Amada ML-2650B User manual

AA06M0666E-34
OPERATION MANUAL
YAG LASER WELDER
ML-2650B/2651B

2ML-2650B/2651B
How to Use This Document
ATTENTION
In this manual, ML-2650B denotes ML-2650B, ML-2650B-CDRH, and
ML-2651B denotes ML-2651B, ML-2651B-CDRH.
Thank you for purchasing our YAG Laser Welder ML-2650B/2651B.
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 YAG
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,
available output, 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-2650B/2651B
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 .............................................11
For Disposal ..................................................15
Sticking Warning/Danger Labels .........................................16
Introduction Part 19
Chapter 1 Overview of the YAG Laser Welder ......................21
1. YAG Laser ........................................................21
2. Mechanism of the YAG Laser..........................................22
3. Functions of the ML-2650B/2651B......................................23
4. Product Composition ................................................24
Packaging ....................................................24
Checking the Packaged Products..................................24
Options ......................................................27
Chapter 2 Name and Functions of Each Section ....................29
1. Name and Function of Each Section on the Front Side ......................29
Front Cover Section ............................................29
Inside of the Front Side..........................................30
2. Name and Function of Each Section on the Top Side .......................32
Top Cover Section .............................................32
Laser Controller (MLE-122A) .....................................33
Laser Oscillator Section .........................................34
3. Name and Function of Each Section on the Lateral Side and Rear Side.........36
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
2. Fixing the Laser Welder ..............................................42
3. Cooling Water......................................................44
Required Quantity of Primary Cooling Water .........................45
Water Quality Standard for Primary Cooling Water ....................45
Chapter 2 Connections and Preparations of Each Section............47
1. Connecting the Power Supply .........................................47
2. Connecting the Hose for Primary Cooling Water ...........................48
3. Preparing the Secondary Cooling Water .................................49
4. Connecting the Optical Fiber ..........................................50

4ML-2650B/2651B
5. Removing the Laser Controller.........................................53
6. Connecting the External Communication Conversion Adapter (Option) .........54
Operating Part 55
Chapter 1 Control Method, and Start and Stop .....................57
1. Control Method.....................................................57
Switching the Control Method.....................................57
2. Start and Stop .....................................................58
How to Start the Laser ..........................................58
How to Stop the Laser ..........................................58
Chapter 2 Various Settings......................................59
1. Setting Welding Schedules. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .59
Welding Schedule Setting Screen .................................59
Setting Laser Light Output Schedules (SCHEDULE Screen).............76
Setting the Output Conditions for Seam Welding (SEAM Screen) .........81
Setting the Output Status (STATUS Screen) .........................84
Checking the State of External Input/Output Signals (EXT.I/O MONITOR Screen) .89
Setting the Output Status Check Screen (MONITOR Screen) ............90
Protecting Set Values (PASSWORD Screen) .........................93
Switching theAccuracy of the Measured Laser Energy Value (J) (MEMORY SWITCH Screen) .97
Switching the Pulse Width Setting Range (MEMORY SWITCH Screen) ...100
2. Setting the Laser Light Delivery .......................................103
Laser Light Sharing............................................103
Operating Branch Shutters on the STATUS Screen ...................106
Controlling Branch Shutters Independently .........................107
3. Changing theAcceptance Time for Laser Start Signal/Schedule Signal (MEMORY SWITCH Screen) . 110
4. Setting the Function of the Output Unit with Fiber Sensor (Option) ............113
Chapter 3 Laser Welding by Laser Controller (PANEL CONTROL) ....115
1. Operation Flow ....................................................115
2. Laser Controller Functions ...........................................116
3. Operating Procedure ...............................................117
Chapter 4 Laser Welding by External Input/ Output Signals (EXTERNAL CONTROL) . 125
1. Operation Flow ....................................................125
2. Preparations for Operations ..........................................126
3. Connector Functions ...............................................127
Pin Arrangement and Functions ..................................127
Example Connections of External Input Signals......................135
Example Connection of External Output Signals .....................137
4. Programming .....................................................138
Chapter 5 Laser Welding by External Communication Control (RS-485 CONTROL) . 143
1. Operation Flow ....................................................143
2. Preparations for Operations ..........................................144
3. Initial Settings .....................................................145
Setting Communication Schedules................................145
Setting Equipment No. .........................................147

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ML-2650B/2651B
4. Commands .......................................................149
Setting Data .................................................151
Reading Data ................................................152
Setting the Control Method, SCHEDULE No., Branch Shutter, etc. .......159
Setting the Mirror of the Timesharing Unit ..........................160
Reading the Control Method, SCHEDULE No., Branch Shutter, etc. ......161
Reading the Timesharing Unit Status ..............................162
Starting a Laser Light Output ....................................162
Stopping a Laser Light Output ...................................163
Stopping an Error Signal Output..................................163
Resetting the Total Number of Outputs.............................163
Resetting the Appropriate Number of Outputs .......................164
Reading Error No. at Occurrence of Trouble ........................164
Chapter 6 Printing Set Values and Measured Values................167
1. Printing Set Values .................................................167
2. Printing Measured Values. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .169
3. Printing Set Values for Seam Welding ..................................170
Maintenance Part 171
Chapter 1 How to Perform Maintenance ..........................173
NOTE .............................................................173
1. Maintenance Parts and Standard Intervals of Inspection/Replacement.........173
2. Maintenance of the Cooler Unit Section.................................176
Cleaning the Solenoid Valve Strainer ..............................176
Draining Water from the Primary Cooling Water......................177
Draining Water form the Secondary Cooling Water Tank ...............179
Changing the Ion-Exchange Resin and Replacing the Ion-Exchanger.....180
Changing the Water Filter and Secondary Cooling Water ..............183
Water Drain When the Laser Welder Is Not Used Over One Month or
the Room Temperature at the Installation Place Goes Down Below 0ºC ...184
3. Maintenance of Laser Oscillator Section ................................187
Replacing the Flashlamp .......................................187
Making an Incident Beam Adjustment of the Optical Fiber ..............191
Cleaning the Optical Fiber ......................................191
Cleaning the Optical Parts ......................................192
4. Maintenance of the Power Supply Section...............................193
Replacing the Lithium Battery for Backup...........................193
Cleaning the Air Filter ..........................................194
Chapter 2 Inspection and Measure To Be Taken at Occurrence of an Error . 195
1. Error Display and How to Take a Measure...............................195
Operation for Closing Interlock ...................................200
2. Troubles not Displaying Fault Code ....................................200
Appendixes 201
Specications .......................................................203

6ML-2650B/2651B
Dimensional Outline Drawings ..........................................205
Available Output .....................................................206
Timing Chart ........................................................208
Explanation of Terminology ............................................214
Output Schedule Data Entry Table .......................................219
Index .......................................................225

For Use in Safety
7
ML-2650B/2651B
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 220 V/380 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

8ML-2650B/2651B
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 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
ML-2650B/2651B
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 ML-2650B/2651B
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.
Maintenance Parts and Standard Intervals of Inspection/Replacement" on page 173.
⇒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.
⇒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.
⇒To prevent damage, do not bend the optical ber beyond its minimum bending
radius or apply any forms of shock to it. For the ber’s minimum bending radius,
see the table below.
Minimum bending radius of the optical ber
Core Diameter Minimum Bending Radius
φ 0.3, 0.4 mm 100 mm
φ 0.6 mm 150 mm
φ 0.8 mm 200 mm
φ 1.0 mm 250 mm
⇒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”