3. Software Setting • Home ▪ Laser Power: laser output power from 0 to 1500W. ▪ Laser Freq: number of laser pulses emitted by the laser per second. ▪ PWM: the ratio of pulse duration to pulse cycle, 0-100%. ▪ Wobble Freq: 0-100Hz. ▪...
  • Page 45 • Basic Setting ▪ Gas in Advance: gas blow duration from laser on to beam shooting. ▪ Gas Delay: gas blow duration after laser off. ▪ Max Power: set as per the rating power of exact laser. The limit of max power is 1500W.
  • Page 46 • Galvo Setting ▪ Wobble: turn on/off wobble function of red beam. It is only used for commissioning of red beam. ▪ Wobble Size: 0-80mm of line range. ▪ Wobble Freq: 0-100Hz adjustable as per process. ▪ X Center Offset: center alignment. Beam alignment is basically to be done before ex-works and a further slight adjustment to align with cleaning objects could be done if it is required for cleaning.

  • Page 47: Troubleshooting

    8. Trouble Shooting 8.1. Troubleshooting of Wire Feeder Faults Reason Solution 24V power cable breaks Change power cable Power LED not ON Power switch fails Change power switch Poor welding / disconnection of Replace the plug and check internal wire inside switch plug of the connecting wire welding head Wire feeding motor fails...
  • Page 48 8.2. Other troubleshooting Faults Description Solution Communication alarm of HMI panel Poor wiring Check wiring and restart after 2 mins. 1. Restart. 2. Check wiring. 3. Check if laser is encrypted. 4. Check QBH for firm lock status if fiber interface interlock is Laser alarm under alarm.
  • Page 49 9. Maintenance Interval Item Purpose 1.Check whether the temperature setting of the chiller is Ensure that the cooling water normal temperature supplied to the laser is normal 2.Check whether the water channel seal, water temperature Ensure the normal operation of the and water pressure of the chiller meet the requirements equipment and prevent water leakage 3.The working environment of the chiller shall be dry,...
  • Page 50 10. Spare Part List...

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