Amada MF-C500A-M User manual

AA04OM1189356-18
FIBER LASER WELDER
MF-C500A-M/ML-6810C/
MF-C1000A-S
OPERATION MANUAL
Original instructions

2MF-C500A-M/ML-6810C/MF-C1000A-S
How to Use This Document
ATTENTION
This operation manual is common to MF-C500A-M, ML-6810C and MF-C1000A-S.
The ML-6810C is used in the explanatory drawings unless there is a signicant
di󰀨erence.
Thank you for purchasing our Fiber Laser Welder MF-C500A-M/ML-6810C/MF-
C1000A-S.
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 Fiber
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. First, this part explains how to
perform each setting and how to operate the laser. Three types
of control (Control by the laser controller, control by external input/
output signals, and control by external communication control) are
explained in the operating method for laser welding.
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
MF-C500A-M/ML-6810C/MF-C1000A-S
Contents
How to Use This Document ..............................................2
For Use in Safety ......................................................7
Safety Precautions ..............................................7
Precautions for Handling ...............................................10
Laser Safety Supervisor .........................................10
Routine Handling ..............................................10
For Transportation .............................................12
For Packaging.................................................13
For Disposal ..................................................17
Sticking Warning/Danger Labels .........................................18
Cautions for Export....................................................20
Introduction Part 21
Chapter 1 Overview of the Fiber Laser Welder......................23
1. Fiber Laser ........................................................23
2. Mechanism of the Fiber Laser .........................................24
3. Functions of the MF-C500A-M/ML-6810C/MF-C1000A-S ....................25
4. Product Composition ................................................26
Packaging ....................................................26
Checking the Packaged Products..................................26
Options ......................................................29
Chapter 2 Name and Functions of Each Section ....................31
1. Name and Function of Each Section on the Front Side ......................31
2. Name and Function of Each Section on the Top Side .......................32
Top Cover Section .............................................32
Laser Controller (MLE-122A) .....................................33
3. Name and Function of Each Section on the Lateral Side and Rear Side.........34
Lateral Side and Rear Side Cover Section ...........................34
Inside of the Connector Cover ....................................35
Installation and Preparation Part 37
Chapter 1 Installation ..........................................39
1. Installation Place ...................................................39
Space Required for Installation....................................39
Environment Suitable for Installation and Precautions ..................40
Allowable Duty Cycle Graph ......................................42
2. Fixing the Laser Welder ..............................................43
Chapter 2 Connections and Preparations of Each Section............45
1. Connecting the Power Supply .........................................45
2. Connecting the Chiller ...............................................47
3. Connecting the Hose for Cooling Water..................................48
Preparing the Cooling Water......................................50
4. Piping the Drain Water ...............................................51

4MF-C500A-M/ML-6810C/MF-C1000A-S
5. Connecting the Optical Fiber ..........................................52
6. Removing the Laser Controller.........................................56
7. Connecting the External Communication Conversion Adapter (Option) .........57
8. Connecting the Cable for the Heat Detector (Option) .......................58
9. Connecting the Dry Air Unit (Option) ....................................60
Dehumidication Function .......................................61
Operating Part 63
Chapter 1 Control Method, and Start and Stop .....................65
1. Control Method.....................................................65
Switching the Control Method.....................................65
2. Start and Stop .....................................................66
How to Start the Laser ..........................................66
How to Stop the Laser ..........................................67
Chapter 2 Various Settings......................................69
1. Screen Conguration ................................................69
Transition of Screens ...........................................69
2. Checking the Equipment Status ........................................73
STATUS Screen ...............................................73
Setting the Output Status ........................................74
TERMINAL MONITOR Screen ....................................76
ERROR LOG Screen ...........................................77
EVENT LOG Screen............................................78
SOFTWARE VERSION Screen ...................................79
3. Changing the Equipment Settings ......................................80
CONFIG Screen ...............................................80
PASSWORD Screen............................................84
Protecting Set Values ...........................................84
INITIALIZE Screen .............................................93
4. Setting the Laser Light Output Schedule .................................96
SCHEDULE Screen (Fixed Waveform (FIX)) .........................96
SCHEDULE Screen (Flexible Waveform (FLEX)) .....................99
SCHEDULE Screen (Flexible Waveform (CW)) ......................100
Setting Laser Light Output Schedules .............................102
SEAM Screen ................................................107
Setting the Output Schedules for Seam Processing...................108
MODULATION Screen .........................................110
Setting the Modulated Waveform .................................112
ACTIVE HEAT CONTROL Screen ................................115
Setting the Active Heat Control Function (Option) ....................117
Editorial Assistant Function......................................121
Limitations of Schedule Setting ..................................122
5. Monitoring Output..................................................123
MONITOR Screen. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .123
Setting the Output Status Check Screen ...........................125

5
MF-C500A-M/ML-6810C/MF-C1000A-S
6. Changing the Acceptance Time for Laser Start Signal/Schedule Signal (CONFIG Screen) .128
Chapter 3 Laser Processing by Laser Controller (PANEL CONTROL)..131
1. Operation Flow ....................................................131
2. Laser Controller Functions ...........................................132
3. Operating Procedure ...............................................133
Chapter 4 Laser Processing by External Input/ Output Signals (EXTERNAL CONTROL) 139
1. Operation Flow ....................................................139
2. Preparations for Operations ..........................................140
3. Connector Functions ...............................................141
Pin Arrangement and Functions ..................................141
Example Connections of External Input/Output Signals ................152
4. Programming .....................................................155
Chapter 5 Laser Processing by External Communication Control (RS-485 CONTROL) . 159
1. Operation Flow ....................................................159
2. Preparations for Operations ..........................................160
3. Initial Settings .....................................................161
Setting Communication Schedules and Equipment No. ................161
4. Commands .......................................................163
Setting Data .................................................165
Reading Data ................................................166
Setting the Control Method, SCHEDULE No., etc. ....................175
Setting the System Date and Time ................................176
Reading the Control Method, SCHEDULE No., etc....................177
Reading the System Date and Time ...............................178
Starting a Laser Light Output ....................................178
Stopping a Laser Light Output ...................................179
Stopping an Error Signal Output..................................179
Resetting the Total Number of Outputs.............................179
Resetting the Appropriate Number of Outputs .......................180
Reading Error No. at Occurrence of Trouble ........................180
Reading the Error History .......................................181
Reading the Software Version ...................................181
Reading the Equipment Name ...................................182
Maintenance Part 183
Chapter 1 How to Perform Maintenance ..........................185
NOTE .............................................................185
1. Maintenance Parts and Standard Intervals of Inspection/Replacement.........186
2. Maintenance of the Laser Oscillator....................................188
Inspecting the Laser Output .....................................188
Correcting the Laser Power .....................................189
Cleaning and Replacing the Protective Glass .......................194
3. Maintenance of the Chiller ...........................................195
Replacing the Filter Cartridge ....................................195
Replacing the Cooling Water ....................................197

6MF-C500A-M/ML-6810C/MF-C1000A-S
Inspecting Water Leaks from the Pump ............................197
Draining the Cooling Water......................................198
Cleaning the Dust-proof Filter....................................199
4. Maintenance of the Dry Air Unit (Option) ................................200
Checking the Dry Air Unit .......................................200
Checking the Filter Separator ....................................201
Checking the Membrane Air Dryer ................................201
Chapter 2 Inspection and Measure To Be Taken at Occurrence of an Error . 203
1. Error Display and How to Take a Measure...............................203
Main Unit....................................................203
Chiller ......................................................209
2. Troubles not Displaying Fault Code ....................................210
Appendixes 211
Specications .......................................................213
Dimensional Outline Drawings ..........................................216
Timing Chart ........................................................219
Explanation of Terminology ............................................225
Output Schedule Data Entry Table .......................................229
Index .......................................................235

For Use in Safety
7
MF-C500A-M/ML-6810C/MF-C1000A-S
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
damage 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 that the content gives notice of DANGER, WARNING or
CAUTION to the operator.
Do not touch the inside of the Laser unnecessarily.
Since source voltage of 3-phase 180 V to 240 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).
DANGER
WARNING
CAUTION
DANGER

8MF-C500A-M/ML-6810C/MF-C1000A-S
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 look into or reach into the light path while the LD is turned on.
Fluorescence emission can cause burn or blindness.
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.
Shield the laser beam.
The laser beam is dangerous to human bodies. Prevent emission through
the air by using a light shielding material (a Class 4 laser beam-absorbing
material).
Persons with pacemakers must stay clear of the Laser.
Those who use a pacemaker must not approach the Laser or walk around
the welding 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
9
MF-C500A-M/ML-6810C/MF-C1000A-S
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

10 MF-C500A-M/ML-6810C/MF-C1000A-S
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.
⇒Install the indicating lamp etc. so that a user can recognize that the Laser is in
use from outside the laser operation area.
⇒When entering a laser operation area for maintenance etc., use the safety
interlock.
⇒When installing the output unit at a place distant from the main unit of the Laser,
enable a user to stop the laser even at a distant place.
* For connections of indication lamp, safety interlock, and emergency stop, use two
contacts. For details, refer to "E-STOP Connector" on page 148.
Routine Handling
⇒Perform inspection periodically referring to the Maintenance Part, Chapter 1 "1.
Maintenance Parts and Standard Intervals of Inspection/Replacement" on page
186.
⇒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
operated 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
POWER switch.
⇒The outer panels and the covers are electrically connected to the main unit by
connecting cables. When the panels, covers and connecting cables are removed
and installed again, make sure that all these components are put back into place
correctly. Also, make sure that the cables do not block the optical path of the
oscillator or get caught between the outer panel and the frame.

Precautions for Handling
11
MF-C500A-M/ML-6810C/MF-C1000A-S
⇒To prevent damage, do not bend the optical ber beyond its minimum bending
radius or apply any forms of shock to it (See table below).
Bending radius Min. 150 mm
Coil radius Min. 200 mm
Tensile force Max. 50 N
Torque (torsion) Max. 0.5 Nm
Torsion Max. 90° per meter
⇒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.
* For other information on managing laser equipment or the MPE level, refer to the
following standards.
CDRH Standards Part 1040 Sec. 1040.10 “Radiation safety standards for laser
equipment”
IEC Standards IEC60825-1 “Safety of laser products Part1: Equipment Classica-
tions, requirements and use’s guide”

12 MF-C500A-M/ML-6810C/MF-C1000A-S
Precautions for Handling
For Transportation
When transporting the laser, observe the following precautions to avoid
hazards.
⇒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 pallet truck of at least 300 kg allowable load.
⇒Do not transport the Laser with its casters. The casters are for ne adjustment.
⇒Retract the level adjuster fully when transporting the Laser.
Precautions for using a pallet truck
The following gure shows fork inserting positions.
⇒As shown at right, adjust the distance between the forks; distance between the
outer sides of the forks must be 400 to 520 mm, but the fork must not hit the level
adjuster.
⇒When transporting, belt the Laser to x and keep it horizontal.
Figures below show example forking; insert the forks fully till the points appear from
under the Laser.
400 to 520
DO DON'T
Fork
Fork

Precautions for Handling
13
MF-C500A-M/ML-6810C/MF-C1000A-S
Precautions for transportation
⇒Fix it firmly using the dedicated packaging materials to prevent a fall, damage
due to vibration.
⇒Retract the level adjuster fully when freighting the Laser.
⇒Insert a broad and thick cushion between the Laser and wall to provide enough
clearance between the wall and the Laser.
For Packaging
Precautions for packaging
⇒The worker must wear a helmet, safety shoes and gloves for safety. (Leather
gloves are recommended.)
⇒Retract the level adjuster fully when packing the Laser.
⇒Take care that the Laser does not fall or slip.
⇒Fix the skid to prevent slipping or install it on the non-slipping surface.
⇒For overseas transportation, put the Laser on the pallet and cover it with plastic
wrap to prevent damage caused by rain.
Cushion
Floor
Wall

14 MF-C500A-M/ML-6810C/MF-C1000A-S
Precautions for Handling
Packaging overview and name of each section
Operating Procedure
(1) Prepare a pallet truck with the following specications.
(2) Prepare two vibrationproof skids and make polypropylene bands (approx. 4 m x 4)
go through grooves as shown below.
(3) Lift up the Laser with the pallet truck and place it on the vibrationproof skids.
Align the positions of “FORK HERE” and the forks and insert the forks vertically
to lift up the Laser.
Height in moving
upward:
170 mm min.
Length: 600 mm min.
Full width: 400 to 520 mm
Withstand load: 300 kg min.
Polypropylene band

Precautions for Handling
15
MF-C500A-M/ML-6810C/MF-C1000A-S
(4) Lower level adjusters (four positions) below the caster and fix them with lock
nuts.
(5) Place the cushioning material on the top of the Laser and then place the optical
ber on it.
⇒Keep the minimum bending radius 200 mm or more and x it with insulation locks
(three positions).
(6) Wrap the connector section of the optical ber with an air cap to protect it.
⇒Conrm that the water-cooling connector is shorted.
Cushioning material
Lock nut
Level adjuster
Optical ber
Air cap
Caster
Short-circuiting tube

16 MF-C500A-M/ML-6810C/MF-C1000A-S
Precautions for Handling
(7) Cover the corrugated cardboard-made top cap on the cushioning material at the
top.
(8) Fix them with four polypropylene bands as shown below.
(9) Protect the Laser with an air cap or packaging wrap.
Polypropylene band
Top cap

Precautions for Handling
17
MF-C500A-M/ML-6810C/MF-C1000A-S
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.

18 MF-C500A-M/ML-6810C/MF-C1000A-S
Sticking Warning/Danger Labels
Sticking Warning/Danger Labels
Warning/danger labels are struck on the laser. Read the precautions provided on
each label for correct use. The numbers correspond to the label gure numbers on
the next page.
(7)
(5)
(4)
(6) (6)
(1)
(7)(8) (8)
(9)
(3)
(10)
(2)

Sticking Warning/Danger Labels
19
MF-C500A-M/ML-6810C/MF-C1000A-S
(1)
(3)
(5)
(7)
(9)
(2)
(4)
(6)
(8)
(10)
MANUFACTURED BY:
95-3 FUTATSUKA NODA-CITY
AMADA WELD TECH CO.,LTD.
MODEL No.
LB1162599
CLASS 4 LASER PRODUCT
SERIAL No. LABEL
1
ms
Hz
INPUT POWER VOLTS
MAX. RMS AMPS
MAX. AVERAGE POWER
MAX. PULSE ENERGY
PULSE DURATION
WAVELENGTH
PULSE REPETITION RATE
MFG:MONTH , YEAR ,
VAC
A
W
J
-
-
μm
50/60Hz
PHASE
～
CHIBA 278-0016 JAPAN
IEC60825-1:2014
ファイバの曲げ半径は
Keep the bend radius of fiber
仕様の範囲内でお取扱下さい
within the specified range.
INVISIBLE LASER RADIATION
AVOID EXPOSURE
IS EMITTED FROM THIS APERTURE
不可視ﾚｰｻﾞ光が出ます。
注意 ここから
不可視ﾚｰｻﾞ光 出口
P-1221
AVOID EYE OR SKIN EXPOSURE TO
DIRECT OR SCATTERED RADIATION
MAX OUTPUT
PULSE DURATION
WAVELENGTH(S)
CLASS Ⅳ LASER PRODUCT
VISIBLE AND/OR INVISIBLE LASER RADIATION
注意
ここを開きセーフティインタロックを解除すると
クラス４のレーザ放射が出ます。ビームや散乱光
の目、又は皮膚への被ばくを避けること。
CAUTION
DEFEATED AVOID EYE OR SKIN EXPOSURE TO DIRECT
OR SCATTERED RADIATION
CLASS 4 LASER RADIATION WHEN OPEN AND INTERLOCKS
注意
装置のキャスターを使って運搬しないでください。
装置の運搬には、許容荷重300kg以上のフォークリフト
又はハンドリフトなどを使用してください。
CAUTION
DO NOT TRANSPORT THE LASER WITH ITS CASTERS.
WHEN TRANSPORTING THE LASER,USE A LIFT TRUCK,
PALLET TRUCK, ETC.,OF AT LEAST 300KG ALLOWABLE LOAD.
クラス４レーザ製品 CLASS 4 LASER PRODUCT IEC60825-1:2014
不可視レーザ放射
INVISIBLE LASER RADIATION
ビームや散乱光の目又は皮膚への被ばくを避けること。
AVOID EYE OR SKIN EXPOSURE TO DIRECT OR SCATTERED RADIATION
最大出力 / MAX : 1300W
パルス持続時間/ PULSE DURATION : 0.05ms～CW
波 長 / WAVE LENGTH : 0.90～1.20μm
可視レーザ放射
VISIBLE LASER RADIATION
レーザ放射 目への直接被ばくを避けること
Avoid direct exposure to eyes
クラス3Rレーザ製品 CLASS 3R LASER PRODUCT IEC60825-1:2014
最大出力 / MAX : <4mW
パルス持続時間/ PULSE DURATION : CW
波 長 / WAVE LENGTH : 0.60～0.70μm

20 MF-C500A-M/ML-6810C/MF-C1000A-S
Cautions for Export
Cautions for Export
The ML-6810C and MF-C1000A-S described in this Operation Manual fall into a con-
trolled 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]