Manual For Holding Welding System Equipment (control part)

Version: V1.01

Contents
Preface1

Audience1

1. System Overview

2

2. Product features

2

3. Main interface description

3

3.1 Homepage

3

3.2 System Setting Interface

3

3.3 Controller configuration interface

5

3.4 Welding work interface

6

3.5 Process selection interface

10

3.6. Advanced parameter description

11

4. Equipment alarm and handling

13

4.1 Equipment alarm

13

4.2 Solutions to the warning

13

5. Program update

15

5.1 Touch screen program update

15

Controller program update

16

6. Equipment installation and wiring

18

6.1 Wiring instructions for touch screen terminals

18

6.2 Controller wiring terminal description

19

7. Wireless module installation and use

23

7.1 Introduction

23

7.2 Wireless control module interface

24

Function and parameter description

25

7.4 Wireless control module installation

26

7.5 Wireless module pairing

26

8. Precautions for the use of equipment

28

9. Equipment dimensions

29

Preface
This document mainly describes the use, installation, wiring and maintenanceof the electric control part of the HWS5000 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 and improvement of product functions, theproduct you received may differ from the statement in this manual in somerespects.

Audience
This manual is mainly applicable to the following staff:⚫

Equipment operator⚫

Equipment maintenance personnel⚫

Equipment installer-1-1. System Overview
The HWS5000 handheld welding control system is mainly composed of acontroller and a touch screen. The user can implement parameter setting, enable
control, switch working mode, view alarm information and other operations
through the touch screen. The controller completes the control of the laser, wire
feeder, and welding torch.
Both the touch screen and the controller use 24V DC power supply, and theexternal wiring is simple and reliable. Users can quickly get started after the system
is powered on and initialized.

2. Product features⚫ Good human-computer interaction interface, providing
users with a friendly operating experience⚫ Support continuous light emission and point lightemission⚫ A variety of parameters can be adjusted to improve thewelding process⚫ Automatically breaks the wire after the light stops, andthe welding wire is easily separated from the workpiece⚫ The system is highly integrated, the peripheral
configuration is rich, and the welding is intelligent-2-

3. Main interface description
3.1 Homepage

Figure 3-1: Home page interface

After the system is powered on and initialized, the welding work interface isentered by default. Click the "Home" button to enter the home page interface.
Under the home page interface, you can enter the system settings, start welding,and controller configuration interfaces.

3.2 System Setting Interface

image 3-2: System setting interface

Click the "System Settings" button under the home page interface to enter thesystem settings interface.
"System Upgrade": See page 14, paragraph 5.2 for details.
"Language switch": This system supports simplified Chinese, traditional Chinese,

English, Korean, Russian and Spanish. After clicking Language Switch, click therequired language, and the language will be displayed on all system interfaces.

-3-

"Touch Calibration": When there is a touch offset or insensitivity, click "Touch

Calibration" and click the "+" on the screen to complete the calibration.

"Version Information": Display thecurrent system's touch screen version,

controller software version, and controller hardware version.
"Alarm sound reminder": Turn on/off, when an alarm occurs, the screen emits asound.
"Product Activation": Query the current device ID and encryption status. The

activation code is divided into six segments, each with 4 digits. After entering thecorrect activation code, click "Activate" to update the encryption time orpermanently decrypt.

"Restore factory settings": The device is restored to the factory state.
"System restart": Restart the device.

-4-

3.3 Controller configuration interface

Figure 3-3: Control configuration interface

Click the ‘controller configuration’ button under the homepage to enter thecontrol configuration interface, you can configure some functions and parameters of
the controller.
Alarm input signal: Configure the corresponding alarm signal as a high-level
alarm or a low-level alarm. The system defaults to a low level alarm and supports
two IO port input signals, namely, the laser alarm input signal and the air pressure
alarm input signal.
Analog output range: You can select the analog voltage output range of thecontroller, and adapt to different lasers by changing the output range.
Stepping wire feeder configuration: Choose to enable or disable the stepping
wire feed (users who use our MARS8000-S series wire feeder, please set this toenable).
Wireless controller configuration: Choose to enable or disable the wirelesscommunication module (users who use our HW960 series handheld laser welding
head, please set this option to enable).
Wireless controller pairing: To communicate and pair with the wireless control
module. This button is available when the wireless controller is configured as"Enable".

-5-

3.4 Welding work interface
After the system is powered on, it will enter the welding work interface by
default, as shown in the figure below:

Figure 3-4: Welding interface

The welding work interface is the most commonly used interface for users.
Under this interface, users can set parameters, turn on/off enable control, switch
working modes, and light emitting methods.
Output power of the welding head = laser power x peak power x PWM duty cycle
Click the "LaserMd" button to switch the light emitting mode.

Figure 3-5: Continuous light emission

Figure 3-6: Point emitting light

The three different light emitting methods are as follows:
Continuous light: After turning on the laser enable, when the light-emitting
conditions are met, the light can be continuously emitted by pressing the lightemitting switch of the welding head, and the light can be turned off by releasing
the light-emitting switch.

-6-

Point shot light: When the light is spotted, after the laser enable is turned on,
the light will be emitted only once per press. The light emission time is determinedby the spotting time. If you need to spot the light again, you need to release theswitch and press the light switch again.
Scaly welding line: after the laser is enabled, the light emitting conditions aremet, the light spot swings slowly to achieve the effect of scaly pattern.
The enable button has an indication function. The closed and open states are
as shown in the figure below:

Figure 3-7: Turn off enable

Figure 3-8: Enable enable

Enable and switch control buttons:"Red light indicator" button: Turn on/off the red light indicator.
"Spot enable" button: Turn on/off the light spot swing.
"Lightemitting

mode" button:

Set

the

light

emitting

modeof"continuous"\"spot shot".
"Laser enable" button: turn on/off the laser enable, only when the laser enable

is turned on can light be emitted.
"Wire feed switch" button: Turn on/off the wire feed.
"Wire feeding mode" button: can switch between inching wire feeding andautomatic wire feeding. When the wire feeding is inching, the wire feeding switch
must be pressed continuously before the wire feeder moves, and the wire feeding
switch stops when the wire feeding switch is released. During automatic wire
feeding, if the wire feeding is turned on, the wire will be fed automatically during
the light emitting process, and the wire will stop automatically when the light is
stopped.

-7-

"Wire feeding direction" button: It can be switched to wire feeding and wire

return. In the automatic wire feeding mode, the wire feeding direction is "Wirefeeding" and cannot be modified.

Description of welding interface parameters:"scanningfrequency”: Set the oscillation frequency of the galvanometer

motor of the gun head. The higher the scan frequency is set, the faster the lightspot moves. This parameter is limited by the sweep width parameter:
Scanning width≤2mm, scanning frequency≤600HZ; 2mm＜
scanning width ≤3mm, scanning frequency ≤400HZ; 3mm＜
scanning width≤4mm, scanning frequency≤350HZ. "Scanwidth": set the beam swing width;"Blowing out of light": Set the delay time of blowing out before light is emitted;"Turn off light and blow": set the blowing delay time after turning off the light;"Peak Power": The maximum power during stable light emission.
"PWM frequency": Adjust the frequency of the PWM pulse signal of the laser.
"PWM Duty Cycle": Adjust the duty cycle (pulse width) of the PWM pulse

signal of the laser. The power of the welding head is adjusted by the peak power
and the PWM duty cycle.
Welding head output power = laser power * peak power * PWM duty cycle.
"Wire feed speed": Set the running speed of the wire feeder.
"Blow before light is emitted": Set the delay time of blowing before light isemitted.
"Blow after light off": Set the delay time for blowing after light off.

Light emitting must meet the following 5 conditions at the same time:
Turn on the laser enable;
The LA-ON-pin of the controller is connected to the metal welding
workpiece through a wire (refer to the device wiring chapter);-8-

The tip of the gun contacts the metal welding workpiece;
Press the light control switch of the welding gun;The device currently has no alarms.
In the case that the laser can work normally, the light cannot be emitted
when one of the above 5 conditions is not met.

The process of power change during light emission is shown in Figure 4-1.

Figure 4-1: Schematic diagram of power changes-9-3.5 Process selection interface

Figure 3-10: Process interface

Click the "PARAM" button under the welding interface to enter the process
selection interface. After selecting a certain group of processes, click "Export" todirectly import this group of process parameters into the welding work interface.
The process parameters under the process interface can be permanently saved
even when the power is off. The user can input the process name to identify
different process parameters.

3.6. Advanced parameter description

Figure 3-11: Advanced parameter interface
The password for entering advanced parameters is 2000. The explanation anddescription of the advanced parameters of the handheld welding control system- 10 -

are listed below. Users can set appropriate parameters according to actual needs
during use.
Fac delay:
When the laser enable is turned on, after stopping the light, the motor stops
rotating after this period of delay. The maximum stop delay is 999s.
Power ramp up
Set the power ramp-up delay (the time required for the output power to risefrom the starting power to the peak power);
Power ramp down
Set the power slow-down delay (the time it takes for the output power todrop from the peak power to the cut-off power).
Note: Only the system with optional wireless control module has the powerslow down function!
Power start:
The power when the light starts.
Power off:
The power when the light is stopped.
WireMoment:
If the control system is equipped with a stepping wire feeder, the torque ofthe stepping wire feeder can be adjusted according to the load of the stepping
wire feeder.
Stop delay:
After setting the light-off delay time, the light will not be turned off
immediately after releasing the off switch of the welding head, but the light will
really stop after the light-off delay period. Use the time of the light-off delay torealize that the welding wire is separated from the workpiece after the light is
stopped.
Note: The light-off delay time is up to 500ms. When the light-off delay timeis set too long, please confirm that the light has been stopped before placing the- 11 -

welding head to prevent laser damage.
Back Feed:
After the light is stopped, the welding wire will automatically return to acertain length, which is convenient for the next welding. The length of the wireback is determined by the set parameters.
Pulse-Time:
Set the light emission time in burst mode, the maximum burst time is 1000ms.
Blow switch
Open/close solenoid valve
OffsetAdjust the lateral offset of the optical core

4. Equipment alarm and handling
4.1 Equipment alarm
When the device is faulty, the interface will pop up an alarm window andprompt the current alarm information, as shown in the following figure:picture4-1: Warning pop-up window

If the alarm is not cleared, there will be a flashing red indicator next to thealarm button. Only after all alarms are cleared (there is no current alarm), the red
indicator next to the alarm button will disappear, as shown in the following figure:- 12 -

Figure 4-2: Alarm not cleared

4-3: Alarm cleared

4.2 Solutions to the warning
Once the equipment is alarmed, the user must stop using the handheld laser
welding equipment immediately, troubleshoot the fault. Use it only after the fault
is resolved. Users can refer to the alarm information in the alarm window totroubleshoot faults. The alarm information and solutions are shown in thefollowing table:

Serialnumb

Warning message

Solution

Remarker
Checkwhether

the

RS485

communication line between the
1

Alarm

Err-E001:

The touch screen and the controller iscontroller is not connected!

properlyconnected,

and

check

whether the controller is normallypowered on and started.
2

3

4

Alarm Err-B001:

The

air

pressure is too low!

is normal.

Alarm Err-L001: Laser failure!

Alarm

Err-W001:

communication failure!

Check whether the air pressure

Wireless

Check whether

the laser isworking properly.
Checkwhether

indicator lightof theflashes normally,- 13 -

the

if

green

This alarm iscontroller onlythegreen optional

for

the

wirelessindicator light is always on, plug andunplug the wireless receiver again.

control module.

Check the communication line

5

Alarm Err-S001: Wire feeder
communication failure!

between the controller and the
stepping wire feeder, and plug thecommunication interface again after

This alarm is
only

for

the

optional stepping
wire feeder.

power off.
Check
6

the

line

connection

This alarm isAlertErr-S002: Stepping wire between the motor and the drive, only
feeder driver alarm

for

the

check whether the power supply

optional stepping

voltage is at 24V.

wire feeder.

After the power is off, check theline connection between the motor
Alarm Err-S003: Motor shaft interface
7

of

the

stepping

wire only

terminal of the driver.
Alarm

Err-C001:

Chiller

alarm!
Alarm

Check whether the chiller works
normally

Err-All:

There

are

9 many faults at present, please

There are many current faults,
please troubleshoot them one bycheck detailed fault information! one.
There is no alarm when the
10

for

the

feeder and the motor driver, and re- optional stepping

lock failure!

plug and unplug the motor

8This alarm isequipment is running normally!

The current device is operating
normally.

- 14 -

wire feeder.

5. Program update
5.1 Touch screen program update
Note: The U disk uses the USB2.0 interface and has a capacity
smaller than 16GB. The format of U disk is FAT32.
Please follow the steps below to update the touch screen program:

1. Insert the U disK with the update file into the USB port on the bacK of
the touch screen, and wait for the screen to see if the DUpgrade SettingsD interface
pops up (Figure 5-1). If the DUpgrade SettingsD interface pops up, clicK DUpgrade
ConfigurationD DYes, wait for the program upgrade to complete, and then pull out
the U disK.

Figure 5-1: Touch screen program upgrade

5.2 Controller program update
Click the "Program Update" button under the homepage to enter thecontroller update interface, as shown in the figure below- 15 -

Figure 5-2: Controller program update

Please follow the steps below to update the controller program:

1. After inserting the U disk with the updateable file into the USB port of thecontroller, click the "Start Update" button. If an updateable file is detected, theautomatic update program will start. If there is no updateable file in the U disk, it
will prompt "No updateable file detected";

2. The progress bar indicates the current update progress. After the program
update is completed (100%), follow the prompts to remove the U disk and restart
the system;

3. If the update fails, you can click the "Start Update Button" again.

Figure 5-3: Touch screen and controller update file

Notice:1）The update files of the touch screen and the controller should be placedin theroot directory of the U disk, as shownin Figure 5-3.

"compile"

Among them,is the update file of the touch screen, and “HWSPart1.bin” and- 16 -

"HWSPart2.bin" are the update files of the controller. The user must not changethese two file names, otherwise the program cannot be updated!
2）It is recommended to use a FAT32 format USB flash drive for updating
the program. (After entering the U disk catalog, right-click "Properties" to viewthe format of the U disk, as shown in the figure below.)注意：

Figure 5-4: U disk format used for upgrade

6. Equipment installation and wiring
6.1 Wiring instructions for touch screen terminals

Figure 6-1: Touch screen wiring terminal

Terminal wiring instructions:
1. Power terminal: The screen uses 24V DC power supply. The terminals from- 17 -

right to left are: power supply positive, power supply negative, and ground wire.
2. RS485 communication terminal: This terminal and the controller RS485
communication terminal are connected through the RS485 communication line.

6.2 Controller wiring terminal description

Figure 6-2: Controller wiring terminal

For detailed description of the controller terminals, please refer to the tablebelow.
Controller terminal description
Port

Input/

NO. screen
printing

OutputPin

Pin Definition

Terminal description

1

RS485

IN/OUT/

RS485

Touch screen communication interface

2

RS232

IN/OUT

/

RS232

3

/

IN/OUT/

USB

RS232 interface (wireless control
receiver)
USB interface (wireless communication/U
disk download)- 18 -

4

5

6

7

POWER

CON1

CON2

CON3

IN

OUT

OUT

IN

1

24+

2

PGND

3

GND

1

PWM+

DC24V\DC5VPWM output signal

2

PWM-

(The output amplitude can be configured)

3 0～10V(0～4V)

Controller DC24V power input

0～10V\0～4V analog output signal(The output range can be configured)

4

AGND

1

LA-EN+

2

LA-EN-

3

GAS+

4

GAS-

1

LA-ALM+

Laser alarm input port

2

LA-ALM-(DC24V high level valid)3

LA-ON+

Connect to the hand gun button switch, turnDC24V laser enable output signal
DC24V output connected to solenoid valve
to control blowing(Drive current Max 2A)

on the light4

LA-ON-(Short the two points to give out light andbreathe out)

IN/OUT
8

CON4
OUT

OUT
9

CON5
IN

10

CON6

OUT

1

RS232-R

2

RS232-T

3

LA-Red+Red light indicating control signal

4LA-Red-(DC24V high level effective)

1

SW-IN1+

2

SW-IN1-

3

+15V

4

GND

5

-15V

1

NC

Reserved

Reserved

Controller DC±15V power input

Reserved- 19 -

11

12

13

CON7

CON8

CON9

14 CON10

OUT

OUT

OUT

IN/OUT

15 GALVO IN/OUT

2

RS485-A

3

RS485-B

4

GND

Reserved

1

DC24V

DC24V power output

2

LED-G

Stepping wire feeder green indicator light3

DRV-SON

Stepping wire feeder enable

4

LED-B

Stepping wire feeder blue indicator light

1

CTRL1

2

GND

3

CTRL2

4

GND

1

+5V

2

DRV-STEP

3

DRV-DIR

4

DIR-EN

1+5V

Reserved

2

CTRL3

Reserved

3

GAS-Alm

4

GND/

Stepping wire feeder communication port

Reserved

Reserved

Reserved

Low air pressure warning input signal
Reserved

10 pin aviation Connect the welding gun (welding gun
plug
control input / output)

surface6-1: Definition of controller wiring terminal

In order to improve the safety performance of the product, the hand-held
welding head adopts the method of contacting light, that is, the welding head andthe welding workpiece must be in contact, and the light can be emitted afterpressing the light switch of the hand-held welding head.

- 20 -

Figure 6-3: Schematic diagram of exposure to light

7. Wireless module installation and use
7.1 Introduction

Figure 7-1 (Introduction to the appearance of the wireless control module)

Display screen: displays the man-machine interaction interface such asparameter functions.
OK key: Short press to enter the parameter editing state, each time you press,- 21 -

the next parameter item is selected, the selected parameter flashes, and theparameter is set by the left or right button; if no key is pressed within 5 seconds or
the parameter is not set, return to non-editing Status, the parameter stops
flashing; long press in the non-editing state to trigger the power slow-downfunction, release it to stop the power slow-down.
Left button: Press to decrease parameter value or switch function state inparameter editing state. Long press in the non-editing state to turn on the wire
feeding function, release it to stop the wire feeding.
Right key: Press to increase the parameter value or switch the function statein the parameter editing state. Long press in the non-editing state to turn on thethread rewinding function, and release it to stop thread rewinding.

7.2 Wireless control module interface

Figure 7-2 (First page)

Figure 7-3 (Second page)

Figure 7-4 (Third page)- 22 -

7.3 Function and parameter description
1. Communication status: (status: normal\disconnected)
Shows whether the wireless connection is successful. "Normal" means that thewireless communication is connected, and "disconnected" means that the wirelesscommunication is not connected.
2. Light emitting mode: (status: spot shooting\continuous\scaly figure)
Corresponding to the touch screen "light mode" parameter. The "continuous"light mode, "spot shot" light mode and "scaly figure" mode can be adjusted
3. Laser power: (range 0%-100%)
Corresponding to the "peak power" parameter of the touch screen, adjust the
maximum power during the stable light emission period.
4. Scanning width: (range 0mm-4mm)
Corresponding to the "scan width" parameter of the touch screen,Set thebeam swing width.
5. Spot enable: (status: on\off)Corresponding to the touch screen "spot enable" parameter, turn on/off theswinging spot.
6. Spotting time: (range: 0S-1.0S)
Set the light emission time in the spot mode corresponding to the "pulse time"parameter in the "advanced parameters" interface of the touch screen.
7. Wire feeding speed: (range: 0%-100%)
Set the running speed of the wire feeder corresponding to the "Wire feeding
speed" parameter on the touch screen.
8. Wireless pairing: (Status: On\Off)
Cooperate with "Enter Pairing" in the "Controller Configuration" interface ofthe touch screen to achieve wireless pairing.
9. Language switching: (Status: Chinese\English\Traditional)
Switch interface language display, support: Simplified Chinese, English,- 23 -

Traditional Chinese.

7.4 Wireless control module installation
The wireless control module is installed on the top of the HW960 handheld
welding head and connected with a 1.25mm-3Pin terminal line. The top of thescreen is fixed with M2.5*12 screws, and the bottom of the button is fixed with
M2.5*8 screws.

Figure 7-5 (Wireless control module installation)

7.5 Wireless module pairing
Check whether the wireless receiver-DB9 is plugged into the DB9 female
connector of the HWS 5000 controller.
Note: The wireless receiver-DB9 cannot be plugged or unplugged underpower.

- 24 -

Figure 7-6 (Wireless receiving module installation)

Open "Home" → "Controller Configuration" on the touch screen. Set "WirelessController Configuration" to enable, click "Enter Pairing" → click "Start".

Figure 7-7 (Touch screen operation pairing)
Short press the "OK button" to move the triangle cursor to the "WirelessPairing" line, and long press the "OK button" to enter the pairing mode. When apaired HWS 5000 controller is detected, the pairing will be successful.

Figure 7-8 (Wireless control module operation pairing)- 25 -

8. Precautions for the use of equipment
In order to ensure the normal use of HWS5000 handheld laser welding
equipment, avoid damage to the welding equipment due to abnormal operations,and protect the personal safety of equipment users when operating theequipment, relevant personnel must carefully read the following precautions:

1、The bar codes of the HWS5000 controller must match thoseof the HW960 welding head. Otherwise, the motor will howl oreven be damaged by overheating；2、The laser welding equipment and the third party welding

machine such as argon arc welding, electric welding, gas
shieldedweldingshould

not

share

the

same welding

workbench (the ground wires of different welders cannot beclamped on the same welding workbench);3、The input power supply of laser welding Equipment athird-party welding machines such as argon arc welding,electric welding and gas shielded welding needs to beisolated (use different AC input, or isolate with isolationtransformer)

4、 It is strictly forbidden to aim the laser welding gun head at
the human body, flammable and explosive objects andother dangerous objects;
5、

The welding gas must be a protective inert gas (argon and- 26 -

nitrogen are recommended);
6、When the laser welding equipment is not used, put thewelding gun head in place and turn off the laser.

9. Equipment dimensions

picture9-1: External dimensions of the controller- 27 -

picture9-2: Dimensions of the touch screen- 28 -