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Pulsar 1212

OPERATOR MANUAL

Amada America, Inc.7025 Firestone Blvd.Buena Park, Ca. 90621Tel. (714) 739-2111Fax. (714) 228-0536

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Copyright © 1994 - 1996 by Amada America Inc., All Rights Reserved.

Version 1.06c

13 November, 1996

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TABLE OF CONTENTS

DESCRIPTION CHAPTER 1

Figure 1: Clamp Protection Zone 2

OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3EW

MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3NE

Motion System 3

Z-AXIS ASSEMBLY 3

SAFETY FEATURES 4

LASER WARNING LIGHT 4

CLAMP PROTECTION ZONE 4

OVERTRAVEL DETECTION DEVICES 4

OTHER FEATURES 5

FOOT SWITCH 5

GAUGE Pins 5

WORK CLAMPS 5

WORK CHUTE 5

SCRAP BOX 5

WORK HOLDERS 6

ASSIST GAS BLOCK 6

CONTROL PANELS 6

LASER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

SUPPORT EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6T EQUIPMENT

CHILLER 6

AIR DRYER (option) 6

DUST COLLECTOR 6

SAFETY CHAPTER 2

GENERAL PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3AL PRECAUTIONS

The Main Laser Beam 3

Machine Laser Aperture 4

The Red Aiming Beam 4

Secondary Radiation 4Fire 4

Poisonous Vapors 4

High-Voltage Power 5

Movement Of Worksheets 5

G04 Function (Dwell Time) 5

FEDERAL REGULATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6L REGULATIONS

Amada America, Inc.Operating the Pulsar 1212 1.06c, 13 November, 1996

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OSHA/ANSI 6

Laser Safety Officer 6

CDRH 6

Classification 6

STATE/LOCAL REGULATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6LATIONS

Labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

DANGER Label for Main Laser 7

Figure 1: DANGER label 7

DANGER Label for red laser 8

Certification Label 8

APERTURE Label 8

Figure 2: DANGER label (red laser) 8

Interlocked Beam Housing Label 9

Other Labels: 9

Figure 3: Certification label 9

Figure 4: Aperture label 9Figure 5: Warning - Interlock 9

Additional Features 10

Procedures Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

CONTROL PANELS CHAPTER 3

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Panel Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Figure 1: Panel Locations 3

NC CABINET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Laser Circuit Breaker 4

Figure 2: NC Circuit Breaker 4

NC PENDANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Figure 3: NC Pendant 5

MDI/CRT Unit 6

Figure 4: MDI/CRT Unit 6

Fanuc Keyboard 8

Figure 5: Fanuc keyboard 8

Program Edit Keys 9

NC OPERATION PANEL 11

Figure 6: NC Operator Panel 11

Handwheel Control (option) 19

Figure 7: Handwheel control 19

MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Operator Panel 20


STATE/LOCAL REGULATIONS MACHINE

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Figure 8: Machine Operator Panel 20

Gas Control Panel 21

Figure 9: Assist Gas panel 21

AHS-100 Height Sensor(option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23Height Sensor(option)

Figure 10: AHS Controller 23

Machine Operation CHAPTER 4

OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3EW

MACHINE STARTUP 3

Figure 1: Laser Gas setting 3

Figure 2: Jog keys 4

Figure 3: Mode Select keys 4

Viewing Laser Status 5

Figure 4: Laser Controls 5

Head And Lens Assembly 9

Identification 9Mounting 9

Figure 5: Ball-Transfer Cutting Head 9

Ball-Transfer Head 10

Figure 6: Cross-section of standard head 10

Figure 7: Nozzle Standoff 10

Capacitive Sensor head 11

Figure 8: Capacitive sensor head 11

Focus Lens 12

AUTOMATIC OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13ATIC OPERATION

MEMORY mode operation 13

MDI mode operation 13

Starting Automatic Operation 13

Program Execution 14

Stopping automatic operation 14

To STOP Operation 15

Machine Halts (Automatic) 16

Manual Feed & Manual Handle Feed 18

TEST OPERATION 19

Program Check 19

STOPPING OPERATION 20

SHUTDOWN PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21OWN PROCEDURE

Laser Shutdown 21

Machine Shutdown 21

NC Operations CHAPTER 5

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3ion

Figure 1: NC Console 3


AHS-100 Height Sensor(option) Introduction

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OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Screen Selection 4

Figure 2: Function keys 4

Screen Displays 5

Main Screen Area 5

Figure 3: CRT display (split) 5

SCREENS and CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6ROLS

Main Screen operation 6

Figure 4: Position, Modal display 7

POSITION Screen 8

Parts Count Reset 8

Run time Reset 8

Relative Coordinate Origin 8

SYSTEM Screen 9

Parameter 9

Diagnostic 9PMC 9

System composition 9

Pitch error setting 9

Servo setting 9

PROGRAM Screens 10

Available Screens 10

Soft key sequences 10

Figure 5: Program screen soft keys 10

Program Listing screen 11

Figure 6: Program Screen (split) 11

LIBRARY (Edit Mode Only) 12Figure 7: Library Screen 12

MDI Screen 13

OFFSET Screen 14

Main CUTTER OFFSET screen 14

Figure 8: Main Offset screen 14

SETTING screen 15

Figure 9: SETTING page of Offset screen 15

Soft Key assignments 16

Figure 10: SETTING soft keys 16

LASER POWER screen 17

Figure 11: Laser Power screen 17

Work Coordinate System screen 18

Macro Variables display 18

MESSAGE Screen 19

GRAPHIC Screen 19

HELP Screens 20

Figure 12: Initial Help Menu 20

Alarms help 21

Figure 13: Alarm Detail menu 21


OVERVIEW SCREENS and CONTROLS

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Operations help 22

Figure 14: Operations Help menu 22

Parameters help 23

Figure 15: Parameters Help menu 23

ADVANCED OPERATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24CED OPERATIONS

Changing Parameters 24Parameter Write Enable 24

Figure 16: SETTING (HANDY) screen 24

Parameter Write Disable 25

The PARAMETER screen 25

Altering a parameter 25

Communications Parameters 26

Figure 17: Parameter Edit soft keys 27

2. Data Output to a floppy disk 28

2-1 NC parameters 28

2-2 Pitch error data 28

2-3 Cutter compensation ( tool offset) 282-4 PMC Parameter data 28

3. Data Input from a floppy disk 29

3-1 NC parameter 29

3-2 Pitch error data 29

3-3 Cutter compensation data ( tool offset ) 29

3-4 PMC Parameter data ( Keep relay 17 bit 1 = 1 ) 29

PROGRAM STORAGE and EDITING CHAPTER 6

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3w

Preparing to Edit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3g to Edit

Program Selection 4

Program Handling 5

Creating a Program 5

Program Delete 5

Edit Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6edures

Cursor Forward 6

Line Forward 6

Page Forward 6

Return to Top of Program 6

Word Search 7

Word Change 7

Inserting Word(s) 7

Word Deletion 8

Figure 1: “delete to word ” before 9

Figure 2: “delete to word ” after 9

Expanded Edit Function 10


ADVANCED OPERATIONS Edit Procedures

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Copying a Program 11

Moving a Program 13

Merging Programs 14

Search and Replace 15

BACKGROUND EDIT 18

Starting a Background Edit 18

Finishing a Background Edit 18

Loading and Saving Programs 19

Setup 19

Figure 3: Soft-keys for Handy-File 19

Directory of a Floppy Disk 20

Figure 4: Soft-Key sequence 20

From NC to Floppy 21

Figure 5: Extended keys for READ, PUNCH 21

NC -> Handy File 22

From Floppy to NC 23

Figure 6: Keys for File Name/Number 23

Handy File -> NC 24Renaming a program on floppy 25

File Search 25

Figure 7: Soft Keys for File Search 25

Cutting Data Screens CHAPTER 7

OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Screen Selection 3

Soft Keys 4

Selecting Full/Split Screen 4

Figure 1: Cut Cond. + Laser Info 4

LASER INFORMATION Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5N Screen

Display Operation 5

Laser Information screen items 6

Figure 2: Material List with Laser Information 6

On-Line Adjustments 8

Preparation 8

Adjustments 9

Cutting Data Library . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Overview 10Figure 3: Material selection in program 11

CUTTING CONDITION Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12N Screen

Display Operation 12

Figure 4: Cut Condition screen 12

Items on Cutting Condition screen 13

Editing Cut Conditions 16

Selection of cut condition 16


OVERVIEW CUTTING CONDITION Screen

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Editing Data 17

Data storage 17

PIERCE CONDITION Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18CONDITION Screen

Figure 5: Piercing screen 18


Display items 19Setting Operation 21

Editing Data 21

EDGE CONDITION Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24ONDITION Screen

Figure 6: Edge Condition screen 24


Display items 25

Editing EDGE conditions 27

Navigation 27

Editing 27

Data storage 27

Using EDGE Control 28

Figure 7: Measurement of EDGE angles 28

Approach Control 29

Figure 8: Edge screen 29

Figure 9: EDGE setup 29

MATERIAL LIST Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30AL LIST Screen


Figure 10: Material List screen 30

Display Items 31

Material List screen items 31

Cutting Data File Operations 32Selecting a material 32

Creating New Material Name 33

Rename a material 33

Copy to new file 34

Deleting a material name 34

Search of material name 35

PARAMETER SETTING Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36ETER SETTING Screen

Figure 11: Laser Parameters screen 36

Setting Operation 37

MACHINE ALARMS Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37NE ALARMS Screen


CUTTING DATA TRANSFER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38G DATA TRANSFER

MAINTENANCE CHAPTER 8

Daily Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2intenance


PIERCE CONDITION Screen Daily Maintenance

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Cleaning 2

Noise 2

Chiller 2

Laser Gas 2

Assist Gas 2

Air System 3

Figure 1: Air, Gas Panel 3

Laser Oscillator 4

Figure 2: Laser Blower Oil Check 4

Figure 3: Laser Cabinet 4

Periodic Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Calendar Schedule 5

Hourly Schedule 6

Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Lubricants 7

Lubrication Points 8Figure 4: Lube Points - from side 8

Figure 5: Detail - Lube Points 8

Figure 6: Lubrication points - front view 9

Figure 7: Lube Points: Y, Z- Carriages 9

Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Cutting Nozzle 10

Figure 8: Y-axis Thrust Bearing 10

Spark Trap 11

Figure 9: Spark trap 11

Scrap Trays 12

NC Cabinet Air Filters. 12Figure 10: Scrap tray locations 12

Replacements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Servicing the Laser Blower 13

Adding Oil 13

Changing Oil 13

Figure 11: Blower service points 13

Servicing the Laser Vacuum Pump 14

Figure 12: Laser Vacuum Pump 14

Air System 15

Adjusting lube rate 15Beam Purge Air 15

Compressed Air Filter 16

Figure 13: Air filter, Mist separator 16

Laser Gas bottle 17

NC Memory Backup Cell 17

Nozzle, Focus Lens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18


Periodic Maintenance Nozzle, Focus Lens

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Description 18

Priorities 18

Centering the Nozzle 18

Figure 14: Un-centered nozzle 18

Setup 19

Figure 15: Adjustment Direction 19

Procedure 20Figure 16: Sparks after centering nozzle 20

Focus Lens 21

Adjusting Focus Position 22

Cutting Test Setup 22

Figure 17: Focus Test 22

Adjustment Procedure 23

Beam Delivery System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24livery System

Description 24

Interlocks 24

Beam Quality 25Before Taking a Mode Burn 25

Figure 18: Mode Burn Profiles 25

Making Burns 26

Figure 19: Mode Burns, top view 26

Figure 20: Crosshair Burn 26

External Bend Mirrors 27

Figure 21: Bend Mirror 27

Beam Alignment 28

Beam Path 28

General Procedure 28

Figure 22: Beam Delivery Path, Top View 28

Adjusting the RED Laser Beam 29

Figure 23: Beam Path from M2 29

Adjustment at the Oscillator Outlet 30

Figure 24: Crosshair Burns for External Alignment 30

Adjusting the first bend mirror 31

Adjusting the Second Bend Mirror. 32

Alignment of Y axis NEAR. FAR 33

Adjusing the Third Bend Mirror 34

Origin Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35djustment

Program example 35

Adjustment Procedure 36

Maintenance Program Listings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37nce Program Listings

ALARMS CHAPTER 9

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3w

ALARM DISPLAYS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3DISPLAYS


Beam Delivery System ALARM DISPLAYS

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Chapter 1

DESCRIPTION


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Notes

worksheet

5.5"

Clamp protection

zone 3.5"

5.5"

clamp

Figure 1: Clamp Protection Zone

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OVERVIEW

The Pulsar 1212 is a 3-axis system. (X, Y, and Z) The X and Y-axes are used for

positioning and contouring, while the Z-axis is normally used for positioning only.

The material is gripped by two or more clamps and moved in the X-direction. The

cutting head and laser beam are moved in the Y-direction. The laser generator c re-

ates a controlled laser beam for material processing, and the chiller removes

excess heat from the laser unit.

Most user controls are located on the main pendant, which houses the NC and ma-

chine control panels. A control panel on the machine provides certain operator

functions, and an assist gas control panel permits checking and setting assist gas

pressures.

MACHINE

Motion System

The motion system consists of a stationary table and moving X, Y, and Z-car-

riages. The main carriage is driven in the X-axis. It has work clamps to hold the

worksheet. The Y- carriage carries the Z-axis and head assembly. The Z-axis sup-

ports the cutting head and lens assembly. The table is equipped with free-travel

bearings to allow smooth motion of the worksheet. Some systems also have non-

marking rollers as well.

All three axes are driven by AC servo motors, and are controlled through motion

and coordinate commands entered into the NC unit or through the manual controls

on either the Machine Control Panel or the Carriage Control Panel.

Z-AXIS ASSEMBLY

The Z-axis provides precise positioning of the cutting head. It includes the follow-

ing items:

BEND MIRROR

This unit dIrects the beam (reflects it from horizontal to vertical) to the focus lens.

CUTTING HEAD ASSEMBLY

This removable assembly is the aperture of the machine. It incorporates the nozzle

assembly, through which the laser beam and assist gases travel.

For further information, see page 4-9.

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OVERVIEW Motion System

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SAFETY FEATURES

LASER WARNING LIGHT

This light will illuminate and rotate when the shutter is opened and the CO 2 beam

is released.

CLAMP PROTECTION ZONE

The clamp protection zone (dead zone) is an area around each work clamp in

which cutting cannot take place.

(not applicable when escaping clamps option is present)

This is to prevent accidental damage to the clamps themselves. When cutting is a t-

tempted in this area, machine operation will stop and an alarm condition will

exist. Dimension “x” is 5.5 inches, and dimension “y” is 3.5 inches.

OVERTRAVEL DETECTION DEVICES

These devices, located at various points around the machine, monitor the position

of the table, carriage, and Z-axis at all times. If any of the three axes are movedbeyond the normal limits of travel, either through manual or programmed com-

mands, machine operation will stop and an alarm condition will exist.

NOTE: Depending on the size and shape of the material being transported, it isstill possible to cause damage to either the material or the machine throughincorrect programming or careless manual movement of the axes.

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SAFETY FEATURES MACHINE

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OTHER FEATURES

FOOT SWITCH

Stepping on the foot switch once will cause the work clamps to open or close, de-

pending on their current status. Stepping on the switch again will return the

clamps to their original position. The machine is interlocked against operationwhile the clamps are open.

GAUGE Pins

These pins are used to locate the worksheet at the X, Y origin when loading it (the

worksheet) into the clamps. The machine is interlocked against operation while

the block is raised.

WORK CLAMPS

Two styles of clamps are available: Fixed, manually-adjustable clamps, and “es-

caping” clamps. Both styles are pneumaticly actuated, attached to the carriage and

are used to hold the worksheet.

The non-escaping clamps can be positioned anywhere along the carriage, and are

relocated by loosening the clamp levers. Four quick- disconnect air ports are lo-

cated along the carriage for easier connections.

When the head gets too close to an escaping clamp, the clamp will release the ma-

terial and turn out of the way. When the head moves away from the clamp, it

swings back into position and re-grips the material.

The escaping clamps can also be positioned along the carriage, but must be spaced

fairly evenly so that any two can hold the worksheet while the third has moved to

clear the cutting head. Also, it must not be possible for two escaping clamps to be

in the release zone at the same time.

WORK CHUTEThe work chute is opened and closed by air pressure. When the proper NC com-

mands are given, the chute will open and/or close to permit a finished part or

scrap material to drop from the cutting area. The chute measures 21" x 66". The

machine is interlocked against operation while the chute is open.

SCRAP BOX

This box collects small scrap and debris created during cutting operation. The ma-

chine is interlocked against operation when the access door to this box is open.

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MACHINE OTHER FEATURES

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WORK HOLDERS

These devices are air driven and hold the material stationary during programmed

repositioning (G25).

ASSIST GAS BLOCK

This block has quick-disconnect ports for several different types of gases that may

be used to enhance the laser cutting operation. Ports are selected by NC code and

the ports are labeled appropriately.

CONTROL PANELS

The Machine, NC, and Carriage control panels are described in detail in chapter 3.

LASER

This unit creates the CO2 laser beam used during the cutting process. By directing

a Radio Frequency (RF) discharge through a circulating mixture of Helium, Carb-

on Dioxide, and Nitrogen gases, this unit can output a laser beam at a wavelengthof 10.6 microns. This unit includes the Solid State laser, which generates a visible

(red) laser light that can be used for program checks and to assure the operator

that the CO2 beam is not being output through the cutting head.

SUPPORT EQUIPMENT

CHILLER

This device circulates water to the Laser unit to remove the excess heat generatedby the laser chamber during the creation of the laser beam. It can be located re-

motely to the machine.

AIR DRYER (option)

This device insures that the air going to the Output Coupler Cooler and the air

used for purging the beam delivery tube is as dry as possible.

DUST COLLECTOR

The dust collector draws dust and cutting effluent from the cutting zone into a fil-

ter system. The standard dust collector is not intended to handle emissions from

cutting non-metallic materials such as Kevlar or PVC plastics.

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CONTROL PANELS LASER

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Chapter 2

SAFETY


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Notes

2 - 2


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GENERALPRECAUTIONS

The Main Laser Beam

The main (CO2) laser beam can be very dangerous. The direct, unfocused beam

can cause burns. The severity of burns can be much greater if contact is made with

the focused beam. Even a stray reflected beam can permanently damage your eye-

sight.

The Nominal Hazard Zone is the area where potentially hazardous reflections can

occur.

This assumes that the laser is running at 1500 Watts, a standard 5" focus lens is in

place, and that the beam is reflected from a mirror-like surface.

The NHZ can be up to 28 feet from point of discharge.

ALWAYS WEAR PROTECTIVE EYEWEAR.

NEVER PUT ANY PART OF YOUR BODY UNDER THE CUTTING HEAD

BEFORE OPERATION, CLEAR THE AREA (NOMINAL HAZARD ZONE) OFUNNECESSARY OR UNINFORMED OBSERVERS.

28 feet

28 feet

2 - 3


GENERAL PRECAUTIONS The Main Laser Beam

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Machine Laser Aperture

During normal operation, the machine aperture, or point at which the laser beam

can exit the machine, is the nozzle in the cutting head. If it is necessary to place

any part of your body under the cutting head for any reason, ensure the He-Ne la-

ser is turned on first. When the He-Ne is on, the shutter is closed by interlocks

and the path of the CO2 beam is blocked by the He-Ne beam bender.

The Red Aiming Beam

The red beam is much less powerful and much less dangerous than the main laser

beam. Casual viewing of the light or its reflection (briefly) is not considered ex-

tremely hazardous. However, DO NOT STARE into the beam or its direct

reflection. This can cause permanent eye damage.

Secondary Radiation

Some substances, such as brick or concrete, can emit ultraviolet radiation when

struck by the laser beam. This invisible U.V. light, as well as some intense visible

light, is called SECONDARY RADIATION (light radiation). It can pass directlythrough clear safety glasses, causing the same kind of discomfort and possible

damage as from watching arc welding.

NEVER LOOK DIRECTLY AT THE POINT AT WHICH THE BEAM COMES INTOCONTACT WITHTHE MATERIAL.

IF VIEWING IS REQUIRED FOR TROUBLESHOOTING OR SERVICE, WEARWELDING PROTECTIVE EYEWEAR, (AWS) GRADE 5 OR BETTER.

See the ANSI publication Z136.1 section 7.4.2 (UV and Visible Radiation) for fur-

ther information.

Fire

Flammable materials will ignite when struck by the laser beam. After cutting such

materials, immediately dispose of the scraps. Clear the area of such materials

when performing any beam alignment procedures.

PoisonousVapors

Some materials (such as coated metals, plastics, and fabric) emit harmful vapors

when laser cut. Ensure the work area is properly ventilated.

Always ensure that the work area is well ventilated.Never breathe fumes from the cutting process.

See the ANSI publication Z136.1 section 7.3 (Laser Generated Air Contaminants)

for further information.

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Poisonous Vapors GENERAL PRECAUTIONS

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High-Voltage Power

High-voltage power is used in the machine to create the laser beam. These are le-

thal voltages, and are easily the greatest danger associated with laser equipment.

Even after power is shut off, a dangerous electrical charge may remain for several

minutes.

Do NOT open the cover panels unless you are a trained service person, or atthe direction of Amada’s Service department.

Always turn the disconnect OFF before opening cabinets.

If electrical problems occur, please contact the A.E.S.I. Laser Departmentrather than attempting to correct them yourself.

Movement Of Worksheets

Worksheets may extend from EITHER END of the table during operation. Before

starting the machine, ensure the area is clear of all uninformed observers.

G04 Function (Dwell Time)

When using the command G04, the machine will stop for the time determined by

the G04 and automatically continue operation. Refer to the Programming Manual

for further information.

2 - 5


GENERAL PRECAUTIONS G04 Function (Dwell Time)

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FEDERAL REGULATIONS

OSHA/ANSI

The OSHA organization looks to certain standards organizations for procedures

and recommendations. For laser equipment, ANSI Z136.1 is called out, which pro-vides various requirements and recommendations. One of the requirements is for a

Laser Safety Operator.

Laser Safety Officer

According to ANSI Z136.1-1993 section 1.3, “an individual shall be designated

the Laser Safety Officer (LSO) with the authority and responsibility to monitor

and enforce the control of laser hazards...”

The Customer is responsible to comply with the OSHA/ANSI standards.

CDRH

The Federal Government has created an agency of the Food and Drug Administra-tion know as the Center for Devices and Radiological Health (CDRH). It is the

purpose of this agency to establish guidelines for all lasers and/or laser systems

sold in the United States. These guidelines are listed in the Code of Federal Regu-

lations, title 21, chapter I, sub-chapter J, as applicable. It is in accordance with

the guidelines that the following information is provided.

Classification

The laser system, as produced by U.S. Amada, Ltd., also complies with all regula-

tions. In addition to all features provided by FANUC, U.S. Amada, Ltd. has

provided the following labels.

The Pulsar machines are rated as class IV laser systems. They have a continuouspower output of over 1500 watts at 10.6 micrometers. The red laser is a solid-state

unit rated class IIIa at a wavelength of 670 nanometers. The laser unit complies

with all Federal regulations as originally produced by the manufacturer, FANUCCorporation.

STATE/LOCAL REGULATIONS

Various states and lcoattiies have regulations concerning safety of lasers and ma-

chine tools. Contact Amada and/or your local sources for information.

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Labels

The laser system, as produced by U.S. Amada, Ltd., also complies with all regula-

tions. In addition to all features provided by FANUC, U.S. Amada, Ltd. has

provided the following labels.

DANGER Label for Main Laser

This label is located on the front of the machine near the warning light.

DANGERLASER RADIATION-

AVOID EYE OR SKIN

EXPOSURE TO DIRECT OR

SCATTERED RADIATION

MODEL: C1500b

MAXIMUM OUTPUT 3000W

RATED OUTPUT 1500 W

PULSE DURATION 100µSec~CWWAVELENGTH 10.6 µm

CLASS IV LASER PRODUCT

Figure 1: DANGER label

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DANGER Label for red laser

This label is located on the front of the machine near the warning light.

Certification Label

Designates the CDRH classification, located above the machine nameplate on thelower right side of the machine.

APERTURE Label

Designates the point at which the laser beam normally exits the machine. Located

on the cutting head.

DANGERLASER RADIATION

AVOID DIRECT EXPOSURE TO BEAM

SEMI-CONDUCTOR LASER

MAX OUTPUT < 5 mw

PULSE DURATION continuous

WAVELENGTH 670 nm

CLASS IIIA Laser

Figure 2: DANGER label (red laser)

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Interlocked Beam Housing Label

Designates a cover or housing which is interlocked against machine operation

when open. Located on the access cover for the Y-Z axes, and in other locations as

needed.

Reproductions of each of the above mentioned labels are pictured on these pages.Other Labels:

Other warning labels are located at various locations where laser or other hazards

can exist.

Figure 3: Certification label

!

DANGERAVOID EXPOSURE -Visible and invisiblelaser radiation is emitted from this opening

Figure 4: Aperture label

DANGER

VISIBLE and / or INVISIBLE LASER RADIATION

WHEN OPEN AND INTERLOCK FAILED OR DEFEATED

AVOID EYE OR SKIN EXPOSURE

TO DIRECT OR SCATTERED RADIATION

Figure 5: Warning - Interlock

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Additional Features

Access doors have redundant interlock protection, as required. All other required

features are unchanged as provided by the laser manufacturer, with the exception

of an additional laser emission indicator, located on top of the machine.

ProceduresWarning

As has been explained above, exposure to the laser beam can be harmful. If the la-

ser beam contacts your skin, it can cause serious cuts or burns. If the laser beam

contacts your eyes, it can cause temporary or permanent blindness. Since the laser

beam is radiated light, the CDRH frequently refers to the laser beam as radiation.

The following statement is made is accordance with CDRH requirements:

Caution - use of controls or adjustments or performance of procedures other thanthose specified herein may result in hazardous radiation exposure.

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Chapter 3

CONTROL PANELS


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Notes

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Overview

This chapter describes the controls and indicators of each of the control panels on

the system. For operating instructions, see the specific chapters (machine opera-

tion, NC operations, Cutting Data).

Panel Locations

Figure 1 shows the locations of major panels on the system.

1 NC cabinet

2 Laser circuit breaker

3 NC Pendant

4 Assist Gas panel

5 Z-Axis sensor control unit

6 Warning light

7 Machine Operator Panel

8 Clamp footswitch

1

8

2

3

5

4

6

7

Figure 1: Panel Locations

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NC CABINET

This Circuit Breaker NFB1 energizes NC and machine power. (see figure 2)This

switch must be “ON” to energize the NC. When you set the handle to OFF, you

turn off all machine power. If a short circuit occurs in the NC system, circuit

breaker 1 will “Trip” and the machine power will be turned off.

Caution:

If NFB1 trips, turn the service disconnect OFF and contact our service department.

Laser Circuit Breaker

Located on left side of the machine, on the end of the laser cabinet. It provides

power to the laser, and should normally be left ON.

NFB1

Figure 2: NC Circuit Breaker

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NC PENDANT

The NC pendant includes the CRT/MDI unit and the NC Operation Panel.

The MDI/CRT unit includes the display screen, the “soft keys” below it, and vari-

ous control and character keys to the side. The NC power ON/OFF keys are on

this unit..

The NC Operation Panel is below the CRT/MDI unit, and includes controls for the

NC, the machine, and various accessories.

CRT/MDI Unit

NC Operation Panel

Figure 3: NC Pendant

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MDI/CRT Unit

The MDI/CRT unit provides controls for NC operation and program handling, and

display of machine status.

Power “OFF” switch (3)

Power “ON” switch (4)

“Soft Keys” (5)

“Previous Menu” key (6)

“Next Menu” key (7)

Fanuc Keyboard (8)

#

%

$

?

HG

BA C D

E F

3 4

5

8

6 7

Figure 4: MDI/CRT Unit

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POWER “OFF” switch (3)

This push-button switch turns NC power OFF.

Caution

The laser must be shut down before the NC system can be turned “OFF”

Turn the Laser key (32) to OFF and wait until the Laser Ready lamp “(35) goesout. Then press the POWER OFF pb.

To power the system down, press Power “OFF” switch (3) first and then turn

NFB1 OFF.

Do not turn NC power OFF during program execution or while reading from NC

program tape or IC card.

POWER “ON” switch (4)

Push-button switch. When activated, turns the NC system ON.

Note:

To start the system, first turn NFB1 ON first, and then press the Power “ON” pb.

Soft Keys (5)

Assignments shown on the CRT, according to active screen and function.

Previous Menu key (6)

Used to select a previous group of soft key menu assignments. (Availability de-

pends on active screen and function)

Next Menu key (7)

Used to select the next available group of soft key menu assignments. (Availabil-

ity depends on active screen and function)

Fanuc Keyboard (8)

Provides control, data input, screen selection, and various other functions. (see fol-

lowing section)

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Fanuc Keyboard

This section describes the controls on the Fanuc keyboard. Numbers refer to the il-

lustration below.

8. RESET key

9. HELP key

10. Data Input Keys

11. BS/CAN key

12. SHIFT key

13. ALT/ALTER key

14. CTRL/INSERT key

15. DEL/DELETE key

16. FUNC key

17. SPACE/EOB key

18. INPUT key

19. MMC/CNC key

20. ESC/CUSTOM key

21. PAGE / POS key

22. PAGE / SYSTEM key

23. / OFFSET key

24. / MESSAGE key

25. / PROG key

26. / GRAPH key

#

%

$

?

HG

BA C D

E F

8 9

10 11

12

14

13

19

20

21

22

23 24 25

15

16

18

17

26

Figure 5: Fanuc keyboard

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RESET key (8)

Halts program execution, resets the NC system. Cancels any active NC alarms.

HELP key (9)

Provides assistance in MDI key operation, displays information on active NC

alarm. (See page 5-20)

DATA INPUT keys (10)

Use when you input characters such as alphabet and numbers.

BS/CAN key (11)

Deletes characters or symbols from the key input buffer.

The contents of the key input buffer are displayed on the CRT. The position where

the next character will go (Input standby position) is displayed as an underbar “_”.

When the program screen is active, the character immediately before “_” is can-

celed (deleted from the buffer) by pressing BS/CAN. For other screens, data input

is all canceled.Example: When the display of key input buffer is “N001X100Y_”, if you press the

CAN key, Y is canceled and it becomes “N001X100_”.

SHIFT key (12)

Many of the data input keys have two characters on the face. To access the charac-

ter on the lower corner of a key, press the shift key first. The symbol “^” is

displayed on the screen, and the next key pressed will have the value of the sec-

ond symbol or character.

Program Edit Keys

ALTER key (13)

Changes “selected word” (usually in a program) to the contents of the key input

buffer.

CTRL/INSET key (14)

Inserts the contents of the key input buffer into the currently selected program af-

ter the selected word.

DELETE key (15)

Deletes one or several words of the current program, or delete an entire program.

See the section on program editing (pages 6-5, 6-8) for full procedures.

FUNC key 16Use with keys 21 ~ 26 for screen selection.

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SPACE/EOB key (17)

Inserts an end-of-block character “;” into the key input buffer.

“SPACE” function not used.

INPUT key (18)

When you press any of the “Data input” keys, each character is held in the “key in-

put buffer” temporarily and displayed on the CRT. Press INPUT key to activate or

enter the keystrokes into a parameter or setting value. Not used in program edit-

ing. (See INSERT, DEL, ALTER)

MMC/CNC key (19)

Not used on this system.

ESC/CUSTOM key (20)

Press to select the Cutting Data screens. The Cutting Data screens include the

Help screen and the Cutting Database screens. The most recently displayed Cut-

ting Data screen is re-displayed. Pressing this key a second time blanks the CRGdisplay. Pressing any key unblanks the screen.

PAGE /POS key (21)

Press singly to move the CRT screen to the previous page, or to move up through

a program or data display. Press along with the FUNC key to display the various

“position” screens.

PAGE /SYSTEM key (22)

Press singly to move the CRT screen to the following page, or to move up through

a program or data display. Press along with the FUNC key displays service-related

screens.

/OFFSET key (23)

Moves the cursor to the lef t on CRT screen. Also used as a function key when

working with cutter offset and/or work origin offset.

/MESSAGE key (24)

Moves the cursor downward by one word. Also used as a function key to display

the history of NC Alarms, operator messages, alarms.

/PROG key (25)

Moves the cursor upward by one word. Also used as a function key to display pro-

gram, edit, display, MDI operation, and model data .

/GRAPH key (26)

Moves the cursor to the r ight on CRT screen.

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NC OPERATION PANEL

The NC operation panel provides control and status indication for various NC and

machine functions.

START switch (30)

Illuminated push button to begin (or resume) program execution. Active in Mem-

ory and MDI operation.

STOP switch (31)

Illuminated latching push button. Stops program execution in Memory and MDI

modes.

This lamp illuminates when latched and during various stop conditions.(Machine

alarms, etc.)

LASER keyswitch (32 )

OFF: laser is OFF.

ON: automatic laser startup, normal operation

Caution

For safety, remove key when the machine is not in operation.

START

STOP

POWER ON

PROGRAMSTOP

MACHINEALARM

EDIT MEMORY M DMANUAL RETRACT

ALARM

RESET

SINGLE

BLOCK

BLOCK

DELETEDRY RUN

100% 0 5

POWER

SHUTOFF

PROGRAMPROTECT

DEAD

ZONE

O /

RELEASE

-X

+X

-Y+Y

-Z

+Z FIRST

PROCESS

OTHERS L

PROCESS PROCESS

SENSOR

MODE

LASERREADY

H/V ON

SHUTTEROPEN

LASER

SHUTTERENABLE

ONO F

O F ON

ASSIST GAS

PRESSURE

LASER

H/V ON

DATAS

OVERRIDE

CUTTINGRATE

POWER FREQUENCY DUTYG A

PRESSURE

%

LASER CUTTINGCONDITION

ENABLE CANCEL+B

-B

CHUTE

OPEN

CHUTE

CLOSE

AVOID

CANCEL

CHUTE

SENSORFREEBEAR

30 313233343536373839404142434445

46

47

48

4950515253

5455565758

5960616263

64

65

66

69

70

71

72

73 67

68

Figure 6: NC Operator Panel

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SHUTTER OPEN lamp (33)

Indicates that the laser’s mechanical shutter is open

H/V ON lamp (34)

OFF: High voltage has not been supplied to the laser.

Blinking: not ready, powering up.

ON: Laser high voltage is ON, laser is ready to cut.

READY lamp (35)

Light OFF: Laser key is OFF, laser is OFF.

Blinking: LASER key is ON, the laser is powering up.

LASER key is OFF, the laser is shutting down.

Light ON: Laser is ready for high voltage.

1/10 switch (36)

Used with override knob.OFF: It counts knob motion by every 10%.

ON: It counts knob motion by every 1%.

OVERRIDE display (37)

When OVERRIDE Switch 38 lamp is on, the values selected from 54, 55, 56, 57,

58 are displayed.

OVERRIDE switch (38)

Illuminated latching pb. When active, permits override of various items related to

laser processing.

You can change the override of items selected by:Turn the OVERRIDE switch 38 ON.

Pressing one of 54, 55, 56, 57, 58 to select the desired item to override.

Turning KNOB 59 so that the desired % is displayed in Override Display 37.

DATA SET switch (39)

Illuminated latching pb.

Available during auto operation. When operation condition screen is active (by

pressing ESC/CUSTOM key (20) to turn the light on) you can change the value of

the cutting condition screen by pressing one of (54, 55, 56, 57, 58) and turning

KNOB (59).

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PROGRAM PROTECT keyswitch (40)

It is a switch for protecting programs and various data stored in NC memory from

mistakenly being erased and changed. The “ON” position means “protection ac-

tive”.

This key affects the following operations:

Editing and registering programs

Entering setting data

Setting offset data

Mode Selection switches (41 ~ 45)

(illuminated). You can select the following operation modes by pressing one of

these switches:

EDIT

MEMORY

MDI

MANUAL

RETRACT

RETRACT (41)

This switch selects RETRACT Mode. You then zero the machine axes using the

manual jog pushbuttons.

MANUAL (42)

This switch selects Manual mode. The X, Y, Z axis can be moved manually using

the manual jog pushbuttons.

MDI (43)

This switch selects MDI mode. The following operations are enabled:Data input, instruction execution using MDI/CRT panel.

Set or alter parameters.

Alter “setting data”

Opening/closing the work chute

Laser beam output for test/alignment

MEMORY (44)

Pressing this switch selects MEMORY mode The following operations are en-

abled:

Executing a program stored in memory.

Searching for a program number and a sequence number in memory.

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EDIT (45)

Pressing this switch selects EDIT mode. The following operations are enabled:

Create, edit or delete a program

Output a program in memory to an IC card or other device.

Search program numbers in memory

MACHINE ALARM Lamp (46)

This lamp illuminates when machine alarms occur. The contents of the alarm are

shown on the alarm display screen.

See the ALARMS chapter for more information.

PROGRAM STOP Lamp (47)

If M00 (program stop) is instructed, the machine stops and this lamp illuminates.

The lamp goes off when the operation is resumed by pressing START.

POWER ON Lamp (48)

This lamp illuminates when NFB1 is “ON”. It indicates AC 200 V is present andthe NC can be powered up.

EMERGENCY STOP button switch (49)

This locking push-button causes the machine to make an emergency stop. Program

execution is halted, and the laser is shut off. EMG is displayed on the lower part

of the CRT screen.

This button halts and prevents machine motion until unlocked.

To unlock, turn the switch clockwise.

After releasing the EMERGENCY STOP, you must turn the laser ON and restart

high voltage. (See the H/V ON switch (52))

Caution

Correct the problem and check around the machine for safety before resetting this

switch.

After resetting the EMERGENCY STOP, return all axes to the origin position.

SHUTTER ENABLE keyswitch (50)

ON: Permits laser beam output during program execution.

OFF: The shutter is disabled and the red laser is emitted from the nozzle. The red

laser is used for adjustment of external alignment, confirmation of position during

operation, and safety confirmation.

GAS PRESSURE display (51)

Digital assist gas pressure display. (ALTAIR only)

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H/V ON switch (52)

To re-start laser high voltage after certain alarms and halts.

CANCEL switch (53)

Returns an overridden item to 100%.

Set OVERRIDE switch (38) on, select item using switches 54, 55, 56, 57, or 58,

then press CANCEL.

GAS PRESSURE switch (54)

Not used at present.

DUTY switch (55)

You can change the laser pulse duty cycle by pressing this and turning KNOB

(59). The OVERRIDE display (37) shows the percent change.

Use the laser display screen (see p.7-5 ) to view laser conditions.

FREQUENCY switch (56)

You can change the laser pulse frequency by pressing this switch and turning

KNOB (59). The OVERRIDE display (37) shows the percent change.

POWER switch (57)

You can change the laser output by pressing this switch and turning KNOB (59).

The OVERRIDE display (37) shows the percent change.

CUTTING RATE switch (58)

You can change the cutting speed by pressing this switch and turning KNOB (59).

The OVERRIDE display (37) shows the percent change.

KNOB (59)

Turning this knob commands a change in the override % of whatever parameter is

selected by switches 55-58, if enabled by the ENABLE switch (60)

The OVERRIDE display shows the override % active.

ENABLE switch (60)

Used when alter ing cutting data during program operation along with the DATA

SET switch (39) and KNOB (59). See the chapter on Cutting Data screens for

more information.

POWER SHUTOFF (61)

not used on PULSAR

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CHUTE CONTROLS (62)

For manual operation of the work chute (PULSAR only)

CHUTE OPEN

opens the work chute.

CHUTE CLOSECloses the workchute.

SENSOR switch (63)

Pressing this switch enables the Z axis following sensor.

DEAD ZONE lamp (64) (option)

Not used on Pulsar.

FREEBEAR (65)

Latching illuminated switch. When on (illuminated), the free-travel bearings are

in the “UP” position.MULTIPLE PART SETTING switches (66)

These are toggle keys, illuminated when active.

Multiple Part Setting Switches

FIRST PROCESS = ON Only the first part is cut.

OTHERS PROCESS = ON Remainder of parts are cut.

ALL PROCESS = ON All parts specified in a multiple part program

are cut.

All OFF Multiple part functions DISABLED.

CHUTE SENSOR (67) (option)

Latching illuminated switch. When on, enables the work chute part sensor.

AVOID/ CANCEL (68)

Enables/disables escaping clamps. When ON, clamps will not move out of the

way. Instead, the machine (stops with a dead zone alarm)

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DEBUG/TEST switches (69)

Mainly for program testing. These include the DRY RUN, BLOCK DELETE, and

SINGLE BLOCK switches.

DRY RUN switch

When ON, programs are executed with axis travel at manual feed speed, instead of using the contouring feedrates (used by G01, G02, G03) set in the program or cut-

ting data library.

Other functions (M, S, T, B codes) are executed except for M00, M02, M30 and

M99. To stop at a particular place in the program, use DRY RUN to get to the gen-

eral area, and activate the SINGLE BLOCK switch to step into the exact location.

BLOCK DELETE switch

When ON, the NC ignores program instruction blocks beginning with “/” (slash).

(ignores program statements between “/” and EOB “;”)

When this switch is off, blocks with “/” are executed normally, ignoring the slash.

SINGLE BLOCK switch

When ON, the machine stops after executing each block of NC program. However,

when the shutter open is instructed by “M760" or executing a user macro-pro-

gram, the machine does not stop a single block.

ALARM RESET (70)

Permits clearing some machine alarms to permit continued operation. Correct the

cause of the alarm and press ALARM RESET. This is not effective for NC Alarms.

In some cases it is necessary to use the RESET key on the Fanuc Keyboard and re-

start the program.

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AXIS JOG switches (group 71)

Use to move the machine axes in MANUAL and RETRACT modes.

KEY RETRACT Mode MANUAL Mode

X+ X axis returns to the origin X axis moves toward + direction

X- X axis returns to the origin when it is

near the origin

X axis moves toward - direction

Y+ Y axis returns to the origin Y axis moves toward + direction

Y- Y axis returns to the origin when it is

near the origin

Y axis moves toward - direction

Z+ Z axis returns to the origin Z axis moves toward + direction

Z- Z axis returns to the origin when it is

near the origin

Z axis moves toward - direction

OT

RELEASE

It is used to release OT (over travel) of X

axis & Y axis

When either axis is in over travel (emergency

stop), this switch must be held pressed until

the alarm clears, then held pressed while using

the appropriate Axis Jog switch (71) to movethe offending axis back into the travel area.

Rapid Override switch (72)

Selects manual jog feedrate and G00 rapid traverse between 100%, 50%, and 25%.

100%: Manual feed speed 18m/min.

50%: Manual feed speed 9m/min.

25%: Manual feed speed 4.5m/min.

Focus Adjust switches (73)

Moves the focus point of the laser beam with respect to the workpiece.

B+ Moves focus point UP from material.

B- Moves focus point DOWN into material. + B

- B

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Handwheel Control (option)

REMOTE CONTROL ON/OFF switch (84)

Illuminated push-buttons. Toggles on/off.

Lamp On: The handwheel is enabled, and the manual jog switches (67) of the NCoperation panel are disabled.

Lamp Off: The handwheel controls are disabled.

Magnification switch (85)

This switch determines how far the selected axis moves for each movement (click)

of the knob.

Setting distance per increment distance per increment

X1 0.0001in 0.001mm

X10 0.001in 0.01mm

X100 0.01in 0.1mm

AXIS SELECT switch (85)

Selects between X, Y, or Z-axes. Axes 4, 5 not used.

KNOB (87)

When REMOTE CONTROL ON/OFF switch (84) is illuminated, the axis selected

by AXIS SELECT switch (86) moves when this knob is rotated.

X1 X10 X100

X

Y Z

45

84

85

86

87

Figure 7: Handwheel control

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MACHINE

Panels and controls on the machine include the Operator Panel, Gas Control

Panel, and the Display Lamp. The AHS (Automatic Height Sensor) controls are

covered seperately.

Operator Panel

START button (Green) (75)

You can start the tape operation, MDI operation or Memory operation. This but-

ton has the same function as the START switch 30 of NC operation panel.

STOP button (Red) (76)

If you press this button, you can stop the tape operation or the Memory operation.

This button has the same function as the STOP switch 31 of NC operation panel

does .

Caution

This is a latching push-button. Turn clockwise to release

FREE BEARING switch (77)

Latching illuminated switch. When ON, moves the free bearings to the UP posi-

tion.

When OFF, the free bearings move to the DOWN position.

JOB switch (78)

Enables manual table

motion.Jog Keys (79)

Use along with the JOG

switch to manually

move the machine.

WORK CLAMP footswitch(80)

Use to open or close

the work clamps.-x

+X

-Y+Y

FREEBEAR J G

STOP START

(78)

(75)(76)

(79)(77)

Figure 8: Machine Operator Panel

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Caution

Set the selector switch to AUTO for normal operation. In any other position, the

manually-selected gas will flow rather than the gas selected by the program or ma-

terial cutting data.

Gases are selected according to the Cutting Database, and selected in the part-pro-

gram by M120(material name) and E1~E10.In the cutting data table, the gases are designated as 1..5.

Auto

Oxygen (low) (gas kind = 1)

Oxygen (middle) (gas kind = 2)

Oxygen (high) (gas kind = 3)

Nitrogen(gas kind = 4)

Air (gas kind = 5)

Assist Gas Pressure Regulators

Select the gas you want to adjust with ASSIST GAS SELECT 99 and adjust withassociated regulator. Pull the handle and turn it to the pressure you want. After ad-

justing, push the handle and lock it.

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AHS-100Height Sensor(option)

Detect the distance between the material and the laser head. Maintains constant

nozzle standoff for stable laser cutting operations. Used for iron or stainless mate-

rials.

Note that the Eddy Current sensor and related controls are not used on Pulsar

1212. Only the Capacitive Sensor head is used for height sensing at this time.

210 METER

211 BALANCE Adjustment

1, 2, potentiometers

212 METER Switch

213 GAIN switch

214 POWER lamp

215 EDDY SETTING switch

216 SENSOR TYPE switch

217 GAP switch

218 5V ADJ knob

219 RESET switch

220 CALIBRATE switch.

METER (210)

Eddy current sensor ONLY: Not

used on Pulsar 1212.

BALANCE Adjustment (211)



METER switch (212)



213

214

211

212

216

217

220

219

218

210

215

Figure 10: AHS Controller

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GAIN switch (213)

Eddy current sensor ONLY: Not used on Pulsar 1212.

POWER lamp (214)

Indicates power “ON”. When you turn the NC power ON, the POWER lamp 214

comes on.

EDDY SETTING switch (215)


SENSOR TYPE switch (216)

It is a switch to select sensor type (capacitive sensor/eddy current sensor).

To use the capacitive sensor, select “CAP”. To use the eddy current sensor, select

“EDDY”.

GAP switch (217)

Selects the nozzle standoff when using the capacitive sensor.Setting standoff purpose

STD 1.5mm normal operation

C.C. 0.3mm Clean Cut™

5V ADJ knob (218)


RESET switch (219

It is a switch to cancel AHS alarms. Illuminates (RED) to indicate an AHS alarm.

Refer to page 9-7 for alarm details.

CALIBRATE switch (220)

It is an illuminated switch used to start calibration. When you press this switch

and start program 9000, the lamp illuminates and the sensor calibrates. The lamp

goes off when calibration i s over.

The SENSOR switch on the operator panel must be on. (item 63, page 16)

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Chapter 4

Machine Operation


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Notes

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OVERVIEW

This chapter covers machine startup and shutdown, loading and running programs,

and general machine operation.

Please read this chapter carefully before operating the machine.

MACHINE STARTUP

Main Power

Turn the NC breaker ON

Laser Chiller

Turn the laser chiller ON. (at disconnect, if necessary, and at chiller’s control

panel)

Confirm that the green light on the chiller is on.

Laser Gas

Open the main valve at the laser gas cylinder. Confirm that the secondary pressure

gauge reads 1.75 +/-.25 kgf/cm (25 +/-3.5 psi)..

a. Main valve

b. Regulator (secondary pressure adjustment)

c. Secondary pressure gauge

d. Primary pressure gauge

e. Laser gas cylinder

Main Air Supply

Check the inlet air pressure gauge, located on the side of the machine. Confirm

that compressed air is supplied to the

machine.

a

e

c

b

d

Figure 1: Laser Gas setting

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Laser Enable

Confirm that the LASER key switch (32) on the NC operation panel is turned OFF

Machine Power

Turn NFB1 ON (on NC cabinet)

NC Power

Press the ON switch (4) of the CRT/MDI console for a few seconds. The NC will

then power-up.

Zero Axes

a. Press the RETRACT switch (41) of the NC operation panel.

b. Use the Jog keys (71) to zero the axes in sequence as below:

If the Z-axis is up (near its origin), press the -Z key of the axis travel switch until the lighton the +Z key comes on. If the Z-axis is not up, press the +Z key until its light comeson.

c. Repeat in the same manner as b. for the X-axis and Y-axis.

O/T

RELEASE

-X

+X

-Y+Y

-Z

+Z

Figure 2: Jog keys

EDIT MEMORY MDI MANUAL RETRACT

41

Figure 3: Mode Select keys

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Start Laser

Turn the LASER key switch (see figure 4) on the NC operation panel to ON.

The LASER READY light (35) will start blinking.

After a few minutes, the LASER READY light (35) will go off and the H/V ON

(34) light starts blinking.When the H/V ON light (34) changes from the blinking state to the lighted state,

the laser is ready for operation.

NOTE:

If an alarm occurs during laser power-up (laser gas low, etc.)

1. Correct the problem

2. Press RESET.

3. Turn the LASER keyswitch OFF until the LASER READY lamp goes out en-

tirely.

Then turn the LASER keyswitch ON again to restart the laser.

Viewing Laser Status

To view the laser sequence (in power-up, etc.) Press the FUNC+SYSTEM keys to

display the DIAGNOSTICS screen.

Items 900+ are for the laser. From the first screen (Diagnostic 1) press the PAGE

/POS key to get into the 900 series

diagnostics.

LASERREADY

H/V ON

SHUTTEROPEN

LASER

SHUTTERENABLE

ONO

O

F

ON

ASSIST GAS

PRESSURE

LASER

H/V ON

35 34 33 32

52 50

Figure 4: Laser Controls

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Prepare Cutting Head

Remove the cutting head, and make sure the focus lens is clean. If you use more

than one focal length lens make sure you have the correct type installed. Make

sure the nozzle and lower head is clean and in good condition. Re-mount the cut-

ting head.

See page 10 f or details.

Adjusting/Confirming lens focus

The lens focus can be adjusted by turning the lens dial on the laser head. (For sys-

tems with motorized focus adjust, use the +B, -B switches (73) on the NC

Operator Panel).

The desired focal point varies according to the type and thickness of material to

be cut.

Adjust the lens focal point as needed. Actual dial readings will depend on the

lens installed and individual machine setup variations.

Nozzle AlignmentCheck/adjust nozzle alignment as needed. (see “Nozzle Centering”, beginning

page 8-18)

Set the assist gas pressure.

(for systems without Programmable Assist Gas option)

1. Turn the assist gas select switch (on the column control panel) to the desired

gas. The selected gas will be discharged out of the cutting nozzle.

2. Check pressure at the assist gas pressure gauge, adjust the regulator knob for

the selected gas as needed.

4. Suitable pressure may vary according to the type of operations ( i.e.: piercing,

cutting, or scribing) to be done, even if the same material or the same worksheet isbeing used. Set up gas pressures accordingly.

5. After setting assist gas pressure(s), turn the assist gas pressure switch to AUTO.

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Calibrate the sensor.

Only when using the optional Capacitive Sensor Head. Program 9000 is used for

sensor calibration.

On the AHS controlle r, set all switches to the RIGHT except for GAP. For stand-

ard tip standoff, set GAP to “STD”. For clean-cutting, set GAP to “C.C.”.

Place a sample of the material to be cut under the head.

Select program 9000. (see page 6-4 for program selection procedures)

Select MEMORY mode

Press the CALIBRATE switch on the AHS controller.

Press START to run program 9000.

When the program ends, check the status of the AHS controller. If no alarms have

occurred, then the sensor is calibrated.

Set Nozzle Standoff

Only when using the ball transfer head. Use the adjusting wheel to set the dis-

tance from tip of nozzle to bottom of transfer balls. (See p age 9 in this chapter)

Confirm Program Readiness

If the PROGRAM display is not active, press the FUNC and PROG keys on the

CRT/MDI operation panel.

Verify that the cursor is at the beginning of the program (just below the program

#) on the CRT screen.

Check Laser

Set the SHUTTER ENABLE key switch (50) on the NC operation panel to ON.

Confirm the pulse set up and condition.

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Check Controls:

Verify settings of the following switches, keys and buttons.

Operation Panel Switches/Keys/Buttons Setting If not set...

NC Operation Panel MEMORY LED light ON (Left top) Press MANUAL+Z LED light ON(Left top) Zero return the Z-axis

OVERRIDE 100% or desired % Set to desired %

SINGLE BLOCK light OFF Press SINGLE BLOCK

button

SENSOR (if using cap

sensor head)

Sensor switch ON Press SENSOR switch

H/V ON Switch light ON Start the laser(Turn the

Laser key switch to

START)

SHUTTER ENABLE ON Turn the switch ON

POWER OVERRIDE 100 % or

desired %

Set to desired %

CONTROL UNIT

(following device)

POWER ON/OFF ON

READY/ADJUSTING READY

AMPLIFIER UNIT

(following device)

ADJUSTING/RUN RUN Turn the toggle switch to

RUN

Table Check

Confirm that the Locating pin is down, and the material to be cut is clamped.

Start the program

Press the START button. (30 or 75)

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Head And Lens Assembly

Two types of cutting heads are available: the ball transfer head, and the capacitive-

sensor head. The lens centering and focus height are set the same way on either

head. The ball transfer head also has an adjustment for nozzle standoff from the

workpiece. Either head can be used with various focal length lenses.

Identification

The lower head assembly can be identified by the the nozzle unit and lower sur-

face of the head. The ball transfer head has free-travel balls arranged around the

periphery of the head, while the capacitive sensor head does not.

Mounting

The lower head is secured by a lock knob. To release the lock knob, pull it out

(about 4 mm) and turn it 1/4 turn either direction. It will then be held in the un-

locked position. Grasp the lower head with two hands, and use the handles to turn

it to the left (CCW looking from the bottom) about 1/8 of a turn. It will then drop

free.

Caution:Do not use the nozzle centering thumbscrews to hold or turn the head

To re-install, insert it into place and rotate it to the right until it stops, and put the

lock knob back in place.

The rectangular “dog” must line up with the microswitcheson the upper head assembly or the machinewon’t run.

UP DOWN

nozzle height

(standoff)

adjust

upper head

focus adjust

motor

assist gas

gauge

handle

lower head

lock knob

focus height

indicator

“dog” for

interlock

Figure 5: Ball-Transfer Cutting Head

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Ball-Transfer Head

The ball transfer head has free-travel balls to maintain a constant distance be-

tween the nozzle and the part surface. They can also apply some flattening force

to hold stacked sheets together, and to hold wavy sheets flat.

An adjustment is provided for nozzle standoff. (distance between nozzle tip and

the top surface of the workpiece). See figure 7.

Check the cutting nozzle: make sure

that the orifice is clean and undamaged.

Anything that disrupts the gas flow out

the nozzle can cause poor cutting re-

sults.

Focus lens

assembly

lens adapter

lower head

assembly

cutting nozzle

head lock knob

nozzle centering

adjustment screw

(1/4)

Figure 6: Cross-section of standard head

workpiece nozzle standoff

Figure 7: Nozzle Standoff

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Capacitive Sensor head

The Capacitive Sensor head provides a signal to the NC so that the NC can main-

tain nozzle standoff during the cutting process. A control box is used between the

sensor and the NC for various functions. See page 3-23 for description of the con-

trols.

Checks

Check to ensure that the ceramic insulator is not cracked or chipped. Remove any

residual spatter from the nozzle face or orifice. Replace the sensor and nozzle if

they are cracked or damaged.

Check nozzle to ensure that there are no obstructions, cracks, or other damage.

Check ceramic to ensure that there is no adhering spatter, and no cracks or other

visible damage.

WARNING

Do not use cracked or damaged sensor. The damaged sensor may be blown off

when gas pressure is applied.

Nozzle

Remove the nozzle tip from the lower head by turning it counter-clockwise

To install, screw it in finger-tight, or just past finger-tight.

WARNING: the nozzle can be broken if excessive force is used.

handle (two used)

cutting nozzle

ceramic insulator

lens centering

adjustment screws

(four used)

Figure 8: Capacitive sensor head

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Focus Lens

The machine can use any one of several focus lens assemblies. Each type of lens

(5", 3.75", 2.5") needs to be used with the corresponding adapter.

Warning

If the lens and adapter are not the same type, the focused spot will be far aboveor below the proper part of the head, and will not clear the nozzle opening. Dam-

age may occur to the lens, nozzle, or other machine components.

The lens adapter can be identified by its length. and the type of lens can be identi-

fied by the number on the lens mount. Normally, a 5" lens is used. The lenses and

approximate adapter lengths are described below.

LENS ADAPTER LENGTH

5 1.4"

3.75 2.65"

2.5 3.9"

Lens Removal

Only about 4-5 mm of the lens assembly protrude from the lens adapter. The lens

adapter is knurled on the gripping surface, while the lens mount is smooth, with

screw heads protruding from the lower surface. Grip the lens mount and unscrew

it (counter-clockwise) to remove it. Avoid touching the surface of the lens with

anything, except when actually cleaning it using approved materials and tech-

niques.

Lens Cleaning

Clean the lens by wiping each surface with a cotton swab saturated with acetone.

DO NOT APPLY PRESSURE while wiping - this can damage the coating and re-

duce the life of the lens. Lens tissue may be folded and used instead of cotton, if

desired.

Lens Installation

When installing a lens assembly, screw it into the adapter finger-tight. Be careful

not to touch the surface of the lens while tightening it.

Adapter removal/installation

The adapter has an O-ring which can make it quite difficult to remove. Remove

the lens assembly first to avoid damage to it. Grasp the knurled portion of the

adapter and unscrew it (counter-clockwise). When installing an adapter, makesure to turn it in until it seats.

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AUTOMATIC OPERATION

Automatic Operation modes include “MDI Operation” and “Automatic Operation”.

Press the MEMORY (44) or MDI (43) key on the Operation panel. (MODE

switches)

MEMORY mode operation

Use MEMORY mode to execute stored program(s) to operate the machine.

1) Load the program into the NC memory, if it isn’t already present.

(Refer to page 6-4. in this manual)

2) Modify the program, if necessary.

(Use EDIT mode for modifying program)

3) Press the MEMORY(44) key on the Fanuc keypanel.

4) Select the program, if it is not already active, and make sure the cursor (start

point) is at the beginning of the program.

5) Press START to begin operation.

MDI mode operation

MDI operation is a way to create and run a “one-shot’ program. It must be keyed

in using the MDI/CRT operation panel, and is temporarily stored into the MDI op-

eration buffer. MDI may be used for various test and adjustment operations.

1) Press the MDI (43) key of the Operation Mode Selection Switch.

2) Store (temporary) program into the MDI operation buffer by keyboard input.

3) Operation will start when the START switch is pressed.

Starting Automatic Operation

Normally, the cursor should be at the beginning of the program before starting.

To start opera tion, select MEMORY mode or MDI mode and press the START

switch (30 or 75).

The START light (30) will turn on while the program is running.

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Program Execution

In Automatic operation, the NC:

1. Starts reading the first block of commands of the selected program .

2. Interprets the first block of commands.

3. Executes the commands.

4. Starts reading the next block of commands.

5. Interprets the next block of commands and prepares for the next execution.

This process is called buffering.

6. Upon execution of a block of commands, immediately starts executing the next

block of commands because the succeeding block of commands has been read

while executing the preceding block of commands.

7. Repeats the process of 4-5-6 while in automatic operation.

Stopping automatic operation

The automatic operation can be stopped by the program which contains the StopCommand (M00). The automatic operation can be also stopped by pressing

switches on the operation panel. Also, the operation will stop when emergency or

alarm occurs.

Program stop (M00)

The automatic operation will stop any time the block of command which contains

“M00" is executed. The modal codes for the operation are saved when the opera-

tion is stopped by the program stop command, and therefore, a stopped operation

can be resumed when START switch is pressed. This is similar to the STOP by

use of Single Blocking. The START light will stay on while the program is being

stopped by M00.

Program end (G50, M30, M02)

M30 and M02 are the codes which indicate the end of the main program. The ma-

chine will not allow the transfer of a program into NC memory (except by

keyboard) without these codes.

When these commands are executed, the machine will end automatic operation

and reset all modal codes, and return to the beginning of the program.

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To STOP Operation

Program execution may be stopped in several ways, depending on the need. The

STOP switch may be used, as can the RESET and EMERGENCY STOP switches.

Emergency Stop

The machine will immediately stop operation when the EMERGENCY STOPswitch on the NC operation panel is pressed. The machine will do the following

when the EMERGENCY STOP switch is pressed:

-Stop all axes

-Stop power discharge of the laser

-Close the shutter

-Turn off the assist gas

To restart the operation,

1) Remove the cause of the stop

2) Unlock the pressed EMERGENCY STOP switch by turning it clockwise

3) Press RESET key

4) Zero-return all axes to their origins

5) Press H/V ON on the NC Operator panel.

RESET

Pressing RESET key releases the current state and operation of the machine and

resets the machine. For example, the RESET key is used to stop an alarm during

automatic operation or to stop automatic operation.

It can be also used to move (the cursor) to the beginning of a program while edit-

ing program.

When the RESET key is pressed, the machine will do the following:

-Stop all axes

-Close the shutter

-Turn off assist gas

To restart the operation

1) Remove the cause to stop

2) Zero-return the Z-axis

3) Return to the beginning of the program

The machine will do the following when the RESET key is pressed when the

switch of the operation mode is set to Edit mode:

-Return the cursor to the beginning of program

-Clears the contents of the buffer by keyboard input.

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STOP (Temporary)

Operation can be interrupted by pressing the STOP switch is pressed.

Warning!

Pressing STOP switch while the axes are in motion or when the shutter is open

may cause damages to the machine. Do not press STOP switch while the axes aremoving or when the shutter is open.

When the STOP switch is pressed during automatic operation, the STOP switch

light will turn on and the machine will do the following:

-Stop all axes

-Close the shutter

-Turn off assist gas

The interrupted operation can be resumed by,

1) Removing the cause of the interruption

2) Pressing down he START switch for about a second if you want to continue op-

erationPress the

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