DMK Relfar FWH30 Series Intelligent Dual Swing Handheld Laser Welding Gun User Manual

1. Introduction

This manual provides essential instructions for the safe and effective operation, setup, and maintenance of the DMK Relfar FWH30 Series Intelligent Dual Swing Handheld Laser Welding Gun. Please read this manual thoroughly before using the equipment to ensure proper functionality and user safety. This series includes models FWH30-D10A and FWH30-D20A, offering advanced laser welding capabilities.

2. Safety Information

WARNING: Laser welding equipment can cause serious injury if not handled properly. Always follow safety guidelines.

• Always wear appropriate personal protective equipment (PPE), including laser safety glasses, welding gloves, and protective clothing.
• Ensure the work area is well-ventilated to prevent inhalation of fumes.
• Never point the laser at yourself or others.
• Keep flammable materials away from the welding area.
• Disconnect power before performing any maintenance or adjustments.
• Only trained personnel should operate this equipment.

3. Product Description and Features

The DMK Relfar FWH30 Series Handheld Laser Welding Gun is an advanced tool designed for precise and efficient welding applications. It incorporates intelligent dual swing technology and offers versatile functionality for various welding scenarios.

Key Features:

• Intelligent Dual Swing Technology: Features an advanced dual swing motion for precise, high-speed welding with reduced heat input. This technology offers six selectable welding patterns, providing greater fault tolerance and improved filling effects compared to single-pendulum systems.
• Handheld Ergonomic Design: Engineered for comfortable operation, enhancing user productivity and control.
• 3000W High Power Output: The powerful 3000W weld head delivers superior performance across a wide range of materials.
• 4-in-1 Functionality: Versatile capabilities allow for welding, cleaning, and cutting, adapting to various industrial tasks.
• Wire Feed Options: Supports both single and double wire feed configurations to suit different application requirements.

4. Components and Package Contents

The standard package for the Relfar FWH30 Series Intelligent Dual Swing Handheld Laser Welding Gun includes the following items:

• Relfar Laser Welding Head (1 unit)
• Associated control unit and power supplies
• Connecting cables
• Wire feed mechanism (single or double, depending on model)
• Nozzles and consumables
• User Manual

5. Setup Instructions

Follow these steps to set up your Relfar FWH30 Series Laser Welding Gun:

1. Unpacking: Carefully remove all components from the packaging and inspect for any damage. Report any damage to your supplier immediately.
2. Placement: Position the main laser welding system (not included with the handheld gun) on a stable, level surface in a well-ventilated area.
3. Connect Welding Head: Connect the FWH30 handheld welding gun to the main laser welding system using the provided cables. Ensure all connections are secure.
4. Power Connection: Connect the main laser welding system to a suitable power source according to its specifications. Do not power on yet.
5. Wire Feed Setup (if applicable):
   • For single wire feed models (e.g., FWH30-D10A), install the single wire feed mechanism and thread the welding wire.
   • For double wire feed models (e.g., FWH30-D20A), install the double wire feed mechanism and thread both welding wires.
6. Nozzle Installation: Attach the appropriate welding nozzle to the front of the welding gun.
7. Safety Checks: Before powering on, ensure all safety precautions are in place, including proper PPE and a clear work area.

6. Operating Instructions

Operating the Relfar FWH30 Series requires familiarity with laser welding principles and the specific control system of your main laser welding machine.

6.1 Power On and Initial Checks

1. Power on the main laser welding system.
2. Verify that the handheld welding gun is properly recognized by the system.
3. Perform a system self-check as per the main system's manual.

6.2 Selecting Welding Parameters

1. Access the control interface of your main laser welding system.
2. Select the desired welding mode (e.g., welding, cleaning, cutting) from the 4-in-1 functionality.
3. Adjust laser power, pulse width, frequency, and other parameters according to the material and thickness being processed.
4. For dual swing operation, select one of the six available welding patterns from the system interface. This adjustment is done graphically within the system, simplifying the process compared to mechanical adjustments.
5. Configure wire feed speed and other wire-related settings if using a wire feed.

6.3 Welding Process

1. Hold the handheld welding gun firmly and comfortably.
2. Position the nozzle at the starting point of the weld seam, maintaining the correct working distance.
3. Activate the laser according to your system's procedure (e.g., trigger button).
4. Move the welding gun smoothly along the seam at a consistent speed. The dual swing motion will automatically apply the selected pattern.
5. Monitor the weld pool and adjust parameters as needed for optimal results.
6. Deactivate the laser upon completion of the weld.

7. Maintenance

Regular maintenance ensures the longevity and optimal performance of your Relfar FWH30 Series Laser Welding Gun.

• Daily Cleaning: After each use, clean the nozzle and surrounding areas to remove spatter and debris. Use a soft cloth and appropriate cleaning solutions.
• Nozzle Inspection: Regularly inspect the welding nozzle for wear or damage. Replace worn nozzles promptly to maintain weld quality.
• Cable Inspection: Check all cables for signs of wear, cuts, or damage. Replace damaged cables immediately.
• Optical Components: Refer to the main laser system's manual for instructions on cleaning and maintaining optical components. Avoid touching optical surfaces with bare hands.
• Storage: Store the welding gun in a clean, dry environment when not in use, protected from dust and physical damage.

8. Troubleshooting

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

Common Issues:

• No Laser Output:
  • Check power connections to the main laser system.
  • Verify emergency stop buttons are disengaged.
  • Ensure all safety interlocks are closed.
  • Consult the main laser system's error codes.
• Poor Weld Quality:
  • Inspect the nozzle for blockages or wear.
  • Adjust welding parameters (power, speed, focus, swing pattern).
  • Ensure proper gas shielding (if applicable).
  • Check material cleanliness.
• Wire Feed Issues:
  • Check wire spool for tangles or depletion.
  • Inspect wire feed rollers for proper tension and cleanliness.
  • Ensure the wire guide tube is clear.

If issues persist after attempting these solutions, please contact DMK technical support.

9. Specifications

10. Warranty and Support

For warranty information, please refer to the documentation provided with your complete laser welding system or contact your point of purchase. For technical support, service, or spare parts, please contact DMK customer service or your authorized Relfar distributor. When contacting support, please have your product model number and purchase date available.