5-in-1 Laser Welding, Cleaning, Cutting Machine User Manual

1. Introduction

This manual provides essential information for the safe and effective operation, maintenance, and troubleshooting of your BWT 5-in-1 Handheld Fiber Laser Welder. Please read this document thoroughly before using the machine to ensure personnel safety, equipment safety, and optimal performance.

Figure 1: BWT 5-in-1 Handheld Laser Welder Machine

1.1 Product Overview

The BWT 5-in-1 Handheld Fiber Laser Welder is a versatile machine capable of performing five distinct functions: Laser Welding, Laser Cutting, Laser Cleaning, Weld Seam Cleaning, and Battery Welding. It is designed for high precision and efficiency across various materials and applications.

1.2 Product Dimensions

Figure 2: Main Unit Dimensions (H=67cm, L=65cm, W=38cm) and Wire Feeder Dimensions (H=40cm, L=59cm, W=27cm)

1.3 Key Features

• 5-in-1 Functionality: Welding, Cutting, Cleaning, Weld Seam Cleaning, Battery Welding.
• High Power Output: Available in 1500W and 2000W configurations.
• User-Friendly Interface: Relfar Intelligent System with 28 language options.
• Safety Features: Multiple safety settings including laser switch, emergency switch, laser disable switch, air switch, welding gun switch, and safe ground wire clamp.
• Versatile Applications: Suitable for various metals and new energy battery welding.

Figure 3: Visual representation of the 5-in-1 functions: Welding, Cutting, Cleaning, Weld Seam Cleaning, Battery Welding.

2. Safety Information

Operating a fiber laser requires strict adherence to safety protocols. Failure to follow these instructions may result in personal injury, equipment damage, or death.

2.1 Safety Conventions

Throughout this manual, the following symbols are used to highlight important safety information:

Symbol	Description
	WARNING: Refers to a potential hazard that may lead to personal injury or death.
	CAUTION: Refers to a potential hazard on the product, or a potential physical injury to personnel.
NO	IMPORTANT: Refers to any information regarding the operation of the product. Please do not overlook this information.

2.2 Laser Classification

This machine emits invisible laser radiation (1080 ± 3nm wavelength) and is classified as a Class 4 laser instrument. Direct or indirect exposure to this light intensity can cause severe damage to eyes and skin.

• Always wear appropriate and approved laser safety protective glasses when the laser is operating.
• Ensure laser safety protective glasses cover the entire range of wavelengths of the laser emission.
• Never look directly into the optical output when the electrical switch is on.
• Do not operate the laser in darkened environments.
• Do not turn on the laser without an optical coupling fiber or the optical output connector.

2.3 Electrical Safety

• Ensure the power source is properly grounded with a PE wire. The machine's shell must also be properly grounded.
• Verify that the input AC voltage and capacity meet the requirements (220V 50/60Hz, 15A).
• If the air switch frequently shuts down, contact the manufacturer.

2.4 Protective Housing and Interlocking System

• The machine's shield is designed to prevent direct access to dangerous areas.
• The laser room (if applicable) should be installed according to professional design and include safety features like maintenance doors, observation windows, and safety interlocks.
• The safety door of the laser room must be connected to the product's remote control chain connector. Opening the door will stop laser emission, preventing radiation exposure.
• The interlocking system restricts access to trained, authorized personnel with appropriate protective equipment.

2.5 Operation Conditions

• Supply Voltage: 220±10% VAC 50/60Hz
• Placement: Flat, upright, no vibration and impact.
• Environment Temperature: 5~40°C
• Relative Humidity: 30%RH~70%RH
• Electromagnetic Environment: Avoid strong electromagnetic interference to prevent false laser alarms.
• Cooling Water Quality: Use deionized water to prevent scaling. Pure water can be used if deionized water is unavailable.
• Antifreeze: If ambient temperature is below 0°C, add antifreeze (30% volume ratio for alcohol) to the cooling water.
• Never use tap water or other cooling water with high ion concentration.
• Replace cooling water regularly to prevent microorganism and ion growth.
• Do not operate in high humidity (>95%) or below the ambient dew point temperature.

Figure 4: Overview of 6 Safety Settings: Laser Switch, Emergency Switch, Laser Disable Switch, Air Switch, Welding Gun Switch, Safe Ground Wire Clamp.

3. Setup and Installation

3.1 Unpacking and Inspection

Machines are packaged in wooden boxes, while wire feeders are in cardboard boxes. Inspect packaging for damage upon arrival. If damaged, notify the shipping agent immediately. Carefully unpack, ensuring the optical fiber is not broken or damaged. Verify all items against the packing list (Figure 5).

Figure 5: Packing List including Machine, Swing Arm, Wire Feeding Machine, BWT Laser Source, Relfar Display, 5-in-1 Laser Welding Gun, Protective Glasses, Nozzles, Protective Lenses, Cleaning Lens, Protective Gloves, Battery Welding Nozzle, Power Cable, Welding Wire, Cleaning Sleeve, Cotton Swabs.

3.2 Preparation Before Startup

1. Fill Water Tank: Fill the water tank with pure water until the water level gauge on the back of the machine reaches the green mark.
2. Power Connection: Connect the power cord to the electrical box. For 110V operation, a transformer is required. Ensure proper wiring: L=220VAC, N=0VAC, PE=ground.
3. Gas Connection: Connect Argon gas or Nitrogen gas. The flow rate should reach 15L/min. For welding and cutting, an air pump is needed (not included, requires 99.9% pure Argon 4.6).
4. Air Pressure Adjustment: Turn the knob on the air pressure gauge on the back of the machine until the pressure reducing valve reaches 0.2Mpa.

3.3 Wire Feeder Connection

1. Install Welding Wire Disc: Rotate counterclockwise to loosen the nut. Install the wire feeding disc, aligning the small hole with the blocking wheel. Ensure the wire rotates counterclockwise and connects to the wire feeding wheel in a horizontal straight line. Tighten the screw feeding disc with the nut.
2. Select Wire Feeding Wheel Specifications: Use the appropriate wire feeding wheel (0.8mm or 1.0mm groove width) matching the wire core diameter.
3. Install Wire Feed Pipe: Align the wire tube with the wire outlet and tighten the screws. The wire nozzle should match the copper nozzle (1:1 ratio based on wire core diameter).

3.4 Power On

1. Toggle the air switch on the back of the machine up, then flip the switch on the control panel. The screen will light up, and the machine will start.
2. Safety Clip: Before turning on the laser, ensure the safety clip is clamped in the correct position to form a circuit with the welding head. In welding mode, clamp it to the workpiece. In cleaning and cutting modes, clamp it to the metal part of the gun.

4. Operation Guide

4.1 Handheld Welding Gun

Figure 6: Exploded view of the 5-in-1 Double Pendulum Handheld Welding Gun components.

The handheld welding gun features a QBH connector, collimating lens, protective glass, and welding nozzle/scale tube. The collimating lens completes fiber collimation and converts the incident laser into a parallel beam. The protective glass shields the focusing lens from slag, extending its lifespan. The welding nozzle guides the focused beam and provides high-speed airflow to protect the molten pool.

4.2 Screen Control System

The Relfar Intelligent System provides a user-friendly interface with 28 language options. It allows control over various parameters for welding, cutting, and cleaning modes.

Figure 7: Control panel showing 28 language options for the Relfar Intelligent System.

4.2.1 Energy Welding Mode (No Wire Feeder)

1. Select Copper Nozzle: Choose the appropriate copper nozzle (square or circular) for your energy welding needs.
2. Install Swing Arm (Optional): If using the swing arm, install it by attaching Part 1 with Screw 1, Part 2 with Screw 2, and Part 3 with Screw 3. Then install the welding gun to the swing arm.
3. Set Parameters: On the control board, set Scanning speed, Laser power, Number of scans, Scan type, Linear selection, Screw pitch, and Spiral diameter as needed. The system supports 9 groups of parameter stores.
4. Start Welding: Turn on the “Laser Switch” and “Emergency Switch”. Click “Laser enable” on the screen. Double-click the laser switch on the welding gun and hold the button to start welding. Keep the welding head at a 45° angle to the workpiece.

4.2.2 Welding Mode (With Wire Feeder)

1. Change Welding Head Mode: If the welding gun is installed on the swing arm, uninstall it.
2. Select Copper Nozzle: Different copper nozzles apply to different materials. For example, FAS-12 for 1.2mm wire.
3. Wire Selection: Choose welding wire based on weld seam width and material (e.g., ER304 for stainless steel, iron wire for carbon steel/galvanized, aluminum wire for aluminum).
4. Connect Welding Wire: Connect the welding wire to the welding head.
5. System Switch and Parameter Setting: Click “System parameter” on the screen, then “Authorization”. Enter password 666666. Click “Working type” and select “Welder”. Confirm and restart the machine.
6. Start Welding: Adjust the scale tube to 0mm for optimal focal length. Keep the “Laser on” and double-click the laser switch on the welding gun, holding the button to start welding. Ensure the safety clip is clamped to the workpiece.

4.2.3 Cutting Mode

1. Change Cutting Nozzle: Replace the welding nozzle with the cutting copper nozzle (FC-20).
2. Parameter Setting: Set “Wobble length” to 0mm. Adjust “Peak power” as needed, ensuring it does not exceed the machine's maximum power.
3. Start Cutting: Clamp the safety clip onto the welding gun. Double-click the laser switch on the welding gun and hold the button to start cutting.

4.2.4 Weld Seam Cleaning Mode

1. Change Nozzle: Change to the weld seam cleaning nozzle.
2. Parameter Setting: On the screen, select “weld bead cleaning”. Set “Wobble length” according to the width of the oxidized or burnt weld seam. Max “Scan width” is 12mm, power usually 300W.
3. Start Cleaning: Clamp the safety clip onto the welding gun. Double-click the laser switch on the welding gun and hold the button to start weld seam cleaning.

4.2.5 Cleaning Mode

1. Remove Copper Nozzle, Install Cleaning Module: Remove the copper nozzle and install the cleaning module.
2. Replace Cleaning Lens (if necessary): For narrow rust/paint/oil removal, use F150 focus lens. For larger cleaning areas, replace with F800 focus lens (cleaning lens).
3. Parameters Setting: Adjust “Scan type”, “Laser power”, “Scan length”, and “Scan width” as required. Scan width must be ≤100mm to avoid burning the welding head. Peak power should not exceed 1200W.
4. Start Cleaning: Clamp the safety clip onto the welding gun. Double-click the laser switch on the welding gun and hold the button to start cleaning. Adjust focus by moving the welding gun up and down until the laser is strongest.

5. Maintenance

5.1 Protective Lens Maintenance

Regularly inspect and replace protective lenses to ensure optimal performance and safety.

1. If there is obvious burning on the surface of the protective lens, replace it directly.
2. Check the white accumulating sealing ring under the protective lens. If scratched or deformed, replace it immediately.

5.1.1 How to Replace Protective Lenses

Perform replacement in a clean environment, wearing dust-free gloves.

1. Protective Glass 01: Hold both sides of the green drawer module handle to pull out the protective glass. Prevent dust from entering the cavity by sealing the exposed window.
2. Protective Glass 02: Take out the green drawer handle module. Gently press the gland down for 90° rotation, and loosen it when two lugs align to two notches to remove the gland and replace the protective glass.

5.2 Cooling System and Antifreeze

• Water Temperature: Set the water cooler to 25 ± 1 °C (no change needed in summer).
• Coolant: Use purified water as cooling water, replaced monthly.
• To prevent mold, add ethanol (10% volume ratio) when adding purified water.
• If ambient temperature is between -10 °C and 0 °C, use 30% ethanol solution, replaced every two months.
• For temperatures below -10 °C, a dual-system water chiller with heating function is required. Ensure uninterrupted operation.
• When starting for the first time, check for water leaks. External water pipes must be connected to IN/OUT ports as marked.
• If not used for a long time, drain cooling water from the system and laser to prevent damage.

6. Troubleshooting

6.1 No Laser Output

1. Gas Supply: Check if gas supply is connected and the pressure reducing valve reaches 0.2Mpa.
2. Water Temperature: Verify water temperature is around 20°C via the display.
3. Laser Enable: Ensure “Laser enable” is turned on in the screen interface.
4. Grounding Clamp: Check if the grounding clamp is properly attached. For welding, clamp to the workpiece; for cleaning/cutting, clamp to the metal part of the gun.
5. Laser Malfunction: If the laser indicator light is red/yellow (fault), contact support.

6.2 Machine Not Welding Continuously

1. Electrical Conductivity: Ensure the welding material conducts electricity well. Test by clamping the safety clip to the metal position of the gun head to see if light is emitted normally.
2. Welding Mode: Check if the system is set to “spot welding” mode. Change to “Continuity” mode if necessary.

6.3 Welding Not Firm or Ugly Result

1. Gas Connection: Check if the gas is connected.
2. Parameter Settings: Verify parameter settings are correct. If welding is weak, increase power or slow down speed.
3. Material Match: Ensure the correct welding material is selected (e.g., steel 304 welding wire for steel 304).
4. Focal Length: Check if the focal length is incorrect.
5. Protective Lens: Inspect the protective lens for damage.

7. Specifications

7.1 Product Nameplate Information

7.2 BWT Laser Source Parameters

7.3 Handheld Gun Configuration Parameters

7.4 Wire Feeder Technical Parameters

7.5 Welding and Cutting Thickness (Reference)

8. User Tips

• Optimal Focal Length: For best welding results, always adjust the scale tube to 0mm.
• Material Matching: Always use welding wire that is compatible with the material being welded to ensure strong and clean welds.
• Cleaning Efficiency: For larger cleaning areas, consider replacing the F150 focus lens with an F800 focus lens for more efficient cleaning.
• Antifreeze for Cold Environments: If operating in temperatures below 0°C, ensure the correct type and concentration of antifreeze is used in the cooling system to prevent damage.
• Grounding is Key: Always ensure the safety clip is properly grounded to the workpiece (for welding) or the gun (for cleaning/cutting) to enable laser emission.

9. Warranty and Support

This product complies with European Union Harmonized legislation and is CE certified. For detailed warranty information and technical support, please refer to the official product documentation or contact Shenzhen Scotle Technology Group Limited directly.

Contact Information:

• Address: No.14, 2F, Building Y1, Bantian Street Creative Park, Longgang District, Shenzhen, Guangdong, 518129 China (Mainland)
• Email: 2850145924@qq.com
• WhatsApp/Skype: +86 15779582962
• After Service (UTC+8): 8:30am-18:00pm, Monday to Friday.

For further assistance or to check error codes, you can download the dedicated app by scanning the QR code provided in the manual and connecting via Bluetooth.