SUNSTONE Orion LZR Benchtop Laser Welder User manual
e Micro Welder Experts
LZR Laser Welder
Benchtop Users Guide
Version 20200708 • Part #1154
ii • Questions? Call or Text +1-801-658-0015
LZR LASER WELDER USERS GUIDE
ATTENTION: Read the Safety Guide before operating this welder!
Operator assumes all liability.
ISSUE DAT E APPROVAL VALID FROM MODEL n ° NOTES
0 7/1/2006 G.M. 7/1/06 MG01100
1 MG01160
2
3 MGO1177
LZR1000
6 LZR1000
GENERAL FORMATTING CHANGES
Limitation of Liability
IN NO EVENT, UNDER ANY CAUSE OF ACTION OF THEORY OF LIABILITY, SHALL SUNSTONE ENGINEERING
LLC, ITS DISTRIBUTORS, OR SUPPLIERS BE LIABLE TO YOU OR ANY THIRD PARTY FOR ANY INDIRECT,
INCIDENTAL, CONSEQUENTIAL, SPECIAL, EXEMPLARY OR PUNITIVE DAMAGES, OF ANY NATURE WHAT-
SOEVER, ARISING OUT OF THE USE OF OR INABILITY TO USE ANY SUNSTONE ENGINEERING LLC PROD-
UCT, INCLUDING, WITHOUT LIMITATION, PROPERTY DAMAGE, LOSS OF VALUE OF THE SUNSTONE ENGI-
NEERING LLC PRODUCT OR ANY THIRD PARTY PRODUCTS THAT ARE USED IN OR WITH THE SUNSTONE
ENGINEERING LLC PRODUCT, OR LOSS OF USE OF THE SUNSTONE ENGINEERING LLC PRODUCT OR ANY
THIRD PARTY PRODUCTS THAT ARE USED IN OR WITH THE SUNSTONE ENGINEERING LLC PRODUCT,
EVEN IF SUNSTONE ENGINEERING LLC HAS BEEN ADVISED OF THE POSSIBILITY OF SUCH DAMAGES.
WITHOUT LIMITING THE FOREGOING, YOU UNDERSTAND AND AGREE THAT SUNSTONE ENGINEERING
LLC HAS NO LIABILITY FOR ANY DAMAGE OR DESTRUCTION TO ANY PROPERTY. NOTWITHSTANDING
ANY DAMAGES THAT YOU MIGHT INCUR FOR ANY REASON WHATSOEVER (INCLUDING, WITHOUT LIMI-
TATION, ALL DAMAGES REFERENCED HEREIN AND ALL DIRECT OR GENERAL DAMAGES IN CONTRACT,
TORT (INCLUDING NEGLIGENCE) OR OTHERWISE), THE ENTIRE AGGREGATE LIABILITY OF SUNSTONE EN-
GINEERING LLC AND ANY OF ITS DISTRIBUTORS AND/OR SUPPLIERS SHALL BE LIMITED TO THE AMOUNT
ACTUALLY PAID BY YOU FOR THE SUNSTONE ENGINEERING LLC PRODUCT GIVING RISE TO LIABILITY.
SOME STATES AND/OR JURISDICTIONS DO NOT ALLOW THE EXCLUSION OR LIMITATION OF INCIDENTAL
OR CONSEQUENTIAL DAMAGES, SO THE ABOVE LIMITATIONS OR EXCLUSIONS MAY NOT APPLY TO YOU.
THE LIMITATIONS OF LIABILITY SET FORTH ABOVE SHALL APPLY TO THE MAXIMUM EXTENT PERMITTED
UNDER APPLICABLE LAW.
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Table of Contents
Chapter 1: General Warnings and Safety 1
Laser Recitation Absorption 3
Powering the Welder for the First Time 10
Chapter 3: Controls 11
Chamber Controls 11
Joystick Control 12
Laser Tab 13
Video Tab 16
Manuals Tab 16
Settings Tab 17
Realigning the Microscope Crosshairs 23
Troubleshooting 27
Chapter 6: Safety Systems 30
Chapter 7: Suggested Settings 32
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LZR LASER WELDER USERS GUIDE
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Chapter 1: General Warnings and Safety
Carefully read and follow all instructions to ensure proper use and maintenance of the equipment. Read all gen-
eral warnings and cautions before operating the welder.
LASER WARNING
see this symbol:
•
the welder is in use.
•
found on the front of the welder.
•
chamber.
• When using the welder, ensure that no one is seated with their face being
•
FIRE WARNING
-
turer during the installation of the welder.
•
•
•
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EXPLOSION WARNING
The Argon gas cylinder is under pressure and can consequently explode if the cylinder
is not handled with the necessary cautions.
•
•
• Place the cylinders away from the welding place and from electric circuits. Use
compressed gas. Regularly inspect and maintain the cylinder and parts.
GAS AND FUMES WARNING
• The welding processes produce fumes and gas, which can be harmful and
dangerous if inhaled.
•
•
•
cleaning substances, and shielding gases.
• When possible, dedicate a room for the use of this welder. If the room is small,
the air causing sickness or death. Assure that the air in the room is safe to
breathe.
•
•
during the weld process.
ELECTRIC WARNING
•
Incorrect installation and/or inappropriate wiring and grounding of the welder is
dangerous.
•
•
maintenance to the welder.
• Ensure that the power cord is correctly connected to both the wall plug and to
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the back of the welder in accordance with this manual and any local standards
and rules.
•
•
welder. 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.
LASER RADIATION
eyes and skin.
NOTE: Direct exposure of a laser beam can cause irreversible damage to eyesight and
vision.
safety guidelines and precautions.
NOTE: It is crucial to be protected from the reected light beams, because they can be
suciently intense to create permanent damages to the eyes or to the skin
NOTE: The laser generated here is a class IV. The risks associated with class IV lasers
include not only the risk of direct or reected radiation, but also of diused radiation.
These lasers can present a remarkable risk for the skin and eyes, as well as a re risk
when working near ammable materials
Laser Recitation Absorption
-
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-
-
tocoagulation for the eye, burning for the skin. The extent of the damage depends on the quantity of absorbed
radiation and on the power and intensity of the radiation source.
CLASSIFICATION AND DANGER LEVELS
-
cording to their output, from Class 1, which describes lasers which are of such low power that they represent no
-
RADIATION VISION CONDITIONS
-
• Direct View of a Laser Beam. This type of exposure is the most dangerous and can occur through the
• Direct View of a Reected Laser Beam.-
• Direct View of a Laser Beam Exiting a Fiber Optic.
• Direct View of a Laser Beam After Focusing Optics. This can happen if the beam is not absorbed at
• Viewing a Diused Laser Beam After Focusing the Optics. This happens when using this welder.
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 REFLECTION. ONLY A
SUITABLE WELD LENS WITH OPTICAL DENSITY GREATER THAN 4 CAN SUFFICIENTLY PROTECT THE SIGHT
FROM THE ACCIDENTAL VIEWING OF HARMFUL LASER RADIATION.
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NOTE: Always use certied eye protection.
RISKS FOR THE EYES AND THE SKIN
-
Skin can also burn if submitted to focused direct radiation. In addition to focused direct exposure, exposure to
SAFETY GENERAL PRESCRIPTIONS
• Operators are familiar with the system functioning procedures;
• Operators are aware of the dangers related to the exposure to radiation, and the biological
•
Manufacturer Seals
NOTE: Removing or breaking certain seals on this welder can have immediate and negative eects on the weld
system.
WARNING: Do not use the welder before it has been declared to be in conformance with actual directives.
NOTE: Do not open and access internal parts of the welder. Only to authorized personnel who are qualied,
trained, and aware of the potential electric risks. Sunstone Engineering denies all responsibility for any interven-
tions on behalf of untrained personnel.
Safety Labels
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PRODUCT IDENTIFICATION LABEL
class of the laser welder.
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Technical Specications
SPECIFICATION DESCRIPTION
Electric Input VAC 110V or 230V
Electric Power Phase Single Phase
100 W
Laser Crystal Type Nd:YAG
Weld Energy 0.1-60 or 0.1-100 J
Weld Length
Repetition Frequency
Peak Power
0.2-2.0mm
Maximum Argon Gas Pressure
Cooling Type Liquid
Fuse 12 A
Weight
<70 dB(A)
Recommended Argon Purity
Shield Gas Consumption (Argon)
Coolant
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LZR LASER WELDER USERS GUIDE
Chapter 2: Installation
Carefully follow these instructions to prepare the Orion LZR laser welder for safe operation:
• Position the welder on a strong, sturdy table or workbench that is able to support the weight of the
table or workbench.
• If using shielding gas, connect it to the Gas Inlet
bar of pressure to the shielding gas connection. The Air
Inlet connection can be used to blow compressed air
on welded pieces that may heat up during the welding
process.
NOTE: Do not exceed 1.5bar of pressure to the shielding gas
connection.
• Connect the power cable to the wall outlet and then to
the back of the welder.
• Connect the Interlock into the Interlock Port on the
• Connect the foot pedal to the Remote Control Port
ATTENTION: Use only the cables and equipment shipped
with the welder or provided by Sunstone. Do not substitute or
change any cables or plugs.
•
them on the tips of the microscope tubes. Tighten the
Note: To align the microscope crosshairs, see chapter 23.
NOTE: As a general practice, the eyepiece with the crosshairs
should be placed in the right ocular tube.
Figure 8.1 Gas Inlet Connections. Argon shield gas is
connected to the “Gas” inlet on the left; compressed air
may be connected to the “Air” inlet on the right.
Figure 8.2 Insert the Interlock into the Interlock port
found on the rear of the welder.
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Adding Cooling Water
NOTE: During the rst setup and installation, extra steps are needed to get the welder functioning. The next
steps are only important during the initial setup, or after changing the water in the welder.
Figure 9.1 Foot Pedal Connection. Figure 9.2 Attach eyepieces to the microscope tubes and tighten the screws with
an Allen wrench. Generally speaking, the eyepiece with the crosshairs is attached
to the right tube.
• Insert the plastic tube and connector shipped with the
located at the bottom of the rear panel, as shown in
water from the welder.
•
• Connect the funnel that was shipped with the welder to
•
the Upper Connector of the tank.
•
Connector, but do not replace the Red Plug yet. To
the connector.
•
the welder. Do not turn the key switch.
•
you hear the fans and the pump turn on. This will force
the air out of the system.
Figure 9.3. To ll the welder with coolant water, attach
the funnel, tube, and connector to the bottom Female
Connector “Remove Water” Port. Remove the Red Plug
from the Upper Connector tube. Fill the welder with
deionized water that comes with the Orion LZR laser
welder.
Figure 9.4. The nal step to
lling the tank is replacing the
Red Plug on the end of the
Upper Connector.
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• Wait about 60 seconds, then turn the key and press start. If an error message appears saying: “ERROR
•
•
• Turn the welder on using the power switch on the rear panel.
•
fans and the pump turn on. The air will be forced out of the system. You should not see the error
• Turn the key and press the Start Button which will appear on the display screen.
•
Powering the Welder for the First Time
• Ensure that the Emergency Stop Button is disengaged
and not pushed in. See Figure 10.1.
•
the welder.
•
See Figure 10.2.
• A Start Button will appear in the touchscreen interface.
weld. See Figure 10.3.
•
-
NOTE: Do not proceed with the installation if the display does
not show as described above. If you encounter any problems or
errors, consult chapter 5 of this document, or contact Sunstone
Engineering.
At this point you will be able to set welding parameters, load
To turn the welder o, turn the key to the Locked position, wait
ATTENTION: When the welder is not being used, ensure that the
key is removed from the welder.
Figure 10.1. Make sure the
Emergency Stop Button is
disengaged.
Figure 10.2. Turn the key
clockwise to access the
touchscreen controls.
Figure 10.3. Touch the Start Button to adjust weld
parameters and start welding.
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Chapter 3: Controls
Chamber Controls
see where these controls are placed. From within the chamber, you are able to:
• Operate the touchscreen display with the Joystick (A).
•
•
•
Figure 11.1. Controls
located inside the welding
chamber:
A. Touchscreen Display
Joystick
B. LED Chamber Lighting
Control
C. Shield Gas Delivery
Stream
D. Compressed Air
Delivery Stream
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JOYSTICK CONTROL
controls, the welder also has a Joystick inside the weld chamber. When using the Joystick, the selected param-
LED CHAMBER LIGHT CONTROL
within the welding chamber. Turn the knob clockwise to increase brightness. Turn the know counter-clockwise
to decrease the brightness.
SHIELD GAS DELIVERY
weld is initiated.
COMPRESSED AIR DELIVERY
Moving the Joystick to the
right will increase the value
of the parameter selected on
the touchscreen interface.
Moving the Joystick to the
left will decease the value of
the parameter selected on
the touchscreen interface.
Moving the Joystick down will cycle down
through the dierent parameters displayed
on the touchscreen interface
Moving the Joystick up will cycle up through
the dierent parameters displayed on the
touchscreen interface
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Touchscreen Display Controls
LASER TAB
Under the Laser Tab you are able to control all aspects of the weld, such as power, length of time of the weld,
Power
model.
Time
desired weld. Adding more time adds more energy to the weld, resulting in a more powerful weld.
Frequency
to weld only when the foot pedal is initially pressed. Each subsequent foot pedal press will cause a weld. With
Figure 13.1. The Orion LZR laser
welder’s features are controlled with
the Touchscreen Display. Touch
the screen with your nger to make
changes to features or control
settings.
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the selected power and time. If changes are made to either the power or the time, slide the Frequency Bar up to
ensure that the welder is set to the maximum weld rate.
Spot Size
Gas Flow
Waveform
-
forms are:
• Normal (Square)
•
•
•
• Pulse (2 square welds)
•
Memory
-
displayed in the box to the right of the memory boxes.
Memory Box
This box will display instructions, status conditions, system settings, warnings, and error messages.
CAMERA TAB
button in the lower right corner to raise or lower the selected parameter (highlighted in blue text). You can also
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Figure 15.1. When you press the Cam
Tab you are able to view the weld area
while still accessing weld parameter
controls.
Joystick-selected parameter is highlighted with an orange box and text.
Power
The Power Slider is used to select the power of the weld. See page 13 for more information.
Time
The Time Slider is used to select the duration of the weld. See page 13 for more information.
Spot
Frequency
Gas
Wave
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Memory
This box will display instructions, status conditions, system settings, warnings, and error messages.
Zoom
Menu
The Menu Button will replace the on-screen weld parameters with certain parameters relating to the camera.
VIDEO TAB
MANUALS
when using the welder. See Figure 17.1 on the next page.
Figure 16.1. Press the Video Tab to
access how-to and other instructional
videos.
Table of contents
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