Amada ML-5020BW User manual

AA04OM1208535-06
OPERATION MANUAL
DIRECT DIODE LASER
ML-5020BW

2ML-5020BW
How to Use This Document
Thank you for purchasing our Direct Diode Laser ML-5020BW.
This operation manual explains its method of operation and precautions for use.
Before using, read this operation manual carefully; after reading, save it in a proper
place for your future reference.
This document is composed of the 4 parts of "Introduction Part", "Installation and
Preparation Part", "Operating Part", and "Maintenance Part", and "Appendixes."
We recommend inexperienced users to read through the whole contents starting from
"Introduction Part."
This document allows the user to understand the whole equipment image, basic
conguration, and how to use the laser.
Experienced users can refer to the desired page from the table of contents.
Organization of This Document and Its Contents
Introduction Part: Explains the outline and functions of the laser. Regarding the
Direct Diode Laser, this part explains the basic configuration and
functional outline of this product including options so that the user
can know the conguration of the laser and equipment composition,
and also the name and function of each component section.
Installation and
Preparation Part:
Explains the installation of the laser and preparatory operations
such as connections of its respective sections.
Operating Part: Explains how to operate the laser processing. First, this part
explains how to perform each setting and how to operate the laser.
Two types of control (Control by the control panel and control by
external input/output signals) are explained in the operating method
for laser processing.
Maintenance Part: Explains how to perform maintenance and how to handle trouble.
Appendixes: For reference materials, specications, dimensional outline drawing,
timing chart, and list of terminology are available. In the output
schedule data entry table, the user can enter registered laser output
schedule data for use.

3
ML-5020BW
Contents
How to Use This Document ..............................................2
For Use in Safety ......................................................5
Safety Precautions ..............................................5
Precautions for Handling ................................................8
Laser Safety Supervisor ..........................................8
Routine Handling ...............................................8
For Transportation ..............................................9
For Packaging..................................................9
For Disposal ...................................................9
Cautions for Export....................................................10
Introduction Part 11
Chapter 1 Overview of the Direct Diode Laser ......................13
1. Direct Diode Laser ..................................................13
2. Mechanism of the Direct Diode Laser ...................................14
3. Functions of the ML-5020BW..........................................15
4. Product Composition ................................................16
Packaging ....................................................16
Checking the Packaged Products..................................16
Chapter 2 Name and Functions of Each Section ....................19
1. Name and Function of Each Section on the Front Side ......................19
Front Cover Section ............................................19
Control Panel .................................................20
2. Name and Function of Each Section on the Rear Side ......................21
Installation and Preparation Part 23
Chapter 1 Installation ..........................................25
1. Installation Place ...................................................25
Space Required for Installation....................................26
Environment Suitable for Installation and Precautions ..................26
2. Fixing the Laser Equipment ...........................................27
Chapter 2 Connections and Preparations of Each Section............29
1. Connecting the Power Supply .........................................29
2. Connecting the Optical Fiber ..........................................30
3. Connecting the Cable for the Heat Detector ..............................32
Operating Part 33
Chapter 1 Control Method, and Start and Stop .....................35
1. Control Method.....................................................35
Switching the Control Method.....................................35
2. Start and Stop .....................................................36
How to Start the Laser ..........................................36
How to Stop the Laser ..........................................36

4ML-5020BW
Chapter 2 Various Settings......................................37
1. Setting Welding Schedules. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37
Welding Schedule Setting Screen .................................37
SCH 1 Screen.................................................38
SCH 2 Screen.................................................39
MONITOR Screen. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42
COUNTER Screen .............................................42
SYSTEM Screen...............................................43
LD Screen....................................................44
Chapter 3 Laser Processing by Control Panel (PANEL) ..............47
1. Operation Flow .....................................................47
2. Control Panel Functions ..............................................48
3. Operating Procedure ................................................49
Chapter 4 Laser Processing by External Input/ Output Signals (EXT)...53
1. Operation Flow .....................................................53
2. Preparations for Operations ...........................................54
3. Connector Functions ................................................55
Pin Arrangement and Functions ...................................55
Example Connections of External Input/Output Signals .................61
Maintenance Part 63
Chapter 1 How to Perform Maintenance ...........................65
NOTE ..............................................................65
1. Cleaning the Cover Hole .............................................66
Chapter 2 Inspection and Measure To Be Taken at Occurrence of an Error ..67
1. Error Display and How to Take a Measure................................67
2. Troubles not Displaying Fault Code .....................................69
Appendixes 71
Specications ........................................................73
Dimensional Outline Drawings ...........................................75
Timing Chart .........................................................76
Ready Signal .................................................76
Laser Output ..................................................76
Error Occurrence ..............................................77
Explanation of Terminology .............................................78
Output Schedule Data Entry Table ........................................81
Index ........................................................82

For Use in Safety
5
ML-5020BW
For Use in Safety
Safety Precautions
Before using, read "Safety Precautions" carefully to understand the correct
method of use.
These precautions are shown for safe use of our products and for prevention of dam-
age or injury to operators or others. Be sure to read each of them, since all of them
are important for safety.
A meaning of a gure sign
Denotes operations and practices that may imminently result in
serious injury or loss of life if not correctly followed.
Denotes operations and practices that may result in serious injury or
loss of life if not correctly followed.
Denotes operations and practices that may result in personal injury
or damage to the equipment if not correctly followed.
Denote "prohibition."
They are warnings about actions out of the scope of the warranty of
the product.
Denote actions which operators must take.
Denotes caution for electrical shock.
Do not touch the inside of the Laser unnecessarily.
Since source voltage of or single-phase 100 V to 220 V AC is applied to
the Laser, high voltages are applied to its inside. Do not touch the inside
of the Laser unnecessarily with the power turned ON.
Never disassemble, repair or modify the Laser.
These actions can cause electric shock and re. Do not do anything other
than the maintenance described in the operation manual.
Do not look at or touch the beam.
Both direct laser beams and scattered laser beams are highly dangerous.
If the beam enters the eye directly, it can cause blindness.
Never burn, destroy, cut, crush or chemically decompose the Laser.
This product incorporates parts containing gallium arsenide (GaAs).
Do not look into or reach into the light path while the LD is turned on.
Fluorescence emission can cause burn or blindness.
Wear protective glasses while the LD is turned on.
DANGER
WARNING
CAUTION
DANGER

6ML-5020BW
For Use in Safety
Wear protective glasses.
Be sure to wear protective glasses having an optical density of at least
7 while using the Laser. Even if you wear them, you may lose your sight
if the laser beam enters your eyes directly through protective glasses.
Protective glasses attenuates the laser beam, but does not block it.
Do not expose your skin to the laser beam.
Your skin may be severely burnt.
Do not touch any processed workpiece during and just after processing
nished.
The processed workpieces are very hot.
Use only specied cables.
Use of a cable of insu󰀩cient capacity or loose connection can cause
electric shock re.
Do not damage the power cable or connecting cables.
Do not tread on, twist or tense any cable. The power cable and connecting
cables may be broken, and that can cause electric shock and re. If any
part needs to be repaired, consult us or your distributor.
Stop the operation if any trouble occurs.
Continuous operation after occurrence of a trouble such as burning smell,
abnormal sound, abnormal heat, smoke, etc. can cause electric shock and
re. If such a trouble occurs, immediately consult us or your distributor.
Ground the Laser.
If the Laser is not grounded, you may get an electric shock when there is
trouble or electricity leaks.
Use a stopper.
The laser beam is dangerous to human bodies. Prevent emission through
the air by using a stopper (a heat-resistant, laser beam-absorbing,
-scattering material).
Persons with pacemakers must stay clear of the Laser.
Those who use a pacemaker must not approach the Laser or walk
around the processing shop while the Laser is in operation, without being
permitted by his/her medical doctor. The Laser generates a magnetic eld
and has e󰀨ects on the operation of the pacemaker while it is turned ON.
WARNING

For Use in Safety
7
ML-5020BW
Do not splash water on the Laser.
Water splashed over the electric parts, can cause electric shock and short circuits.
Use proper tools (wire strippers, pressure wire connectors, etc.) for
termination of the connecting cables.
Do not cut the wire conductor. A re or electric shock will occur.
Install the Laser on a rm and level surface.
If the Laser falls or drops, injury may result.
Do not place a water container on the Laser.
If water spills, insulation of the Laser will deteriorate, and that can cause
electric leaks and re.
Keep combustible matter away from the Laser.
Surface ash and expulsion can ignite combustible matter. If it is impossible
to remove all combustible matter, cover it with non-combustible material.
Do not apply the laser beam to combustible materials.
To avoid risk of re never apply the laser beam to ammable or
combustible materials.
Do not cover the Laser with a blanket, cloth, etc.
Do not cover the Laser with a blanket, cloth, etc. while you are using it.
The cover may be overheated and burn.
Do not use this Laser for purposes other than metal processing.
Use of the Laser in a manner other than specied can cause electric shock
and re.
Protective gear must be worn.
Put on protective gear such as protective gloves, long-sleeve jacket, leather
apron, etc. Surface ash and expulsion can burn the skin if they touch the skin.
Keep a re extinguisher nearby.
Keep a re extinguisher in the processing shop in case of re.
Maintain and inspect the Laser periodically.
Maintain and inspect the Laser periodically, and repair any damage before
starting operation.
CAUTION

8ML-5020BW
Precautions for Handling
Precautions for Handling
Laser Safety Supervisor
⇒Appoint a safety supervisor for all laser work.
The appointed safety supervisor must have su󰀩cient knowledge and experience
regarding both lasers and laser work.
⇒The supervisor must control the keyswitch of the Laser, and must be responsible
for instructing operators in safety aspects of the Laser as well as directing the
laser work.
⇒Establish and control a laser operation area.
The responsible person must isolate the laser operation area from other areas
and control it by fences and display signs indicating that the area is o󰀨-limits to
unauthorized personnel.
Routine Handling
⇒Perform inspection periodically referring to the Maintenance Part, Chapter 1 "1.
Cleaning the Cover Hole" on page 64.
⇒If the outside of the Laser is stained, wipe it with a dry cloth or a moistened cloth.
If it is badly stained, use neutral detergent or alcohol to clean it. Do not use paint
thinner, benzine, etc. which can discolor or deform the parts.
⇒Do not put screws, coins, etc. in the Laser, since they can cause a malfunction.
⇒Operate the switches and buttons carefully by hand. If they are operated roughly
or with the tip of a screwdriver, a pen, etc. they may be broken.
⇒Operate the switches and buttons one at a time. If two or more of them are oper-
ated at a time, the Laser may have trouble or may be broken.
⇒To restart the Laser, ensure that the Laser stops before turning ON the MAIN
switch.
⇒To prevent damage, do not bend the optical ber beyond its minimum bending
radius (xed part: 35 mm, movable part: 50 mm) or apply any forms of shock to
it.
⇒When a supervisor or operator enters the area where the laser is used, protective
measures not to exceed the MPE* level must be taken.
* MPE: The maximum level of permissible exposure of the eyes or skin to laser beams. Abbreviation of
Maximum Permissible Exposure.
⇒Use the product in a place where the ambient temperature is 20 to 30ºC and the
ambient humidity is 20 to 85% RH and yet a sudden temperature change does
not occur.
* For other information on managing laser equipment or the MPE level, refer to the follow-
ing standards.
Japanese Industrial Standards JIS C 6802 “Safety of Laser Products”
Notication by the Ministry of Labor No. 0325002 “Laser Damage Prevention Mea-
sures”

Precautions for Handling
9
ML-5020BW
For Transportation
When transporting the laser, observe the following precautions to avoid haz-
ards.
⇒Package the Laser when transporting it.
⇒The worker must wear a helmet, safety shoes and gloves for safety. (Leather
gloves are recommended.)
⇒When transporting the Laser, use a lift truck, pallet truck, etc., of at least 30 kg al-
lowable load.
Precautions for transportation
⇒Transport it using a dedicated package to prevent a fall, damage due to vibration.
For Packaging
Precautions for packaging
⇒The worker must wear a helmet, safety shoes and gloves for safety. (Leather
gloves are recommended.)
For Disposal
This product incorporates parts containing gallium arsenide (GaAs). At the time of
disposal, separate it from general industrial waste or domestic waste and carry out
the disposal in accordance with applicable laws and regulations.

10 ML-5020BW
Cautions for Export
Cautions for Export
The product described in this Operation Manual falls into a controlled item specied
in the Foreign Exchange and Foreign Trade Law.
When exporting the product from Japan, you need approval based on the said law.
For details, please visit the Security Export Control’s website or contact the Security
Export Licensing Division, Ministry of Economy, Trade and Industry directly.
Security Export Control’s website of Ministry of Economy, Trade and Industry
http://www.meti.go.jp/policy/anpo/index.html
Security Export Licensing Division, Ministry of Economy, Trade and Industry
Phone: [phone]

Introduction Part

1. Direct Diode Laser
13
ML-5020BW
Introduction Part Installation and
Preparation Part Operating Part Maintenance Part Appendixes
Chapter 1
●Overview of the Direct Diode Laser
1. Direct Diode Laser
Laser means the equipment to generate powerful light by amplifying light
(electromagnetic wave) or means this light itself. In direct diode laser, diode laser (LD)
can be applied to the heat processing directly without passing through a crystaline
body such as YAG and YVO4.
The laser wavelength generated in this laser equipment is 915 nm of near infrared
rays that are invisible to the human eye. Most of laser equipment for laser
processing belongs to class 4 laser that is the most hazardous in the classication
of laser products specied in JIS. When the laser light greets the eye, it is focused
by crystalline lens and reaches the retina, thereby inviting a loss of eyesight. Do
not look at the laser light in any case. Because both beams and scattered light are
hazardous, do not touch or look at them.
To check where invisible laser is irradiated on the workpiece, red guide light is
generally mounted in the laser equipment. When the output unit is provided with a
CCD camera, cross lines are generally displayed on the monitor and the cross point
of these cross lines is an irradiation point. In this laser, a red point appears on the
workpiece when guide light is output.
Introduction Part
Chapter 1 Overview of the Direct Diode Laser

14 ML-5020BW
2. Mechanism of the Direct Diode Laser
2. Mechanism of the Direct Diode Laser
The direct diode laser consists of a power supply, light source, optical ber, output
unit, etc. Laser light can be transferred to a place remote from the main unit by opti-
cal ber, so that only the optical ber and output unit can be mounted in the manufac-
turing line for processing.
Direct Diode Laser Conguration
Output unit
Workpiece
FC-LD
Power supply
Optical ber

3. Functions of the ML-5020BW
15
ML-5020BW
Introduction Part Installation and
Preparation Part Operating Part Maintenance Part Appendixes Chapter 1 Overview of the Direct Diode Laser
3. Functions of the ML-5020BW
⇒Direct diode laser oscillation function
■ The laser is capable of processing workpieces under a small spot diameter.
■ The laser employs an LD, which signicantly reduces the number of required
maintenance operations.
■ The laser provides high energy e󰀩ciency for lower power consumption.
⇒Simple operations and maintenance
■ Fully air-cooled-no coolant or coolant lters needed.
⇒Active heat control function
■ This function varies the laser output while detecting the temperature of the
processing part coaxially with the laser light to control heat input.
⇒The factory environment can be improved by space saving.
■ The laser power supply and laser light source are integrated into a single
piece for easy transport and installation of the Laser.
⇒The Laser conforms to JIS C 6802 and Notication by the Ministry of Labor No.
0325002.

16 ML-5020BW
4. Product Composition
4. Product Composition
Packaging
The main unit and accessories are packed together. The dimensions and mass are
as follows.
Dimensions Mass (including packaged products)
Approx. 400 (H) × 500 (W) × 600 (D) mm Approx. 25 kg
Checking the Packaged Products
Make sure that all the packaged products are included.
⇒The model numbers of accessories are subject to change without notice. De-
pending on the part to be changed, the mounting screw shape may change and a
necessary tool may be di󰀨erent. For the latest parts information, contact a near-
est sales o󰀩ce.
Product name Model No. Q’ty
Direcr Diode Laser ML-5020BW 1
Cable with a round-type connector (2 m) *1 AS1178984 1
Protective glasses YL-717 Fiber Laser 1
Operation manual AS1208267(OM1208268+OM1208269) 1
Connector
Assembly A-03376-001 1
Plug HDCB-37P(05) 1
Case HDC-CTH(10) 1
*1: The cable with a round-type connector is included in the laser main unit.

4. Product Composition
17
ML-5020BW
Introduction Part Installation and
Preparation Part Operating Part Maintenance Part Appendixes
Main Unit and Output Unit
This product is used in combination with the output unit as shown below.
Main unit x 1 +Output unit x 2
Main unit
Provided with optical bers.
Model Specication Length of optical ber
ML-5020BW Simultaneous output to 2 bers 5 m
Output unit
The output unit with the specication that you selected at the time of purchase is con-
nected to the main unit.
Cylinder type With CCD
camera
With CCD camera and
active heat control function
-FOCH-30C-□□□ FOCH-30C-□□□-AHC
⇒As the spot diameter is bigger, the visibility of guide light becomes lower.
⇒When emitting laser on a material other than solder and
resin, tilt the output unit at an angle of 10 degrees or
more to prevent reected light.
Chapter 1 Overview of the Direct Diode Laser
W1 :11.50AW2:11.50A
W1:5.0 0 W2:5.00sec
SC H 31 T EMP140℃
U:5.0 0 S:5.00 D :5.00
ON
OFF
POWER
LASERREADY ERROR
C
N
E
G
R
E
M
E
P
O
T
S
Y
START/STOP
EMISSION
CONTROL
LASER
U W1 S W2 D
-
ENT
+
MENU
CURR1
CURR2
Main unit
Optical ber Output unit
10° or more
Workpiece

18 ML-5020BW
4. Product Composition
⇒Mechanism of the Active Heat Control
This function controls the laser output while detecting the temperature of the pro-
cessing part coaxially with the laser light to keep heat input constant.
W1 :11.50AW2:11.50 A
W1:5.0 0 W2:5.00sec
SC H 31 TEMP140℃
U:5.0 0 S:5.00 D:5.0 0
ON
OFF
POWER
LASERREADY ERROR
C
N
E
G
R
E
M
E
P
O
T
S
Y
START/STOP
EMISSION
CONTROL
LASER
U W1 S W2 D
-
ENT
+
MENU
CURR1
CURR2
Direct Diode Laser
ML-5020BW
Output Unit
FOCH-30C series
Heat
detector
Camera
Optical Fiber
Cable for the Heat Detector
Connected to
the dedicated
connector (TH)

1. Name and Function of Each Section on the Front Side
19
ML-5020BW
Introduction Part Installation and
Preparation Part Operating Part Maintenance Part Appendixes
Chapter 2
●Name and Functions of Each Section
1. Name and Function of Each Section on the Front Side
Front Cover Section
This section explains each section of the front cover of the main unit.
Function of Each Section on the Front Cover
(1) CONTROL
Keyswitch
When the CONTROL keyswitch is turned ON, the laser equipment be-
comes operable.
Aldo, when the CONTROL keyswitch is turned OFF after abnormality pro-
cessing, an abnormal display is cleared and the screen is reset.
(2) POWER Lamp When the CONTROL keyswitch is turned ON, the POWER lamp comes on.
(3) Control Panel This controller sets processing conditions and operates the laser equip-
ment.
Setting items and set values are displayed on the touch panel type liquid
crystal display.
(4) EMERGENCY
STOP Button
With this button pressed, the laser output is stopped. When the pressed
button is turned in the direction of RESET (clockwise), the button is reset to
the initial state.
(5) READY Lamp Lights up when laser is ready for outputting.
(6) LASER Lamp Indicates that laser is being output.
(7) ERROR Lamp Indicates that an error occurs.
Introduction Part
Chapter 2 Name and Functions of Each Section
W1:11.50AW2:11.5 0 A
W1:5.00 W 2:5.00sec
SCH 3 1 TEMP140℃
U:5.00 S :5.00 D:5.0 0
ON
OFF
POWER
LASERREADY ERROR
C
N
E
G
R
E
M
E
P
O
T
S
Y
START/STOP
EMISSION
CONTROL
LASER
U W1 S W2 D
-ENT
+MENU
CURR1
CURR2
(1) (2) (3) (4)
(5) (6) (7)

20 ML-5020BW
1. Name and Function of Each Section on the Front Side
Control Panel
In the following, the buttons and keys on the control panel are explained.
On the control panel, the operator can set welding schedules and perform laser light
output operations.
Function of Each Section on the Control Panel
(1) Liquid Crys-
tal Display
Displays the setting conditions and monitor data in 20 characters x 4 lines.
(2) CURSOR
Key
This key moves the cursor (■) in the upward/downward or left/right direc-
tion on the screen.
(3)+ / - Key This key changes the numeric value or alphabet at the cursor position.
(4) ENT Key This key denitively sets the changed value. When moving the cursor with-
out pressing the ENT key, the changed value is invalid.
(5) MENU Key This switches the screen of the liquid crystal display.
(6) LASER
START/STOP
(Button)
EMISSION
(Lamp)
If you press the button while the READY lamp is lighting up, laser light is
output. If the button is pressed again while laser light is output, the output
is stopped.
When the LD is turned on, the EMISSION lamp comes on.
W1:11.50AW2:11.50 A
W1:5.00 W2:5.00sec
SCH 31 TEMP140℃
U:5.00 S:5.00 D:5.0 0
ON
OFF
POWER
LASERREADY ERROR
C
N
E
G
R
E
M
E
P
O
T
S
Y
START/STOP
EMISSION
CONTROL
LASER
U W1 S W2 D
-
ENT
+
MENU
CURR1
CURR2
(1)
(2) (4)(3) (6) (5)