Demark FWH20-S10A Intelligent Single Pendulum Handheld Welding Head Owner’s Manual

Demark FWH20-S10A Intelligent Single Pendulum Handheld Welding Head

Product Information

Specifications

• Name: Intelligent Single Pendulum Handheld Welding Head
• Model: FWH20-S10A
• Fiber Interface: QBH
• Wavelength Range: N/A
• Rated Power: 3000W
• Collimating Focal Length: 50mm
• Focus Length: 150mm
• Focus Adjustment Range: -10mm to +10mm
• Spot Adjustment Range: 0-5mm
• Auxiliary Gas Pressure: 1Mpa
• Weight: 0.72Kg

Product Usage Instructions

• To ensure personal safety, please wear special fiber laser protective glass before operation.
• Keep the product clean and prevent the entry of cooling liquid, condensed water, or any other objects into the cavity to avoid impacting its function.
• The cooling pipe and auxiliary gas pipe should be connected securely for proper functioning.

Fiber Input and Installation

1. Place the QBH horizontally and remove the dust seal cover.
2. Align the red point on the optical fiber head with that in QBH, and slowly insert the optical fiber head into QBH.
3. Tighten QHB to the locked state by rotating it clockwise to the limit position with a click, then lift the rotary knob up and rotate it clockwise again until it presses down on the optical fiber head.

Maintenance

• Replaceable components should be equipped in a dust-free environment.
• The modules of the optical lens should not be assembled or disassembled except for the drawer of the protective lens.
• If necessary to check the collimating lens, focusing lens, and galvanometer lens, do so in a clean environment.

FAQ

• Q: Can I disassemble the optical lens components myself?
• A: In general, the optical lens components should not be disassembled except for the protective lens drawer. If you need to check other lenses, it is recommended to do so in a clean environment to avoid damage.

Introduction

• Thanks for choosing our products!
  To ensure you an overall understanding of this product, the manual has made a detailed introduction on features, structure, technical parameters, instructions and maintenance of this product.

• Before using the product, please read the manual carefully to help you use it better.

• For the constant renovation of function for the product, I want to apologize for that there may be differences between the product and the manual.

• If you have any questions when using it, please call us in time. We will help you as possible as we can.

Overview

Product Parameter

Name| Intelligent single pendulum handheld

welding head

---|---
Model| FWH20-S10A
Fiber interface| QBH
Wavelength range| 1070±20nm
Rated power| ≤3000W
Collimating focal length| 50mm
Focus length| 150mm
Focus adjustment range| -10mm～+10mm
Spot adjustment range| 0～5mm
Auxiliary gas pressure| ≤1Mpa
Weight| 0.72Kg

Cautions

• To ensure personal safety, please wear special fiber laser protective glass before operation.
• Please keep the product clean and stop the entry into the cavity of cooling liquid, condensate water and other objects to, otherwise, the function may be impacted.

Structure and Feature

Product Structure

Product Assembly

Tube connection

• The cooling pipe and auxiliary gas pipe are connected.

The connection between cooling water and protective gas as well as the operating requirements
Attention: commonly used gas: compressed air ( It’s necessary to filter oil and water) Compressed used gas: Argon, Nitrogen and compressed air ( It’s necessary to filter oil and water)

1. Cooling water: connected with 6mm gas pipe. When the light path in the cavity generates heat, the internal waterway will remove excess heat to ensure the welding performance. Cooling water pipe requires series and connection with the inlet and outlet pipes.
2. Protective gas: connected with 6mm gas pipe. It is used for the protection of welding gas with an input pressure of less than 1Mpa.

Fiber input installation

• Put QBH horizontally and take out the dust seal cover

• Align the red point on the optical fiber head with that in QBH, and insert the optical fiber head into QBH slowly.

• Tighten QHB to the locked state: rotate the QHB clockwise to the limit position with a “click”, then lift the rotary knob up and rotate the knob clockwise again until it presses down on the optical fiber head.

Maintain

• Replaceable components should be equipped in the dust-free plant.
• In principle, the modules of the optical lens can’t be assembled or disassembled except the drawer of the protective lens.
• If you have to check the collimating lens, focusing lens, and galvanometer lens, please disassemble them in a clean environment.

Operating method and cautions
Tool: dust-free gloves or dust-free fingertips, dust-free cotton swabs, isopropyl alcohol, and canned dry pure compressed air.
Spray the isopropyl alcohol onto the dust-free cotton swab, make the lens face your eyes, gently pinch the side edge of the lens with the thumb and forefinger of your left hand, wipe the front and back of the lens in one direction from left to right or from top to bottom with dust-free cotton swab held in the right hand ( remember not to wipe the lens back and forth to avoid the second contamination), and blow the surface of the lens with dry pure compressed air to ensure there is no dust on the lens.

Tool: 2mm inner hexagon wrench, special fixture wrench, clean cotton swab, and alcohol.
The disassembly of the lens should be operated with hand-wearing dust-free gloves or fingertips in a clean environment.
Steps:

• Step 1: remove all the dust on the surface of the laser head
• Step 2: loosen the 3-M4*6 set screw in the figure with a 2mm inner hexagon wrench.
• Step 3: take out the QBH module and seal the port with masking tape to stop the entry of dust into the cavity.
• Step 4: use the special fixture for the disassembly of the lens cone, rotate counterclockwise to loosen the locking spring ring and slowly take out the welding head download. Seal the port with masking tape to stop the entry into the cavity of dust. Change the collimating lens. (Pay attention to the position and thickness of the washer because it will impact the light path. After disassembly, take a record of the thickness and size of the washer.)

Tool: 2mm inner hexagon wrench, clean cotton swab, alcohol, and masking tape The assembly and disassembly of the lens should be operated with hands wearing dust-free gloves or fingertips in a clean environment.

Steps

• Step 1: loosen M4 screw with a 2mm inner hexagon wrench.
• Step 2: pull out of the focusing module horizontally
• Step 3: seal the port with masking tape to stop dust from entering the cavity to cause contamination.
• Step 4: the cover is gently pressed down and rotated 90°.Align the two convex places with the left and right openings. Take out the cover upward and the protective lens can be changed.
  (Note: install lens in concave and convex direction.)

The assembly and disassembly of the lens should be operated with hands wearing dust-free gloves or fingertips in a clean environment.
Steps
Change protective glass 01

• Step 1: hold both sides of the green drawer handle module 1 in hand and pull out the protective lens horizontally. Take care of the dust, seal the port exposed on the cavity with masking tape to stop the entry of dust into the cavity and replace the protective glass.
• Step 2: the cover is gently pressed down and rotated 90°. Loosen it when the two sides align with the two notches. Take out the cover and change the protective lens.

Change protective glass 02

• Step 1: take out the green drawer handle module 1 and pull out the protective lens horizontally. Take care of the dust, seal the port exposed on the cavity with masking tape to stop the entry of dust into the cavity and replace the protective glass.
• Step 2: the cover is gently pressed down and rotated 90°. Loosen it when the two sides align with the two notches. Take out the cover and change the protective lens.

Welding System

Product dimension figure

• Dimension of touch screen
• mm Size:（209.515024)mm
• Dimension figure of touch screen:

Mainboard dimension figure

Supplies

Electrical material list

List

Serial

number

| Name| Picture| Number| Remark

1

| ****

Intelligent handheld welding head

| |

1PCS

|

2

| ****

24V power box

| |

1PCS

|

3

| ****

15V power box

| |

1PCS

|

4

| ****

Earth clamp assembly

| |

1PCS

|

5

| ****

Display screen

| |

1PCS

|

6

| ****

Touch screen 4-core cable-1.5m- black

| |

1PCS

|

7

| ****

Bluetooth antenna

| |

1PCS

|

8

| ****

V2 welding system control

| |

1PCS

|

System wiring

• The following is the wiring diagram of the whole system.
• System can refer to this diagram.
• For the detailed interface definition, please refer to the relevant chapter.

Important
Do not connect the pins reserved on the mainboard.

CN5 power supply interface
The power supply interface is a 6-pin green terminal and a power interface is provided for the mainboard and galvanometer by an external part. The voltage is DC 24V and DC ±15. Chart 6.3.1 shows the definition of the CN5 power supply interface.

Chart 6.3.1

1

|

24V+

|

Power input

|

+ 24 V external power input. The power output current is more than 3A.

2| 24V-| GND| —
3| PGND| External shield

ground

| Generally connected to the ground or case
4| +15V| Power input| + 15 V external power input. The power

output current is more than 3A.

5| GND| GND| —
6| -15V| Power input| – 15 V external power input. The power

output current is more than 3A.

CN1 wire feeder interface
CN1 wire feeder is a 8-pin green terminal supporting motor wire feeding and IO wire feeding. The definition of wire feeder is shown in Chart 6.4.1.

Chart 6.4.1

1

|

Pulse+

| Motor wire feeding pulse+ interface| PUL+

Used during motor wire feeding, connected with driver PUL+

2| Pulse-| Motor wire feeding

pulse- interface

| Used during motor wire feeding,

connected with driver PUL-

3| DIR+| Motor wire feeding

Dir+ interface

| Dir+Used during motor wire feeding,

connected with driver Dir+

4| DIR-| Motor wire feeding

Dir- interface

| Dir-Used during motor wire feeding,

connected with driver Dir-

5| GND| GND| —
6| Feed| Wire feeding

control interface

| Used for automatic wire feeding by IO

controlled wire feeder

7| Backoff| Wire drawing

control interface

| Used for automatic wire drawing by IO

controlled wire feeder

8| OVCC| +24V power output| The power supply can output 500mA at most

CN2 laser interface
The laser interface is an 8-pin green terminal. Chart 6.5.1 shows the definition of laser interface.

Chart 6.5.1

level

2| PWM-| Modulating signal-| The duty cycle from1% to 99% is adjustable, 24V

level

3| DA| Analog voltage

output

| 0-10 V analog voltage is used for adjustment

of laser peak power

4| GND| GND| Generally connected with DA- and Enable

terminals

5| OVCC| +24V power output| power supply, maximum output 500mA
6| Enable| Laser enable signal|

24V level, a high level is effective

7| Alarm| Laser fault alarm

input

| —
8| GATE| Red light indicator

signal

| Part of the laser needs this signal and this

the function is reserved before delivery.

CN3 temperature sensor interface

CN3 temperature sensor interface is a 4-pin green terminal. Users can directly insert the connecting wire with the terminal into this interface. Chart 6.6.1 shows the definition of the temperature sensor interface.

Chart 6.6.1

500mA

2| Light| Sensor L interface| —
3| Temp| Sensor T interface| —
4| GND| Sensor G interface| —

HMI touchscreen interface
The HMI interface is a 4-pin green terminal through which the mainboard supplies power to HMI and communicates with it. Chart 6.7.1 shows the definition of the HMI interface.
Chart 6.7.1

CN4 reserved serial port interface

CN4 reserved serial port interface is a 4-pin green terminal without wiring.
Chart 6.8.1 shows the definition of the CN4 interface.

Chart 6.8.1

CN6 external start and interlock interface
CN6 interface is a 4-pin green terminal, the definition of which is shown in Chart 6.9.1.

Chart 6.9.1

switch+ on the welding head

3

|

Injector

| Injector signal input| The pin must be contacted by the injector. Before

welding, clamp the safety clamp to the metal material.

4

|

Interlock

| Interlock signal input| The pin must be contacted to the nozzle of the handheld head. When welding, the nozzle should be in contact with the metal material.

CN7 general input interface 1
CN7 interface is a 6-pin green terminal of NPN type. Chart 6.10.1 shows the definition of CN7 interface.

Chart 6.10.1

input

|
3| GND| GND| —
4| Input1| Reserve| —
5| Input2| Reserve| —
6| Input3| Reserve| —

CN8 general output interface
CN8 is a 6-pin green terminal adopting OC output to drive relax directly with the maximum current adding up to 500mA. Chart 6.11.1 shows the wiring diagram.

Wiring diagram of output port relax

Chart 6.11.1

2 CN2 general input interface 2

CN9 interface is a 4-pin green terminal. Chart 6.12.1 shows the definition of CN9 interface.

Chart 6.12.1

Galvanometer interface

• The system provides two DB9 galvanometer interfaces, one for males and the other for females.

HMI Operating Instruction

HMI function introduction

The handheld laser welding control system operating panel (“HMI” for short) adopts a 7-inch configuration TFT touchscreen with a beautiful interface and convenient operation. It can set laser-related parameters. On the main interface, the input and output IO status, alarm information, and motion state can be displayed in real-time. HMI main interface is shown in the figure below:

HMI main interface

• Bluetooth logo: to show whether this device is connected to the mobile terminal through bluetooth.
• Swing off: to set the galvanometer motor swing on or off Safety lock: to start or close the safety lock. When the lock is started, during the welding, the laser will stop when the welding head does not touch the welding material.
• Automatic wire feeding off: to control whether to start automatic wire feeding during welding. It will start automatic wire feeding only when the laser emits light.
• Emit laser: to start emitting laser or stop emitting laser Alarm status area: when an alarm signal is enabled, protective gas low pressure, cool water flow alarm, laser alarm and temperature alarm status will be displayed in real-time. When the safety lock is started, its status will be displayed in real-time. When the alarm signal is not triggered, the alarm icon is blue; when it is triggered, the alarm icon is blue and red alternately.
• Homepage/ Wire feeding parameter/ Diagnosis/ System parameter: to display the type of parameter on the current page. Click an icon to enter the switch of the corresponding parameter page. For instance, if the icon on the homepage turns on, the parameter in the current display area is the parameter of the homepage. When it needs to switch to the wire feeding parameter, just click the position of the wire feeding, and the icon of this parameter will turn on.
• Blowing manually/ Wire feeder: for manual blowing test and the wire feeding and wire withdrawing tests of the wire feeder. For example, a long press manual blowing key, and it will blow all the time; loosen this key, and it will stop blowing. For manual wire feeding and wire withdrawing, long press the corresponding small triangle area.

HMI operation introduction

Parameter setting

• Parameter setting includes the home page, System parameter, Wire feeding parameter and Diagnosis page
• Home page: used to set parameters related to laser, swing and process library when welding.
• Process library: click the white box area in the process library. The set process library parameter can be selected.
• Welding model: to set welding mode, continuous and pulse modes.
• Power: to set the peak power of the laser when welding PWM frequency: used to set the frequency of laser PWM modulating signal Duty cycle: used to set the duty cycle of PWM signal with the range from 1% to 100%
• Swing frequency: used to set motor swing frequency Swing length: used to set motor swing length Wire feeding parameter: used to set system parameters, including wire feeding, slow rise and fall parameters
• Light emission time: the time that processing lasts when single-point welding mode is set.

Point welding mode: click to enter the single point light emission mode System parameter: used to set the basic parameters of the device. Generally, the setting is performed by manufacturers. Before entering the page, users need to enter a password.

System Password: 666888

• Pulse on time: the time to start light emission in pulse mode
• Pulse off time: the time to stop light emission in pulse mode
• Slow rise time: used to set the time that the laser analog voltage rises from initial power to the maximum power when it is enabled.
• Slow fall time: used to set the time that laser analog voltage falls from the maximum power to initial power when it is stopped.
• Light on power: used to set the initial power of the laser, the percentage of welding power
• Light on asymptotic time: the time to control the light on the power of a laser to rise slowly to the set power
• Light off the power: used to set the light off the power of the laser, the percentage of welding power
• Light off asymptotic time: the time to control the light off power to fall slowly
• Language: to switch language
• Advance gas on delay: when starting processing, users can set gas activation delay. When the external start button is pressed, after blowing delay for some time, the laser can emit light.
• Gas off delay: when stopping processing, users can set gas closure delay. When processing is stopped, stop the laser first. After a delay for some time, stop gas blowing.

Automatic swing: used to set whether the galvanometer swings automatically.

• When the automatic swing function is enabled and the safety lock is connected, But if the safety lock is not connected, make the motor not carry out automatic swing after delay for some time.
• Device parameter: used to switch to the device parameter page. It requires a password.
• Authorization: for the authorization management of mainboard Device number: used to set the bluetooth number of a control system. When users have multiple devices, they can define the number for management.
• Offset in middle: for the setting of the offset in the middle of the red light.

Wire feeding parameter: used to set parameters related to wire feeding, wire supplement and withdrawal.
Wire withdrawal speed: the wire withdrawal speed of the motor when the start button is loosened.

• Wire withdrawal time: the time for motor wire withdrawal
• Wire supplement speed: the speed of motor wire supplement
• Wire supplement time: the time for motor wire supplement
• Wire feeding delay time: wire feeding after light delay for a period, generally it’s 0.
• Continuous wire feeding: used to change wire for the wire feeder. Click once for continuous wire feeding, click again to stop it.
• Continuous wire withdrawal: used to change wire for the wire feeder. Click once for continuous wire withdrawal, and click again to stop it.
• Diagnosis: to monitor the IO status of the current system

Device parameter: used to set parameters related to the device

• Laser-rated power: used to set the rated power of the laser
• Maximum deflection angle of galvanometer: used to set the range of the maximum deflection angle of the galvanometer.
• Maximum frequency: set the maximum frequency of the laser PWM signal. When the PWM frequency set by the welding parameter exceeds the maximum frequency, the frequency will be limited to the maximum value.
• Maximum swing length: set the maximum length during swing. When the length set by the welding parameter exceeds the maximum length, the length will be limited to the maximum length.
• Wire feeding step: used to set the step during motor wire feeding.
• The direction of motor wire feeding: used to set the direction polarity of motor wire feeding.
• Galvanometer correction coefficient: when there is a nuance in the set length and the actual length, it can be modified by this parameter. When there is no need for correction, it is usually set as 1.
• Lens temperature alarm enable: enable lens temperature alarm. When the temperature exceeds the limited value, the alarm signal will be generated.
• Lens temperature alarm limited value: the limited value of lens temperature Laser alarm enable: used to enable laser alarm. When the laser generates an alarm, the alarm signal will be generated.
• Laser alarm level: used to set laser alarm to trigger the level logic.
• Water-cooling machine alarm enables: used to enable water-cooling machine alarm.
• When the water cooling machine generates an alarm, the alarm signal will be generated.
• Water-cooling machine alarm level: used to set the water-cooling machine alarm to trigger the level logic.
• Low-pressure alarm enable: used to enable gas alarm. When gas low pressure generates an alarm, the alarm signal will be generated.
• Low-pressure level: used to set the low-pressure alarm to trigger the level logic.

Chapter 9 Monitoring Protection Device

Temperature parameter setting of Protective Lens
Home page-System parameter-Device parameter-Enter password 888666-Next page- Limited value of lens temperature alarm
The lens temperature value is proposed to be 50. When the temperature exceeds this value, there will be an alarm prompt on the home page and at the same time, the indicator light on the side of the handheld head turns red.

• For the first use, users need to download the Farguard mini program, which provides after-sales service. Note: presently, this APP only supports the Android system. The icon for the mini-program is shown as follows:

• In the monitoring main screen, users can select the welding system and cleaning system as required.

• The current use status can be viewed in the device status page.

Chapter 9 Replacement of Cleaning Module
The schematic diagram for the replacement of part of the structure is as follows

Module replacement

• Wire feeding bracket module: loosen the 2-M3 screw and take out the module (Figure 1)
• Copper nozzle connecting part: loosen the 4-M2.5 screw and take out the module (Figure 2)

Assembly and Replacement

Assembly and Replacement
Outer case assembly: install them in order of 1,2 and 3.
Focusing drawer assembly: loosen the 4-M2.5 screw and take out the focusing module directly. Pay attention that the side with a small dot in the middle is on the top when replacing and cleaning the focusing module. The replaced welding focusing module should be protected from dust for easy replacement.

Processing Mode Switch

Select processing type
Taking the welding mode switched into 80mm cleaning mode as an example, enter the System parameter, License, and then Processing type. Finally, enter password 666666. When the password is correct, enter the Select system type as follows:

Prompt of module replacement
After selecting the system type by users, the system will give a prompt for the gun head components in the form of words and pictures. Then, users click OK after confirming the corresponding hardware components and the replacement conditions, and the system will prompt them to power on. The user interface should power off the device and replace the corresponding component

Complete switch
After completing component replacement by users, power on the device. The system will prompt whether to confirm the replacement of the corresponding hardware components. Click OK after confirming the completion of the component replacement according to the prompt. Then, the system processing mode is switched.

Thanks for using our products!

• Web: www.relfar.com
• Tel: 0755-23143635
• Address: E Block, Siyuan Zone 1, Peace Community, Fuhai Avenue, Bao’an
• District, Shenzhen City, Guangdong Province.

CONTACT

• Shenzhen RelFar Intelligent Technology Co., Ltd.
• Web: www.relfar.com
• Tel: 0755-23143635
• Address: E Block, Siyuan Zone 1, Peace Community, Fuhai Avenue, Bao’an
• District, Shenzhen City, Guangdong Province.

References

• BWIN·必赢(中国)唯一官方网站

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