Miller OptX 2kW - User Manual

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OWNER’S MANUAL

OM-296747A

2024-0

Processes

Laser Welding

Description

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Main Page

Important Safety Information3
Important Safety Information (Cont.)4
Legal Notices5
Preface6
Table of Contents9
List of Figures13
List of Tables15
Overview17
Introduction17
Types of Use17
Intended Use17
Non-Intended Use (Foreseeable Misuse)18
Target Groups18
Personnel Qualifications19
Professional Qualification19
Product Specific Qualification19
Overview Task / Qualification20
Certification21
Models Covered21
Safety and Compliance Information23
Safety Information23
Safety Signal Words and Symbols23
Table 1 Signal Words Used in this Owner's Manual24
Table 2 Safety Symbols Used in this Owner's Manual25
Laser Safety Information27
Key Control27
Emission-ON Safety Indicators27
Laser Classification28
Table 3 Laser Classification Information28
Laser Safety Eyewear and Welding Helmet29
Laser and Heat Resistant Clothing PPE31
Table 4 Laser Safety Equipment Suppliers31
Laser Technical Data and Safety Hazard Calculations32
Table 5 Heat Protective Clothing Suppliers32
Table 6 Laser Technical Data32
Table 7 Laser Safety Terms and Definitions33
Table 8 Laser Safety Hazard Calculations34
Device Safety Label Locations35
Figure 1 Laser Safety Banner Label - Primary Laser35
Figure 2 Laser Safety Banner Label - Guide Laser35
Table 9 Safety Label Description and Location36
Figure 3 Label Placement - Device Panels and Torch39
Regulatory Compliance40
Table 10 Compliance Standards Listing40
Class a Digital Device41
Electromagnetic Compatibility41
Important Operation Safety Information42
Secondary Radiation Hazard42
Protective Eyewear for Laser Welding and Cleaning42
Skin Hazard43
Fire Hazard44
Reflected Beam Hazard During Welding45
Table 11 Welding and Cleaning Nozzle Selection Chart46
Figure 4 Torch Angle, Reflections and Viewing Position47
Process By-Products and Fume Hazards48
Gas Cylinder Safety49
General Safety Instructions50
Establish a Laser Controlled Area50
Optical Safety51
Equipment51
Electrical Safety52
Environmental Safety52
Emitted Noise Level During Use53
Humidity53
Cooling and Temperature53
Recycling and Disposal54
Safety, Training, and Standards Resources54
General Information54
Laser Training Resources55
Table 12 Laser Training Resources55
Optx Device Operation Training Resources56
Additional Resources57
Table 13 Applicable Standards Resources57
Additional Product Specific Safety Features59
Activation Code Required at First Power up59
Figure 5 Scan the QR Code to Access the Product Activation Portal59
Figure 6 Unit Locked on First Power up60
Laser Welder Device Description61
Accessories61
Table 14 List of Available Accessories61
Weld Unit Front View63
Table 15 Weld Unit Front Panel Features63
Weld Unit Rear View65
Table 16 Weld Unit Rear Panel Features65
Hand Laser Torch67
Table 17 Torch Feature Descriptions67
Torch Protective Accessories69
Figure 7 Torch Protective Cover (#301798)69
Figure 8 Torch Cradle (#301803)69
Layout and Dimensions70
Figure 9 Device Layout and Dimensions70
Figure 10 Center of Gravity71
Figure 11 Torch Layout and Dimensions71
Fiber Cable Output Connection72
Figure 12 Optical Fiber End Connector (Model LC-8) with Cap and Sleeve72
Delivery and Transport73
Delivery73
Inspection Upon Delivery73
Table 18 Shipping Container Impact Indicators and Labeling74
Unpacking from Shipping Container75
Transport to Installation Location76
Figure 13 Domestic Shipments - Collapsible Crate76
Installing Welding Device77
Precautions77
Figure 14 Connecting the Equipment77
Air Flow and Installation Clearances78
Connect Work Sense Clamp Cable78
Figure 15 Unit Air Flow and Installation Clearances78
Figure 16 Connect Work Sense Clamp Cable to Shank78
Connect Welding Gas79
Connect Torch I/O Cable79
Table 19 Shield Gas Specifications79
Customer Interface Connections80
12-Pin Interface Connector and Pinout80
Figure 17 Connect Torch I/O Cable80
Table 20 12-Pin Interface Connection and Pinout Table80
Figure 18 12-Pin Interface Output Pin Pairs (5-6, 7-8 and 9-10)81
Connect Electrical Power82
Wiring the AC Line Cord Pigtail82
Table 21 Wiring AC Line Input82
Figure 19 Wiring the AC Line Cord Pigtail to the Disconnect Device83
Connections to External Circuits84
Operating in the Vicinity of GTAW Equipment84
Laser Controlled Area Door Interlock Example84
Door Switch Entry Interlock Example85
Figure 20 Allen-Bradley Door Switch Example Case85
Table 22 Door Switch to Optx Connector Wiring for Allen-Bradley Example Case85
Mounting the Door Switch86
Figure 21 Interconnection Example for the Door Interlock Integration in the Optx Device Safety Logic86
Figure 22 Terminal Connection and Tighten Connector Screws to Secure Connector86
Figure 23 Mounting Alignment of Door Switch Sensor and Actuator87
Table 23 Specifications for Allen-Bradley Example Door Switch (301804)87
Testing Door Entry Safety Interlocks88
Figure 24 Door Interlock Closed - Safety Interlock Is Satisfied89
System Startup90
System Shutdown91
Figure 25 IP Address will Flash When Unit Is First Turned on91
Operating Front Panel Controls93
Rotary Control Knobs93
Laser Power Rotary Control Knob93
Wobble Frequency Rotary Control Knob93
Figure 26 Laser Power Rotary Control Knob93
Figure 27 Wobble Frequency Rotary Control Knob93
Wobble Length Rotary Control Knob94
Program Mode Recipe Selection Buttons94
Figure 28 Wobble Length Rotary Control Knob94
Figure 29 Program Mode Recipe Selection94
Table 24 Program Mode Button Functions95
Device Front Panel Setup Mode96
Figure 30 Front Panel Setup Mode Control96
Table 25 Y0 Setup State Program Mode97
Operating Laser Welder101
Safety Precautions101
Fiber Interlock101
External Interlocks101
Torch Nozzle and Work Sense Clamp Interlock102
Torch Two Level Trigger102
Overheating Control102
Figure 31 Torch Trigger Controls102
Plasma Detection103
Figure 32 Torch Thermal Fuse and Plasma Sensor103
Gas Pressure Monitoring104
Emergency Stop Button (E-Stop)104
Figure 33 Gas Pressure Monitoring Block Diagram104
Figure 34 Emergency Stop Button104
Warning and Status Lights105
Integrated Beam Wobble Function106
Figure 35 Beam Wobble Function106
Torch Nozzle Tip and Tube107
Nozzle Tip Types107
Table 26 Welding and Cleaning Nozzle Selection Chart108
Installing Nozzle Tip for Welding109
Changing Nozzle and Adjusting Rotation109
Figure 36 Nozzle Tip Installation109
Table 27 Changing And/Or Adjusting the Torch Nozzle110
Table 28 Examples of Correct Nozzle Placement and Orientation111
Quick Start Welding Using Preset Programs112
Quick Start Cleaning Using Preset Programs115
Figure 37 Optx System Operator Performing Laser Cleaning117
Program Recipes and Parameters119
Quick Start Parameters Set119
Welding Mode Descriptions119
CW Mode Parameters - Seam Welding119
TACK Mode Parameters - Tack Welding120
Pulsed Mode Parameters - Thin Joints & Foils120
HPP Mode Parameters - Reflective Materials121
STITCH Mode Parameters - Stitch Welding121
CLEAN Mode Parameters122
ADV STITCH Mode Parameters122
Front Panel Knob Adjustments123
Figure 38 Program Display Control Knob Adjustments123
Table 29 Front Panel Knob Adjustment Range Vs Recipe Setting124
Glossary of Program Parameter Terms125
Computer Connection to Device127
Ethernet Connection127
Figure 39 Connect Ethernet Cable from Laser Device to Host PC127
Table 30 Default IP Configuration for Laser Device and Host Computer127
PC Ethernet Configuration - WINDOWS 10 os128
Figure 40 Windows Start Menu128
Figure 41 Windows Control Panel128
Figure 42 Network & Sharing Center Window129
Figure 43 Local Area Connection Status Window129
Figure 44 Local Area Connection Properties Window130
Figure 45 Internet Protocol Version 4 Properties Window130
Webpage Interface131
Accessing Device Webpages131
Figure 46 Type Device Default IP Address here131
Figure 47 Tabs to Switch between Device Webpages131
Laser Welder Page132
Figure 48 Laser Welder Page - User Program Recipe132
Welder Status Indicator Pane133
Figure 49 Laser Welder Page - Preset Program Recipe133
Figure 50 Welder Status Indicator Panel133
Table 31 Welder Status Indicator Pane Features133
User Mode Program Recipe Setup135
Table 32 Effects of Power Compensation Setting136
Table 33 User Mode Recipe Configuration for each Laser Mode136
Preset Mode Program Recipe Setup138
Network Settings Page138
Figure 51 Preset Mode Recipe Configuration Per Laser Mode138
Figure 52 Network Settings Page138
Product Support Page139
Figure 53 Product Support Page139
Buzzer Setup - Advanced Settings140
User Program Data - Advanced Settings141
Creating User Program Data File141
Upload User Program Data File141
Pulse Shape Generation - Advanced Settings142
Figure 54 Advanced Feature - Uploading User Program Data142
Figure 55 Example Pulse Shape142
Creating Pulse Shape Files143
Uploading Pulse Shapes143
Figure 56 CSV Formatted Pulse Shape Wave File143
Figure 57 Advanced Feature - Uploading Example User Pulse Wave Shapes144
Configure Misc. Settings - Advanced Settings145
Table 34 Effects of Ramp up Scale and Ramp down Scale145
Reseller Setting Lock Unit - Advanced Settings147
Locking Device Front Panel Controls148
Test Settings - Advanced Settings149
Enabling the Cobot Option151
Troubleshooting153
Table 35 Welder Status Alarms Bit Table153
Maintenance157
Torch Maintenance157
Table 36 Recommended Maintenance and Intervals157
Protective Window Replacement158
Table 37 List of Field Replaceable Parts158
Figure 58 Disengaging Window/Nozzle Assembly159
Figure 59 Accessing Protective Window159
Figure 60 Reattach Window/Nozzle Assembly - Align the Red Marks159
Focus Lens Replacement160
Figure 61 Reattach Window/Nozzle Assembly - Align Balls with Circular Cutouts160
Figure 62 Reattach Window/Nozzle Assembly - Turn Nut to Lock Assembly160
Figure 63 Lens Cell Replacement - Remove the Nozzle Assembly and Insert Tool160
Wearing of Safety-Related Components161
Figure 64 Lens Cell Replacement - Pull out Damaged Lens Cell and Replace161
Figure 65 Lens Cell Replacement - Align the Red Dots and Twist to Lock161
Replacing the Torch162
Table 38 Torch Trigger Switch Replacement162
Connect/Disconnect Fiber Output163
Precautions for Fiber Maintenance Procedures163
Figure 66 Disconnecting Torch163
Disconnect Fiber Output164
Figure 67 Removing Boot from Torch to Expose Fiber Connector164
Figure 68 Rotate Receiver Nut to Align Red Dots164
Figure 69 Pulling out Fiber Connector from Torch165
Figure 70 Fiber End Connector with Protective Cap and Sleeve165
Connecting Fiber Cable to Torch166
Output Termination Cleaning Procedure167
Recommended Cleaning Supplies167
Cleaning the Quartz Block (Generic Procedure)168
Figure 71 Recommended Cleaning Supplies (Not Included)168
Figure 72 Isopropanol on Lens Tissue169
Figure 73 Lateral Wipe Across Surface169
Service and Support171
Technical Support171
Accessing Product Support Webpage171
Figure 74 Scan the QR Code on the Yellow Safety Label171
Remote Troubleshooting with Teamviewer172
Figure 75 Input Serial Number to Access Support Page172
Figure 76 Teamviewer Executable Security Dialog172
Figure 77 Teamviewer License Agreement Dialog173
Figure 78 Teamviewer Connection ID and Password173
Product Returns175
Returns to the United States175
Glossary177
Index179
Owner's Record184
For Service184

Brand	Miller
Model	OptX 2kW
Category	Welding System
Language	English

Miller OptX 2kW - User Manual

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Miller OptX 2kW Specifications

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