HWS2000 system manual

Manual For Holding Welding System Equipment

Version：V1.00
 LIST

1.Target Audience ...................................................................................................................................................4

2. Interface description ....................................................................................................................................7

2.1 Operation interface level switching diagram ........................................................................................7

2.2 Continuous (CW) working mode interface ............................................................................................7

2.3 Modulation (PWM) operating mode continuous output light interface.....................................11

2.4 The modulation (PWM) working mode points out the light interface ........................................12

2.5 Process parameter setting/selection interface ...................................................................................14

2.6 Welding head setting interface ..............................................................................................................16

3. Parameter description......................................................................................................................................18

4.Equipment alarm and handling ......................................................................................................................20

5.Equipment installation and wiring.................................................................................................................23

5.1Touch screen terminal wiring instructions ............................................................................................23

7. Control box size .................................................................................................................................................29

8.Touch screen installation size

.................30
This document mainly for the Hws2000 hand-held laser welding equipment control part of the use,

installation and wiring, maintenance and so on to do. Before using this controller and related

equipment, please read this manual carefully to help you better use this equipment.

Due to the continuous updating of the product features, the products you receive may differ in some

aspects from the statements in this manual.

1.Target Audience

This manual is intended primarily for the following staff:

 Equipment operator

 Equipment maintenance personnel

 Equipment installer
1.Preface
This document mainly describes the use, installation, wiring and maintenance of the

control part of the HWS2000 handheld laser welding equipment. Before using this

controller and related equipment, please read this manual carefully to help you use this

equipment better.

Due to the continuous update of product functions, the product you received may differ

from the statement in this manual in some respects. I apologize.

1.1 Product features

 Good human-computer interaction interface, providing users with a friendly operating

experience

 Support continuous (CW) working mode and modulation (PWM) working mode

 Support continuous light emission and point light emission

 Support memorizing the parameter settings in the last working mode, which is

convenient for users to quickly put into work when switching between different modes

 Support the user to save the process parameters, so that the saved parameters can be

quickly recalled when the machine is turned on next time, and the work efficiency is

improved

 Support manual wire feeding and control the wire feeding direction

 Support automatic wire feeding, automatic wire feeding after light emission, wire

feeding speed can be controlled

 Support automatic wire breaking, the welding wire can be automatically blown after

welding
2. Interface description
2.1 Operation interface level switching diagram

Figure 2-1 Operation interface level switching diagram

2.2 Continuous (CW) working mode interface

After the system is powered on and initialized each time, it will enter the following interface:
 Figure 2-2 Enter the interface by default after power-on

After the system is powerd on,the system enters the PWM working mode interface by

default,click the PWM button to enter the continuous working mode.The

interface is as shown in Figure 2-3.

 Figure 2-3 Continuous working interface(CW)

The continuous working mode interface is divided into the following three columns.

1.Work mode selecting bar

Figure 2-4 Work mode selecting bar

This button indicates that the current working mode is continuous

mode,click this button to switch PWM working mode.

2.Parameter setting bar

 Figure 2-5 Parameter setting bar

In the parameter setting column, users can set various parameters according to actual

needs，the default PWM duty cycle in continuous mode is 100%，unchangeable。

Attention： The parameter value is based on the actual screen display value ， The

parameter values shown in this figure are for explanation purposes only.

3.Control bar：

Figure 2-6 Control bar

Red light indicator button：ON/OFF Red light indicator

Laser enable button：Enable/Prohibit Launch laser

Blow enable button：Enable/Prohibit Blow

When the button is gray, it means that the function corresponding to this button is not

turned on, and when the button is colored, it means that the function corresponding to this
button is turned on. Click the button to turn on or turn off the function corresponding to this

button.

For example ：

Indicates that the current laser has enabled, the red light indicator has not turned on, and the blowing

enable has not turned on

2.3 Modulation (PWM) operating mode continuous output light interface

In continuous (CW) mode, click After clicking the button, the continuous light

output interface can be switched from CW mode to PWM mode.

图 2-7 调制(PWM)工作模式下连续出光界面

The modulation (PWM) working mode interface is also divided into 3 columns. Different from the
continuous (CW) working mode interface, the modulation working mode interface has more opt-out

mode buttons 。This button indicates the current mode of light emitting. Click this

button to switch the mode of light emitting. The device provides two modes of continuous light

emitting and point light emitting.Click button，Return to continuous (CW) mode.

When selecting the modulation (PWM) working mode, the laser power is determined jointly by the

analog quantity and PWM wave. At this time, the output power of the laser welding joint = laser power

* peak power *PWM duty ratio. Under the mode of selected modulation (PWM), the parameter

Settings on the interface are all effective, and users can set various parameters according to their

needs.

For the description of the control bar of continuous light output under the modulation (PWM) working

mode, please refer to the description of the control bar of the modulation (PWM) working mode in

Section 2.2.

2.4 The modulation (PWM) working mode points out the light interface

Under the continuous output light interface of modulation (PWM) working mode, click

button，You can switch to the modulation (PWM) mode of operation. The output

light interface is shown below:

 图 2-8 调制(PWM)工作模式下点射出光界面

Click the button to switch out the light mode.

Click Click the button to switch to continuous mode.

Work in modulation (PWM) mode of some directly out of the way of light, the number of PWM

pulse can be set user can set the maximum number of PWM pulse PWM pulse frequency value shall

not be higher than setting, i.e. some light time is less than 1 second user after the option radiates light

way, after pressed the trigger of laser welding head, the light time is determined by the setting of

PWM pulse number, the light time = / PWM frequency PWM pulse number.

Please refer to the description of the control bar of the point emitting light in the modulation

(PWM) working mode in Section 2.2.

2.5 Process parameter setting/selection interface

After clicking the button, you can enter the process setting/selection interface as

follows:

图 2-9 工艺设置/选择界面

For the continuous light output mode under the common modulation (PWM) working mode, the

process setting/selection function can set and save the welding process parameters commonly used or

preferred by the user. Input the current process name to be saved in the process name, such as steel

welding 3mm, and input at most 7 Chinese characters or 14 English letters in the process name.
 After power on, the user can quickly set the parameters of continuous light emission in the

modulation (PWM) working mode through this function. After entering the interface and selecting the

process, click the button ，This set of process parameters can be selected as the current

parameters to be set, while switching to the modulation (PWM) mode of continuous light interface,

users can view the current selection of the process in the instructions.

For example, after selecting the process, click the OK button, jump to the modulation (PWM) mode of

continuous light interface, the interface parameters are automatically set to the parameters of the

selected process, users can also modify the selected process parameters according to their needs.

Users can save up to 6 sets of process parameters, automatically save after modifying the process

parameters, and directly access the saved process parameters after the next boot.

Figure 2-10 Selected process

2.6 Welding head setting interface

Click to enter the welding head setting interface. When setting this interface, you

need to turn off the laser enable. The interface is as follows.

Figure 2-11 Welding head setting

To adjust the welding head motor speed, you can set the motor speed bar parameters for

adjustment control. The motor speed range is 0-100%, the larger the value, the faster the speed. The

motor stop delay column can set the motor stop delay time. The motor stop delay time range is

0-1800 seconds. The larger the value, the longer the delay time, as shown in Figure 2-12.
 Figure 2-12 Welding head motor control

Click the wire feeding mode button to switch between automatic wire feeding and manual wire

feeding, as shown in Figure 2-13.

Figure 2-13 Wire feed function button

In the automatic wire feeding mode, click to turn on the wire feeding. When the laser is enabled,

the wire feeder will automatically feed the wire.

In manual wire feeding mode, set the wire feeding direction to wire feeding, and the wire feeder

will perform wire feeding after the wire feeding is turned on. Set the wire feeding direction to wire

return, and the wire feeder will return wire after the wire feed is turned on. In manual wire feeding

mode, it will not be controlled by laser enable, and the wire feeder will execute corresponding actions

immediately after wire feeding is turned on.

To adjust the wire feeding speed, you can modify the parameters in the wire feeding speed

column to adjust, the range is 0-100%, the larger the value, the faster the wire feeding speed, as shown

in Figure 2-14.

For different welding processes, in order to prevent the welding wire from not fusing after the

light is stopped, the wire stopping time can be set in advance. Modify the parameters of early wire stop,

adjust the time of early wire stop, the range is 1-500mS, the larger the value, the longer the time, as
shown in Figure 2-14.

Figure 2-14 Wire feeding control parameters

3. Parameter description

Blowing delay:

1）Before light emission: set the blowing delay time before light emission

2）After turning off the light: set the blowing delay time after turning off the light

Power delay:

1）Slow rise time: set the power slow rise delay (the time it takes for the power to increase from 0 to

the newly set power)

2）Slow down time: set the power slow down delay (the time it takes for the power to drop from the

set power to 0)

Note: The slow down time is up to 500ms

Peak power:

Set the light output power of the welding head. In continuous (CW) mode, the output power is only

adjusted by analog quantity. In this mode, PWM does not participate in power setting, and the user

setting is invalid

Welding head output power = laser power * peak power.

PWM duty cycle:

Set to adjust the duty cycle of the PWM wave of the laser. In the modulation (PWM) mode, the welding

head power is adjusted by the peak power and the PWM duty cycle.

Welding head output power = laser power * peak power * PWM duty cycle.

PWM frequency:

Set and adjust the frequency of the PWM wave of the laser, and the frequency value adjusts the light

frequency of the welding head.

Number of PWM pulses:

Set to adjust the number of pulses emitted by the PWM wave of the laser.

This parameter is only valid in the burst mode. In the point emitting light

mode, the number of pulses determines the point emitting light time. The

emitting time = the number of pulses/pulse frequency, and the point

emitting light time is at most 1s.

Motor speed:

Set the motor speed that drives the lens to rotate.

Note: Please turn off the laser enable before setting the motor speed and motor stop delay.

Motor stop delay:

When the laser enable is turned on, the light is stopped, and the motor stops rotating after this delay.

(This parameter is mainly used to extend the life of the motor.)

Note: The motor stop delay time is up to 1800 seconds.

Wire feeding speed:

Set the wire feeding speed of the wire feeder.

Stop wire in advance:

After the welding head light trigger is released, there will be a delay in the wire feeder to stop and

break the wire

Note: The maximum delay time for stopping the wire in advance is 500MS. When the setting is

too long, please confirm that the light has been stopped before placing the welding head to

prevent laser damage.

4.Equipment alarm and handling

When the equipment is operating normally and when an alarm occurs, the alarm indication button is

as shown in the figure below:

Figure 3-1 Normal operation of equipment 图 3-2 设备出现告警

When the equipment fails, the interface will pop up an alarm window and indicate the current

failure. At the same time, a red flashing alarm light will appear next to the alarm indication button.

After the failure is removed, the red alarm indicator will disappear. The user can click the alarm

indication button to view the current device alarm status.

 Figure 3-3 Alarm window

After an alarm occurs, the user needs to immediately stop using the handheld laser welding

equipment, troubleshoot the fault, and continue to use it after the fault is resolved. Users can refer to

the alarm information in the alarm window to troubleshoot faults. The alarm information and solutions

are shown in the table below.

 Warning message Solution

Check whether the RS485

Alarm 00: The controller is not communication line of the touch screen and

connected the controller is properly connected, and

check whether the controller is normally

powered on and started

Alarm 01: Air pressure is too low Check whether the air pressure is

normal

Alarm 02: Laser failure Check whether the laser is

malfunctioning

The equipment is operating normally Indicates that the equipment is

without warning operating normally and there is no alarm

Table 3-1: Alarm information and solutions

5.Equipment installation and wiring

5.1Touch screen terminal wiring instructions

Figure 4-1 Touch screen terminal

1. Terminal wiring instructions:

2. Power terminal: The screen uses 24V DC power supply, the terminals from right to left are:

power supply positive, power supply negative, and ground wire

3. RS485 communication terminal: This terminal and the controller RS485 communication

terminal are connected through the RS485 communication line.

 4.5.2 Description of controller wiring terminal

Figure 4-2 Controller wiring terminal

Please refer to the table below for detailed description of the controller terminals.
Controller terminal description
Port input Pin Terminal
Label Pin
silkscreen Output definition description
This terminal is connected to
1 OUT RS485 the RS485 terminal of the touch
screen
2 OUT RS232 Reserved
1 24+
Controller power
3 POWER IN 2 PGND
input
3 GND
1 PWM+
DC24V PWMoutput signal
2 PWM-
4 CON1 OUT
3 0～10V
0～10V Analog output signal
4 AGND
1 LA-EN+ DC24V Laser enable output
2 LA-EN- signal
5 CON2 OUT 3 GAS+ DC24V The output is connected
to the solenoid valve to control
4 GAS-
the blowing
 (Drive current Max 2A)
1 LA-ALM+ Laser alarm input port
(DC24V high level
2 LA-ALM-
effective）
3 LA-ON+ Connect the hand gun button
6 CON3 IN
switch, turn on the light
(Short-circuit at two points
4 LA-ON-
to give out light and
breathe out)
1 SW-IN1+
IN Reserved
2 SW-IN1-
3 LA-Red+ Red light indicating control
7 CON4
signal
OUT
4 LA-Red- (DC24V high level is
effective)
1 Motor_U
2 Motor_V motor
8 CON5 OUT 3 Motor_W
4 Motor_Alm+
Reserved
5 Motor_Alm-
1 GND Common ground point
2 RS232-T
Reserved
9 CON6 OUT 3 RS232-R
Wire feeding speed control
4 WF-V
voltage
1 LED-Y
2 LED-R Reserved
10 CON7 OUT
3 LED-G
4 DC 24V DC24V Power Output
1 WF-EN- Wire feed enable control
2 WF-EN+ (Active low)
3 WF-DIR- Wire feeding direction
11 CON8 OUT
control
4 WF-DIR+ (High level wire feed, low
level wire return)
1 AGND
2 AC-IN2
12 CON9 IN Reserved
3 AGND
4 AD-IN1
13 CON10 IN 1 GND Reserved
 2 SW-P
3 SW-IN3
4 SW-IN1
Table 4-1: Controller terminal description

In order to improve the safety performance of the product, the handheld welding head adopts the

method of contacting light, that is, when the welding head and the welding workpiece are in contact,

the light can be emitted after pressing the light switch of the handheld welding head.

手持枪开关

+24V KA
手持枪外壳

工作台接地点

GND

Laser+ Laser-

Figure 4-3: Schematic diagram of exposure to light

Figure 4-4: Wiring diagram of control box
 6. HWS2000 handheld welding system network

diagram

HWS2000 LA-ON+
Dedicated display Motor-U
DB9 Communication line
Motor-V Cable Welding head
Motor-W

0-10V LA-ON-
Artifact
HWS2000
AGND Controller
GND
PWM+
Laser Source WF-V
+24V Wire
PWM- WF-EN+ Cable Feeder

WF-DIR+
GAS+

Blow control relay GAS-

Figure 5-1: HWS2000 handheld welding system network diagram

7. Control box size
196mm
96m
m

Figure 6-1: Length and width of control box

62mm

Figure 6-2: Height dimension of control box

8.Touch screen installation size

Figure 7-1: Touch screen installation size