Raycus Relfar 3000W 4-in-1 Handheld Fiber Laser Welding Machine User Manual

1. Introduction

This manual provides essential information for the safe and efficient operation of your Raycus Relfar 3000W 4-in-1 Handheld Fiber Laser Welding Machine. This versatile machine integrates welding, cutting, cleaning, and weld cleaning functions, offering high performance for various metal processing tasks.

Key features include:

• Four-in-one intelligent mode: Seamless switching between welding, cutting, cleaning, and weld cleaning for different materials and thickness requirements.
• High beam quality: Stable fiber laser output with concentrated energy, resulting in excellent weld depth-to-width ratio and minimal heat-affected zone.
• Precision technology: Produces smooth and flat weld seams, often eliminating the need for secondary grinding. Airtightness up to IP68 standard.
• High efficiency: Welding speeds 3-10 times faster than traditional methods, improving productivity and reducing labor costs.
• Low cost: Welding process requires no consumables, minimizing additional expenses.
• Lightweight design: The handheld gun weighs approximately 0.7kg, allowing for extended use without fatigue.

2. Safety Warnings and Precautions

WARNING: Laser radiation can cause severe eye and skin damage. Always wear appropriate personal protective equipment (PPE) and follow all safety guidelines.

2.1 General Safety

• Ensure the machine is properly grounded before operation.
• Never look directly into the laser beam or its reflection.
• Keep the work area clean and free of flammable materials.
• Do not operate the machine if any components are damaged or malfunctioning.
• Only trained personnel should operate and maintain this equipment.

2.2 Personal Protective Equipment (PPE)

Always wear the following PPE during operation:

• OD7 Level Laser Safety Glasses: Essential for eye protection against laser radiation.
• Welding Helmet/Mask: Provides additional face and eye protection during welding.
• Welding Gloves: Protect hands from heat, sparks, and laser radiation.
• Protective Clothing: Wear long sleeves and pants made of flame-resistant material.

2.3 Safety Features

The machine is equipped with several safety designs:

1. Air Switch
2. Laser Switch 1
3. Emergency Stop Button
4. Safety Ground Wire Clamp
5. Laser Switch 3
6. Laser Switch 2

3. Package Contents

Verify that all items listed below are included in your package:

• 1x S&A CWFL series Water Chiller
• 1x Wire Feeder (Single or Dual, as selected)
• 1x Raycus Laser Source (1000W/1500W/2000W/3000W, as selected)
• 1x Handheld Laser Gun
• 1 set Nozzles
• 1x LCD Display Screen
• 1 Pair Gloves
• 1x Protective Helmet
• 1x OD7 Level Glasses
• 10 Pcs Protective Lenses
• 1 Pcs F800 Cleaning Lens
• 4x Wheels and Wire Feed Wheel
• 1x Power Cable
• 1x Cable for Laser Source
• 1 roll 1.2mm ER304 Steel Welding Wire
• 1x Safe Clip and Wrench

4. Product Overview

The Raycus Relfar 4-in-1 laser machine consists of the main laser unit, a water chiller, a wire feeder, and a handheld laser gun. Below are diagrams illustrating the main components and their connections.

4.1 Main Unit Features

• Customized Chassis: High-material carbon steel shell with anti-corrosion plastic spraying.
• S&A Water Tank: Industrial-grade water cooler for efficient cooling and extended component lifespan.
• 10m Fiber Optic Cable: Provides flexibility for working in various positions and higher places.
• Universal Wheels: Resistant to oil, dirt, and impact, with easy locking for stability.

4.2 Handheld Laser Gun

The handheld laser gun is designed for ergonomic use and supports various applications by changing the welding/cutting/cleaning heads.

5. Setup Instructions

Follow these steps to set up your laser welding machine:

1. Unpacking: Carefully unpack all components and verify against the packing list.
2. Placement: Position the main laser unit and water chiller on a stable, level surface in a well-ventilated area. Ensure sufficient space around the units for air circulation.
3. Wheel Installation: Attach the four universal wheels to the main unit for mobility, if not already installed.
4. Water Chiller Connection: Connect the S&A water chiller to the main laser unit using the provided cooling tubes. Ensure proper water flow direction as indicated on the chiller. Fill the chiller with distilled or deionized water to the recommended level.
5. Fiber Optic Cable Connection: Connect the 10m fiber optic cable from the laser source to the handheld laser gun. Handle the fiber optic cable with care to avoid damage.
6. Wire Feeder Connection (if applicable): If using a wire feeder, connect it to the main unit and install the welding wire (e.g., 1.2mm ER304 Steel Welding Wire). Ensure the wire feeding port is correctly aligned.
7. Power Connection: Connect the main power cable to the laser unit and a suitable power outlet (380V for 3000W models). Ensure the air switch is in the OFF position before connecting.
8. Grounding: Attach the safety ground wire clamp to a reliable ground point.
9. Initial Checks: Before powering on, double-check all connections, water levels, and ensure all safety switches are accessible.

6. Operating Instructions

6.1 Power On and System Initialization

1. Ensure all safety precautions are in place and PPE is worn.
2. Turn on the main air switch.
3. Activate Laser Switch 1 and Laser Switch 2 (if applicable).
4. The LCD display screen will power on. Use the touch screen to navigate the control system.
5. Select your preferred language (supports 28 languages).
6. Check for any status alerts on the display.

6.2 Function Selection (4-in-1 Modes)

The machine offers four primary functions: Welding, Cutting, Cleaning, and Weld Cleaning. Select the desired mode from the touch screen interface.

6.3 Parameter Setting

Access the 'Parameter Setting' menu on the touch screen to adjust laser power, frequency, pulse width, and other settings according to the material and desired application. Refer to the specific application guidelines for optimal parameters.

6.4 Welding Operation

The handheld laser gun supports 7 welding modes for various joint types.

Steps:

1. Select 'Welding' mode.
2. Choose the appropriate welding head and attach it to the handheld gun.
3. Adjust welding parameters for your material.
4. Position the handheld gun over the workpiece, ensuring proper focus.
5. Activate the laser using the trigger on the handheld gun.
6. Move the gun steadily along the weld path.

6.5 Cutting Operation

The machine can perform precise metal cutting.

Steps:

1. Select 'Cutting' mode.
2. Attach the cutting head to the handheld gun.
3. Adjust cutting parameters based on material thickness and type.
4. Position the gun and activate the laser to begin cutting.

6.6 Cleaning Operation

The laser cleaning function removes rust, paint, and other contaminants without damaging the substrate. The laser cleaning gun offers 9 cleaning modes.

Steps:

1. Select 'Cleaning' mode.
2. Attach the descaling head to the handheld gun.
3. Choose the appropriate cleaning mode and adjust parameters.
4. Direct the laser beam over the surface to be cleaned.

6.7 Weld Cleaning Operation

This function is specifically designed to clean weld seams after welding.

Steps:

1. Select 'Weld Cleaning' mode.
2. Use the descaling head.
3. Adjust parameters for weld cleaning.
4. Apply the laser to the weld seam for a clean finish.

6.8 Emergency Stop

In case of any emergency or malfunction, immediately press the red Emergency Stop button on the main unit to cut off power to the laser.

7. Maintenance

Regular maintenance ensures the longevity and optimal performance of your laser welding machine.

• Water Chiller: Regularly check and maintain the water level in the S&A water chiller. Replace the cooling water periodically (e.g., every 3-6 months) with distilled or deionized water to prevent mineral buildup and ensure efficient cooling.
• Protective Lenses: Inspect and replace protective lenses as needed. The package includes 10 spare protective lenses.
• Nozzles: Clean or replace nozzles on the handheld gun regularly to ensure consistent beam quality and gas flow (if applicable).
• Fiber Optic Cable: Handle the fiber optic cable with care. Avoid bending it sharply or exposing it to excessive force, as this can damage the internal fibers.
• General Cleaning: Keep the machine's exterior and ventilation grilles clean and free of dust and debris to prevent overheating.
• Software Updates: Check for any available software updates for the control system to ensure optimal performance and new features.

8. Troubleshooting

This section addresses common issues you might encounter. For more complex problems, contact technical support.

• No Laser Output:
  - Check if all safety switches (Air Switch, Laser Switches) are engaged.
  - Verify the emergency stop button is not pressed.
  - Ensure the water chiller is running and water flow is adequate.
  - Check for any error messages on the LCD display.
• Poor Weld/Cut/Clean Quality:
  - Review and adjust laser parameters (power, frequency, speed) for the specific material and application.
  - Ensure the focus lens and protective lenses are clean and undamaged.
  - Check the distance between the handheld gun and the workpiece.
  - For welding, ensure the wire feeder is supplying wire correctly and the wire type is appropriate.
• Overheating:
  - Check the water level and temperature of the chiller. Ensure it's functioning correctly.
  - Clean any dust or obstructions from the machine's ventilation grilles and the chiller's condenser.
• Wire Feeding Issues:
  - Check if the welding wire is properly loaded and not tangled.
  - Inspect the wire feeder motor and rollers for any obstructions or wear.
  - Ensure the wire feeder power is connected.

9. Specifications

9.1 General Product Properties

9.2 Chiller (Water Tank) Specifications

9.3 Laser Welding Wire Feeder Specifications

9.4 Laser Source Specifications (3000W Model)

10. User Tips

• Practice on Scrap Material: Before working on important projects, practice on scrap pieces of the same material to fine-tune your settings and technique.
• Maintain Consistent Speed: For smooth and uniform results, try to maintain a consistent travel speed with the handheld gun.
• Proper Ventilation: Always ensure excellent ventilation in your workspace to remove fumes and protect air quality.
• Regular Checks: Periodically check all connections and the condition of the fiber optic cable and gun heads for any signs of wear or damage.
• Keep Lenses Clean: Dust and debris on the protective and focus lenses can degrade laser performance. Clean them regularly with appropriate lens cleaning supplies.

11. Warranty and Support

11.1 Warranty

This product comes with a two-year warranty from the date of purchase. The warranty covers manufacturing defects and malfunctions under normal operating conditions. Please retain your proof of purchase for warranty claims.

11.2 Technical Support

For technical assistance, troubleshooting, or warranty inquiries, please contact our support team:

• WhatsApp: +86 15779582962
• Skype: +86 15779582962
• Email: 2850145924@qq.com

Support hours: 8:30 am - 6:00 pm (UTC+8), Monday to Friday.