Orion Welders LZR series User manual

Orion Laser Welder User Manual
Orion LZR

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Introduction
Use and Installation
Contractual Guarantee/Warranty
Chapter 1: Symbols
Chapter 2: Safety
2.1: Laser Radiation Absorption
2.2: Classification and Dangerousness
2.3: Radiation Vision Conditions
2.4: Risks for the Eyes and the Skin
2.5: Safety General Prescriptions
Chapter 3: Seals
3.1: Labels
3.2: Labels Positioning
Chapter 4: Technical Data
4.1: Laser Specifications
4.2: Other Data
Chapter 5: Controls Description
5.1: Machine Controls
5.2: Joystick Controls
5.3: Display Touchscreen Controls
Chapter: 6 Installation
6.1: Internal Controls
6.2: Joystick Controls
6.3: Display Touch Screen Controls
6.4: Additional Interface Screens
Table of Contents

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Chapter 7: Maintenance
7.1: Clean or Replace the Protection Lens
7.2: Realigning the Cross hairs
7.3: Periodically Change the Cooling Water
7.4: How to Remove the Water
7.5: How to Refill the Cooling System
Chapter 8: Error Messages and Troubleshooting
8.1: Other Anomalies
Chapter 9: Safety Systems
9.1: Resonator Shutter
9.2: Microscope Shutter
9.3: Microscope Infrared Filter
9.4: Weld Chamber Infrared Filter
9.5: Leather Strips Protecting the Chamber Opening
Chapter 10: Technical Assistance

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INTRODUCTION:
ank You for Choosing Orion Welders and congratulations on your purchase!
You are now the proud owner of an Orion Laser Welder. is manual was designed to help you set up
the welder and begin welding. Please read and follow all safety precautions before proceeding with
the welding process.
Sunstone Engineering is the parent company of Orion Welders. At Sunstone & Orion we are
committed to producing quality products and ensuring complete owner satisfaction. If you require
assistance after reading this manual please contact us with the information provided below.
Orion Welders, a Subsidiary of
Sunstone Engineering R&D Corp.
1693 American Way Suite #5
Payson, UT 84651
Email: [e-mail]
Voice: 801-658-0015
Fax: [phone]
NOTE: e information contained in this manual is subject to change as improvements are made to
our products. Visit www.SunstoneWelders.com for the latest version of this document.
Orion Welders
LZR User Manual

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ORION LZR LASER WELDERS
USE AND INSTALLATION
IMPORTANT
Carefully verify the content of this manual, paying attention to the information and warnings
for the installation, use, and the maintenance of this machine. Any repairs or services should only be
performed by a qualified technician. With any questions or needed assistance, please contact Sun-
stone Engineering and Orion Welders.
Sunstone Engineering R&D Corp.
and Orion Welders
1693 American Way #5
Payson, UT, USA 84651
[phone]
www.SunstoneEngineering.com
www.OrionWelders.com
Caution: Improper use of this equipment can result in harmful exposure to laser radiation. Carefully
follow all instructions and warnings included in this document.
CONTENT GUARANTEE
e information included in this manual is subject to modifications without notice. Sunstone Engi-
neering and Orion Welders will be not responsible for errors included in this document nor for any
incidental damages or consequences due to any erroneous interpretation of this manual.
DOCUMENT ISSUES
Issue Date Approval Valid from model
n°
Notes
0 7/1/2006 G.M. 7/1/06 MG01100
1 6/4/2009 G.M. 6/4/2009 MG01160
2 4/19/2010 G.M. 4/19/2010 MG01147
3 2/4/2011 G.M. 2/4/2011 MG01177
4 4/28/2014 G.M. 4/28/2014 MG01345

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INTENDED USAGE
e Orion LZR laser welding machines are destined for making small-sized welds on metal parts.
NOTE
is equipment should only be used for its intended use and purpose. It is not allowed to modify,
change, or use any part of the equipment for any purposes other than the intended usage. Sunstone
Engineering and Orion Welders declines all responsibility for any non-conformance use of the equip-
ment.

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Sunstone Engineering and Orion Welders
CONTRACTUAL GUARANTEE / WARRANTY
Sunstone Engineering guarantees this product will be free of any defects for the duration of two
years from the date of purchase. e warranty covers all components excluding the following: the LED
lamps found in the weld chamber, fuses, protection glass, fire lens and all consumable material. Sun-
stone Engineering will, at its discretion, chose to repair or replace any defective part during the 2 year
warranty period. If an issue should arise during the 2 year warranty, Sunstone Engineering will be re-
sponsible for any costs associated with the repair or replacement on any components, excluding any
shipping costs. Any damaged and replaced parts will become property of Sunstone Engineering. Any
replaced or repaired parts will also be covered under this guarantee until the 2 year term is expired.
e guarantee is void under the following circumstances:
• e buyer fails to report to Sunstone Engineering any initial defects or issues due to shipping
within seven days from the installation date.
• e device or its parts have been used in a way different from that which it was intended to be
used.
• e device has been entrusted for repair to an unauthorized agent or company, or the device or its
pieces have had some modifications not authorized by Sunstone Engineering.
• e recommendations and procedures regarding the use and the maintenance of the machine
found in this manual have not been respected and followed.
• e warranty seals and stickers on the machine have been removed or broken without authoriza-
tion from Sunstone Engineering.
Any other defects or damages caused by normal wear and tear are also excluded from the warranty.
If there is a defect during the warranty period, Sunstone Engineering will take action to completely
resolve the problem in accordance with this guarantee.
Sunstone Engineering Stamp or sign for acceptance of the
included warranty conditions

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Chapter 1: Symbols
GENERIC WARNING:
is symbol indicates a need to carefully read and follow instructions found here to
ensure proper use and maintenance of the equipment.
LASER WARNING:
is symbol shows the danger of being exposed to visible and invisible laser radia-
tion. is symbol can be included also on the machine in corresponding areas of risk to
exposure. If you see this symbol:
• Don’t ever introduce mirrors or reflecting objects in the welding chamber while
the machine is in use.
• Check the weld chamber exclusively through the green-tinted viewing glass
found on the front of the machine.
• Don’t ever remove the leather strip curtains that cover the opening to the weld
chamber.
When using the machine, ensure that no one is seated with their face being eye-level
with the weld chamber. is includes children whose standing height would be level
with the weld chamber.
It is also recommended that the weld operator use adequate and approved working
gloves when using the machine.
FIRE WARNING:
is symbol shows the danger of fire when working with flammable materials are
processed. When there is a danger of fire, it is very important to follow the instructions
provided from the manufacturer during the installation of the machine.
Don’t weld near flammable materials.
Remove all flammable materials from nearby the welder. If this is not possible, care-
fully cover all flammable material with fireproof material.
Also, it is recommended to keep fire extinguishers in the vicinity of this machine.
EXPLOSION WARNING:
is symbol shows that the gas contained in the cylinders is under pressure and can
consequently explode if the cylinders aren’t handled with the necessary cautions.

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Protect any cylinder from excessive heat and mechanical stresses.
Install the cylinders in a vertical position and position them with a fixed support chain
or with a proper cylinder case to avoid falls or knocks.
Maintain the cylinders far away from the welding place and from any electric circuits.
Use only regulation cylinders, pressure reducers, pipes and joints approved for the
specific use; maintain them in good conditions together with the connected parts.
GAS AND FUMES WARNING:
e welding processes produce fumes and gas, which can be harmful and dangerous
if inhaled.
Do not breathe any welding fumes.
Don’t cover the grids and vents placed on the machine.
Carefully read the supplied instructions regarding the different types of metals, clean-
ing substances and shielding gases.
When possible, dedicate a room for the use of this machine. If the room is small, use
it only if well ventilated. e shielding gas used to weld can gradually change the air
causing sickness or death. Assure that the air in the room is safe to breathe.
Don’t weld near any degreasing, cleaning or vaporization areas. e heat could react
with the vapors to form very toxic and irritating gases.
Check that the metals do not have impurities that may produce fumes or gases during
the weld process.
ELECTRIC WARNING:
is symbol shows dangerous voltages associated to the laser which may have suffi-
cient power to cause electric risk. is symbol can also be found on the machine.
Touching electric parts under voltage can cause fatal damages or serious burns. e
electric circuits are always under voltage when the machine is switched on. Incorrect
installation and/or inappropriate wiring and grounding of the machine is dangerous.
Don’t touch electric parts under voltage.
Remove the power plug from the machine before installing or performing any mainte-
nance to the machine.
Ensure that the power cord is correctly connected to both the wall plug and to the back
of the machine- according to this manual and any local standards and rules.

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Switch off the machine when not in use.
Do not use any power cables that are damaged or that are not rated for this machine.
Ensure that the cables are not near any heat sources.
Use the equipment only when in perfect conditions. Immediately repair or change any
damaged parts.
IMPORTANT WARNING:
is symbol shows the need to pay special attention to suggestions or warnings in-
cluded in this manual.

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Chapter 2: Safety
is chapter discusses matters relating to the safety of the individuals using this machine.
When used properly, this laser welding machine is safe and reliable. It is necessary, however, that the
operator is informed about the precautionary standards so as to avoid possible damages to them-
selves or to the machine.
LASER RADIATION
Laser radiation is an electromagnetic emission with micrometric wavelengths that are placed in the
far infrared (CO2 laser), in the near infrared (laser at Nd-YAG, Nd-YVO4), in the visible (laser He: Ne or
Argon), or in the ultraviolet (excimer laser) ranges. Laser radiation produced from the LZR machines
is invisible and therefore can be very dangerous, especially dangerous to eyes and skin.
NOTE
Direct exposure of a laser beam can provoke irreversible damages to eyesight
and vision
To avoid permanent damage to the operator and others nearby, it is necessary to follow some pre-
cautions.
Everyone in the near vicinity of the machine and who may be exposed to harmful levels of laser radia-
tion, must be informed when the laser is active.
Due to the high power of the laser generated in this machine, there is a potential that the laser may
reflect off of welded pieces. If this happens, the reflected light can be potentially dangerous for the
eyes and the skin. As stated previously, the laser generated in the LRZ welder is invisible, and there-
fore it is not easy to identify if the laser is reflecting off the piece, nor is it easy to know where the
laser may be travelling once reflected.
NOTE
It is crucial to be protected from the reflected light beams, because they can be
sufficiently intense to create permanent damages to the eyes or to the skin

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NOTE
e laser generated here is a class IV. e risks associated with class IV lasers
include not only the risk of direct or reflected radiation, but also of diffused radia-
tion. ese lasers can present a remarkable risk for the skin and eyes, as well as a
fire risk when working near flammable materials
2.1: LASER RADIATION ABSORPTION
e human tissue absorbs electromagnetic radiation in different ways, depending on the wavelength
of the radiation. Eyes and skin accept some wavelengths, while refracting others. Specifically relat-
ing to the eye, the cornea and the lens both allow lasers within the 400-1400nm wavelengths to pass
through and reach the retina. e wavelength of the LZR machines is 1064nm, and therefore it will
pass through unobstructed to the retina.
In regards to skin, the absorption of the radiation will vary from one person to the next, regardless of
the wavelength. erefore, seeing as the absorption may vary, the exact and specific details are hard
to state regarding the maximum tolerable exposure levels.
Picture 1: Eyeball
e extent of damages due to radiation absorption depends on the wavelength. e short wave-
lengths (ultraviolet UV-C 180-280nm, UV-B 180-280nm, UV-A 315-400nm) generally provoke and
cause photochemistry effects: cataract or opacification of the lens in the eye, blackening or reddening
for the skin. Major wavelengths (infrared: IR-a 780-1400nm IR-c 3000-10 E6nm) generally provoke
thermal effects: retinal detachment and photocoagulation for the eye, burning for the skin.

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e extent of the damage depends on the quantity of absorbed radiation and on the power and inten-
sity of the radiation source.
2.2: CLASSIFICATION AND DANGEROUSNESS
Laser classifications are based on the laser’s ability to cause damage to people. All lasers are clas-
sified according to their output, from Class 1, which describes lasers which are of such low power that
they represent no hazard at all, to Class 4 lasers which are always hazardous.
e LZR lasers belong to the class IV and can produce risks, not only from direct or reflected radiation,
but also from diffused radiation. For these reasons users must take all precautions to assure that
safety guidelines are established and followed. In addition, the operator must be informed of the risks
deriving from the exposure to laser radiation, and he/she must be provided with the proper personal
protective equipment, potentially consisting of certified protection glasses for the laser radiation.
2.3: RADIATION VISION CONDITIONS
e laser beam is highly collimated and intense as it is generated and leaves the internal resonator.
If this collimated beam were to pass through to a person’s retina, this focused beam of high-dense
power can be very dangerous. Conversely, if the beam becomes divergent and spreads out, then the
beam is much less dense and therefore less dangerous. Below are some different scenarios related
to viewing the laser beam.
DIRECT VIEW OF A LASER BEAM
is type of exposure is the most dangerous and can occur through the opening to the weld
chamber, or if the optics have been removed.
DIRECT VIEW OF A REFLECTED LASER BEAM
is can happen anytime the laser beam reflects off a reflective surface. A reflected beam
can be equally dangerous as a direct view of a laser beam.
DIRECT VIEW OF A LASER BEAM EXITING A FIBER OPTIC
is can happen anytime the optical fiber is connected to the resonator. e beam can be
dangerous even if viewed from considerably far away.

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DIRECT VIEW OF A LASER BEAM AFTER FOCUSING OPTICS
is can happen if the beam is not absorbed at the end of its path. is beam can be danger-
ous even if viewed over considerable distances. Filters and protective glasses can guarantee
the safety for short exposures, on the condition that they are well dimensioned and certified
to be safe for the relating wavelength.
VIEWING A DIFFUSED LASER BEAM AFTER FOCUSING OPTICS
is scenario is the most likely to occur when using this machine. Viewing a diffused beam
after the focusing optics is not dangerous if not over a short distance, and viewing through
filter and lenses can guarantee the safety, even for long exposure times.
THE NOMINAL OCULAR HAZARD DISTANCES NOHD FOR THE LZR LASERS IS LESS THAN 15M FOR
DIRECT OR SPECULAR REFLECTED RADIATION, AND LESS THAN 0.5M FOR THE DIFFUSED REFLEC
TION. ONLY A SUITABLE WELD LENS WITH OPTICAL DENSITY GREATER THAN 4 CAN SUFFICIENTLY
PROTECT THE SIGHT FROM THE ACCIDENTAL VIEWING OF THE HARMFUL LASER RADIATION.
NOTE
Always use certified eye protection.
2.4: RISKS FOR THE EYES AND THE SKIN
e cornea and the retina can be burned and damaged, possibly irreversibly, if exposed to an intense
laser radiation, regardless of duration. Also, exposure to a less intense laser radiation over a long du-
ration, can result in similar dangerous and possibly irreversible outcomes. is danger is completely
realistic in any case of direct vision of any Class IV laser beam.
Skin can also burn, if submitted to the focused direct radiation. In addition to focused direct exposure,
exposure to ultraviolet radiation over time can also cause negative consequences to skin.
2.5: SAFETY GENERAL PRESCRIPTIONS
We recommend developing a Standard Operating Procedure (SOP) to follow when operating and ser-
vicing the machine. A written copy of this procedure should be easily accessible to any operator using
the machine. Training and review of the process over time is recommended as well to ensure:

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• Operators are familiar with the system functioning procedures
• Operators are aware of the dangers related to the exposure to radiation, and the biological
effects that could result from exposure to the skin and eyes
• Operators understand the need to use Individual Protection Devices (IPDs)

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Chapter 3: Seals
ere are various seals in and on the LZR machines. ese seals must not be, for any reason, broken
or removed without authorization from Sunstone Engineering.
NOTE
Removing or breaking certain seals on this machine can have immediate and
negative effects on the weld system.
ATTENTION
e manufacturer denies all responsibility for the nonconformance use of this
machine.
It is prohibited to start the equipment before the machine is declared in confor-
mance with the actual directives.
NOTE
Opening the laser and accessing the internal parts of the equipment is allowed
only to authorized personnel who are qualified, trained, and aware of the potential
electric risks.
Sunstone Engineering denies all responsibility for any interventions on behalf of
untrained personnel.
NOTE
Access to the internal parts of the laser resonator is allowed only to authorized
personnel who are qualified, trained, and aware of the optical risks.
Sunstone Engineering denies all responsibility for any interventions on behalf of
untrained personnel.
3.1: SAFETY LABELS
e labels and the stickers are applied on the equipment in conformance with the FDA and European
safety rules. ey must not be removed or damaged. For possible changes you can contact Sunstone
Engineering.

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LASER WARNING LABELS:
Label Shape and type Sizes (mm)
Laser N. 1
Laser warning
Side 22
Side 50
Laser N. 2
Laser class information
104 x 52
52 x 26
Laser N. 3
Radiation information
104 x 52
52 x 26
Laser N. 4
Laser exposure information
56 x 40

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Laser N.5
Laser technical data
104 x 25
Laser N.6
Laser opening information
104 x 26
ELECTRIC WARNING LABELS
Label Shape and type Sizes ( mm)
Electric N.1
Electricity warning
Side 22
Side 50
PRODUCT IDENTIFICATION LABEL
is label shows the data about the manufacturer (Ref A), the electric specifications (Ref B), the gen-
erator power (Ref C) and the risk class of the laser machine (Ref D).
A
B
C D

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3.2: LABELS POSITIONING
e Laser warning labels are placed on the machine in the following ways:
Picture 2: Outside laser warning labels
Picture 3: Internal laser warning labels
e Laser warning labels are placed on the backside of the machine in the following way:
Picture 4: Backside laser warning labels
LASER N.3
LASER N.1
LASER N.6
LASER N.4
LASER N.2
LASER N.5
IDENTIFICATION
LABEL