Amada ML-3030AS User manual

AA04OM1178497-20
OPERATION MANUAL
PULSED FIBER LASER WELDER
ML-3030AS/3015AS
Original instructions

2ML-3030AS/3015AS
How to Use This Document
ATTENTION
This operation manual is common to both ML-3030AS and ML-3015AS. The
ML-3030AS is used in the explanatory drawings unless there is a significant
di󰀨erence.
Thank you for purchasing our Pulsed Fiber Laser Welder ML-3030AS/ 3015AS.
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 control panel, 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, definition of memory switch, 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-3030AS/3015AS
Contents
How to Use This Document ..............................................2
For Use in Safety ......................................................6
Safety Precautions ..............................................6
Precautions for Handling ................................................9
Laser Safety Supervisor ..........................................9
Routine Handling ...............................................9
For Transportation .............................................11
For Packaging.................................................12
For Disposal ..................................................18
Sticking Warning/Danger Labels .........................................19
Introduction Part 21
Chapter 1 Overview of the Pulsed Fiber Laser Welder ...............23
1. Fiber Laser ........................................................23
2. Mechanism of the Fiber Laser .........................................24
3. Functions of the ML-3030AS/3015AS ...................................25
4. Product Composition ................................................26
Packaging ....................................................26
Checking the Packaged Products..................................26
Options ......................................................28
Chapter 2 Name and Functions of Each Section ....................31
1. Name and Function of Each Section on the Front Side ......................31
Front Cover Section ............................................31
Inside of the Front Side..........................................32
2. Name and Function of Each Section on the Top Side .......................33
3. Name and Function of Each Section on the Rear Side ......................34
Installation and Preparation Part 37
Chapter 1 Installation ..........................................39
1. Installation Place ...................................................39
Space Required for Installation....................................40
Environment Suitable for Installation and Precautions ..................40
2. Fixing the Laser Welder ..............................................41
Chapter 2 Connections and Preparations of Each Section............43
1. Connecting the Power Supply .........................................43
2. Connecting the Optical Fiber ..........................................44
Models other than ML-30□□AS-110 ................................44
ML-30□□AS-110 ...............................................47
3. Connecting the Laser Controller (Option).................................50
4. Connecting the External Communication Conversion Adapter (Option) .........51
Operating Part 53
Chapter 1 Control Method, and Start and Stop .....................55

4ML-3030AS/3015AS
1. Control Method.....................................................55
Switching the Control Method.....................................55
2. Start and Stop .....................................................56
How to Start the Laser ..........................................56
How to Stop the Laser ..........................................56
Chapter 2 Various Settings......................................57
1. Screen Conguration ................................................57
Transition of Screens ...........................................57
2. Checking the Equipment Status ........................................61
STATUS Screen ...............................................61
Setting the Output Status ........................................62
TERMINAL MONITOR Screen ....................................64
ERROR LOG Screen ...........................................65
EVENT LOG Screen............................................66
SOFTWARE VERSION Screen ...................................67
3. Changing the Equipment Settings ......................................69
CONFIG Screen ...............................................69
PASSWORD Screen............................................73
Protecting Set Values ...........................................73
INITIALIZE Screen .............................................80
4. Setting the Laser Light Output Schedule .................................83
SCHEDULE Screen (Fixed Waveform (FIX)) .........................83
SCHEDULE Screen (Flexible Waveform (FLEX)) .....................85
SCHEDULE Screen (Flexible Waveform (CW)) .......................87
Setting Laser Light Output Schedules ..............................88
SEAM Screen .................................................92
Setting the Output Schedules for Seam Welding ......................93
MODULATION Screen ..........................................95
Setting the Modulated Waveform ..................................97
Editorial Assistant Function.......................................99
Limitations of Schedule Setting ..................................100
5. Monitoring Output..................................................103
MONITOR Screen. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .103
Setting the Output Status Check Screen ...........................104
6. Setting the Laser Light Delivery .......................................106
Laser Light Sharing............................................106
Operating Safety Shutters on Each Screen .........................108
7. Changing the Acceptance Time for Laser Start Signal/Schedule Signal (CONFIG Screen) .109
Chapter 3 Laser Welding by Control Panel (PANEL CONTROL).......111
1. Operation Flow ....................................................111
2. Control Panel Functions .............................................112
3. Operating Procedure ...............................................113
Chapter 4 Laser Welding by External Input/ Output Signals (EXTERNAL CONTROL) . 119
1. Operation Flow ....................................................119
2. Preparations for Operations ..........................................120

5
ML-3030AS/3015AS
3. Connector Functions ...............................................121
Pin Arrangement and Functions ..................................121
Example Connections of External Input/Output Signals ................132
4. Programming .....................................................135
Chapter 5 Laser Welding by External Communication Control (RS-485 CONTROL) . 139
1. Operation Flow ....................................................139
2. Preparations for Operations ..........................................140
3. Initial Settings .....................................................141
Setting Communication Schedules and Equipment No. ................141
4. Commands .......................................................143
Setting Data .................................................145
Reading Data ................................................146
Setting the Control Method, SCHEDULE No., Safety Shutter, etc. .......155
Setting the System Date and Time ................................156
Reading the Control Method, SCHEDULE No., Safety Shutter, etc. ......157
Reading the System Date and Time ...............................158
Starting a Laser Light Output ....................................158
Stopping a Laser Light Output ...................................159
Stopping an Error Signal Output..................................159
Resetting the Total Number of Outputs.............................160
Resetting the Appropriate Number of Outputs .......................160
Reading Error No. at Occurrence of Trouble ........................160
Reading the Error History .......................................161
Reading the Software Version ...................................161
Reading the Equipment Name ...................................162
Maintenance Part 163
Chapter 1 How to Perform Maintenance ..........................165
NOTE .............................................................165
1. Maintenance Parts and Standard Intervals of Inspection/Replacement.........166
2. Maintenance of the Power Supply Section...............................168
Cleaning the Air Filter ..........................................168
Chapter 2 Inspection and Measure To Be Taken at Occurrence of an Error . 169
1. Error Display and How to Take a Measure...............................169
2. Troubles not Displaying Fault Code ....................................174
Appendixes 175
Specications .......................................................177
Dimensional Outline Drawings ..........................................183
Timing Chart ........................................................184
Explanation of Terminology ............................................190
Output Schedule Data Entry Table .......................................194
Index .......................................................200

6ML-3030AS/3015AS
For Use in Safety
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 200 V/220 V/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

For Use in Safety
7
ML-3030AS/3015AS
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.
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

8ML-3030AS/3015AS
For Use in Safety
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

Precautions for Handling
9
ML-3030AS/3015AS
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
165.
⇒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
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 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 0.05, 0.1, 0.2, 0.3, 0.4 mm 100 mm
φ 0.6 mm 150 mm
φ 0.8 mm 200 mm
⇒When outputting laser light, conrm that the optical ber(s) based on the num-
ber of deliveries is/are connected. Laser light cannot be output with the optical
ber(s) disconnected.
⇒When a supervisor or operator enters the area where the laser is used, protective
measures not to exceed the MPE* level must be taken.

10 ML-3030AS/3015AS
Precautions for Handling
* 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 10 to 35ºC and the
ambient humidity is 50 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.
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”

Precautions for Handling
11
ML-3030AS/3015AS
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 170 kg
allowable load.
⇒Do not transport the Laser with its casters. The casters are for ne adjustment of
installation position.
⇒Retract the level adjuster fully when transporting the Laser.
Precautions for using a fork lift
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 250 to 330 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.
Fork
Adjuster
250 to 330
DO DON'T
Fork Fork

12 ML-3030AS/3015AS
Precautions for Handling
Precautions for transportation
⇒Transport it using a dedicated package to prevent a fall, damage due to vibration.
⇒Retract the level adjuster fully when freighting 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.
⇒When putting the Laser up on the skid with a slope, do not push it up by main
force. When it is hard to push it up, consult us.
⇒For overseas transportation, put the Laser on the pallet and cover it with plastic
wrap to prevent damage caused by rain.

Precautions for Handling
13
ML-3030AS/3015AS
Packaging overview and name of each section
Operating Procedure
(1) Open the package and install the slope.
(2) Put the equipment on the skid using the slope.
⇒To avoid bending the slope, put laminated cardboard blocks (2 positions) at the
bottom of slope with the hook and loop fastener.
Optical ber
Skid
Slope
Laminated cardboard
blocks

14 ML-3030AS/3015AS
Precautions for Handling
(3) Remove laminated cardboard blocks after putting the equipment in place.
(4) Stand the slope straight up.
Laminated cardboard
block
Hook and loop
fastener
Hook and loop
fastener
Slope

Precautions for Handling
15
ML-3030AS/3015AS
(5) Put the removed laminated cardboard blocks in place with the hook and loop
fastener.
(6) Secure the corners of the bottom cap with joint clips.
Hook and loop
fastener
(Rear of block)
Bottom cap
(4 positions)

16 ML-3030AS/3015AS
Precautions for Handling
(7) Put the cushion for cable storage on the top of the equipment and store the opti-
cal ber in it.
⇒Be careful of the bending radius of ber.
(8) Install an external packaging sleeve.
External packaging
sleeve
Cushion for cable storage

Precautions for Handling
17
ML-3030AS/3015AS
(9) Put rear cushions.
(10)Put front cushions.
Front cushions
Rear cushions

18 ML-3030AS/3015AS
Precautions for Handling
(11) Install the top cap and x the package with bands.
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.
Top cap
Bands

Sticking Warning/Danger Labels
19
ML-3030AS/3015AS
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.
FIBER.OUT 1
(7)
(3)
(9)
(6)
(5) (5)
(2)
(1)
(7)(11) (11)
(4)
(10)
(8)

20 ML-3030AS/3015AS
Sticking Warning/Danger Labels
(1)
(3)
(5)
(7)
(8)
(10)
(2)
(4)
(6)
(9)
(11)
(MAX OUTPUT) ML-3030AS: 5000W
ML-3015AS: 2500W
VAC
W
A
Phase 50/60Hz
,
MAX. RMS AMPS
INPUT POWER VOLTS
Hz
CLASS Ⅳ LASER PRODUCT
MFG:MONTH , YEAR
LB1174646
AMADA WELD TECH CO.,LTD.
SERIAL No. LABEL
MODEL No.
95-3 FUTATSUKA NODA-CITY
MANUFACTURED BY:
200-240
MAX. AVERAGE LASER POWER
JMAX. PULSE ENERGY
nm
PULSE REPETITION RATE
-
CW-ms
-Hz1
1000
1067
0.2
1073
WAVELENGTH
PULSE DURATION
CHIBA 278-0016 JAPAN
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.
AVOID EXPOSURE
IS EMITTED FROM THIS APERTURE
VISIBLE AND INVISIBLE LASER RADIATION
可視及び不可視レーザ放射が出る
被ばく回避のこと - この開口から
レーザ放射の出口
可視及び不可視
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
危険
ここを開き,そしてインタロックを解除すると,
クラス４のレーザ放射が出る ビームや散乱光
の目又は皮膚への被ばくを避けること
DANGER
INTERLOCKS DEFEATED AVOID EYE OR SKIN
EXPOSURE TO DIRECT OR SCATTERED RADIATION
CLASS 4 LASER RADIATION WHEN OPEN AND
危険 DANGER
ここを開き,そしてインタロックを解除すると,
クラス４のレーザ放射が出る ビームや散乱光
の目又は皮膚への被ばくを避けること INTERLOCKS DEFEATED AVOID EYE OR SKIN
EXPOSURE TO DIRECT OR SCATTERED RADIATION
CLASS 4 LASER RADIATION WHEN OPEN AND
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170kg以上のフォーク
リフト、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 170KG ALLOWABLE LOAD.
クラス４レーザ製品 CLASS 4 LASER PRODUCT
JIS C6802:2014
最大出力 / MAX :
パルス持続時間/ PULSE DURATION : 0.2ms～CW
波 長 / WAVE LENGTH : 0.90～1.20μm
危険 - 不可視レーザ放射
DANGER - INVISIBLE LASER RADIATION
AVOID EYE OR SKIN EXPOSURE TO DIRECT OR SCATTERED 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
ビームを見たり,望遠光学計器を使って見ないこと
最大出力 / MAX : <1mW
パルス持続時間/ PULSE DURATION : CW
波 長 / WAVE LENGTH : 0.60～0.70μm
注意 - 可視レーザ放射
CAUTION VISIBLE LASER RADIATION
DO NOT STARE INTO BEAM OR EXPOSE USERS TELESCOPIC OPTICS CLASS 2M LASER PRODUCT
クラス2Mレーザ製品 CLASS 2M LASER PRODUCT
JIS C6802:2014