1. Introduction
Thank you for choosing the Axrayser 1500W Multi-Functional Laser Welding Machine. This manual provides detailed instructions for the installation, operation, and maintenance of your laser processing system. It is designed to help you quickly and safely utilize the product's capabilities for welding, cutting, and cleaning applications.
This machine is a versatile 4-in-1 system, featuring a Raycus Laser Source and a Raytools welding head, capable of strong cutting and welding. It operates on 220V 60Hz and includes a water-cooled system for optimal performance.
2. Safety Instructions
Please read and understand all safety instructions before operating the machine. Failure to comply with these instructions may result in serious injury or damage to the equipment.
2.1 General Safety
- Ensure the product is used in a dry environment and complies with EMC standards.
- Operate the product only within the parameters specified in the technical data.
- Only use spare parts provided by the manufacturer or designated professional team for installation and maintenance.
- Unauthorized modifications or use of non-original parts will void the warranty.
2.2 Guard against Danger
- Never place hands or other body parts under the laser head during operation.
- Perform repair and maintenance work only after the power is turned off.
- Do not exceed the specified maximum pressure.
- Ensure the laser head is in normal condition at all times.
- All fasteners, such as bolts and nuts, must be tightened securely.
2.3 Laser Caution
- Avoid direct laser radiation or scattering to the skin.
- Do not stare at the laser beam, even when wearing optical equipment.
- Use special laser protective eyeglasses that meet the requirements of safety standards IEC 60825-1.
2.4 Prevent Waterway Corrosion
- Use the specified coolant and comply with relevant requirements and maintenance intervals to prevent corrosion.
2.5 Noise Prevention
- Observe and implement measures to prevent harm from noise when the cutting air pressure is high.
2.6 Storage and Transportation
- Observe the storage temperature range allowed by the technical data.
- Take reasonable measures to prevent fire, vibration, or impact.
- Do not store in or near magnetic fields.
3. Product Overview
The Axrayser 1500W Multi-Functional Laser Welding Machine is designed for high-performance industrial applications, offering welding, cutting, and cleaning capabilities. It features a robust design with universal wheels for flexible movement and a high-quality touch screen for easy operation.
3.1 Main Components
- Laser Welding Machine: The main unit, equipped with universal wheels for mobility.
- Wire Feeder Machine: Light, small, and convenient with industrial-grade high-speed microprocessor, strong anti-interference ability, stable performance, easy operation, automatic memory storage, and overload protection.
- Raycus Laser Source (RFL-C015H1): High average power up to 1500W, good beam quality, customizable output fiber length, high electro-optic conversion efficiency, and a service life exceeding 100,000+ hours.
- HANLI Water Chiller: Features double temperature controls, efficiency and environmental protection, temperature control accuracy ±1°C, and high cooling rate for good weldline and joint performance.
- Laser Welding Gun: High quality multifunctional welding gun.
- LED Smart Display: For monitoring and control.
3.2 Packing List
The standard package includes the following items:
- Laser Welding Machine
- Welding Nozzle (1 Set)
- Laser Welding Gun
- Wrench
- Protective Lens (5 PCS)
- Wire Feed Rolls (×4)
- LED Smart Display
- Laser Wire Feeder
- Wire Nozzle (×4)
- Safe Clip
- Air Feed Pipe
- Raycus Laser Source RFL-C015H1
- Protective Glasses
- Wire Feeding Tube
4. Setup Instructions
4.1 Laser Processing Head Connection (QBH)
The laser processing head connects via a QBH interface. Ensure proper connection to prevent damage and maintain optimal performance.
- Remove the dust cover of the optical fiber and check if the protective cap of the fiber crystal head is locked.
- Clean the optical fiber head with a dust-free cotton swab and absolute ethanol to ensure the optical fiber section is clean and dust-free.
- Place the welding head horizontally.
- Align the red point at the end of the QBH interface to the red point of the handwheel.
- Remove the QBH dustproof cover.
- Align the red mark of the male fiber end to the red mark on the female QBH of the cutting head when inserting the fiber end straightly to the bottom of the QBH interface.
- Turn the QBH handwheel clockwise until you hear a "Da" sound, then pull the handwheel up and turn clockwise to the end.
4.2 Dismantling and Mounting of Cover Glass
Regular inspection and cleaning of the cover glass are essential. Follow these steps for safe handling:
4.2.1 Middle Cover Glass
- Unscrew the bolt of the focus lens holder in a dust-free environment to remove the focus lens holder.
- Seal any openings with textured paper to prevent dust.
- Take out the seal ring and cover glass using a lens tool for cleaning or replacement.
4.2.2 Bottom Cover Glass
- Manually loosen the screw of the cover glass to pull out the holder. Seal openings with textured paper. This cover glass is the outer one of the double cover glasses.
- Remove the seal ring and carefully take out the cover glass for cleaning or replacement.
4.3 Overall Wiring
Proper wiring is crucial for the safe and correct operation of the machine. The system includes connections for the HMI panel, laser, power supply, gas valve, chiller, and wire feeder.
4.3.1 HMI Panel to Controller Wiring
Connect the HMI panel to the controller using the 24V power cable and signal cable as shown in the diagram.
4.3.2 Laser to Controller Wiring
The laser processing head connects to the controller via a DB15 connector and a single core safety lock cable.
- The DB15 connector of the handheld laser welding head plugs into the controller.
- The single core cable as a safety lock connects between the controller and the alligator clamp.
4.3.3 Power Supply to Controller Wiring
The controller requires one 24V power supply and one ±15V power supply, both included in the standard kit.
4.3.4 Gas Valve and Chiller to Controller Wiring
Connect the gas valve and chiller to the controller as follows:
- Gas Valve: The gas valve + (red line of solenoid valve) is a 24V+ relay output. The gas valve - (black line) is 0V. Ensure proper connection of air inlet and outlet pipes.
- Water Cooling Alarm: These are switch signals. If the chiller lacks a water pressure alarm interface, the positive and negative interfaces can be directly shorted.
4.3.5 Wire Feeder to Controller Wiring
Connect the wire feeder to the controller using the control cable.
4.4 Wire Feeder Installation
Proper installation of the wire feeder is essential for consistent wire feeding.
- The two 24V input wires of the wire feeder connect to the 24V power supply or switching power supply of the laser welding machine (power supply power ≥ 80W).
- The two signal wires SS1 and SS2 connect to the relevant positions on the handheld welding controller.
- Hang the welding wire reel on the reel shaft in the wire feeder.
- Select the groove diameter of the wire feeding wheel. Loosen the tension regulator and pass the welding wire through the wire leading nozzle. Align it with the groove of the wire feeding wheel and tighten the tension regulator.
- Assemble the wire feeding mechanism and lead the wire out by pressing "Manual Feeding". Fix the wire feeding mechanism onto the wire feeder and tighten it by bolt.
- Adjust the tension regulator for stable wire feeding. Deliver the wire to the wire feeding nozzle by manual feeding.
4.5 Connection of Wire Feeding Mechanism to Laser Processing Head
- Use M2.5*5 screws to fix the wire feeding connecting block onto the handheld processing head.
- Tighten the wire feeding adapter block with M4*12 screws. Control the wire feeding angle by adjusting the adapter block.
- The feeding distance can be adjusted by loosening the screw.
- Lock the wire feeding hose with M5*4 jacking screw.
5. Operating Instructions
5.1 HMI Panel Overview
The Human-Machine Interface (HMI) panel provides control and monitoring for the laser welding machine. It features a touch screen for easy navigation.
5.1.1 Wire Feeder HMI Panel
- Set: Function switching. Parameters can be modified using "+" and "-".
- Run: Confirms settings.
- Manual Feeding: Press and hold to feed wire continuously.
- Manual Pumpback: Press and hold to pull back wire continuously.
- Simulation Run: Press and hold to feed wire continuously as per set parameters.
- Feeding Speed: Adjust with "+" "-" keys.
- Delay Feeding: Adjust with "+" "-" keys.
- Filling Distance: Adjust with "+" "-" keys.
- Pumpback Distance: Adjust with "+" "-" keys.
5.1.2 Laser Welding Control System HMI
- Laser Power: Laser output power (0 to 2000W).
- Pattern: Spot Weld or Line Wobble Weld.
- Laser Freq: Number of laser pulses per second.
- Wobble Freq: 0-200Hz.
- PWM: Ratio of pulse duration to pulse cycle (0-100%).
- Wobble Size: Line spot width (0-5mm) for wobble welding.
- Laser: Turn on/off laser.
- Wire Feeding: Turn on/off wire feeding.
- ScaleWeld: Turn on for spot welding.
- Gas-Manual: Continuous gas blow for independent test.
- Process No: 16 processes can be saved.
- Safety Lock: Shows status (green for conduction, grey for non-conduction).
- Setting: Enter submenu for basic or galvo settings.
- Process: Enter submenu to modify parameters or select process.
- Monitoring: Shows alerts (red if alert occurs).
- HMI Lock: Prevents accidental screen touches.
5.2 Parameter Setting
Parameters can be adjusted via the HMI panel. After changing parameters, the last shutdown data is defaulted upon restart. To restore factory settings, press "+" and "-" keys simultaneously for 3 seconds until "888" is displayed.
5.2.1 Basic Setting
- Gas in Advance: Gas blow duration from laser on to beam shooting.
- Gas Delay: Gas blow duration after laser off.
- Beam Off Delay: Laser shooting duration after laser off (used to weld off welding wires).
- On Power: Starting power of ascent process.
- Off Power: Ending power of descent process.
- Ascent: Duration from on power to set power after beam on.
- Descent: Duration from set power to off power after beam off.
- Max Power: Set as per the rating power of exact laser (limit 2000W).
- Alarm Signal: PNP 24V effective.
- NozzleBreak Duration: Duration of beam shooting when the nozzle is not in contact with workpiece.
- ScaleWeld Duration: Adjust beam shooting duration for spot welding.
- ScaleWeld Interval: Beam off interval during spot welding.
5.2.2 Galvo Setting
- Wobble: Turn on/off wobble function (for red beam commissioning only).
- Pattern: Line or spot.
- Wobble Size: 0-5mm line range.
- Wobble Freq: 0-200Hz.
- X Center Offset: Center alignment (primarily done ex-works, minor adjustments for wire feeding).
- X Magn: Debugged ex-works, minor adjustments if required.
5.3 Auxiliary Functions
The machine supports various auxiliary functions accessible via the HMI's "MultiFunc Switch" page.
5.3.1 Cut Function
Handheld laser cutting is one of the 4-in-1 functions. It involves removing the wire feeding mechanism and welding nozzle, then mounting the cutting nozzle to the extension tube.
The laser beam melts or boils the workpiece, and high-pressure gas blows away molten metal, creating a slit for cutting. It's commonly used in sheet metal, hardware, electrical appliances, and manufacturing.
5.3.2 WeldSeam Clean Function
Handheld weld seam laser cleaning is another 4-in-1 function. It involves removing the wire feeding mechanism, welding nozzle, and extension tube, then mounting the clean tube.
This function is used for removing paint, coatings, rust, oxides, grease, resin, glue, dust, and production residues from metal or glass surfaces. It's also suitable for mold cleaning and pre-welding/bonding treatment.
5.3.3 Remote Clean Function
Similar to WeldSeam Clean, Remote Clean is used for surface preparation and cleaning tasks. It offers low power, medium scan range, non-contact operation, and flexible use.
6. Maintenance
6.1 Daily Inspection
- Check if the cover glass is polluted before daily use and replace if necessary.
- Check if the QBH connector is loose and ensure the lock does not shake.
- Check if the copper nozzle is blocked or if it is conductive between the copper nozzle and safety lock. Replace if blocked or conductivity is poor.
- Check for water leakage in wiring before daily use.
- Ensure gas (middle) and water (both sides, one inlet, one outlet) connections are correct, with pipes of Ø6mm.
6.2 Daily Maintenance of Wire Feeder
- When not in use, shut down the wire feeder and place it in a cool, dry, dust-free area.
- Do not place other objects on the wire feeder.
- Before installing a new wire reel, blow compressed air through the feeding tube to remove impurities.
- Keep the wire guide tube smooth, without extrusion, deformation, or folding.
- Regularly clean dust from the machine and check the motor's smooth rotation and noise.
6.3 Cautions for Wire Feeder
- This machine is for indoor use (IP2X protection grade). Do not use where water drops or raindrops are present.
- Operating temperature range: -10°C to 40°C.
- Do not place on surfaces with strong vibration or impact.
- When installing the wire disc or inserting wire into the guide tube, do not wear gloves to avoid winding accidents.
- Confirm the wire reel weight (not greater than 20kg) to prevent it from falling off.
- During welding, close the right side plate to prevent electric shock or winding accidents.
- Before welding, confirm the disc shaft end cover is tightened to prevent the wire disc from falling off.
7. Troubleshooting
This section provides solutions for common issues encountered during operation.
| Fault | Reason | Solution |
|---|---|---|
| Power LED not ON | 24V power cable breaks Power switch fails | Change power cable Change power switch |
| Wire feeding fails by operating welding head | Poor welding / disconnection of internal wire inside switch plug of welding head Wire feeding motor fails Out of wire Motor plug loose on motion card Welding wire knotted Wire feeding tube knotted Wire blocked at outlet of wire feeder Wire feeding tube blocked Insufficient tension Control board fails | Replace plug and check connecting wire Replace wire feeding motor Replace welding wire disc Replug Loosen tension regulator and rewind wire Straighten wire feeding tube Adjust wire guide tube to align with outlet Replace wire feeding tube Loosen welding wire disc brake Replace control board |
| Communication alarm of HMI panel | Wiring issue | Check wiring and restart in 2 mins. |
| Beam shooting not coming out | Laser alarm / encryption / optics contamination | 1. Restart. 2. Check wiring. 3. Check if laser is encrypted. 4. Check QBH for firm lock status if fiber interface interlock is under alarm. 5. Replace QBH if alarm stays intermittently or continuously. 6. If red beam indication is normal, wobble in red beam to see whether it is centered. 7. If it can wobble normally, check the process parameter setting. 8. Check whether the beam is locked or the focus is wrong. 9. Check if optics contamination occurs in head or laser can work independently. |
| Wire feeder not working | Wiring / Installation issue | Check wiring as per Clause 3. Independent power supply is suggested. Check installation from wire feeder to wire feeding mechanism. |
| Unstable wire feeding speed and poor wire feeding | Wire knotted in reel Mismatch or wear of wire feeding tube Improper wire feeding reel Incorrect tension by tension regulator Wire feeding motor fails Drive card fails Jam of wire feeding tube Bending angle of wire feeding tube less than 30 degrees Deformation of wire feeding tube after extrusion | Remove knotted part and rewind wire Replace wire feeding tube Replace wire feeding reel Modify tension Replace wire feeding motor Replace drive card Replace or clean wire feeding tube Put wire feeding tube straight as much as possible Replace wire feeding tube |
8. Specifications
8.1 General Product Specifications
| Attribute | Value |
|---|---|
| Brand Name | Axrayser |
| Model Number | RFL-C015H1 |
| Max. Output Power | 1500W |
| Certification | CE |
| Origin | Mainland China |
| Wavelength | 1080±10nm |
| Use | Laser Welding Machine/Laser Cleaning Machine/Laser Cutting Machine |
| Laser Source Power | 1500W |
| Laser Type | Continuous/Modulation |
| Maximum Modulation Frequency | 20KHz |
| Cable Length | 10m |
| Scan Width | 10-160mm |
| Power Configuration | AC220V±10%(10KW) |
| Cooling Method | Water cooling (Medium: Deionized water, distilled water or purified water) |
| Water Tank Capacity | 16L (14-15L of water to be added) |
| Speed range of welder | 0~120 mm/s |
| Operating temperature range | 15~35 ℃ |
| Operating humidity range | < 70% |
| Welding thickness | 0.5-3mm |
| Welding gap | ≤0.5mm |
| Cooling chiller | Industrial water chiller |
| Power adjustment range | 10%-100% |
| Laser Source Brand | RFL-C015H1 |
| Welding Head Brand | Raytools BW101 |
| Service life | 100000H |
| Machine compatible languages | 24 national languages |
8.2 Wire Feeder Technical Data
| Model | RT-HWS-DM80A |
|---|---|
| P/N | 3150140008 |
| Voltage | DC24V (≥80W) |
| Phase | Single phase |
| Motor | DC PM |
| Rotation | 1200rpm |
| Wire Size | 0.8/1.0/1.2/1.6mm |
| Feeding Speed | 0.1-18M/min |
| Size | 440*250*580MM |
| Weight | 15kg |
8.3 Welding Nozzle Options
8.4 Welding Process Reference Table
For detailed welding parameters with and without wire feeding, please refer to the comprehensive tables provided in the full user manual PDF. These tables include recommended settings for various materials (SS, AL-5 series, MS) and thicknesses, covering power, PWM, frequency, focus, wobble width, wobble frequency, feeding speed/wire diameter, and melting depth.
9. User Tips
- Regular Cleaning: Keep the cover glass and wire feeding tube clean to ensure consistent performance and prevent issues like unstable wire feeding.
- Check Connections: Before each use, quickly verify all QBH, power, gas, and water connections are secure to avoid operational faults.
- Parameter Adjustment: Experiment with the HMI parameters (Feeding Speed, Delay Feeding, Wobble Size, etc.) to find optimal settings for different materials and desired weld/cut/clean quality. Remember to save your preferred settings.
10. Warranty and Support
For detailed warranty information, service terms, and technical support, please refer to the official user manual PDF provided by the manufacturer. You can access the full user manual at https://manuals.plus/m/6cd432087bc39bd36590adb6c151436676c7578aaed8f8ca5239fe1c8bf56461.
RayTools AG can be contacted via email at sales@raytools.com or through their website at www.raytools.ch for further assistance.