THEO 取扱説明書

Safety regulations #

Structure of the warnings #

DANGER #

Hazard type and source

Consequences of ignoring the hazard.

1. Measures to prevent the hazard.

Explanation of symbols and notices #

DANGER #

Risk of fatal injury

This warning indicates an imminent threat to life and health. Ignoring this warning will lead to serious or fatal injuries.

WARNING #

High risk of injury

This notice warns of a hazardous situation that poses a serious risk to health. Ignoring this warning may lead to serious or fatal injuries.

CAUTION #

Risk of injury

This notice warns of a potentially dangerous situation that poses a risk to health. Ignoring this warning may lead to minor injuries.

NOTICE #

This notice provides additional information.

Warning labels #

The pictograms shown below are found on the laser welding system and/or are used in the operating manual.

These warning labels are for personal safety and must be observed without fail.

Mandatory signs #

The pictograms shown below are found on the laser welding system and/or are used in the operating manual.

These mandatory signs are for personal safety and must be observed without fail.

Intended use #

This laser welding system, which consists of a laser welder and wire feeder, is a machine for manual welding of various materials such as steel, aluminum and stainless steel.

Areas of application:

• The laser is only intended for commercial use in an industrial environment (indoors) and not for private use.
• The MA1 series is suitable for welding and soldering applications.
• The laser can be used in the following industries: Hardware, building materials, kitchen appliances, the aerospace industry and the automotive industry.

Potential foreseeable misuse #

The following practices must be avoided due to the safety risks involved:

• Operation of the laser without the safety equipment specified by the manufacturer.
• Use of the machine by children or individuals who are not capable for operating the machine safely or correctly, and use of the machine in unventilated spaces.
• Manipulating, bypassing or disabling the existing safety equipment.
• Disassembly of the machine.
• The intentional manipulation of the operating elements, and any modification, change or expansion of the machine and electrical system not stipulated by the manufacturer.
• Interference with the electronics by carrying strong magnets or other strongly radiating objects.
• Use of machine or its parts when damaged, especially the laser head or safety equipment.
• Exceeding the operating parameters stipulated by the manufacturer.
• Pointing the welding torch at persons. When in use, the laser must only be pointed at the working surface.
• Use of the machine without personal protective equipment.
• Exposing the machine to high and rapid temperature fluctuations and to humid and wet environments.
• Use of the laser in an explosive environment or in the vicinity of combustible liquids/gases (NO Ex protection).

General safety instructions #

Hand-held laser welders belong to laser product category class 4 because they emit invisible, infrared laser radiation with a wavelength of 1080 nm.

The high-intensity light emitted by the weld head averages more than 1 W and can cause direct or indirect damage to eyes and skin. In particular, exposure to this laser radiation can cause irreversible damage to the retina or cornea.

To ensure safe operation, it is essential to wear appropriately certified near-infrared laser safety goggles for 1080 nm before operating a hand-held laser welder.

Safe use #

WARNING #

Laser radiation hazard!

Exposure to laser radiation can lead to irreversible damage to the retina or cornea.

1. To avoid possible eye injuries, avoid looking directly into the torch outlet and be sure to wear suitable laser safety goggles while using the laser.
2. Do not open the hand-held laser welding system as there are no parts or repair possibilities intended for the user.

• Train your personnel regularly and point out the hazards that are inherent in this technology. Safe use and responsibility for use lie with the user.
• Instruct everyone, even people who only occasionally come into the area, to determine in advance if the laser is in operation.
• Any operation or setting that is not in compliance with the instructions in this operating manual can lead to damage to or malfunctions in the system.
• Diffuse laser radiation can cause damage to the skin and other tissues. For this reason, regularly check the safety glass and nozzle for contamination. If in doubt, replace the safety glass (see Schutzglas wechseln) and the nozzle (see Changing the nozzles).

Requirements of personnel #

• The laser welding system may only be operated by qualified personnel.
• Qualified personnel are individuals who:
• Have been trained in the operation and the applicable safety regulations.
• Have successfully completed the training course from Maxphotonics, THEO or their authorized trade and service partners.
• Have read and understood the operating manual.
• The locally applicable legal regulations and technical rules must be observed during assembly, installation and use.
• Access to the machine is strictly prohibited for individuals who are not assigned or authorized to operate it. Unauthorized persons must be instructed to leave the operating area.
• Personnel must always wear suitable personal protective equipment.
• The laser welding system must not be used by people with psychological or physical impairments, children or older individuals.
• All individuals located at the workpiece or in the room must be located behind the welding torch during laser welding.

Laser safety officer #

• Before operating class 3R, 3B or 4 laser equipment, the employer must appoint a laser safety officer if the employer lacks the necessary technical expertise.
• The responsibilities of the laser safety officer are outlined in the applicable European standards.
• The laser safety officer must have the technical expertise necessary to fulfill their responsibilities. Professional qualification must be demonstrated through successful participation in a training course and maintained through ongoing further education.
• The laser safety officer supports the employer with:
• Performing the risk assessment
• Implementing the necessary safety measures
• Monitoring safe operation of the lasers.
• In carrying out his or her duties, the laser safety officer collaborates with the occupational safety officer and the company physician.

Requirements of the operating environment #

• Hand-held laser welders are generally used:
• In approved laser welding cells
• Below an elevation of 2000 meters
• Overvoltage category II
• Pollution degree 2
• Ensure that the assembly location is safe, protected and dry. More information can be found in the technical data (see Technische Daten).
• Provide a separate room or area and/or create an adequate safety area with suitable laser safety partition walls or curtains as well as laser safety-relevant components (warning light, coded safety switch, signal) that fulfills the laser safety requirements in accordance with local regulations.

• Use a suitable laser safety enclosure and inform others in your work environment.
• Affix laser warning symbols at all access points to the laser zone to indicate that a (class 4) laser is in operation.
• Gas: The laser welding system requires argon as shielding gas/stainless steel and aluminum are welded with nitrogen (N2).
• Workpieces: Ensure that the workpiece is safely positioned and prevent it from slipping spontaneously or changing its position.
• Extraction: Laser welding generates fumes and dust that are harmful to the human organism. Provide for adequate extraction.

Optical safety measures #

• Do not look directly into the laser output aperture of the hand-held laser welder or into the pilot laser.
• Hold the hand-held laser welder and the associated optical output devices below eye level and away from the user at all times.
• Ensure that the entire personal protective equipment (PPE) is designed for the power output and the wavelength range specified on the laser safety label on the product.
• Do not use the hand-held laser welder in dark environments.
• Ensure that the hand-held laser welder is switched off and that the power supply is interrupted (see Switching off the laser welder) to install or repair the safety glass, copper nozzle and wire feeder module.
• The laser power is transmitted through a safety glass. Ensure that the safety glass is clean and of high quality. Any dust on the heat unit can damage the safety glass and the laser.
• When eliminating a fault, the laser must be switched off. Switch the laser on again after the fault has been eliminated.
• Operate the device strictly as described in this operating manual; otherwise the safety equipment and the power of the device may be impaired, for which the manufacturer cannot be held responsible.

NOHD value #

The Nominal Ocular Hazard Distance (NOHD) is the danger zone within which gazing directly into the laser beam may cause eye damage.

It is essential that you abide by the limit value indicated by the NOHD value (see Optical properties) and wear the appropriate personal protective equipment (see Personal protective equipment (PPE)).

Electrical operating regulations #

• When operating the device, ensure that the power supply is properly grounded and has the correct voltage.
• Before operating the device, verify that the connected power supply is also properly grounded via a protective earth connection.
• To minimize the fire hazard, only use fuses of the same type and rating when necessary. Do not use other fuses or materials for this purpose.
• Verify that the input AC voltage of the hand-held laser welder falls within the normal single-phase range of 200–240 V AC, and that the wiring is correct. Incorrect wiring can cause personal injury or damage to the device.
• Connect the device to a suitable connection (depending on the device: 16 A or 32 A) and check the cables for possible damage.
• Users are not permitted to perform repairs on any parts, components or modules except for maintenance involving consumable materials of the welding torch. All repairs must be performed by service technicians.
• It is strictly forbidden for the user to independently disassemble and reassemble the hand-held laser welder as this may result in electric shock, burns or damage to the involved components.
• Disassembling the product without approval will void the warranty.

Cooling and temperature #

• The laser unit is air-cooled. Operation at higher temperatures accelerates the aging process, increases the threshold current and reduces the diffraction efficiency.
• Before starting the laser, verify that the ambient temperature and the air humidity are within the recommended specification (see Laserschweißanlage).
• Operating the device at elevated temperatures can accelerate the aging process, increase the threshold current and reduce the sensitivity and conversion efficiency of the device. Contact Service if the device overheats (see Importeur/Service).
• If the laser temperature is too high, the device issues an alarm and stops emitting light.

Service life #

The manufacturer recommends the following steps to extend the service life:

• Provide for adequate ventilation in the work area and set up the machine in a dry, cool and clean environment. Avoid high temperatures, humidity and water hazards.
• When operating the device, ensure that the air intake at the bottom of the laser remains unobstructed, and maintain a contamination-free zone within a 1-meter radius to allow uninterrupted airflow. Ensure that the upper air outlet is elevated by 1 meter.
• Stop foreign elements (including liquids) from entering the laser welder from above, as this may damage the device and lead to personal injuries.

Cleaning #

• Do not kink the cable-hose assembly as this would break the glass fibers within.
• Regularly remove dust and dirt from the device.
• Clean the welding torch using dry towels only; do not use compressed air.
• If any damage is found, contact Maxphotonics Service.
• In the interest of safe operation, the machine should undergo regular inspection by our Service team.
• Nozzles and safety glasses must be inspected and replaced at the first signs of damage (see Changing the nozzles and Changing the safety glass).

Laser welding hazards #

Laser radiation #

• Abide by the safety instructions to avoid accidental exposure to invisible direct or reflected beams.
• Operate the system within the designated laser controlled area only.

Damage to health #

Laser exposure can cause serious damage to the retina or cornea, which may result in permanent eye damage and possibly skin damage.

Damage to eyes #

Laser welder #

During welding, visible and invisible radiation are emitted, which can pose a hazard to the user. The interaction between the high-power laser beam and the material being welded can lead to diffuse laser radiation.

Welding can generate a plasma that emits ultraviolet radiation and “blue light”. These emissions can cause conjunctivitis, photochemical damage to the retina and skin reactions that resemble sunburns. Users who are exposed to the UV light without appropriate protection may sustain permanent eye damage.

• The manufacturer recommends that all persons in the laser area wear personal protective equipment, including laser safety goggles/laser welding helmet, to protect the eyes and skin against the reflected and diffuse laser beam and against strong laser light, ultraviolet light, heat and sparks.

Wire feeder #

When threading and manually moving the welding wire, eye injuries may result.

• Do not gaze directly into the connection for the torch liner on the wire feeder.
• Do not gaze directly into the outlet of the torch liner.
• Do not gaze directly into the wire feeding nozzle.
• Wear personal protective equipment such as safety goggles, a laser welding helmet or a laser welding mask to protect the face and eyes.

Damage to skin #

During welding, users are exposed to the risk of skin damage from infrared and ultraviolet radiation. These types of radiation can cause skin burns that increase the risk of skin cancer and premature aging of the skin. Welding sparks can also cause burns. After laser welding, processed materials can remain extremely hot.

• It is recommended that the user and third parties in the laser controlled area wear protective clothing such as laser safety clothing, heat-resistance gloves, hats, leather aprons and other laser and heat-resistant clothing.
• Keep sleeves and collars buttoned.
• Never set processed parts down in a position in which the laser can penetrate the workpiece as this can be dangerous.

Danger from reflections #

The output aperture of the hand-held laser welder can generate a secondary laser beam that is emitted at various angles. This process, in which the main beam generates a divergent beam when reflected on a flat surface, is referred to as specular reflection.

Although the energy of the secondary laser beam is markedly lower than that of the primary laser beam, its intensity may still be sufficient to damage the eyes, skin, or certain material surfaces.

• Wear suitable personal protective equipment: laser safety goggles/laser welding helmet, laser safety gloves, laser safety apron.
• The user and third parties must always be mindful of possible reflections. An incorrect configuration of laser settings may lead to more reflections.
• The user and third parties must always remain behind the welding torch.
• Ensure that no one is located in the reflection area and that no combustible materials are present during the welding process.
• Use a nozzle that is suitable for the welding position.
• When welding highly reflective materials (e.g., aluminum or copper), exercise special caution, as some of the laser beam energy may be reflected by the target welding area.
• Verify that you know the expected reflection cone for each processed part and avoid looking into the expected reflection cone or moving any part of your body into it.

Secondary radiation hazard #

Both visible and invisible light radiation is generated during the welding process. The interaction between the high-power laser beam and the material being welded can lead to the generation of ultraviolet (UV) light and plasmas that emit “blue light”. This radiation can lead to various health problems, such as conjunctivitis, photochemical damage to the retina and skin reactions similar to sunburns.

Users who are exposed to these invisible UV rays without appropriate protective measures are in danger of sustaining permanent eye damage. Even brief exposure to UV rays during welding can cause symptoms such as blurred vision, burning sensations, excessive tearing, eye pain and irritation – often described as feeling like there is sand in the eyes.

• Consult a physician immediately if symptoms arise.

Explosion hazard #

Gas cylinders pose an explosion hazard if damaged or located in the vicinity of the welding area.

• Store the shielding gas cylinders in a safe place where they cannot be damaged by impacts or exposure to laser welding.
• Keep the shielding gas cylinders away from heat sources, sparks and flames.
• Secure the shielding gas cylinders in an upright position and fasten them to a sturdy gas cylinder holder.
• Verify that the regulator is operational and appropriately rated for the specific gas and pressure in use.
• Ensure that the gas pressure is properly set.
• Check that the hoses and connections are suited for the application and in optimal condition.

Fire hazard #

The heat and sparking generated during welding may ignite combustible materials in the vicinity of the welding area or cause them to explode.

• Keep combustible materials away from the welding area as the heat and sparking generated during the welding process may cause fires or explosions.
• Do not work in environments that contain flammable or combustible substances. Only perform laser welding in areas that are free of combustible materials.
• Never perform welding work on containers that contain, or are thought to contain, flammable or combustible materials.
• Keep fire extinguishers nearby in an easily accessible location and ensure that personnel is trained in their proper use.
• The laser may ignite volatile substances such as alcohol, gasoline, ether and other solvents. Take the necessary safety precautions and avoid exposure to solvents or combustible materials and gases during installation and operation of the device.

Welding fumes hazard #

Welding fumes may consist of fine particles and gases that arise from the combination of welding materials, filler materials, shielding gases, paints, coatings, chemical reactions and air pollution. Welding fumes can have a negative effect on lungs, heart, kidneys and the central nervous system.

The interaction of the laser with target materials such as plastics, metals and composites can cause them to vaporize and produce toxic and dangerous clouds of fumes and vapors. These are often invisible and pose a serious health risk. Performing welding work in enclosed spaces with poor ventilation is extremely hazardous, as toxic concentrations of fumes and gases can quickly accumulate, potentially leading to unconsciousness or suffocation. The ultraviolet radiation emitted during welding reacts with oxygen and nitrogen in the air to generate ozone and nitrogen oxide, which can be deadly at high concentrations. The shielding gases used during welding can displace air, causing bodily harm or even death.

To reduce these risks:

• Install fume extraction systems to remove hazardous fumes, vapors, particles and hazardous residues from the work area.
• Read the safety data sheets and warnings delivered with the welding materials and comply with these.
• Note that, in addition to the extraction system, a fresh air supply may be necessary in small spaces or other risky situations.
• Always work in well-ventilated spaces.
• Monitor the air quality regularly to determine the concentration of harmful fumes in the work area.
• Keep your head away from the source of fumes while welding to avoid being exposed to the dangerous fumes while welding.
• Use respiratory protection in small spaces or in other situations in which this may be necessary.

Laser safety measures #

Personal protective equipment (PPE) #

Regardless of whether a laser is installed in a new system or an existing system is retrofitted, the user bears sole responsibility for determining the suitability of the personal protective equipment.

All personal protective equipment must be suitable for the output power and wavelength range of the machine and must provide adequate protection. The secondary radiation hazards posed by the welding process must also be taken into consideration.

To prevent eye and skin injuries and hearing damage, clothing and protective equipment that meet the applicable regulations must be worn.

Clothing must be practical (close-fitting) and must not restrict movement. Long hair absolutely must be worn in a hair net.

The personal protective equipment consists of:

• レーザー安全ゴーグル
• Laser welding helmet
• Hearing protection
• Safety gloves
• Safety shoes
• Long clothing

Laser safety goggles or laser welding helmet #

Wear EN 207:2017 certified laser safety goggles or a laser welding helmet that meets the requirements for the laser output power. The laser safety goggles and the laser welding helmet must provide protection over the entire wavelength range of the device.

Laser safety goggles or a laser welding helmet and a face mask are obligatory when operating or handling the product.

Persons in the immediate vicinity of the machine must wear the same personal protective equipment.

For laser power: up to 2000 W in continuous wave operation (CW)

And direct or near indirect exposure (e.g. < 1 m distance)

Recommended laser protection level of safety equipment:

• OD9+ for 1070 nm to 1075 nm, D LB6 + IR LB8 + M LB9
• OD8+ for 1075 nm to 1080 nm, D LB6 + IRM LB8
• OD7+ for 1080 nm to 1087 nm, D LB6 + IRM LB7

Laser welding helmet: PPE Regulation (EU) 2016/425 EN ISO 16321-1:2022, EN ISO 16321-2:2021, EN207:2017

Laser protection level of material: 900-1100 D LB5 / LB7 R LB8 CE

Laser protection level of viewing window: 900-1080 D LB7 IR LB8 CE

Recommendation #

Laser safety gloves #

Wear laser and heat-resistant safety gloves that provide protection against mechanical risks as per EN 388:2016+A1 and are suitable for welders as per EN 12477:2001+A1:2005.

Safety gloves must offer protection against laser radiation at a wavelength of 1070 nm to prevent skin exposure from exceeding the maximum permissible limit. Safety gloves must be suitable as per standard EN ISO 11611 for use over protective clothing for welding and similar processes. They must also be suitable as per standard EN ISO 11612 for use over protective clothing for providing protection against heat and flames.

Laser safety apron #

Wear certified protective clothing for welding and similar processes as per EN ISO 13688:2013+A1:20221 and EN ISO 11611:2015.

Safety and protective equipment #

Authorization code #

The laser welder must be activated using an authorization code. The code is sent to you by e-mail after you successfully complete a training course.

Personnel training #

Only individuals who have received proper instruction and training are authorized to operate the laser welding system.

Personal protective equipment #

Wear personal protective equipment (see Personal protective equipment (PPE)) with the appropriate laser protection level. The specification can be found in the technical data.

Safety key #

Without the safety key, the laser welding device can be switched on via the power switch but it will not be possible to operate the laser.

• Position 1: Laser activated.
• Position 0: Laser deactivated.

Door interlock switch and laser safety enclosure #

The laser welder may only be operated in a laser welding cell or in an enclosure with interlocked safety devices. In the event of unexpected entry, the interlock (door contact switch) automatically switches off the laser welding system. The laser is deactivated.

The operator is responsible for correctly installing a suitable door contact switch granting access to the controlled laser work area and for ensuring its reliable operation.

Emergency stop switch #

The emergency stop switch switches the laser off immediately. The message Emergency stop active! is displayed on the control panel.

• The emergency stop switch remains locked in the depressed position. Welding is no longer possible.
• Turning the emergency stop switch unlocks it and it returns to its initial position.

Castors with brake #

The laser welder and wire feeder are fitted with castors with brakes for stability.

Function control in the welding torch #

The welding process is not triggered until the laser tip of the welding torch comes into contact with the workpiece surface and the laser trigger is activated.

Workstation equipment #

• The workstation to be occupied is defined by the operator.
• Ensure the availability of sufficient workspaces, functional areas, storage areas and traffic/escape routes.
• The laser welder is operated by a single person.

Operating elements on the device #

• Handle on the housing of the laser welder for mobile use. The device can be moved and maneuvered.
• Control panel for commissioning and adjustment work on the laser welder
• Welding torch for welding workpieces

Laser safety enclosure #

Work in a suitable laser safety enclosure as per IEC 60825-4:2006:

• Laser protection booth/laser welding cell
• Laser safety curtain
• Laser safety partition wall

Welding fume extraction #

Install fume extraction systems to remove hazardous fumes, vapors, particles and hazardous residues from the work area.

Work instructions #

Danger zone #

Standards and regulations #

In accordance with EU and national standards and requirements, lasers must be categorized based on their output power and wavelength. All laser products of the MA1 series are categorized as class 4 laser products as per EN 60825-1.

Immunity against electromagnetic compatibility #

• EN IEC 61000-6-4:2019
• EN IEC 61000-6-2:2019

Safety of the power supply #

• EN 62368-1:2014+A11:2017

Laser safety #

• ISO 12100:2010
• ISO 11553-2017
• EN 60204-1:2018

Functional safety #

• EN 60825-1:2014+A11:2021
• CDRH 21 CFR 1040.10

Theo Academy #

The THEO Academy is an online learning platform that gives operators basic training in the safe use and maintenance of THEO laser welders.

For more training courses, instructions on machine setup and safety videos, please visit the THEO Academy at: https://academy.theo.inc/.

Key offers of the THEO Academy:

• Machine setup and operation: Step-by-step video tutorials on the setup and basic operation of the hand-held laser welders of the MA1 series.
• Laser safety reports: Training videos and instructions on the hazards of class 4 lasers with an emphasis on risk assessment and safety measures.
• Personal protective equipment (PPE): Detailed tutorials on the correct use of 1080-nm infrared laser safety goggles and other required protective equipment.
• Safe work practices: Online courses on proper handling, maintenance routines and safety procedures to ensure compliance with industry standards.

Operators can complete the module of the THEO Academy online at their own pace. The video tutorials and written materials are designed for beginners and for experienced users, promoting safe working practices and maximum performance.

Upon successful completion of the courses, participants are awarded a certificate.

Please register with the serial number of your MA1 device to be gain access to additional resources and to obtain the machine software license. Registration ensures that you will have access to the full scope of functions and features as well as to product support.

Scope of delivery #

Symbols on the machine #

Product overview #

Laser welder #

Front view #

The laser welding system has a 7-inch industrial screen that is directly connected to the control unit and the laser system. This connection enables control of the devices and status monitoring.

MA1-35 #

1	非常停止スイッチ	2	Safety loop interface
3	Welding torch connection	4	Castors with brake
5	Lock ring (key switch)	6	Cable reel
7	表示

MA1-45, MA1-65, MA1-ULTRA #

1	非常停止スイッチ	2	Safety loop interface
3	Welding torch connection	4	Castors with brake
5	Lock ring (key switch)	6	Cable reel
7	表示

Rear view #

The external control connection of the laser welder features an RS232 interface (DB9) and an EX-CTRL interface (DB25).

MA1-35 #

1	Power switch	2	EX-CTRL connection
3	RS 232: Maintenance connection	4	Power connection
5	Ground connection	6	FEEDER: Wire feed connection
7	Shielding gas inlet port

MA1-45, MA1-65, MA1-ULTRA #

1	EX-CTRL connection	2	RS 232: Maintenance connection
3	FEEDER: Wire feed connection	4	Ground connection
5	Power switch	6	Shielding gas inlet port
7	Power connection

Side view #

Welding torch #

Wire feeder #

• The welding wire feeding system features a control system and wire positioning.
• The device has a direct laser connection, a mechanism with a two-roller drive, closed wiring and a robust housing for improved efficiency and durability.
• Wire feed/pulling speeds of 2 to 100 mm/s
• Continuous and pulsed wire feed options
• Equipped with automatic pumping and filling functions
• Compatibility of welding wire diameter: 0.8 / 1.0 / 1.2 / 1.6 mm

Indicator lights #

The indicator light (1) of the weld head indicates various operating states.

Connections #

Safety interface #

NOTICE #

Additional functions such as a cobot/robot connection are optionally available via an authorization code.

Accessories #

Welding nozzles #

When wire welding workpieces, it is important to use a suitable welding nozzle.

Welding with wire feed #

Welding without wire feed #

1	Nozzles for skip welding	2	Nozzles for inside corner welding
3	Nozzles for lap welding	4	Nozzles for edge joint welding
5	Nozzles for outside corner welding

Wire feeding nozzle #

When wire welding, a suitable wire feeding nozzle (0.8 – 1.6 mm) must be used for the respective wire diameter to ensure that the wire is guided smoothly.

Unpacking #

WARNING #

Risk of injury from heavy loads

Lifting and transporting heavy loads can result in back injuries.

1. Do not carry heavy loads alone.
2. Ensure that the maximum permissible carrying weight per person is not exceeded.
3. Only use suitable and technically sound lifting equipment with sufficient lifting capacity.

CAUTION #

Risk of property damage

The machine may be damaged by lifting it out of the packaging by the cable-hose assembly or by the cable.

1. Do not lift the machine out by the cable-hose assembly or by the cable.
2. Do not kink, crush or twist the cable-hose assembly or cable.
3. Lift the machine out individually.

Performing a visual check #

Please observe the following instructions when unpacking the device from the shipping container:

Activating the laser welder #

NOTICE #

Activating the laser

The machine must be activated for operation once with an authorization code.

1. Watch the training videos attentively.
2. Successfully complete the test.

Follow the following instructions to activate your hand-held laser welder:

Setting up the laser welding system #

CAUTION #

Risk of injury during setup

When setting up the laser welding system, it may not yet be stable. There is a risk of injury from machine parts toppling over, falling or rolling away.

1. Wear safety gloves and sturdy shoes when setting up the machine.
2. Set up the machine on a level surface.
3. Secure the castors on the machine with the brakes to prevent the machine from rolling away.

CAUTION #

Risk of tripping and falling

Improperly routed cables can lead to injuries from tripping or falling.

1. After setting up and before commissioning the laser welding system, ensure that cables are laid correctly and do not form loops or obstacles.

NOTICE #

Before operation, the laser welding system must be safely set up and fully connected.

Connecting the laser welder #

CAUTION #

Risk of device damage

The laser welder will be irreparably damaged if the workpiece clamp is connected to the welding torch.

1. Only connect the workpiece clamp to the workpiece to be welded.

NOTICE #

Ensure that the power switch on the laser welder is switched off before connecting the laser welding system.

NOTICE #

Door interlock switch

The on-site connection of the door interlock switch is the responsibility of the operator.

Connecting the wire feeder to the laser welder #

Connecting the wire feeder to the welding torch #

Procedure for electrostatic grounding #

It is important to establish a secure connection between the ground nut of the laser housing and the plant ground using the ground cable supplied in order to avoid possible damage to the laser due to static electricity.

Connection the gas #

The welding head is cooled by shielding gas, which requires the maintenance of optimum gas purity and air pressure. Generally, nitrogen and argon are used as shielding gas. The purity of the shielding gas must be 99.99% and the inlet gas pressure must be between 0.8 and 1.5 bar. For an effective welding process, it is essential to use a pressure reducing valve with a flow meter (nominal flow rate of at least 8 l/min) to precisely control the air flow.

Changing the nozzles #

To change the welding and wire feeding nozzles, unscrew the nozzle from the fixture and screw on the new nozzle.

Preparing the wire feeder #

CAUTION #

Risk of crushing when opening and closing the housing

Hand and finger injuries may occur.

1. Watch out for your hands and fingers when opening and closing the housing.

Changing the wire spool #

Spools are available with different hole sizes. This may make the use of an adapter necessary.

Changing the wire feed rollers #

The wire type (U, V) and the wire thickness are indicated on the wire feed rollers. U wire feed rollers are used for welding with aluminum wire and V rollers are used for welding with stainless steel or steel wire.

Threading the welding wire #

WARNING #

Risk of injury

When threading and manually moving the welding wire, eye injuries may result.

1. Do not gaze directly into the connection for the torch liner on the wire feeder.
2. Do not gaze directly into the outlet of the torch liner.
3. Do not gaze directly into the wire feeding nozzle.
4. Wear safety goggles.

Connecting the torch liner to the wire feeder #

Preparing the welding torch #

Mounting the wire feed module #

NOTICE #

When mounting the wire feeder module, ensure that the wire feeding nozzle is parallel to the welding nozzle. The pilot laser, which is emitted from the output aperture of the welding torch, must hit the center of the extended welding wire.

Connecting the torch liner to the welding torch #

WARNING #

Risk of injury

When threading and manually moving the welding wire, eye injuries may result.

1. Do not gaze directly into the connection for the torch liner on the wire feeder.
2. Do not gaze directly into the outlet of the torch liner.
3. Do not gaze directly into the wire feeding nozzle.
4. Wear safety goggles.

NOTICE #

If possible, lay out the torch liner straight or with a large radius so that the welding wire does not pierce the cable-hose assembly when it is extended.

If the welding wire has been rethreaded, the welding wire must be run once completely through the torch liner to the end.

Setting the focal plane of the laser #

A scale (2) of -15 to +15 is located on the scale tube (1). Depending on which workpiece is being welded, the focal plane of the laser beam can be adjusted accordingly.

Operating the laser welder #

WARNING #

Risk of injury due to unauthorized use

During operation, accidents may occur due to unauthorized use of the machine by unauthorized persons.

1. Do not leave the machine unattended during operation.
2. Remove the safety key to prevent unauthorized persons from operating the machine.

Switching on the laser welder #

Starting the welding process #

DANGER #

Inhaling welding fumes

The interaction of the laser with target materials such as plastics, metals and composites can cause them to vaporize and produce toxic and dangerous clouds of fumes and vapors. These are often invisible and pose a serious health risk. Exposure to welding fumes can have a negative effect on lungs, heart, kidneys and the central nervous system.

With poor ventilation in closed rooms, toxic fume and gas concentrations can lead to unconsciousness or asphyxiation, and nitrogen oxides produced in high concentrations can lead to death.

1. Install fume extraction systems to remove hazardous fumes, vapors, particles and hazardous residues from the work area.
2. Check the safety data sheets and warning instructions for all welding materials used and comply with them.
3. Note that, in addition to the extraction system, a fresh air supply may be necessary in small spaces or other risky situations.
4. Always work in well-ventilated spaces.
5. Monitor the air quality regularly to determine the concentration of harmful fumes in the work area.
6. Keep your head away from the source of fumes while welding to avoid being exposed to the dangerous fumes while welding.
7. Use respiratory protection in small spaces or in other situations in which this may be necessary.

WARNING #

Laser radiation hazard!

Exposure to laser radiation can lead to irreversible damage to the retina or cornea.

1. To avoid possible eye injuries, avoid looking directly into the torch outlet and be sure to wear suitable laser safety goggles while using the laser.
2. Do not open the hand-held laser welding system as there are no parts or repair possibilities intended for the user.

WARNING #

Risk of injury from reflections

Diffuse as well as specular reflections can be produced during the welding process and can be generated at different angles near the welding torch’s output aperture and can cause severe retinal or corneal damage. This can potentially cause permanent eye damage. Class 4 laser beams can also cause fire, skin and material damage when handling devices or in their vicinity.

1. Wear suitable personal protective equipment: laser safety goggles/laser welding helmet, laser safety gloves, laser safety apron.
2. The user and third parties must always be mindful of possible reflections. An incorrect configuration of laser settings may lead to more reflections.
3. The user and third parties must always remain behind the welding torch.
4. Ensure that no one is located in the reflection area and that no combustible materials are present during the welding process.
5. Use a nozzle that is suitable for the welding position.
6. When welding highly reflective materials (e.g., aluminum or copper), exercise special caution, as some of the laser beam energy may be reflected by the target welding area.
7. Verify that you know the expected reflection cone for each processed part and avoid looking into the expected reflection cone or moving any part of your body into it.

WARNING #

Risk of burns on hot surfaces

Touching hot surfaces on workpieces can lead to burns.

1. Wear the personal protective equipment: Laser safety gloves.

CAUTION #

Risk of hearing damage

Laser welding of noise-generating workpieces generates noise that can cause hearing damage.

1. Wear hearing protection.

Stopping the welding process #

Switching off the laser welder #

Operating the user interface #

WARNING #

Operation hazard when the laser welding system is operated by untrained personnel

Incorrect settings made by untrained personnel can lead to serious injuries and damage to the system.

1. Ensure that entries on the display are made by trained personnel only.

Adjusting the parameters #

Basic Mode #

• The Basic Mode (1) menu makes the material (2), thickness (3) and welding method (4) parameters available.
• The wire feed is started using the Wire Feed (5) button.
• The fish scale pattern is activated via the Fish scale (6) button.

Mode D #

Mode D is only available for the laser welder MA1-35.

The mode is activated and deactivated via the off button. The values -1 to +2 can be set on the controller. Mode D+ can only be activated if the machine performance is ≥ 90%. By selecting various options, the machine can be set to increase its performance to over 100% to achieve a better welding depth.

Expert Mode #

Click on the Expert Mode button to open the Expert Mode user interface and to make advanced welding settings and detailed settings.

Settings can be made in the Expert Mode menu on the Home, Details, Status and Warning tabs.

Home tab #

Click on the Home tab to open the user interface and set the parameters.

Details tab #

Click on the Details tab to open the user interface and make the detailed parameter settings.

NOTICE #

The values for the Laser Power, Wobble Frequency and Wobble Width on this interface correspond to those displayed on the main page.

Setting the Light Mode #

The Light Mode comes in three variants (4). Click on one of the buttons to make the settings in the respective mode on the user interface.

Setting the wire feed parameters #

NOTICE #

The wire feeder and the wire feeder module must be connected to the laser welder to be able to make changes to the wire feed parameters.

The Wire Feed Setting menu is also accessible via the Wire Feed Setting button in the Process parameters menu (see Process parameters).

Status tab #

Click on the Status tab to access the user interface and view the current gas pressure, the temperature of the safety glass and information on the working status of the laser welding system.

Warning tab #

Click on the Warning tab to display all alarm information generated by the laser welding system.

You are made aware of problems or potential problems that require troubleshooting.

All other fault messages are intended for Service only (see Importeur/Service) and do not involve steps to be performed by the user.

Process parameters #

Click on the Process parameters (1) button to open the user interface and create and administer the parameter sets on the Parameters Library (2) and Customize (3) tabs.

Four pages are available on which a total of 32 parameter sets can be saved.

For more information on the parameters, see the Expert Mode section; see Expert Mode.

Parameters Library #

On the user interface of the Parameters Library (2) tab, setting can be made in preset parameter sets.

Customize #

On the user interface of the Customized (3) tab, setting can be made in preset parameter sets.

Administering the parameter sets #

Creating a parameter set #

Deleting a parameter set #

If the maximum number of parameter sets has been reached, the parameter set must be overwritten or deleted.

When saving the parameter set, overwrite the parameter set name or enter the new parameter set name EMPTY and save to delete the parameter set.

System Information #

Click on the System Information button to view the details of the system.

Click on the arrow at the bottom right to view the laser information.

Normal information #

The following information is displayed In the Normal Information area:

• Order date
• Expired date
• Authorization code
• Machine date
• Machine time

The authorization code acquired through the training course can be entered in the Normal Information to unlock the machine or extend the possible machine hours.

If the expiration date of the software is approaching, a dialog box appears informing the user of the impending expiration.

 

To ensure uninterrupted use of the device, Service must be contacted (see Importeur/Service) and a new license code must be requested.

Laser Information #

System settings #

You require a service password to access the system settings. The service password is only issued to authorized dealers who have successfully completed the training course at Maxphotonics.

There are no settings here that the user needs to make in order to operate the system.

Operating the wire feeder #

WARNING #

Risk of injury

When threading and manually moving the welding wire, eye injuries may result.

1. Do not gaze directly into the connection for the torch liner on the wire feeder.
2. Do not gaze directly into the outlet of the torch liner.
3. Do not gaze directly into the wire feeding nozzle.
4. Wear safety goggles.

Laser welder #

WARNING #

Risk of injury

Before performing cleaning work, disconnect the device from the line supply.

1. Have repair work on the device performed by Maxphotonics only.

Visual inspection of the laser welder #

Cleaning the laser welder #

The hand-held laser welder is air-cooled. The ventilation channels and grille must therefore be cleaned regularly and at least every two months.

The user must regularly use a vacuum cleaner and compressed air to vacuum or blow out the dust inside the laser welder.

We recommend cleaning the device once a week with a maximum of 2 bar compressed air.

Cleaning the grille (suction) #

NOTICE #

Clean the grille on the hand-held laser welding system regularly, at least every three months, to remove dust and contamination from the air inlet.

Welding torch #

Cleaning the welding torch #

NOTICE #

Clean the welding torch with a dry towel, not with compressed air.

Changing the safety glass #

CAUTION #

Damage to the device

The optical output of the hand-held laser welder is transmitted through a safety glass with an anti-reflective coating. Any dust or dirt on the safety glass can cause serious damage, resulting in burning of the hand-held laser welder or malfunction of downstream optical devices.

1. Replace the safety glass at regular intervals depending on the use of the laser welder.

NOTICE #

Do not touch the safety glass directly with your fingers. Direct contact with the skin can contaminate the safety glass and render it unusable.

If soot forms during the welding process or the laser loses power, this may be due to a contaminated safety glass.

Wire feeder #

Visual inspection of wire feeder #

Before operating the wire feeder, check the following components for damage:

• Control cable and connector
• Power supply and wire feed button functionality
• Brake mechanism of castors
• Torch liner (kinks and damage)

Cleaning the wire feeder #

At least once per month, clean the device with a dry cloth and vacuum it out.

Cleaning the torch liner #

Use compressed air to remove minor blockages caused by metal chips. NOTICE! Replace the torch liner if the blockages are considerable.

System messages #

Warning #

The Warning tab in the Expert Mode menu displays all alarm information generated by the laser welding system (see Warning tab).

You are made aware of problems or potential problems that require troubleshooting.

Dimensions #

MA1-35 #

a	512 mm	b	577 mm
c	265 mm	d	577 mm

MA1-45 and MA1-65 and MA1-ULTRA #

a	542 mm	b	667 mm
c	276 mm	d	667 mm

Wire feeder #

a	360 mm	b	580 mm
c	244.5 mm

Laser welding system #

General characteristic parameters #

Optical properties #

Wire feeder #

Welding process parameters #

Process parameters for hand-held laser welding #

NOTICE #

Note the process parameters for butt welding, fillet welding, lap welding, etc.