SUP-20S Welding Instructions

Thankyou for choosing Super Weiye Handheld Welding System. This user manual providesyou with important safety, operation, maintenance and other information.Therefore, please read this user manual carefully before using this product.

Inorder to ensure safe operation and optimal operation of the product, pleaseobserve the following cautions and warnings and other information in thismanual.

1、Overview

This manual covers the basic installation,factory setting, operation and maintenance service of SUP series welding headproducts.

Super welding head is a handheld welding cuttinghead launched in 2019. The product covers hand-held welding guns andself-developed control systems, and is equipped with multiple safety alarms andactive safe power and light-off settings. This product can be adapted tovarious brands of fiber lasers; the optimized optical and water-cooled designallows the laser head to work stably for a long time under 2000W.

Features

   Basic features: Self-developed controlsystem, multiple safety alarms, smaller size, flexible operation and easy touse.

   More stable: All parameters are visible,real-time monitoring of the status of the whole machine, to avoid problems inadvance, more convenient to troubleshoot and solve problems, to ensure thestable operation of the welding head.

   Process: All parameters are visible, thewelding quality is more perfect, the deformation is small, and the penetrationis high.

   Stable parameters and high repeatability: thedetermined nozzle air pressure and lens state, as long as the laser power isstable, the process parameters must be repeatable. Greatly improve efficiency,while also reducing operator requirements.

1.1Operating environmentand parameters

1.2 Attention information

1) Ensure reliable grounding before power supply.

2) The laser output head is connected with thewelding head. Please check the laser output head carefully when using it toprevent dust or other pollution. When cleaning the laser output head, pleaseuse special lens paper.

3) If the equipment is not used in accordancewith the methods specified in this manual, it may be in abnormal workingcondition and cause damage.

4) When replacing the protective lens, pleasemake sure to protect it.

5) Please note: When using for the first time,when the red light cannot come out of the copper mouth, be sure not to emitlight

2、Install

2.1 Controller wiring definition

2.1.1 Controller power supply terminal

The power supply uses the 5P interface, and the supplied24V switching power supply and 15V switching power supply are used for powersupply

Please note that the 15V switching power supplydistinguishes the positive and negative poles, V1 is connected to 15V+, V2 isconnected to 15V-, and any COM on the 15V switching power supply is connectedto pin 2 GND!

Please note that the switching power supply mustbe grounded!

2.1.2 Controller LCD24/5000   

The LCD cable is delivered with the device andcan be connected directly. See the figure above for specific definitions

2.1.3 Controller signal interface 1

①/②Pin is the air pressure alarm signal input, ifyou need to enable (wiring required), please set the air pressure alarm levelin the background as high, otherwise it is low

The ③/④ pin is the water tank alarm signal input.If you need to enable it (wiring is required), please set the air pressurealarm level in the background as high, otherwise it is low

⑤The number pin is the reference ground for thesafety ground lock, and it is directly connected to the processing workpiecewith a wire

⑥ No. pin is the safety ground lock of thewelding head, connected to the blue wire of the three-core wire, when thewelding head touches the workpiece, the safety lock is on at this time

⑦The number pin is the switch of the weldinghead, connected to the brown wire of the three-core wire

⑧Pin No. is the light switch of the welding head,connected to the black wire of the three-core wire, when the trigger is pulled,the trigger button is on

Please note that only when there isno alarm, and the signal of the safe lock and trigger button is on, the outputsignal of the subsequent port will be sent out.

2.1.4 Controller signal interface 2

The 2 end of thesignal interface uses a 6P interface, and the air valve is related to the wirefeeding

①Reserved feet

②Reserved feet (synchronized with 4-pin signal)

③/④The foot is the valve 24V output, connect tothe valve

⑤/⑥The pin is the signal wire of the wire feeder,the signal port of the wire feeder, regardless of positive or negative

2.1.5 Controller signal interface 3

①Pin is the laser alarm signal input +, if youneed to enable it, please set the air pressure alarm level to high in thebackground

②Pin is enable+, connect to laser enable+

③The pin is 24V output, directly output 24V+after power on

④Pet No. is a common ground (reference ground forfeet 1/2/3/5)

⑤The number pin is analog quantity + output, theanalog quantity is given

⑥Pin is PWM-modulated signal

⑦The number pin is PWM+ modulation signal

2.2 Controller wiring diagram

Note: The COM terminal of ±15Vswitching power supply and the -V (0V) terminal of +24V switching power supplymust be connected to GND and fully connected to the workpiece at the same time.The shell of the switching power supply must be connected to the ground,otherwise, a safety ground lock alarm may occur, and no light will be emitted.

2.3 Optical input interface

SUPwelding head is suitable for most industrial laser generators. Commonly usedoptical fiber connectors include IPG, Ruike, Chuangxin, Fibo, Tottenham, Jept,Kaplin, etc. The optics must be kept clean and all dust must be removed beforeuse

Whenthe fiber is inserted, the cutting head must be rotated 90 degrees to behorizontal, and then the fiber is used to prevent dust from falling into theinterface.

installationmethod（Applets )

2.4 Shielding gas and water chillerinterface

Thewater pipe and air pipe interface can be installed with hoses with an outerdiameter of 6MM and an inner diameter of 4MM. The air path enters in themiddle, and the two sides are Water inlet and outletpipelines (regardless of the direction of inlet and outlet)，Asshown below:

The cooling system is divided into the watercircuit part of the welding head and the water circuit part of the opticalfiber head, which are connected in series, as shown in the figure below:

2.5 Welding gun and control box connection interface

The welding gun and the control box use threewires to connect, including: two-core motor power line, five-core motor signalline, three-core safety ground lock and trigger button line

The motor power/signal wires (two black wires)are directly connected to the motor part of the welding head and can bedisassembled (two options are available:1. Open the motor cover and sideplate of the handheld welding gun 2. Open the control box All are plugs)

Safely lock and trigger button three-core wireused Removable aviation plug:Safely lock and button wires, of which 1 isblue, 2 is black, and 3 is brown (connected to pin 6/7/8 of signal interface 1,see the wiring definition of the control box above for details)

2.6 Wire feeder installation

The two-core aerial plug at thetail of the wire feeder is connected to pin 5/6 of signal interface 2. Refer tothe following for the specific installation method

Click: Wire Feeder Installation Instructions(Applets)

3.Controlpanel and operation guide (the following is V3.3 version)

3.1 Operation summary and operation guide

The operation panel of SUP series is mainlycomposed of touch screen and control box. Touch the main page, process,setting, and monitoring of the operation interface.

3.1.1 Touch screen operation main screen

①In this interface, you can see the current process parameters andinstant alarm information.

②The laser is enabled and the indicator red light is ON when it isturned on.

③The safety lock is usually gray, and when the welding head touchesthe workpiece, it becomes green and can be processed.

④ Welding mode selection, the default is continuous. When itis set to spot welding, it can emit light intermittently for spot weldingoperation, which is convenient for controlling the spot welding time due tohuman error. This function needs to be set as needed (V3.3 version is the abovefunction)

3.1.2 Process operation main screen

①The processinterface contains the process parameters for debugging, which can be modifiedby clicking the box. After the modification is completed, click OK, and thensave it in the shortcut process. When using it, click Import(Modify-Save-Import).

②The scanningspeed range is 2-6000mm/S, and the scanning width range is 0^5mm. The scanningspeed is limited by the scanning width. The limitation relationship is:10≤scanning speed/(scanning width*2) ≤1000 If it exceeds the limit, it willautomatically become the limit value. When the scan width is set to 0, it willnot scan (ie point light source) (the most commonly used scan speed: 300mm/S,width 2.5mm).

③The peakpower must be less than or equal to the laser power on the parameter page (forexample, the laser power is 1000W, then the value is not higher than

1000).

④Duty ratiorange 0~100 (default 100, usually do not need to change).

⑤Therecommended pulse frequency range is 5-5000Hz (the default is 2000, usually itdoes not need to be changed).

⑥Click theHELP button on the upper right to get more related parameter explanations.

Processreference (subject to actual conditions, the following is for reference only)

3.1.3 Set operation main screen

Password123456

①The laserpower is the maximum power of the laser used.

②The switchair delay defaults to 200ms, and the range is 200ms-3000ms.

③When thelight is turned on, it will gradually increase from N1% of the process power to100%; when the light is turned off, it will gradually increase from 100% of theprocess power.

To N2; (asshown in the figure below).

④Wire feedingdelay compensation is the wire feeding advance time relative to the lightsignal, which can be used in conjunction with the withdrawal function.

⑤The maximumtemperature alarm threshold is 70℃. When the value is set to 0, the temperaturealarm will not be detected.

⑥Scancorrection coefficient range 0.01~4, coefficient target line width/measurementline width: generally 1.25.

⑦Laser centeroffset -3~3mm, reduce it and move it to the left, increase it and move it tothe right.

⑧The alarmlevel signal is the default, and the shielded alarm can be directly changed tothe corresponding level detection.

⑨Spotwelding duration is the light emitting time after pulling the trigger, that is,even if the button is released, the light will still be emitted according tothe time spent (V3.3 version is the above function)

⑩Spotwelding interval time is the stop light time between two spot welding afterpulling the trigger button (V3.3 version and above function)

⑧Click theHELP button on the upper right to get more related parameter explanation.

This interfaceshows the status of each detection signal and device information

Click on thedevice authorization to enter the authorized use time interface, after enteringthe password, the system can be authorized for the use time

Theauthorization encryption and decryption methods are the same:

System decryption method（Applets）

四、Maintain

4.1 How to maintain and replaceprotective lenses:

① The processing characteristics of laser weldingrequire regular maintenance of the lens. If the welding effect is found to bepoor, check that the protective lens is dirty, and the protective lens shouldbe replaced in time.

② The cleaning technology of the lens isextremely important. If it is not cleaned well, the performance of the lenswill be reduced, and the lens will be damaged if it is not cleaned. Therefore,you must be very careful when cleaning the lenses.

③ Before operation, wash your hands withdetergent and dry them, then wipe your hands again with cotton with alcohol.

④ Before cleaning, prepare a balloon (leathertiger), a set of clocks, dust-proof non-stick tape, anhydrous absorbent cotton(fine cotton), more than 99% industrial alcohol, finger cots or rubber gloves,and lens cleaning paper.

⑤ Remove the screws of the protective lenscompartment cover in a relatively dust-free place, pull out the protective lensholder, and check the protective lens. If the protective lens is contaminated,it must be wiped clean with lens cleaning paper dipped in absolute alcohol. (Ifthere are obvious burning spots on the surface of the protective lens, itshould be replaced directly.)

⑥ Then check the white accumulating sealing ringunder the protective lens. (If there is any scratch or deformation of theaccumulating sealing ring

They cannot be used and must be replacedimmediately.

⑦ Use a cotton ball dipped in alcohol to wipe themouth of the compartment and the inside of the compartment cover, quicklyinsert the protective lens holder into the protective lens compartment, andtighten the screw.

4.2 Laser center adjustment method (oblique viewing angle)

（Click to browse video)（Applets）

Whenthe red light cannot completely come out of the copper nozzle, manualadjustment is required at this time to prevent the copper nozzle from beingburnt Please note: When using for the first time, whenthe red light cannot come out from the copper mouth, be sure not to emit light

① Asshown in the figure below, no red light can be seen completely coming out ofthe copper mouth at this time

②. We need to remove the back cover, you can seefour adjustment screws, adjust the center according to the video

③. Finally, this effect can be achieved

④. The slight left-right deviation can be set bysetting the panel laser center offset

五、Common exceptionhandling

5.1.Prompt laser/water cooler/airpressure alarm

①If the above alarm occurs without using thealarm signal, please change the alarm level.

②If the above alarm occurs when the alarm signalis used, check whether the alarm of the corresponding equipment or the high andlow levels of the alarm signal are set incorrectly.

5.2.The screen does not light up/clickno response

①The screen does not light up. If the controlleris powered on (the fan is rotating), check whether the four-core wire betweenthe controller and the screen is correctly wired, and whether the 24V voltageof the 1st pin and the 4th pin is normal

②If the click does not work during normal use,check whether the temperature of the whole machine is too high.

③Tap to fail to input, check whether thefour-core wire between the controller and the screen is connected correctly,and whether the second and third pins are normal. For details, please refer to2.1.2 LCD screen terminal of the controller

④If the newly installed equipment clicks andthere is no response, it may be that the system version does not match, justre-flash the program. Please contact our company for the SD card.

5.3.No light

① The monitoring interface can exclude other alarms. When the weldinghead touches the workpiece to be processed, the safety lock is displayed ingreen, and it can be processed at this time. If it is gray, check whether theconnection of the safety lock is normal.

That is, check whether all the readysignals are normal

Normally, the failure of the air outlet andthe wire to emit light is caused by the laser failure or the wiring problem. Ifthe air does not emit and the wire is not fed, it may be a signal problem. Fordetails, please refer to: 2.1.3 Controller signal interface 1

5.4.Suddenlystop emitting light during processing

The monitoring interface checks whether thesafety lock and other alarms are normal, and at the same time checks whetherthe temperature exceeds the temperature alarm threshold.

5.5.Redlight polarization

For details, please refer to 4.2 LaserCenter Adjustment Method

Laser welding machine three-phasepower wiring reference

Note: Two-phase or three-phase electricitydepends on the power supply required by the laser and chiller, not the amountof wiring harness

Warning: Please do not move/install privately,please contact our after-sales company to provide the definition of powersupply for the whole machine before preparing, and the whole machine must begrounded! !