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Pulsar 1212

OPERATOR MANUAL

Amada America, Inc.


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

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

Version 1.06c
13 November, 1996

TABLE OF CONTENTS
DESCRIPTION

CHAPTER 1

Figure 1: Clamp Protection Zone

OVERVIEW

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

MACHINE

MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Motion System
Z-AXIS ASSEMBLY
SAFETY FEATURES
LASER WARNING LIGHT
CLAMP PROTECTION ZONE
OVERTRAVEL DETECTION DEVICES
OTHER FEATURES
FOOT SWITCH
GAUGE Pins
WORK CLAMPS
WORK CHUTE
SCRAP BOX
WORK HOLDERS
ASSIST GAS BLOCK
CONTROL PANELS

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3
4
4
4
4
5
5
5
5
5
5
6
6
6

LASER

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

SUPPORT EQUIPMENT

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

GENERAL PRECAUTIONS

FEDERAL REGULATIONS

CHILLER
AIR DRYER (option)
DUST COLLECTOR

6
6
6

SAFETY

CHAPTER 2

GENERAL PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
The Main Laser Beam
Machine Laser Aperture
The Red Aiming Beam
Secondary Radiation
Fire
Poisonous Vapors
High-Voltage Power
Movement Of Worksheets
G04 Function (Dwell Time)

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4
4
4
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5
5
5

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

Amada America, Inc.Operating the Pulsar 1212

1.06c, 13 November, 1996

L REGULATIONS

arning

ns

STATE/LOCAL REGULATIONS

MACHINE

OSHA/ANSI
Laser Safety Officer
CDRH
Classification

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6
6
6

STATE/LOCAL REGULATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
DANGER Label for Main Laser
Figure 1: DANGER label

7
7

DANGER Label for red laser


Certification Label
APERTURE Label
Figure 2: DANGER label (red laser)

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8
8
8

Interlocked Beam Housing Label


Other Labels:
Figure 3: Certification label
Figure 4: Aperture label
Figure 5: Warning - Interlock

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9
9
9
9

Additional Features

10

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

CONTROL PANELS

CHAPTER 3

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Panel Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Figure 1: Panel Locations

NC CABINET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Laser Circuit Breaker
Figure 2: NC Circuit Breaker

4
4

NC PENDANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Figure 3: NC Pendant

MDI/CRT Unit
Figure 4: MDI/CRT Unit
Fanuc Keyboard
Figure 5: Fanuc keyboard
Program Edit Keys
NC OPERATION PANEL
Figure 6: NC Operator Panel

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6
8
8
9
11
11

Handwheel Control (option)


Figure 7: Handwheel control

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19

MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Operator Panel
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AHS-100 Height Sensor(option)

OVERVIEW

AUTOMATIC OPERATION

SHUTDOWN PROCEDURE

Introduction

AHS-100 Height Sensor(option)

Introduction

Figure 8: Machine Operator Panel

20

Gas Control Panel


Figure 9: Assist Gas panel

21
21

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


Figure 10: AHS Controller

23

Machine Operation

CHAPTER 4

OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
MACHINE STARTUP
Figure 1: Laser Gas setting
Figure 2: Jog keys
Figure 3: Mode Select keys
Viewing Laser Status
Figure 4: Laser Controls

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3
4
4
5
5

Head And Lens Assembly


Identification
Mounting
Figure 5: Ball-Transfer Cutting Head
Ball-Transfer Head
Figure 6: Cross-section of standard head
Figure 7: Nozzle Standoff
Capacitive Sensor head
Figure 8: Capacitive sensor head
Focus Lens

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11
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12

AUTOMATIC OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
MEMORY mode operation
MDI mode operation
Starting Automatic Operation
Program Execution
Stopping automatic operation
To STOP Operation
Machine Halts (Automatic)
Manual Feed & Manual Handle Feed
TEST OPERATION
Program Check
STOPPING OPERATION

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13
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14
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15
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20

SHUTDOWN PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Laser Shutdown
Machine Shutdown

21
21

NC Operations

CHAPTER 5

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Figure 1: NC Console
Amada America, Inc.Operating the Pulsar 1212

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1.06c, 13 November, 1996

d CONTROLS

OVERVIEW

SCREENS and CONTROLS

OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Screen Selection
Figure 2: Function keys

4
4

Screen Displays
Main Screen Area
Figure 3: CRT display (split)

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5
5

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


Main Screen operation
Figure 4: Position, Modal display

6
7

POSITION Screen
Parts Count Reset
Run time Reset
Relative Coordinate Origin
SYSTEM Screen
Parameter
Diagnostic
PMC
System composition
Pitch error setting
Servo setting
PROGRAM Screens
Available Screens
Soft key sequences
Figure 5: Program screen soft keys
Program Listing screen
Figure 6: Program Screen (split)
LIBRARY (Edit Mode Only)
Figure 7: Library Screen
MDI Screen
OFFSET Screen
Main CUTTER OFFSET screen
Figure 8: Main Offset screen
SETTING screen
Figure 9: SETTING page of Offset screen
Soft Key assignments
Figure 10: SETTING soft keys
LASER POWER screen
Figure 11: Laser Power screen
Work Coordinate System screen
Macro Variables display
MESSAGE Screen
GRAPHIC Screen
HELP Screens
Figure 12: Initial Help Menu
Alarms help
Figure 13: Alarm Detail menu
Amada America, Inc.Operating the Pulsar 1212

1.06c, 13 November, 1996

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21

ADVANCED OPERATIONS

ADVANCED OPERATIONS

Edit Procedures

Operations help
Figure 14: Operations Help menu
Parameters help
Figure 15: Parameters Help menu

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23

ADVANCED OPERATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Changing Parameters
Parameter Write Enable
Figure 16: SETTING (HANDY) screen
Parameter Write Disable
The PARAMETER screen
Altering a parameter
Communications Parameters
Figure 17: Parameter Edit soft keys

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24
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25
25
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27

2. Data Output to a floppy disk


2-1 NC parameters
2-2 Pitch error data
2-3 Cutter compensation ( tool offset)
2-4 PMC Parameter data
3. Data Input from a floppy disk
3-1 NC parameter
3-2 Pitch error data
3-3 Cutter compensation data ( tool offset )
3-4 PMC Parameter data ( Keep relay 17 bit 1 = 1 )

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29

PROGRAM STORAGE and EDITING

CHAPTER 6

Overview

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

Preparing to Edit

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

Edit Procedures

Program Selection
Program Handling
Creating a Program
Program Delete

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5
5
5

Edit Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Cursor Forward
Line Forward
Page Forward
Return to Top of Program
Word Search
Word Change
Inserting Word(s)
Word Deletion
Figure 1: delete to word before
Figure 2: delete to word after

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9

Expanded Edit Function


Amada America, Inc.Operating the Pulsar 1212

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1.06c, 13 November, 1996

RMATION Screen

Library

ONDITION Screen

OVERVIEW

CUTTING CONDITION Screen

Copying a Program
Moving a Program
Merging Programs
Search and Replace
BACKGROUND EDIT
Starting a Background Edit
Finishing a Background Edit
Loading and Saving Programs
Setup
Figure 3: Soft-keys for Handy-File
Directory of a Floppy Disk
Figure 4: Soft-Key sequence
From NC to Floppy
Figure 5: Extended keys for READ, PUNCH
NC -> Handy File
From Floppy to NC
Figure 6: Keys for File Name/Number
Handy File -> NC
Renaming a program on floppy
File Search
Figure 7: Soft Keys for File Search

Cutting Data Screens

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25

CHAPTER 7

OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Screen Selection
Soft Keys
Selecting Full/Split Screen
Figure 1: Cut Cond. + Laser Info

3
4
4
4

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


Display Operation
Laser Information screen items
Figure 2: Material List with Laser Information

5
6
6

On-Line Adjustments
Preparation
Adjustments

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8
9

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


Overview
Figure 3: Material selection in program

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11

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


Display Operation
Figure 4: Cut Condition screen
Items on Cutting Condition screen
Editing Cut Conditions
Selection of cut condition
Amada America, Inc.Operating the Pulsar 1212

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1.06c, 13 November, 1996

PIERCE CONDITION Screen

EDGE CONDITION Screen

MATERIAL LIST Screen

PARAMETER SETTING Screen

MACHINE ALARMS Screen

CUTTING DATA TRANSFER

Daily Maintenance

PIERCE CONDITION Screen

Daily Maintenance

Editing Data
Data storage

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17

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


Figure 5: Piercing screen

18

Display Operation
Display items
Setting Operation
Editing Data

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21

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


Figure 6: Edge Condition screen

24

Display Operation
Display items
Editing EDGE conditions
Navigation
Editing
Data storage
Using EDGE Control
Figure 7: Measurement of EDGE angles
Approach Control
Figure 8: Edge screen
Figure 9: EDGE setup

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


Display Operation
Figure 10: Material List screen
Display Items
Material List screen items

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31

Cutting Data File Operations


Selecting a material
Creating New Material Name
Rename a material
Copy to new file
Deleting a material name
Search of material name

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35

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


Figure 11: Laser Parameters screen

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Setting Operation

37

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


Display Operation

37

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

MAINTENANCE

CHAPTER 8

Daily Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Amada America, Inc.Operating the Pulsar 1212

1.06c, 13 November, 1996

Periodic Maintenance

Nozzle, Focus Lens

Cleaning
Noise
Chiller
Laser Gas
Assist Gas
Air System
Figure 1: Air, Gas Panel
Laser Oscillator
Figure 2: Laser Blower Oil Check
Figure 3: Laser Cabinet

tenance

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2
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4

Periodic Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Calendar Schedule
Hourly Schedule

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6

Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Lubricants
Lubrication Points
Figure 4:
Figure 5:
Figure 6:
Figure 7:

Lube Points - from side


Detail - Lube Points
Lubrication points - front view
Lube Points: Y, Z- Carriages

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9

Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Cutting Nozzle
Figure 8: Y-axis Thrust Bearing
Spark Trap
Figure 9: Spark trap
Scrap Trays
NC Cabinet Air Filters.
Figure 10: Scrap tray locations

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12
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12

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

Lens

Servicing the Laser Blower


Adding Oil
Changing Oil
Figure 11: Blower service points

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13

Servicing the Laser Vacuum Pump


Figure 12: Laser Vacuum Pump

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14

Air System
Adjusting lube rate
Beam Purge Air
Compressed Air Filter
Figure 13: Air filter, Mist separator

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16

Laser Gas bottle


NC Memory Backup Cell

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17

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

Amada America, Inc.Operating the Pulsar 1212

1.06c, 13 November, 1996

Beam Delivery System

Origin Adjustment

Maintenance Program Listings

Beam Delivery System

ALARM DISPLAYS

Description
Priorities
Centering the Nozzle
Figure 14: Un-centered nozzle
Setup
Figure 15: Adjustment Direction
Procedure
Figure 16: Sparks after centering nozzle

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20

Focus Lens
Adjusting Focus Position
Cutting Test Setup
Figure 17: Focus Test
Adjustment Procedure

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23

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


Description
Interlocks
Beam Quality
Before Taking a Mode Burn
Figure 18: Mode Burn Profiles
Making Burns
Figure 19: Mode Burns, top view
Figure 20: Crosshair Burn
External Bend Mirrors
Figure 21: Bend Mirror

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Beam Alignment
Beam Path
General Procedure
Figure 22: Beam Delivery Path, Top View
Adjusting the RED Laser Beam
Figure 23: Beam Path from M2
Adjustment at the Oscillator Outlet
Figure 24: Crosshair Burns for External Alignment
Adjusting the first bend mirror
Adjusting the Second Bend Mirror.
Alignment of Y axis NEAR. FAR
Adjusing the Third Bend Mirror

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34

Origin Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Program example
Adjustment Procedure

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36

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

ALARMS

CHAPTER 9

Overview

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

ALARM DISPLAYS

ALARM DISPLAYS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Amada America, Inc.Operating the Pulsar 1212

1.06c, 13 November, 1996

MACHINE ALARMS

Laser alarms

LARMS

MACHINE ALARMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Alarms

Height Sensor Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

(Option, Altair only)

AHC Alarms (Option, Altair only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8


NC Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

(P/S alarms)

Program Error (P/S alarms) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

dit Alarms (BP/S)

Background Edit Alarms (BP/S) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

e Code (APC) Alarms

Absolute Pulse Code (APC) Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

oder (SPC) alarms

Serial Pulse Coder (SPC) alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

larms

Servosystem alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

rms

Overtravel alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

ms

Overheat alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
System alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Laser alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

INDEX

CHAPTER 10

ADDITIONAL INFORMATION

CHAPTER 11

Amada America, Inc.Operating the Pulsar 1212

1.06c, 13 November, 1996

Chapter 1

DESCRIPTION

Amada America, Inc.O perating the Pulsar 1212

1.06c, 13 November, 1996

1-2

Notes

5.5"

5.5"

Clamp protection
zone

3.5"

worksheet

clamp

Figure 1: Clamp Protection Zone

Amada America, Inc.O perating the Pulsar 1212

1.06c, 13 November, 1996

OVERVIEW

Motion System

1-3

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 creates 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 machine 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-carriages. 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 supports 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 nonmarking 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 following 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.

Amada America, Inc.O perating the Pulsar 1212

1.06c, 13 November, 1996

1-4

SAFETY FEATURES

MACHINE

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 attempted 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 moved
beyond the normal limits of travel, either through manual or programmed commands, machine operation will stop and an alarm condition will exist.
NOTE: Depending on the size and shape of the material being transported, it is
still possible to cause damage to either the material or the machine through
incorrect programming or careless manual movement of the axes.

Amada America, Inc.O perating the Pulsar 1212

1.06c, 13 November, 1996

MACHINE

OTHER FEATURES

OTHER FEATURES
FOOT SWITCH
Stepping on the foot switch once will cause the work clamps to open or close, depending on their current status. Stepping on the switch again will return the
clamps to their original position. The machine is interlocked against operation
while 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 escaping 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 located along the carriage for easier connections.
When the head gets too close to an escaping clamp, the clamp will release the material 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 CHUTE
The work chute is opened and closed by air pressure. When the proper NC commands 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 machine is interlocked against operation when the access door to this box is open.

Amada America, Inc.O perating the Pulsar 1212

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1-5

1-6

CONTROL PANELS

LASER

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 CO 2 laser beam used during the cutting process. By directing
a Radio Frequency (RF) discharge through a circulating mixture of Helium, Carbon Dioxide, and Nitrogen gases, this unit can output a laser beam at a wavelength
of 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 CO 2 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 generated
by the laser chamber during the creation of the laser beam. It can be located remotely 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 filter 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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Chapter 2

SAFETY

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2-2

Notes

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GENERAL PRECAUTIONS

The Main Laser Beam

GENERAL PRECAUTIONS

The Main Laser Beam


The main (CO 2 ) 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 eyesight.
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) OF
UNNECESSARY OR UNINFORMED OBSERVERS.

28 feet

28 feet

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2-3

2-4

Poisonous Vapors

GENERAL PRECAUTIONS

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 laser 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 extremely 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 directly
through 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 INTO
CONTACT WITH THE MATERIAL.
IF VIEWING IS REQUIRED FOR TROUBLESHOOTING OR SERVICE, WEAR
WELDING PROTECTIVE EYEWEAR, (AWS) GRADE 5 OR BETTER.
See the ANSI publication Z136.1 section 7.4.2 (UV and Visible Radiation) for further 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.

Poisonous Vapors
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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GENERAL PRECAUTIONS

G04 Function (Dwell Time)

High-Voltage Power
High-voltage power is used in the machine to create the laser beam. These are lethal 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 at
the direction of Amadas Service department.
Always turn the disconnect OFF before opening cabinets.
If electrical problems occur, please contact the A.E.S.I. Laser Department
rather 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.

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2-5

2-6

Classification

FEDERAL REGULATIONS

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 provides 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 Administration 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 Regulations, 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 regulations. 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 continuous
power 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, FANUC
Corporation.

STATE/LOCAL REGULATIONS
Various states and lcoattiies have regulations concerning safety of lasers and machine tools. Contact Amada and/or your local sources for information.

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Labels

DANGER Label for Main Laser

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

DANGER
LASER RADIATIONAVOID EYE OR SKIN
EXPOSURE TO DIRECT OR
SCATTERED RADIATION

MODEL: C1500b
MAXIMUM OUTPUT
RATED OUTPUT
1500 W
PULSE DURATION 100Sec~CW
WAVELENGTH
10.6 m

3000W

CLASS IV LASER PRODUCT

Figure 1: DANGER label

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2-8

APERTURE Label

Labels

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 the
lower right side of the machine.

APERTURE Label
Designates the point at which the laser beam normally exits the machine. Located
on the cutting head.

DANGER
LASER 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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Labels

Other Labels:

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.

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

Figure 3: Certification label

DANGER

AVOID EXPOSURE -Visible and invisible


laser radiation is emitted from this opening
Figure 4: Aperture label

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2 - 10

Additional Features

Procedures Warning

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 laser 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 than
those specified herein may result in hazardous radiation exposure.

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Chapter 3

CONTROL PANELS

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3-2

Notes

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3-3

Overview

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 operation, NC operations, Cutting Data).

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

NC cabinet

Z-Axis sensor control unit

Laser circuit breaker

Warning light

NC Pendant

Machine Operator Panel

Assist Gas panel

Clamp footswitch

1
3

5
6
8

Figure 1: Panel Locations

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3-4

Laser Circuit Breaker

NC CABINET

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

Laser Circuit Breaker

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 various 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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3-6

MDI/CRT Unit

NC PENDANT

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)

A
E%

8
3

Figure 4: MDI/CRT Unit

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NC PENDANT

MDI/CRT Unit

3-7

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) goes
out. 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 depends on active screen and function)
Next Menu key (7)

Used to select the next available group of soft key menu assignments. (Availability depends on active screen and function)
Fanuc Keyboard (8)

Provides control, data input, screen selection, and various other functions. (see following section)

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3-8

MDI/CRT Unit

NC PENDANT

Fanuc Keyboard
This section describes the controls on the Fanuc keyboard. Numbers refer to the illustration below.
8. RESET key
9. HELP key
8
9
10. Data Input Keys
11. BS/CAN key
12. SHIFT key
13. ALT/ALTER key
A
D $
C#
B
14. CTRL/INSERT key
15. DEL/DELETE key
G
H
E%
F
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
10
11
24. / MESSAGE key
25. / PROG key
12
26. / GRAPH key

15
13

16
14

17

19

18
20

21
26
22
23

24

25

Figure 5: Fanuc keyboard

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NC PENDANT

MDI/CRT Unit

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 canceled (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 character 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 second 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 after 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 16

Use with keys 21 ~ 26 for screen selection.

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3 - 10

MDI/CRT Unit

NC PENDANT

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 input 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 editing. (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 Cutting Data screen is re-displayed. Pressing this key a second time blanks the CRG
display. 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 left 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 program, edit, display, MDI operation, and model data.

/GRAPH key (26)


Moves the cursor to the right on CRT screen.

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NC PENDANT

NC OPERATION PANEL

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 Memory 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.

45 44 43 42 41

48
47

40 39

69

EDIT MEMORY

RETRACT
MANUAL D

36

35 34

LASER
READY

%
DATA

33

ALARM

SINGLE

BLOCK

RESET

BLOCK

DELETE

LASER
O

F ON

-X

71

+Z

+B

-Y

-Z

-B

73
70

START

DRY RUN
CUTTING
RATE

72
+X

31

H/V ON

OVERRIDE

POWER

FREQUENCY

DUTY

G
PRESSURE

SHUTTER
ENABLE

H/V ON
O

RELEASE

30

SHUTTER
OPEN

MACHINE
ALARM

+Y

32

LASER

PROGRAM
PROTECT

PROGRAM
STOP

100%

37

LASER CUTTING
CONDITION

MODE
POWER ON

46

38

L POWER
FIRST
OTHERS
PROCESS PROCESS PROCESS SHUTOFF
AVOID

DEAD

CANCEL

ZONE

CHUTE
SENSOR

67
68

ASSIST GAS
PRESSURE

OPEN

FREEBEAR SENSOR

CHUTE
CLOSE

63
64

STOP

CANCEL

CHUTE

65
66

ENABLE

F ON

62

61 60

59

53

52

51

50

58 57 56 55 54

Figure 6: NC Operator Panel

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49

3 - 11

3 - 12

NC OPERATION PANEL

NC PENDANT

SHUTTER OPEN lamp (33)

Indicates that the lasers 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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NC PENDANT

NC OPERATION PANEL

3 - 13

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 active.
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 enabled:
Executing a program stored in memory.
Searching for a program number and a sequence number in memory.

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3 - 14

NC OPERATION PANEL

NC PENDANT

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 and
the 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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NC PENDANT

NC OPERATION PANEL

3 - 15

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 altering 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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3 - 16

NC OPERATION PANEL

NC PENDANT

CHUTE CONTROLS (62)

For manual operation of the work chute (PULSAR only)


CHUTE OPEN
opens the work chute.
CHUTE CLOSE
Closes 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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NC PENDANT

NC OPERATION PANEL

3 - 17

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 cutting 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 general 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-program, 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 restart the program.

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3 - 18

NC OPERATION PANEL

NC PENDANT

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 move
the 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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NC PENDANT

Handwheel Control (option)

3 - 19

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 NC
operation 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
X1
X10
X100

distance per increment


0.0001in
0.001in
0.01in

distance per increment


0.001mm
0.01mm
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.

84
X1 X10 X100

4
5
86

87

85

Figure 7: Handwheel control

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3 - 20

Operator Panel

MACHINE

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 button 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 position.
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.

(76)

STOP

(75)

START

WORK CLAMP footswitch


(80)

Use to open or close


the work clamps.

(79)

(77)

-x

FREEBEAR

-Y

+Y

+X

Figure 8: Machine Operator Panel


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(78)
JG

MACHINE

Gas Control Panel

Gas Control Panel


ASSIST GAS SELECT switch (99 )
Selection switch to adjust assist gas pressure. The associated regulators are present on the same panel.
AUTO:
Normal position for NC operation. Cutting Gas is selected by the
program.
Oxygen (low): Low pressure oxygen flows to the nozzle.
Oxygen(mid): Medium pressure oxygen flows to the nozzle.
Oxygen(high): High pressure oxygen flows to the nozzle.
CLEAN CUT: The Clean Cut gas flows to the nozzle.
Air:
Assist air flows to the nozzle.

O2

OXYGEN
(low)

AUTO

O2

OXYGEN
(mid)
O2

OXYGEN
(high)

N2

99

CLEAN
CUT
Air

Figure 9: Assist Gas panel

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3 - 21

3 - 22

Gas Control Panel

MACHINE

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 material cutting data.
Gases are selected according to the Cutting Database, and selected in the part-program 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 with
associated regulator. Pull the handle and turn it to the pressure you want. After adjusting, push the handle and lock it.

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AHS-100 Height Sensor(option)

Gas Control Panel

3 - 23

AHS-100 Height 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 materials.
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
213
214
215
216
217
218
219
220

METER Switch
GAIN switch
POWER lamp
EDDY SETTING switch
SENSOR TYPE switch
GAP switch
5V ADJ knob
RESET switch
CALIBRATE switch.

211

210

212

METER (210)

Eddy current sensor ONLY: Not


used on Pulsar 1212.
BALANCE Adjustment (211)

Eddy current sensor ONLY: Not


used on Pulsar 1212.

213
214
220

215

216

219

METER switch (212)

Eddy current sensor ONLY: Not


used on Pulsar 1212.

217

218

Figure 10: AHS Controller

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3 - 24

Gas Control Panel

AHS-100 Height Sensor(option)

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)

Eddy current sensor ONLY: Not used on Pulsar 1212.


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)

Eddy current sensor ONLY: Not used on Pulsar 1212.


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 is 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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4-2

Notes

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OVERVIEW

MACHINE STARTUP

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 chillers 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.
d

b
e

Figure 1: Laser Gas setting

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4-3

4-4

MACHINE STARTUP

OVERVIEW

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 light
on the +Z key comes on. If the Z-axis is not up, press the +Z key until its light comes
on.

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

41

EDIT

MEMORY

MDI

MANUAL RETRACT

Figure 3: Mode Select keys

-X

+Y

O/T
RELEASE

+Z

-Y

+X
Figure 2: Jog keys

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-Z

OVERVIEW

MACHINE STARTUP

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 entirely.
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.

35

34

33

32

LASER
LASER
READY

LASER
O

ON

H/V ON
SHUTTER
OPEN
SHUTTER
F
ENABLE

H/V ON
O

ON

ASSIST GAS
PRESSURE

52

50

Figure 4: Laser Controls


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4-5

4-6

MACHINE STARTUP

OVERVIEW

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 cutting head.
See page 10 for details.
Adjusting/Confirming lens focus

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

Check/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 is
being 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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OVERVIEW

MACHINE STARTUP

Calibrate the sensor.

Only when using the optional Capacitive Sensor Head. Program 9000 is used for
sensor calibration.
On the AHS controller, set all switches to the RIGHT except for GAP. For standard 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 distance from tip of nozzle to bottom of transfer balls. (See page 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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4-7

4-8

MACHINE STARTUP

OVERVIEW

Check Controls:

Verify settings of the following switches, keys and buttons.


Operation Panel
NC Operation Panel

Switches/Keys/Buttons
MEMORY
+Z
OVERRIDE
SINGLE BLOCK

Setting
LED light ON (Left top)
LED light ON(Left top)
100% or desired %
light OFF

SENSOR (if using cap


sensor head)
H/V ON

Sensor switch ON

SHUTTER ENABLE
POWER
CONTROL UNIT
(following device)
AMPLIFIER UNIT
(following device)

POWER ON/OFF
READY/ADJUSTING
ADJUSTING/RUN

Switch light ON

ON
OVERRIDE 100 % or
desired %
ON
READY
RUN

If not set...
Press MANUAL
Zero return the Z-axis
Set to desired %
Press SINGLE BLOCK
button
Press SENSOR switch
Start the laser(Turn the
Laser key switch to
START)
Turn the switch ON
Set to desired %

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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OVERVIEW

Head And Lens Assembly

4-9

Head And Lens Assembly


Two types of cutting heads are available: the ball transfer head, and the capacitivesensor 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 surface 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 unlocked 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 microswitches
on the upper head assembly or the machine
wont run.
upper head
focus adjust
motor
focus height
indicator
dog for
interlock

assist gas
gauge

handle
lock knob
UP

DOWN

lower head

nozzle height
(standoff)
adjust

Figure 5: Ball-Transfer Cutting Head


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4 - 10

Head And Lens Assembly

OVERVIEW

Ball-Transfer Head
The ball transfer head has free-travel balls to maintain a constant distance between 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 results.

workpiece

nozzle standoff

Figure 7: Nozzle Standoff

head lock knob

lens adapter

Focus lens
assembly

nozzle centering
adjustment screw
(1/4)

lower head
assembly

cutting nozzle

Figure 6: Cross-section of standard head

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OVERVIEW

Head And Lens Assembly

4 - 11

Capacitive Sensor head


The Capacitive Sensor head provides a signal to the NC so that the NC can maintain 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 controls.
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)

lens centering
adjustment screws
(four used)

ceramic insulator
cutting nozzle

Figure 8: Capacitive sensor head


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4 - 12

Head And Lens Assembly

OVERVIEW

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 above
or below the proper part of the head, and will not clear the nozzle opening. Damage 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 identified 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

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 techniques.
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 reduce 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, make
sure to turn it in until it seats.

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AUTOMATIC OPERATION

Starting Automatic Operation

4 - 13

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 isnt 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 operation 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 operation, 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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4 - 14

Program Execution

AUTOMATIC OPERATION

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 Stop
Command (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 operation 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 machine 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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AUTOMATIC OPERATION

Program Execution

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 STOP
switch 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 editing 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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4 - 15

4 - 16

Program Execution

AUTOMATIC OPERATION

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 are
moving 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 operation
Press the RESET key if you dont want to continue operation
Refer to the RESET procedure above (see page 4-15 )
Warning!
The machine will stop at its current state/position when the STOP switch is
pressed.
Therefore, turn the STOP switch of the table control panel to clockwise and press
again the STOP switch of the NC operation panel.

Machine Halts (Automatic)


Various machine conditions will cause operation to stop. Depending on specifics,
you may or may not be able to continue operation.
Dead Zone (without escaping clamp option)

If the laser head moves into a dead zone and the alarm occurs, you must restart
the operation:
1) Press the MANUAL switch (42)
2) Raise the Z-axis slightly
3) Press RESET key and release the alarm
4) Press +Y switch to move the Y-axis out of the dead zone
5) Press the Zero - return switch (41)
6) Zero - return the Z-axis, then the X and Y-axes.

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AUTOMATIC OPERATION

Program Execution

4 - 17

Overtravels (soft)

When the axes move beyond the stroke area , the Overtravel NC alarm occurs
and operation stops.
To restart the operation:
1) Press MANUAL key of the operational mode select switch
2) Press the switch that has opposite direction to the over travel signal (e.g., when
the over travel is -Z, press +Z) in order to move the axis back to the stroke area.
Alarm

Sign

Switch to select

Over travel

+Z

-Z

Over travel

-Z

+Z

3) Press RESET key to release the alarm.


4) Press Zero-return key (41) of the operational mode select key
5) Zero-return the Z-axis.
Overtravels (emergency stop)

When an axis moves beyond the (soft) overtravel zone and activates an Emergency
Stop Over Travel limit switch, NOT READY will be displayed at the left bottom
corner of the screen and axis motion stops.
To restart the operation
1) Press the MANUAL (42) mode select switch
2) Press down the OT RELEASE SWITCH (69) for a few seconds, the alarm
lamp (46) (red) and the NOT READY display of the CRT display will go off.
3) Keep pressing down the OT RELEASE SWITCH (69) while using the necessary AXIS JOG Pbs to move the axes back to the normal travel area.
4) Press RESET key to release the alarm.
5) Press the RETRACT key (41) of the operational mode select switch.
6) Retract the Z-axis.
7) Retract the X-axis and Y-axis.
Warning:
The laser discharge (High Voltage) will be turned off when the operation is
stopped by an emergency. Do the following :
8) Press H/V ON on the NC Operator panel.

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4 - 18

Program Execution

AUTOMATIC OPERATION

Manual Feed & Manual Handle Feed


The axes can be moved manually by using the Jog switches or the manual handwheel (option).
Manual Jog

Press the MANUAL key (42)


Select the jog feedrate by selecting one of the switches ( group 72) to 25%, 50%,
or 100%.
( The speed of the X-axis and Y-axis are 20m/min. when set to 100%)

Press the axis travel switch of the axis you want to move. (group 71)
Handle Feed

Press the REMOTE CONTROL ON/OFF button (84) on the remote control panel.
Select an axis you want to move from axis select handle (86).
Manual Feed can be performed by turning the knob (88).
Set per scale travel by knob (85).
Turn the manual handle (87) to move the selected axis.

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AUTOMATIC OPERATION

TEST OPERATION

TEST OPERATION
Program Check
Check to confirm that the correct programs are registered in the memory and in
the new NC program tape before execution.
Execute the commands of programs in only NC without using the laser emission.
Procedure:
1) Turn the laser key switch (32) on the NC operation panel to START or STOP.
2) Select HeNe of the laser select key switch (50).
3) Run the machine just as in normal automatic operation. (Cutting speed should
be set to the axis jog travel speed)
Testing Operation is recommended for the following situations:

Any program which has been edited since prior test.


Programs made by digitizer.
Testing for laser beam path compensation overcut alarm
Warning:
Always Retract the all axes after test operation.
Retract the axes even when test operation is canceled in the middle to start actual
operation.
Confirm that there are no obstacles and persons around the machine because the
table (axes) will start moving.

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4 - 19

4 - 20

STOPPING OPERATION

AUTOMATIC OPERATION

STOPPING OPERATION
When it is necessary to stop operation, you can stop the operation in the following
two manners:
Stop (Reset) Operation

Press RESET key to stop operation. Note that when the operation is stopped by using the RESET key, pressing START switch will not restart the operation.
1) When multiple cut program is being used,
Press RESET key and the START switch first, it will Zero-return the all axes. After removing the cause of the stop, modify the operation start point of the multiple
cut program and restart the operation.
2) When multiple cut program is not being used,
Remove the cause of the stop after pressing RESET key, and Zero-return the Zaxis. Move to the operation start point by using Manual Feed or MDI operation
and then restart the operation.
Warning
Confirm that the cursor is returned to the beginning of the program before you
start the next operation.
Stop Operation (Temporary)

Press STOP switch if you want to interrupt operation.


Warning:
The STOP switch is not effective when the machine is actually cutting . Press the
RESET key to stop operation while it is actually cutting .
The operation can be interrupted when the laser beam is OFF. If STOP is pressed
in this conditions, press START switch to continue the operation.
If the machine (or part) cant be continued, press the RESET key to stop operation.

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SHUTDOWN PROCEDURE

STOPPING OPERATION

SHUTDOWN PROCEDURE
Laser Shutdown
Turn the Laser switch (32) to STOP. This will begin the automatic Laser Shutdown Procedure.

Machine Shutdown
1) Zero-return all the axes to their origins.
2) Remove the lens and the laser head.
Inspect the removed lens, clean it if necessary, and store it in the case.
3) Inspect the nozzle unit, clean it if necessary. Replace it by turning it clockwise,
and push in the lock bar.
4) When the laser has finished shutting down, press the POWER OFF switch on
the NC operation panel.
Note:
The POWER OFF switch is IGNORED until the Laser Shutdown Procedure is
complete.
5) Turn off the NC operation panel circuit breaker (1) located on the side of the
NC operation panel.
6) Turn off the laser circuit breaker.
7) Close the assist gas (O2, N2, etc.) valves.
8) Turn off the NC auto breaker and the laser auto breaker switch. Do not turn off
the chiller auto breaker switch.
9) Close the laser gas cylinder valve and the main valve.
See page 3 for illustration.

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4 - 21

4 - 22

STOPPING OPERATION

SHUTDOWN PROCEDURE

NOTES

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Chapter 5

NC Operations

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5-2
Notes

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5-3

Introduction

Introduction
The machine uses a Fanuc 16L series control. It provides control of the machine
and laser, as well as various display and editing functions. In this manuals it is
called the NC, or the Fanuc NC.
Two different sets of displays are available: NC screens (provided by Fanuc), and
the Cutting Data screen (provided by Amada).
The NC screens include POSITION, SYSTEM, PROGRAM, OFFSET, MESSAGE, GRAPHIC, and HELP screens.
The Cutting Data screen handles Amadas Material Cutting Data and Machine
Alarm displays.

E%

Figure 1: NC Console

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5-4

Screen Selection

OVERVIEW

OVERVIEW
The home screen for the system is a split-screen display, showing system status,
machine position, and related information in the main part of the screen. This section presents an overview of screen selection and layout. The next section
describes operations possible from each screen.
For use of Amadas Custom/Cutting Data screens see chapter 7.
For program editing procedures, see chapter 6.

Screen Selection
Selection of main screens is done using Function keys on the Fanuc keyboard.
(see figure 2 below) To select one of the NC screens, press the FUNC key and the
function key designating the desired screen ( POS, SYSTEM, PROG, OFFSET, MESSAGE, GRAPH ).
Press the CUSTOM key to go to the Cutting Data screen from any NC screen.
General purpose/contents of screens:
OFFSET: Laser Beam Compensation, Work coordinate system, Macro-variables,
Laser power (1), Cutting Data (2).
SYSTEM: PARAMETER, Diagnostics, PMC (3), System composition, Memory
content, Pitch error setting, Servo-setting, settings of part count, run time, etc.(4)
MESSAGE: Alarm message, Operator message, Alarm history.
PROGRAM: Program Library, Floppy Program, (MDI) Next block Re-programming
GRAPHIC: Graphic Parameters, Drawing
HELP: Alarms, Controls, Parameters.
Once a screen is selected, soft keys become available to select other screens
and/or perform various functions.
NOTE
Some screens can only be entered or exited by use of FUNC+ function key.

Figure 2: Function keys

1
2
3
4

The Cutting Data screen is preferred for display of this information.


The Cutting Data screen is preferred for display of this information.
Authorized service personnel only
Also available using Position display and soft-key operations (OPRT)

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OVERVIEW

Screen Displays

Screen Displays
The screen will either display as a split-screen or a single full-page screen. When
the split screen is active, it consists of a larger area (main screen area), and a
smaller area (sub-screen area).

Main Screen area

(CURRENT PROGRAM ID)

Sub-screen area

soft-key captions

Figure 3: CRT display (split)

Main Screen Area


1. Screen name

Displays the name of the current screen.

2. Program name

Displays the current program name.

3. Program No.

Displays the current program number.

4. Sequence No.

Displays the current sequence number.

5. Present position

Displays information about the current axis position.

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5-5

5-6

Main Screen operation

SCREENS and CONTROLS

SCREENS and CONTROLS


Main Screen operation
Press FUNC and POS keys to select PRESENT POSITION. The following
four screens are available using soft keys:
screen 1: Absolute display

Press the ABS soft key to display the present position on the program coordinate
system set with G92". The following information is shown:
Present position in Absolute coordinates, Machine coordinates
Distance To Go.
Modal status (active G-code modes and M-code modes)
Part Count, Run Time, Cycle time
The soft key assignments are:
ABS

Absolute

REL

Relative

ALL

General

HNDL

Handle

(OPRT) more options/ advanced operations


Screen 2: Relative display

Press the REL soft key to display the present position in the relative coordinate
system. This coordinate system is settable by the operator. Refer to page 8 for preset procedure.
Present position in Absolute coordinate, Machine coordinates.
Distance To Go
Modal status (active G-code modes and M-code modes)
Part Count, Run Time, Cycle time
The soft key assignments are the same as above.
Screen 3: General display

Press the ALL soft key to display the present position in each of Relative, Absolute , and Machine coordinates. Distance to Go is also displayed in MEMORY and
MDI modes. Figure 4 shows all coordinates.
1 Present position in Absolute coordinates, Machine coordinates, Distance To Go.
2 Modal status (active G-code modes and M-code modes)
3 Part Count, Run Time, Cycle time

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SCREENS and CONTROLS

Main Screen operation

The soft key assignments are:


ABS

Absolute

REL

Relative

ALL

General

HNDL

Handle

(OPRT)

more options/ advanced operations

Screen 4: Position display of handle interruption

Press soft key HNDL to display the position regarding the following handle interruption.
Input unit: Handle interruption move amount of input unit system
Output unit: Handle interruption move amount of output unit system
Relative coordinate: Program coordinate system
Distance to Go: Remaining distance of current instruction (displayed only in Auto
and MDI modes).

Figure 4: Position, Modal display

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5-7

5-8

POSITION Screen

SCREENS and CONTROLS

POSITION Screen
Use the FUNC + POS keys to select the FULL SCREEN position display.
To exit any of the following operations, use FUNC + (function key) to reselect the
preferred screen.

Parts Count Reset


1) Press soft key (OPRT) the soft key display changes.
2) Press soft key PTSPRE. PARTS COUNT on the screen blinks.
3) Press soft key EXEC. PARTS COUNT is then reset to 0".

Run time Reset


1) Press soft key (OPRT) the soft key display changes.
2) Press soft key RUNPRE. RUN TIME on the screen blinks.
3) Press soft key EXEC. RUN TIME is reset to 0".

Relative Coordinate Origin


The relative coordinate system can be zeroed or preset with arbitrary values for X,
Y, Z.
Reset to 0:

1) Select RELATIVE or GENERAL display with soft key (REL or ALL).


2) Press soft key (OPRT), the soft key display changes.
3) Press soft key ORIGIN. When you want a specific axis to be 0", key in the
name of axis with Address/Numerical value key (e.g. X"). When you want all
axes to be 0", press soft key ALLEXE".
4) Press soft key EXEC to reset the coordinate value of the designated axis to
0".
Preset to arbitrary numerical value.

1) Select (RELATIVE) display from the General display with soft key REL.
2) Press soft key (OPRT), the soft key display changes.
3) Key in the name of axis and the numerical value you want to preset with Address/Numerical value key (e.g. X100").
In the (RELATIVE) display at the top left of the screen, the selected axis (with
current value) blinks.
4) Press soft key PRESET. Then the coordinate value of the axis designated is
preset to the numerical value instructed.

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SCREENS and CONTROLS

SYSTEM Screen

SYSTEM Screen
Press FUNC and SYSTEM keys to select the SYSTEM screen. It is a function
screen used for maintenance and adjustment. This is a split screen, with the SYSTEM screen in the small portion.
Caution:
The SYSTEM function deals with various parameters to operate the machine normally. Normally it is protected. If the contents are changed, the machine may not
operate normally and/or its precision may deteriorate. Use only if/as instructed by
representatives of AMADA.
Operation of SYSTEM Screen

Press FUNC + SYSTEM keys to display the SYSTEM screen.

Parameter
Press the PARAM soft key to show the parameter screen. Standard parameters
are installed by Amada or FANUC.

Diagnostic
Press the DGNOS soft key to show the diagnosis screen. It is used to diagnose
each condition of NC.

PMC
Press the PMC soft key to show the PMC screen. Standard parameters are installed by Amada or FANUC.

System composition
Press the SYSTEM soft key to show the system screen. Standard parameters are
installed by Amada or FANUC.
Note:
To show either of the following two screens, select system screen, then use the
soft key to display the PITCH, SV-PRM captions.

Pitch error setting


From the SYSTEM display, press the PITCH soft key to show the pitch error setting screen. Standard parameters are installed by Amada or FANUC.

Servo setting
Press soft key SV-PRM to show the servo setting and adjustment screen.

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5-9

5 - 10

PROGRAM Screens

SCREENS and CONTROLS

PROGRAM Screens
This section covers the screens available in EDIT mode. Some of these screens
and options are not available in other modes. For MDI mode, see page 13.
Press FUNC and PROG keys to display the PROGRAM screen. The PGM
(program), LIB (Library), and MDI screens are available. See figure 5 for the
screen and soft keys sequence.
Available Screens
The Following screens are
available in EDIT mode:
1. Main screen (split or full
screen) with initial soft key
assignments.
2. Main screen with extended soft keys for editing.
3. Main screen with extended soft keys for program handling.
4. Extended soft keys for
Floppy disk. (option)
5. Floppy disk directory.
(option)
6. File handling with
Floppy disk.(option)

1
EDIT ***** *** *** 12:54:32
PGRM

LIB

(OPRT) +

EDIT ***** *** *** 12:54:32


BG-EDT O SRH SRH

<

SRH

REWIND +

EDIT ***** *** *** 12:54:32


F SRH

READ PUNCH DELETE EX-EDT +

Soft key sequences


A number of screens are
available in the Program
group of screens. They are
accessed by use of soft keys.
The illustration in figure 5
shows the relationships and
how to get from one screen
to the next.

EDIT ***** *** *** 12:54:32

FLOPPY

EDIT ***** *** *** 12:54:32


PRGRM

<

(OPRT) +

DIR

(OPRT)

EDIT ***** *** *** 12:54:32


F SRH

READ PUNCH DELETE RENAME

Figure 5: Program screen soft keys

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SCREENS and CONTROLS

PROGRAM Screens

Program Listing screen


See page 5 for overall view of split screen. See below for items in the Program
portion of the screen.
Press the PRGRM soft key to display the PROGRAM screen. The active program is displayed. Press the"PRGRM" soft key again to toggle between split
display and full screen display. Refer to PROGRAM EDIT for program editing
procedures.

Program Listing in split display


item
purpose
(1) PGM soft key
selects Program screen
(2) LIB soft key
selects Library screen
(3) (OPRT) soft key
selects Advanced options
(4) Current mode
(EDIT, MDI, MANUAL, etc)
(5) Current time
(6) Program listing of currently selected program

Figure 6: Program Screen (split)

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5 - 12

PROGRAM Screens

SCREENS and CONTROLS

LIBRARY (Edit Mode Only)


Press the LIB soft key to display the Library Screen. This is a full screen display, listing all programs stored in the NC. The following information is also
displayed:
System Edition
Number of registered programs
Memory usage
Soft Key Assignments are PRGRM, LIB, and (OPRT). The PRGRM and LIB soft
keys select the Program and Library screens, respectively. The (OPRT) soft key
displays the BG EDT and O-SRH soft keys.

+
Figure 7: Library Screen

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SCREENS and CONTROLS

PROGRAM Screens

FLOPPY

The + soft key displays the FLOPPY soft key. If you press soft key FLOPPY,
a directory screen is displayed. (If no device is attached or recognized, the directory will be empty) This is a full screen.

MDI Screen
PROGRAM (MDI) (MDI Mode Only)
Press the MDI soft key to show the Manual Data Input screen. It can be used
to do various one-shot operations. In this mode, You create a program to be run
only once. It may have one or more instructions. This temporary program can not
be saved, and is erased after running. For operations which will be repeated or
done on a regular basis, use a regular program instead.
MDI
NEXT
(OPRT)
NEXT BLOCK (Auto, MDI, Manual, Zero Return Mode Only)
If you press the PRGMsoft key , the Next Block screen is displayed. It is not
used on this machine.

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5 - 13

5 - 14

OFFSET Screen

SCREENS and CONTROLS

OFFSET Screen
The OFFSET screens are used for adjustment/setting of cutter offset and setting
data.. Press the FUNC and OFFSET keys to cycle between the three major
screens in this group. Other screens may be selected pressing soft keys.

Main CUTTER OFFSET screen


Press the Offsetsoft key to show the laser beam compensation screen. This is a
full screen display.
Item

Meaning

(1)
(2)
(3)
(4)

offset number
distance to offset from programmed path
Key input buffer display
mode and time-of-day

Figure 8: Main Offset screen

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SCREENS and CONTROLS

OFFSET Screen

SETTING screen
Press the SETING soft key or FUNC and OFFSET keys to show the setting screen.
Use the PAGE UP and PAGE DOWN keys to display items on setting screen as
needed. The (OPRT) soft key permits searching for a particular setting item.
See next page for soft key listing and explanation.

Figure 9: SETTING page of Offset screen

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5 - 16

OFFSET Screen

SCREENS and CONTROLS

Soft Key assignments


The following table lists the SETTING soft keys and meanings (see figure 10).

Soft key

Purpose

OFFSET
SETING
WORK
(OPRT)
NO.SRH
ON:1
OFF:0
+INPUT
INPUT

Selects OFFSET screen


Selects SETTING screen.
Selects Coordinate System Offsets screen.
Selects extended soft key assignments
To search for a numbered setting item: Key number in, then press NO.SRH
sets selected item to 1 (ON)
sets selected item to 0 (OFF)
Adds input value to current value: Select item, key value to add, press +INPUT
Replaces previous value with input value: Select item, key new value, press INPUT.
(same as INPUT key on Fanuc keypad)
Show next group of soft-key assignments

+
<

Return to previous soft-key assignments

EDIT ***** *** *** 12:54:32


NO.SRH

ON:1

OFF:0

+ INPUT INPUT

EDIT ***** *** *** 12:54:32

<

OFFSET

SETING

WORK

(OPRT) +

Figure 10: SETTING soft keys

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SCREENS and CONTROLS

OFFSET Screen

LASER POWER screen


Press FUNC and OFFSET keys until the POWER soft key is displayed.
Press the POWER soft key to show the Laser Power screen. It displays data regarding laser status and output. (The Laser Information screen of the Cutting Data
screen is also available, using the

E
CUSTOM

key)

Figure 11: Laser Power screen

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5 - 18

OFFSET Screen

SCREENS and CONTROLS

LASER STATUS screen

From the Laser Power screen, press the + soft key to display the STATUS soft
key.
Press the STATUS soft key to show the status screen. This is a full screen display showing current laser output and certain selected cutting parameters. The
laser information screen of the Cutting Data screen is also available to monitor
the laser.
To return to the OFFSET screen, press the FUNC and OFFSET keys.
Use the

E
CUSTOM

key to activate the Cutting Data screen. (see chapter 7. )

Laser Setting screen

Press FUNC and OFFSET keys several times until the Laser Power screen is
displayed. The POWER, SET, and DATA soft keys are displayed.
Press the SET soft key to display the laser setting screen, along with the SET and
TRACE soft keys. This screen is not used - use the Cutting Data screens instead.
(see chapter 7. ) Do not change the contents of the screen.
Trace Setting

The tracer setting screen is not used on Pulsar 1212- use the Cutting Data screens
instead. (see chapter 7. ) Do not change the content of the screen.
From the Laser Setting screen, press the TRACE soft key to show the tracer setting screen.
Cutting data

Press the FUNC and OFFSET keys several times to show the DATA soft
key. Press the DATA soft key to show the manufacture data setting screen or
the pierce setting screen. These screens are not used - use the Cutting Data
screens instead. (see chapter 7.)

Work Coordinate System screen


The work coordinate system setting screen is not used in this machine. Do not
change the contents of this screen.
Press the WORK soft key to show the work coordinate system setting screen .

Macro Variables display


This screen displays values of the Macro Variables used in various Amada programs. Unless you are creating programs which use Macro Variables, this screen
can be ignored.
Display the Work Coordinate System screen (see above) then press the + soft
key to display the MACRO soft key. The Macro soft key displays the macro variable screen. Do not change without consulting AMADA. Caution: If the contents
are changed, the machine may not operate normally or its precision may deteriorate.

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SCREENS and CONTROLS

GRAPHIC Screen

MESSAGE Screen
Press the FUNC and MESSAGE keys to show the message screen. On the
message screen, the following three screens are selectable using soft keys.
Alarm message

This screen displays Fanuc alarms. For machine alarms, use the Cutting Data
screens (see page 5-3 for more information). Press the ALARM soft key to show
the alarm message screen. Usually, when NC alarm occurs, an alarm and its content are displayed.
Notes
1. Refer to alarm section for the detailed content of alarm and the method of canceling alarms.
2. When an NC alarm occurs, you cannot continue auto-operation.
Operator message

Press the MSG soft key to show the operator message screen. When a message
occurs, a prompt appears at the bottom of the screen.
Alarm history

Press the HISTRY soft key to show the alarm history screen. It displays the past
25 NC alarms.
Press PAGE UP, PAGE DOWN keys to change the page. Five alarms per page are
displayed
To clear alarm history:

1) Press the HISTRY soft key on the ALARMS HISTORY screen. The soft key
display then changes, and shows (OPRT).
2) Press the (OPRT) key to display the CLEAR soft key.
3) Press the CLEAR soft key to clear alarms history.
4) Press

<

to restore the previous soft key assignments.

GRAPHIC Screen
The graphics functions are not supported by Amada. Even though the basic contouring instructions can be graphed, none of the special offsets, macros, patterns,
and so forth are supported. Therefore, use of these screens is not recommended.

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5 - 20

HELP Screens

SCREENS and CONTROLS

HELP Screens
From any of the NC screens (not the Cutting Data screens) press the HELP key to
display the (Fanuc) Help Screen.
From any of the Cutting Data Screens, use FUNC + POS (or PROG, or ...) to select an NC screen. Then press the HELP key.
On the Help Screen, a menu is displayed and the following three screens are available by soft key selection:
1. ALARM DETAIL
2. OPERATION METHOD
3. PARAMETER CONTENTS
The ALARM DETAIL page displays the text message for any current alarm, and permits lookup of any valid alarm number.
The OPERATION METHOD pages provide information about a variety of NC control
operator tasks.
The PARAMETER CONTENTS pages list major groups of parameters by function,
and the parameter numbers that apply (for example) to I/O device setup or coordinate scaling.

Figure 12: Initial Help Menu

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SCREENS and CONTROLS

HELP Screens

5 - 21

Alarms help
Press the ALARMsoft key to show the ALARM DETAIL screen. When an NC
alarm occurs, its explanation is available on this screen.
To display the message for an alarm number that is not active:
Key-in the numerical value of the alarm number you want to investigate and press
the SELECT soft key.
The alarm message for that alarm number is then displayed.
You can also press the (OPRT) soft key to show the SELECT soft key.

Figure 13: Alarm Detail menu

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HELP Screens

SCREENS and CONTROLS

Operations help
Press the 2 OPR soft key to show the OPERATION METHOD menu screen
If you press soft key SELECT after control number you want to investigate, each
control explanation screen is displayed. The page number is displayed on the right
hand corner of the screen. Use the PAGE UP, PAGE DOWN keys to select pages as
needed.

Figure 14: Operations Help menu

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SCREENS and CONTROLS

HELP Screens

5 - 23

Parameters help
If you press the 3 PARA soft key, the first of the PARAMETER TABLE pages is displayed.
The functional groups are listed, along with the parameter number range that applies for each group.
The page number is displayed on the right hand corner of the screen. Use the PAGE
UP, PAGE DOWN keys to select pages as needed.

Figure 15: Parameters Help menu

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5 - 24

Changing Parameters

ADVANCED OPERATIONS

ADVANCED OPERATIONS
This section mainly covers data transfer between the NC and the floppy disk
drive. It also covers enabling/disabling parameter write and setting up the parameters necessary to use the floppy disk drive and various external devices.

Changing Parameters
Parameters are stored information which govern many kinds of machine behavoir and operation.
WARNING:
DO NOT attempt to change parameters unless you fully understand what you
are doing, or you are following the instructions of an Amada or Amada
Engineering representitive. Improper changes can prevent the machine from
operating properly.

Parameter Write Enable


Normally, parameters are kept read only. To change any parameters, parameter
write must be enabled.

Select the SETTING


(HANDY) screen as follows:
Select MDI mode (press the
MDI key on the operator
panel).
Press the OFFSET key to display the SETING soft
key.
Press the SETING soft key.
Use the PAGE UP or PAGE
DOWN keys if necessary
to display the screen
shown in figure 16

Figure 16: SETTING (HANDY) screen

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ADVANCED OPERATIONS

Changing Parameters

5 - 25

Enable parameter write as follows:


Use the cursor keys to select PARAMETER WRITE.
Press the 1" key, then INPUT. (either the soft key or on the keyboard )
Alarm 100 will occur. (this confirms that parameter writing is enabled.)

Parameter Write Disable


To return the system to normal operation, follow the procedure above to set PARAMETER WRITE to 0".

The PARAMETER screen


Press the SYSTEM key until the PARAM soft key is visible.
If parameters are not visible, press the PARAM soft key.
To select a particular parameter, the cursor keys, the PAGE UP or PAGE DOWN
keys, and the NO. SRG soft key may be used.

Altering a parameter
Parameters can only be altered in MDI mode.
Various soft keys are provided for parameter editing. Press the (OPRT) soft key to
display the NO.SRH, ON:1, OFF:0, +INPUT, and INPUT soft keys.
Soft key Purpose
NO.SRH Search for a particular parameter by number
ON:1
set the selected parameter ON (a value of 1")
OFF:0
set the selected parameter OFF (a value of 0")
+INPUT add a value to the selected parameter
INPUT
set the selected parameter to the input value
To alter a selected parameter, you can key a new value in and press INPUT (on the
Fanuc key panel or the INPUT soft key), or use one of the other soft keys as preferred.

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5 - 26

Communications Parameters

ADVANCED OPERATIONS

Communications Parameters
Confirm or set the parameters in the following table:
Parameters for Communications
Parameter

value

notes

9921 bit 6

9921 bit 1

9931 bit 6

9936 bit 6

0020

channel select

0101

10000001

settings for channel = 0

0102

0103

11

11=9600 baud (standard)


10 = 4800 baud (some machines)

0111

1000001

settings for channel = 1

0112

0113

11

11=9600 baud (standard)


10 = 4800 baud (some machines)

Notes
Transferring TO floppy, dont need parameter write enabled
Floppy must be in place and door closed, else get alarm 86

Amada America, Inc.O perating the Pulsar 1212

1.06c, 13 November, 1996

ADVANCED OPERATIONS

Communications Parameters

MDI ***** *** *** 12:54:32


PARAM DGNOS

<

SYSTEM (OPRT)

MDI ***** *** *** 12:55:01


NO.SRH

<

PMC

ON:1

OFF:0

+INPUT INPUT

MDI ***** *** *** 12:55:18


PITCH SV-PRM

<

(OPRT)

Figure 17: Parameter Edit soft keys

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5 - 27

5 - 28

2. Data Output to a floppy disk

ADVANCED OPERATIONS

2. Data Output to a floppy disk


The following procedures assume that the floppy disk is in place, and that the
door is closed. The system should be in EDIT mode.

2-1 NC parameters
Press the SYSTEM key to display the parameter screen.
Press the + soft key.
Press the PUNCH soft key.
This creates a file named ALL.PAR on disk.

2-2 Pitch error data


To display the pitch error data screen:
Press the SYSTEM key to display the parameter screen.
Press the + soft key.
Press the PUNCH soft key.
This creates a file named PITCH.DAT on disk.

2-3 Cutter compensation ( tool offset)


To display the Cutter compensation data screen:
Press the OFFSET key to display the offsets screen.
Press the + soft key.
Press the PUNCH soft key.
This creates a file named OFFSET.DAT on disk.

2-4 PMC Parameter data


( Keep relay 17 bit 1 = 1 )
Select PMC, then set SPEED parameter
BAUD RATE = 3
PARITY BIT = 0
STOP BIT

=1

Select I/O screen and set parameter


CHANNEL

=1

DEVICE

= FDCAS

FUNCTION

= WRITE

DATA KIND = PARAM


FILE No. = -1
Execute by soft key [EXEC]
The file name will be #0001.DAT, #0002.DAT, and so on.
Dont use FILE No. = 0

Amada America, Inc.O perating the Pulsar 1212

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ADVANCED OPERATIONS

3. Data Input from a floppy disk

3. Data Input from a floppy disk


3-1 NC parameter
Go to PROGRAM screen and EDIT mode.
Select [floppy] soft key after [+] soft key.
Select [F-search] ( left side soft key)
Input file number which is for the parameter data ( 1,2,....), then hit [F-set]
( display the file directory of a floppy disk )
Go to parameter screen and execute [READ] command.

3-2 Pitch error data


Go to PROGRAM screen and EDIT mode.
Select [floppy] soft key after [+] soft key.
Select [F-search] ( left side soft key)
Input file number which is for the pitch error data ( 1,2,....), then hit [F-set]
( display the file directory of a floppy disk )
Go to pitch error data screen and execute [READ] command.

3-3 Cutter compensation data ( tool offset )


Go to PROGRAM screen and EDIT mode.
Select [floppy] soft key after [+] soft key.
Select [F-search] ( left side soft key)
Input file number which is for the cutter compensation data ( 1,2,....), then hit [Fset]
( display the file directory of a floppy disk )
Go to cutter compensation screen and execute [READ] command.

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


Select PMC, then set SPEED parameter
BAUD RATE = 3
PARITY BIT = 0
STOP BIT
=1
Select I/O screen and set parameter
CHANNEL
=1
DEVICE
= FDCAS
FUNCTION
= READ
DATA KIND =
FILE No. = 1 ( select PMC parameter data file No. )
Execute by soft key [EXEC]
( The DATA KIND goes to = PARAM after hit [EXEC] key )

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5 - 29

5 - 30

3. Data Input from a floppy disk

ADVANCED OPERATIONS

Notes

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Chapter 6

PROGRAM STORAGE and EDITING

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Page 6-1

6-2

Notes

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6-3

Overview

Overview
This chapter covers creation, selection, editing, and transfer of programs to and
from the NC. For programming codes and techniques, see the Programming Manual. For machine operation, see chapters 3, 4.
Each program in the NC is identified by a program number. The available numbers for user programs are 0001 to 8999.
Program numbers 9000 to 9999 are reserved for Amada programs.
Program number 0000 may be used in certain Extended Edit operations, and
should be left as a scratchpad area.
If, while executing a program, you stop operation temporarily by single block stop
or stop and alter the program (insert, delete, or change any data within it) you cannot continue to execute the program. After editing a program, always press
RESET before attempting to re-run it.

Preparing to Edit
When you store a program or edit it in NC memory, do the following:
1) Turn the memory protect key OFF (operator panel)
2) Select EDIT mode
3) Press the FUNC and PROG keys to display the program screen. Press the
PRGRM soft key (if needed) to display the program listing.
4) Press the (OPRT) soft key to change the soft keys for editing. (Even if you
dont press soft key (OPRT), the soft keys change for editing when any of the
address or numeric keys are pressed).
5) When you transfer data to or from a device such as Fanucs Handy File, remember to set the input or output mode. (SETTING screen)
The following section assumes that the NC is in EDIT mode with memory protect OFF.
Notes
Program numbers 08000 ~ 08999" can be protected by a parameter, and are
recommended for programs which are to be kept in the NC and not edited.
Program numbers 09000 ~ 09999" are reserved by Amada for custom/machine
programs.

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6-4

Program Selection

Preparing to Edit

Program Selection
To search through programs in the memory, you can view the program directory
(LIB soft key), search by program number, or just display programs one-at-a-time
until you find the right one.
Select by Program Number

(In EDIT or AUTO mode only)


To search using the cursor down key
Input a program number you want to select by pressing the O key (not zero) and
the numbers. Example: O1313

Press the MESSAGE cursor key.


To search using the O SRCH soft key:
Input the program number you want (dont need the O key ), and press the
O SRCH soft key.
After finishing search, the program number and its name (if found) are displayed
on the upper part of the CRT.
Program Scan

Press the O SRCH soft key repeatedly to display each program in memory one
by one. After all program numbers registered are displayed, it goes back to the
first program. They are displayed in the order registered in memory, not by program number.

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Preparing to Edit

Program Handling

Program Handling
Programs may be created off-line and transferred into the NC, or simply keyed-in
at the MDI/CRT panel.

Creating a Program
To create a program at the MDI/CRT panel:
Press O (not zero), and key the desired program number in. Press the INSERT
key to store the program number in memory.
Input program data word by word by using the Address/Numeric keys as necessary. The keyboard input goes to the key input buffer and is displayed on screen.
Press the INSERT key to transfer contents of the key input buffer to program
memory
Continue to key-in and insert necessary instructions to create the program.

Program Delete
Once the NC deletes a program, no recovery is possible. When in doubt, be sure
that a backup exists off-line before deleting a program from the NC.
Deleting One Program

You can delete one program registered in the memory.


Input the program number to be deleted by keying in O and the number.
If you press DELETE key, the program whose number was input is deleted. If you
delete a program, the next program (in memory) is displayed.
Deleting all programs

Key-in O-9999"
Warning: This kills ALL programs in memory.

Press DELETE key to delete all programs in memory.

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6-5

6-6

Program Handling

Edit Procedures

Edit Procedures
This section covers basics of program editing. For further information, refer to the
Fanuc Series 16 LA (or 16 LB, as appropriate) Operator Manual.

Cursor Forward
If you press the left/right arrow , the cursor moves word by word.
If you press , the cursor moves word by word to the right.
If you press , the cursor moves word by word to the left.
If you keep pressing , , the cursor keeps moving.

Line Forward
If you press cursor UP, DOWN, the cursor moves one row at a time:
Cursor DOWN moves the cursor one row down
Cursor UP moves the cursor one row up
If you press and hold the Cursor DOWN or UP key, the cursor keeps moving.

Page Forward
If you press Page key DOWN, the screen changes to the next one and the cursor
moves to the beginning word.
If you press Page key UP, the screen changes to the previous one and cursor
moves to the beginning word.
If you keep pressing Page key DOWN, UP, the pages change continuously.

Return to Top of Program


There are two ways to return the cursor to the beginning of a program.
Press the REWIND soft key.
This is effective in EDIT or MEMORY mode. The cursor goes back to the beginning of the program and the content of the program is displayed form its beginning.
Press the RESET key.
This is effective in MEMORY or EDIT mode. If you are in background edit and
the foreground program is being executed, its execution stops.

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Edit Procedures

Program Handling

Word Search
If you press the SRH soft key , the cursor searches for a word designated to
the forward direction.
In the above program, input E with key and press SRH , and then the search
begins. (You can use Cursor key DOWN, instead of SRH ).
Once the search is completed, the cursor is displayed on E001".
When you search for M30" in the same program, input M30" with key and
press SRH and then the search begins. (You can use Cursor Key DOWN instead of SRH .)
Once the search is completed, the cursor is displayed on M30".
Note
You cannot search for M30" by inputting only M3" with key.
If you press soft key Search UP, the cursor searches for a word designated to
the backward direction.
In the above program, when you search for G90", input G90" with key and
press Search UP. Then the search begins. (You can use Cursor UP, (
instead of Search UP/
Once the search is completed, the cursor is displayed on G90".

Word Change
How to change words in a stored program:
G111 X150 Y80 I120 J10;
Move the cursor to a word you want to change with, say Word Search. In this
case, we want to change I20 to I18, move the cursor to I20"
Input the word you want to change with key. In this case, input I18" with key.
Press ALTER key and I20" is changed to I18".
G111 X150 Y80 I18 J10;

Inserting Word(s)
Heres how to insert a word between two existing words:
G111 X150 Y80 I18 J10;
Move the cursor to a word immediate before the place you want to insert by using
say, Word search. Since we want to insert R3" between J10" and ;, move the
cursor to J10".
Input a word you want to insert with key. In this case, input R3" with key.
Press INSERT key and R3" is inserted
G111 X150 Y80 I18 J10 123;

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Page 6-7

6-7

6-8

Program Handling

Edit Procedures

Word Deletion
Word Delete

Heres how to delete a single word from a stored program:


(before)
G111 X150 Y80 J10 R3;
Move the cursor to a word you want to delete. To delete R3", move the cursor so
that R3" is selected.
Press DELETE key and R3" is deleted.
(after)
G111 X150 Y80 I18 J10;
Delete to EOB

Heres how to delete unnecessary words from a certain word to EOB (;).
(before)
G111 X150 Y80 I18 J10 25 R3;
G00 X100 Y-5;
E003
Move the cursor to a word where you want to start deleting. In this example, we
want to delete from J10" to ;". Therefore, move the cursor to J10".
Input ; with key and press DELETE key and the words form J10" to ;" are deleted.
(after)
G111 X150 Y80 I18;
G00 X100 Y-5;
E003
Deleting several blocks

To delete everything from the cursor position to a block where a designated sequence number is:
Move the cursor to the beginning of a block that you want to start deleting by, say,
word search. In this example, since we want to delete blocks from (I) to (II),
move the cursor to the beginning of the block
Input N20" with key and press DELETE key and the blocks from (I) to (II) are deleted. The cursor moves to the next block.
Note
When you want to delete from the middle of a block, not from the beginning,
over several blocks, the words before the designated cursor position are left.
After the deletion, since the next block to the designated sequence number
is connected with the left word, insert EOB (;).

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Edit Procedures

Program Handling

Deleting to a designated word

To delete a group of words from a word to a designated in a block


Move the cursor to a word you want to start deleting. In this example, since we
want to delete the words from G00" of (I) to X25" of (II), move the cursor to
G00" of (I)
Input X25" for the last word you want to delete with key and press the DELETE
key. The words from the cursor position to the first word designated is deleted..
The cursor moves to the next word beyond the deleted items.
Note
1. The first matching word ends the search/deletion.
2. When the word you start deleting and the word designated to delete are in
the middle of the block, the words before and after the words deleted are
left as they are. After deleting, they are connected. If the codes of the same
group overlap, insert EOB (;).

G93 X.5 Y29.5 Z.06;


G00 G42 X-.2 Y0;
M103;
G01 X6;
(I)
G00;

G93 X.5 Y29.5 Z.06;


G00 G42 X-.2 Y0;
M103;
G01 X6;
(II)
Y4;

X14.5 Y4.;
X25 Y4;

X3 Y6;
X0;
Y0;

(II)

X3 Y6;
X0;
Y0;

Figure 1: "delete to word " before

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Figure 2: "delete to word " after

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Page 6-9

6-9

6 - 10

Expanded Edit Function

Edit Procedures

Expanded Edit Function


The following operations are available by Expanded Edit function. These operations are accessed using soft keys
COPY To copy a whole program or part of a program to another program.
MOVE To move a whole program or part of a program to another program.
MERGE To insert another program into a program
CHANGE Search-and-replace operations within a program
By using these functions, you can create a revised version of a program while leaving the original program intact, write a program containing a similar part, or
change command values and addresses of a program with ease.
Notes
The expanded tape edit function is possible in foreground edit and background
edit
Operation is performed with soft keys.

Starting the Expanded Tape Edit function

Press the next page soft key to display the EX-EDT soft key. Press the EXEDT soft key to display the following set of soft-keys:

COPY

Page 6-10

MOVE

Operating the Pulsar 1212

MERGE

CHANGE

1.06c, 13 November, 1996 Amada America Inc

Edit Procedures

Expanded Edit Function

Copying a Program
Use the COPY soft key to copy a program. The soft keys change as follows:
COPY

MOVE

MERGE

CSR ~

~ CSR

CHANGE

~ BTTM

ALL

EXEC

Key

Purpose

CSR ~

Marks beginning of range to copy or move

~ CSR

Marks the END of the range of instructions to copy or move.

~ BTTM End of program becomes end of range.


ALL

Copy or move the entire program.

Copying a whole program

a) Press soft key COPY


b) Press soft key ALL
c) Input the new program number with numeric keys
d) Press INPUT on the CRT/MDI keypad.
e) Press the EXEC soft key.
Notes
1. If you press the EXEC soft key without designating a program number, the
selected instructions are copied into program 00000. Any previous program
in 00000 is overwritten.
2. When the system is waiting for a program number input, you can not edit
anything.

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Page 6-11

6 - 11

6 - 12

Expanded Edit Function

Edit Procedures

Copying part of a program

a) Press the COPY soft key.


b) Move the insertion point to the BEGINNING of the instructions to copy.
c) Press the CSR ~ soft key.
d) Move the insertion point to the END of the instructions to copy.
e) Press the ~ CSR or ~ BTTM soft key.
f) Input the program number with numeric key, and press INPUT.
3) Press the EXEC soft key.
Notes
1. If you press the EXEC soft key without designating a program number, the
selected instructions are copied into program 00000. Any previous program
in 00000 is overwritten.
2. You can not edit while the system is waiting for a program number input.
3. Only an unused program number may be copied to.
4. You can set an edit range start point (CSR ~) repeatedly until setting an
edit range finish point (~ CSR or ~ BTTM)
5. The edit range start point and the edit range finish point are effective until
the following operation is performed.
When operation except for address search, word search, cursor up-down, page up- down,
and return to the program beginning (home) is performed after setting a start point or a
finish point.
When going back to operation selection after setting a start point or a finish point.

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Edit Procedures

Expanded Edit Function

6 - 13

Moving a Program
To move a portion of a program from where it is to a new program, press the
MOVE soft key. The soft keys change as shown at the bottom of this page.
Note that this operation REMOVES the selected program instructions from the
source program and puts them into a new one. If you dont want them removed,
use COPY instead.
Moving part of a program

1) Press the MOVE soft key.


2) Positioning the cursor to the beginning of the program segment to move and press
the CSR ~ soft key.
3) Designate the end of the program segment to move by:
a. position the cursor to the end of the segment and pressing the ~ CSR soft key.
b. Press the ~ BTTM soft key to include everything to the end of the program.
4) Key in the new program number using the numeric keys.
(program # must be unused )
5) Press INPUT on the CRT/MDI keypad.
6) Press the EXEC soft key.
NOTES
1. If you press the EXEC soft key without designating a program number, the
execution is ignored.
2. You can not edit while waiting for a program number input.
3. Always input a unused program number.
4. You can set an edit range start point (CSR ~) repeatedly until setting an
edit range finish point. (~ CSR or ~ BTTM)
5. The edit range start point and the edit range finish point are effective until
any of the following operations are performed:
Any operation except for address search, word search, cursor up-down, page up- down,
and return to the program beginning (home) is performed after setting a start point or a
finish point.
When going back to operation selection after setting a start point or a finish point.

COPY

MOVE

CSR ~

MERGE

~ CSR

CHANGE

~ BTTM

ALL

EXEC

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Page 6-13

6 - 14

Expanded Edit Function

Edit Procedures

Merging Programs
To insert another program into the selected program, press the MERGE soft key.
The soft keys will change as shown below.
Inserting a program into a program

To insert a program into the middle of an existing program:


a) Select the program to be added to, and move the cursor to the desired insertion point.
b) Press the MERGE soft key
c) Press the ~ CSR soft key
d) Designate the program number to be inserted (use the numeric keys)
e) Press INPUT on the CRT/MDI keypad.
f) Press the EXEC soft key
Notes
1. You can not edit while waiting for a program number input
2. The designated program is inserted after the cursor

Appending a program

To append one program to the end of another:


a) Select the program to be added to.
b) Press the MERGE soft key
c) Press the ~ BTTM soft key
d) Designate the program number to be inserted (use the numeric keys)
e) Press INPUT on the CRT/MDI keypad.
f) Press the EXEC soft key

COPY

MOVE

CSR ~

MERGE

~ CSR

CHANGE

~ BTTM

ALL

EXEC

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Operating the Pulsar 1212

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Edit Procedures

Expanded Edit Function

Search and Replace


To perform search-and-replace operations within a program, press the CHANGE
soft key. The soft keys change as shown below.
Soft Keys for Search and Replace
Key

Purpose

EXEC

Replaces all

Replaces all matching words and addresses after the


cursor, to the end of the program. (ignores the word
where the cursor starts)

EX-SGL

Replace one

It replaces the first instance of the designated word


and address found after the cursor start point, and
stops.

SKIP

Find Next

It searches the first instance of the designated word


and address after the cursor, and stops. (ignores the
word where the cursor starts)

COPY

MOVE

Explanation

MERGE

CHANGE

EX-SGL

EXEC

BEFORE

AFTER

SKIP

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6 - 15

6 - 16

Expanded Edit Function

Edit Procedures

How to replace all words designated after the cursor

a) Press soft key CHANGE


b) Input words you want to replace with data input key
c) Press soft key Before replace
d) Input a word after replacing with data input key
e) Press soft key After replace
f) Press soft key EXEC
Notes
1. This operation always starts at the next word after the cursor. To operate on
the entire program, move he cursor to the beginning of the program first.
2. You can designate maximum 40 words for starting replace and after replace
words.
3. Can change part of word if desired, as changing X to Y. This will change
G00 X1000; to G00 Y1000;

How to replace designated words one by one

a) Press soft key CHANGE


b) Input words you want to replace with data input key
c) Press soft key Before replace
d) Input the word after replace with data input key
e) Press soft key After replace
f) Press soft key EX-SGL
g) When you do the same replacement, repeat f)
Notes
1. Replace starts from the words next to the cursor.
2. You can designate maximum 40 words for starting replace and after replace
words.

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Edit Procedures

Expanded Edit Function

6 - 17

Search and Replace with Confirm

a) Press soft key CHANGE


b) Input the words you want to replace with data input keys
c) Press soft key Before replace
d) Input the words after replace with data input keys.
e) Press soft key After replace
f) Press soft key SKIP
g) When you replace a word where the cursor stops, press the cursor up key and
then press soft key EX-SGL.
Perform f) after replace. When you search next word without replacing, perform f).
Caution
1. Replacement starts from the word next to the cursor.
2. Replace start and after replace words are designated with maximum 40
words.

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6 - 18

BACKGROUND EDIT

Edit Procedures

BACKGROUND EDIT
The NC system permits program transfer and editing under any operation mode
conditions on the NC. (whether or not it is during auto operation). When operation
mode is EDIT mode, it is called Foreground Edit. On the other hand, when NC
is operation at any mode except for EDIT mode, an Edit performed in the background is called Background Edit (BG Edit) or Back Edit. (Background Edit is
possible even when Foreground is in EDIT mode.
NC alarms which occurs when loading and editing a program in the background
do not affect any operation in the foreground. Background editing is not affected
by alarms from the foreground. You cannot execute a program being edited in the
background.

Starting a Background Edit


On the program display screen, press soft key BG edit and then the background
edit starts. The display at the upper changeable portion changes from Program
to Program (BG-EDIT) which indicates that the background editing is in progress. Program edit is the same as the program edit in the foreground.

Finishing a Background Edit


Finish a background editing by pressing the BG finish soft key.
Notes
1. You cannot background edit a program that is currently selected in the
foreground. If this is attempted, BP/S alarm (140) occurs.
2. When a program is in background edit and is called as a subprogram in the
foreground, P/S alarm (78) occurs in the foreground.
3. You cannot delete the whole program while editing in the background
4. You can cancel NC alarm occurred in the background edit by pressing any
key. However, if you press RESET by mistake the operation in the
foreground is reset.

Page 6-18

Operating the Pulsar 1212

1.06c, 13 November, 1996 Amada America Inc

Edit Procedures

Loading and Saving Programs

6 - 19

Loading and Saving Programs


This section covers use of the Fanuc Handy File unit.
Program transfer operations may be done in EDIT mode. To read programs into
the NC, the PROGRAM PROTECT key must be OFF.
Programs may be loaded and saved using either the Handy-file technique or the
Floppy drive technique. To use the Handy-file technique, use the soft keys
shown in figure 3. To use the Floppy drive technique, use the figures following.
The FLOPPY operations screen is accessed using soft keys. The initial sequence
is shown in figure 4 on page 20.
NOTE:
If the floppy drive cover door is not closed, Error 86 DR SIGNAL OFF will
occur when you try to access the floppy.

Setup
For setup and related information, see page 5-26.
For more insormation on NC screens and soft key assignments, see page 5-10.

1
EDIT ***** *** *** 12:54:32
PGRM

LIB

EDIT ***** *** *** 12:54:32


BG-EDT O SRH SRH

<

(OPRT) +

SRH

REWIND+

EDIT ***** *** *** 12:54:32


F SRH

READ PUNCH DELETEEX-EDT +

Figure 3: Soft-keys for Handy-File

Amada America, Inc.Operating the Pulsar 1212

1.06c, 13 November, 1996

Page 6-19

6 - 20

Loading and Saving Programs

Edit Procedures

Directory of a Floppy Disk


Select EDIT mode, and then select the FLOPPY screen as show below. Then press
the DIR soft key, and then the PAGE key on the Fanuc keyboard.
SEARCH will flash on the NC screen, and the directory listing will be displayed. If not all of the directory is displayed, use the PAGE , PAGE keys
as needed.
Each file has a file number displayed in front of the file name. This number may
be used for most purposes, instead of having to type the filename in.

1
EDIT ***** *** *** 12:54:32
PGRM

(OPRT) +

2
EDIT ***** *** *** 12:54:43
FLOPPY

(OPRT) +

EDIT ***** *** *** 12:55:02


PRGRM

return to
PROG screen

DIR

(OPRT)

for directory
of floppy

for READ,
PUNCH, etc.

Figure 4: Soft-Key sequence

Page 6-20

Operating the Pulsar 1212

1.06c, 13 November, 1996 Amada America Inc

Edit Procedures

Loading and Saving Programs

From NC to Floppy
To transfer a program stored in NC memory to the floppy drive:
Insert a formatted 3.5 FD (floppy disc) and close the door.
(1) Select the program you want to output to disk, and press the PUNCH soft key.
Press the EXEC soft key to output the program.
(file name becomes Onnnn.DAT, where nnnn is the program number.)
(2) Select the FLOPPY screen, as seen in figure 4 on page 20.
Press the (OPRT) soft key to display the keys for floppy read, punch (see figure 5
on page 21).
Key in the program number and press the O SET soft key.
Press the EXEC soft key.
(file name becomes Onnnn.DAT, where nnnn is the program number.)
Output blinks on the screen during execution. The Output display disappears
when the operation is complete.
.

EDIT ***** *** *** 12:55:32


F SRH READ PUNCH DELETE RENAME

<

2
EDIT ***** *** *** 12:55:32

<

F SET

O SET

CAN

EXEC

Figure 5: Extended keys for READ, PUNCH

Amada America, Inc.Operating the Pulsar 1212

1.06c, 13 November, 1996

Page 6-21

6 - 21

6 - 22

Loading and Saving Programs

Edit Procedures

NC -> Handy File


To transfer a program stored in NC memory to the Handy file. (NC indicates NC
side control and HF indicates handy file side control)
1) HF: Insert a formatted 3.5 FD (floppy disc) to Handy file and close the door.
Turn on the power and let the handy file show Preparation completed
2) HF: Press WRITE SET key.
3) Input a file name and press ENTER.
4) HF: New file is made OK? is displayed
5) HF: Press the START key. Waiting is displayed
6) NC: Select the program you want to output to Handy file
7) NC: Press the PUNCH soft key, then the EXEC" soft key to output the program. Output blinks on CRT during execution. Output display disappears
when the operation is complete.
HF: Executing is displayed on the crystal liquid panel during execution
8) HF: File No. and file name are displayed after execution. The program is registered in the very end of FD in Handy file
9) HD: If you have other programs to be registered, start from 3). If you dont,
press the END key again

Page 6-22

Operating the Pulsar 1212

1.06c, 13 November, 1996 Amada America Inc

Edit Procedures

Loading and Saving Programs

From Floppy to NC
To transfer programs from FD (Floppy Disk) to the NC:
Get the floppy which has the program(s) to be transferred, insert it into the drive,
and close the access door.
Select the FLOPPY screen, as seen in figure 4 on page 20.
Press the (OPRT) soft key to display the keys for floppy read, punch (see figure 5
on page 21).
Press the READ soft key.
Input the program number to use., and press O SET
Input the file number and press F SET.
Press the EXEC soft key to read the program into the NC.
Input blinks on the screen during execution. The Input display disappears after execution.
.

EDIT ***** *** *** 12:55:32


F SRH READ PUNCH DELETE RENAME

<

2
EDIT ***** *** *** 12:55:32

<

F SET

F NAME

CAN

EXEC

Figure 6: Keys for File Name/Number

Amada America, Inc.Operating the Pulsar 1212

1.06c, 13 November, 1996

Page 6-23

6 - 23

6 - 24

Loading and Saving Programs

Edit Procedures

Handy File -> NC


You can transfer programs from FD (Floppy Disk) to the NC. (NC: indicates NC
side Operation and HF indicates handy file side operation).
1) HF: Get the floppy which has the program(s) to be transferred. and insert it into the
Handy File and turn on the power. Wait for the Handy File to display preparation completed.
2) HF: Press Read out/auxiliary key
3) HF: Press the up or down-arrow keys to display a program name to be transferred into
the NC.
4) NC: Input the program number to use. This must be O+ number 1~8999 using the numeric keys,
5) Press the READ soft key, then the EXEC soft key to read the program into the NC.
Input blinks on CRT during execution. The Input display disappears after execution.
HF: Executing is displayed on the crystal liquid panel during execution.
After finishing execution, press END key is displayed.
6) HF: Press the END key.

7) HF: If you have other programs to be registered, start from 3). If you are done,
press the END key again

Page 6-24

Operating the Pulsar 1212

1.06c, 13 November, 1996 Amada America Inc

Edit Procedures

Loading and Saving Programs

Renaming a program on floppy


To rename a program on floppy:
Display the disk directory, note the FILE NO. of the program to be renamed.
Press the (OPRT) soft key, then the RENAME soft key. (see figure 6)
Key the file number (FILE NO. in the directory listing) in, and press the F SET
soft key.
Key in the new name, and press the F NAME soft key.
Press the EXEC soft key to perform the name change.

File Search
This function is to begin a file listing with a particular file number.
Press the F SRH soft key.
Key in the file number to begin the directory listing with and press F SET.
Press EXEC to list the files.

EDIT ***** *** *** 12:55:32


F SRH READ PUNCH DELETE RENAME

<

2
EDIT ***** *** *** 12:55:32

<

F SET

CAN

EXEC

Figure 7: Soft Keys for File Search

Amada America, Inc.Operating the Pulsar 1212

1.06c, 13 November, 1996

Page 6-25

6 - 25

6 - 26

Loading and Saving Programs

Edit Procedures

Notes

Page 6-26

Operating the Pulsar 1212

1.06c, 13 November, 1996 Amada America Inc

Chapter 7

Cutting Data Screens

Amada America, Inc.O perating the Pulsar 1212

1.06c, 13 November, 1996

7-2

Notes

Amada America, Inc.O perating the Pulsar 1212

1.06c, 13 November, 1996

OVERVIEW

Screen Selection

OVERVIEW
The Cutting Data Screens deal with Amadas Cutting Data Library, machine parameters, and machine alarms.
The Cutting Data Screens are independent from the NC screens. They are selected
using the CUSTOM key, and include the following 6 screens plus one split screen
(laser information screen)
SCREEN

PURPOSE

Page

Cutting Condition

Permits display and editing of cutting data (full screen or split


with Laser Information )

12

Pierce Condition

Permits display and editing of piercing data (full screen or split


with Laser Information )

18

Edge Condition

Permits display and editing of edge data. (full screen or split


with Laser Information )

24

Material List

Lists materials by various categories, permits loading and


saving data. (full screen or split with Laser Information )

30

Parameter

To set parameters relating to sensor operation and Z-axis retract.


(full screen )

36

Alarm

Displays Amadas machine alarms. Full screen.

37

Laser Information

(split) Displays the present condition of the laser. Available with


Cutting, Pierce, and Edge Condition screens, and the Material
List screen.

Screen Selection
When the Cutting Data Screens are active, the HELP key toggles between the
Alarm screen and the other most recently selected Cutting Data Screen.
To select the Cutting Data Screens

Press the CUSTOM key to go from any NC screen to the Cutting Data Screen.
The most recently displayed Cutting Data Screen is shown when you go from NC
screen to Cutting Data Screen.
NOTE:
Pressing the CUSTOM key again blanks the NC screen. If the screen is completely
blank for more than ten seconds or so, and power is on, press the CUSTOM key
firmly for 1-2 seconds and release it.
To return from a Cutting Data Screen to an NC screen

Press the FUNC key and any function key ( POS, SYSTEM, PROG, OFFSET, MESSAGE ,
or GRAPH ) to go from a Cutting Data Screen to that NC screen.

Amada America, Inc.O perating the Pulsar 1212

1.06c, 13 November, 1996

7-3

7-4

Screen Selection

OVERVIEW

Soft Keys
Selecting among the Cutting Data Screens is mainly done with soft keys. See figure 1 for main soft key designations.

Selecting Full/Split Screen


Laser status may be displayed on the right half of the screen. The most recently selected Cutting Data Screen (Cutting Condition, Pierce Condition, Edge Condition
screen, or Material Table) is displayed on the left half. If you press the highlighted soft-key ( Cut Cond or Mtrl List ), the display toggles between full-screen
view and split-screen with the Laser Information displayed.

Cutting Condition
screen (split)

Laser Information
screen

O 0006

[Mtrl name]
[Type]
[Mtrl info] Std/Thick/Clean/Alumi
[WACS] ON/OFF

N 00001

[Mtrl name] A-SUS1.0


[Type]

STAIN

Cut Feed Pwr Freq Duty Gas Gas


Cond Rate [S]
[%] prss. kind

[Cond. no]

1.
2.
3.
4.

Feed

12.0
120.1
120.1
120.1

300
300
300
300

12
50
50
50

0
0
0
0

0
0
0
0

5. 120.1 1400 300


6. 120.1 1400 300
7. 120.1 1400 300
8. 120.1 1400 300
9. 120.1 1400 300
[ Etch]

50
50
50
50
50

0
0
0
0
0

0
0
0
0
0

50

10. 120.1

1200
1400
1400
1400

1400 300

Power

Item (field)
selected for
editing

Gas type
0
Def
0
focal (inch) 0
Head
2
X 0.000
Z 0.000
Y 0.000

Mtrl
List

selects cutting condition


screen (active)

Pierc

selects Material
List screen

%
%
%
%

Edit

Save +

For selection and editing


of cutting condition

selects Edge
screen

Figure 1: Cut Cond. + Laser Info

Amada America, Inc.O perating the Pulsar 1212

13:25:01

Edge Select

selects Piercing
info. screen

120
100
100
100
100

Purge time 1.5


Comp.(inch) 0.0039
pulse
0
Pierce no. 101
act. v
128.5
ave pwr. 850.5

EDIT ***** **** ****

Cut
Cond

Key input goes here: Press


INPUT to activate.

[Mtrl info] STD

12.01 inch
m
1500 W
Pwr
300 Hz
Freq.
0 %
Duty
Gas prs. 0.00

]>

<

E1

[Thick] .039

1.06c, 13 November, 1996

LASER INFORMATION Screen

Display Operation

LASER INFORMATION Screen


The Laser Information screen displays the present machine/laser status.
A sample screen is shown in Figure 1 on page 4.

Display Operation
If an NC screen is active, press the CUSTOM function key to display the Cutting
Data Screen. The most recently displayed Cutting Data Screen is shown again.
The laser information screen is not displayed on the parameter screen and the
alarm table screen.
From the parameter screen, press the END soft key. Then follow the procedure
for whatever screen is active.
While the laser information screen is displayed

Press Page key UP, DOWN (arrow) to switch the right and the left of the base
screen while the laser information screen is displayed.
To switch to a full screen

From the material table screen, press the Mtrl List soft key to toggle between
full-screen and split material table/laser information screen.
From the Cutting Condition, the Pierce, or the Edge screen, press the Cut
Cond. soft key
Note
When the Override or Data setting buttons on the control panel are on, the
screen cannot be switched to a full screen.

Amada America, Inc.O perating the Pulsar 1212

1.06c, 13 November, 1996

7-5

7-6

Display Operation

LASER INFORMATION Screen

Laser Information screen items


ITEM

PURPOSE

O oooo

Displays the active/selected program number

N nnnnn

It displays the current or most recent program sequence number

[Mtrl name]

Material name currently selected

[Type]

Type or classification of material.

[Thick]

Worksheet thickness

[Cond. no]

Selected Condition# (E1 ... E10)

[Mtrl info]

Displays the process category for this material.: Standard, Thick,


Clean, or Aluminum (see page 13)

Feed

commanded feedrate (inch/min or mm/min) and override [%]

Pwr

commanded laser power(during CW) (Watts) and override [%]

Freq

commanded laser pulse frequency (Hz) and override [%]

O 0006

N 00001

[Mtrl name]
[Search]
ALL
SPC/SPH
Stain
A
Others
ThIckness
Std.
Thick
Clean
Alumi

[Mtrl name] A-SUS1.0


1. A-SUS1.0
2. A-SUS1.5
3.
4.
5.
6.
7.
8.
9.
10
11.
12.
13.
14.
15 C-SUS2.0

Rem mtrl

[Type]

STAIN

[Cond. no]

E1

[Thick] .039
[Mtrl info] STD

12.01 inch
m
1500 W
Pwr
300 Hz
Freq.
0 %
Duty
Gas prs. 0.00
Feed

Gas type
0
Def
0
focal (inch) 0
Head
2
X 0.000
Z 0.000
Y 0.000

Number

mtrl name A-SUS1.5


Open (Rename) Copy

Cut
Cond

Mtrl
List

OPEN

NEW

Figure 2: Material List with Laser Information

Amada America, Inc.O perating the Pulsar 1212

%
%
%
%
%

Purge time 1.5


Comp.(inch) 0.0039
pulse
0
Pierce no. 101
act. v
128.5
ave pwr. 850.5

EDIT ***** **** ****


<

120
100
100
100
100

1.06c, 13 November, 1996

13:25:01
SEARCH +

LASER INFORMATION Screen

Display Operation

Laser Information screen items


ITEM

PURPOSE

Duty

commanded laser pulsing duty cycle (%) and override [%]

Gas prs.

commanded assist gas pressure and override [%]


(meaningful only with NC gas pressure control)

Gas type

Selected assist gas type (1-5)

Purge time

It displays purge time when starting assist gas prior to any


piercing operation.

Def. amount

Not used

comp.

current cutter offset value

Focal

Displays a focus position of lens. It is not applicable to the


machine without NC focus control (option).

Pulse

Not used with Fanuc laser.

Head

Only used with Automatic Head Changer (option).

Pierc No.

currently selected piercing routine

X, Y, Z

machine position in absolute coordinates.

Act. V

machine speed

Ave. pwr

Not used

Amada America, Inc.O perating the Pulsar 1212

1.06c, 13 November, 1996

7-7

7-8

On-Line Adjustments

LASER INFORMATION Screen

On-Line Adjustments
It is possible to alter the cutting data (speed, power, frequency, duty, and gas pressure) while a program is running. This is done using the override knob on the
operation panel.
Cutting gas pressure is controllable from the NC only when the Programmable
Gas Pressure option is present.
This operation can permanently change the stored cutting data.
SAVE any current cutting data edits before attempting this
Afterwards, do not save without verifying the changes you have made.
Data can also be edited using the Fanuc keypad. (see page 16)

Preparation
Select the Cutting Data Screen.
Only the currently selected material and cutting condition can be altered using
this procedure.
The item to be altered is selected by the buttons above the override knob. ( CUTTING RATE, POWER, FREQUENCY, DUTY, GAS PRESSURE)

Adjustment step size

The step size for each step of the override knob is controlled by the 1/10 button.
Light off: Normal step size
Light on: Changes at 1/10 the normal step size.

Amada America, Inc.O perating the Pulsar 1212

1.06c, 13 November, 1996

LASER INFORMATION Screen

On-Line Adjustments

Adjustments
This changes data for the active material and cutting condition. (shown by green
highlight on screen)
1) While the program is running, press the DATA SET button on the operation
panel. (illuminates when active)
When you activate DATA SET, the Cutting Condition screen is shown if the Material Table screen, the Pierce Condition screen, or the Edge Condition screen was
active.
The DATA SET button disables soft keys and the Fanuc keypad while active.
Release it to use the keypad or soft keys. It goes off automatically when the auto
operation is over.
2) Press the button of the item you want to change. (illuminates when active)
3) Set by turning the knob while pressing ENABLE button.
Clockwise: + direction
Counterclockwise: - direction
Notes
1. The knob has no effect unless DATA SET is active and the ENABLE button
is pressed at the same time as the knob is turned.
2. Only values within the setting range of each item are available.
3. SAVE any desired changes before running any program which performs material selection by M102 (material name ). Otherwise, a new working copy of the
data is created, and any unsaved changes are discarded.
The above operation is not the same as using the OVERRIDE function, which
only applies a multiplier to the values commanded in the cutting data file. This
function alters the working copy of the data file.
To store the changed values created by the OVERRIDE function, you must manually input them on each screen of cut or pierce, and then SAVE them.

Amada America, Inc.O perating the Pulsar 1212

1.06c, 13 November, 1996

7-9

7 - 10

Overview

Cutting Data Library

Cutting Data Library


The Cutting Data Library contains data for a variety of material types and thicknesses. This data is stored in the NC, and can also be transferred to/from floppy
disk for various purposes. See page 38 for information on loading and saving cutting data.

Overview
Each type/thickness is referred to as a cutting data file. Each cutting data file
must have a unique name (such as CRS063) which is used to select it for editing
and operation. Each named material (cutting data file) contains ten sets of cutting
conditions, and various other information about processing the material.
A part-program can select any named material (cutting data file) and any of the
cutting conditions within that file. The feedrate, power, and all other parameters
from that file are then automatically used by the NC until another named material
is selected. A program can switch between material conditions as needed while
running.
Each cutting data file in the library is classified by material, worksheet thickness,
and process category (clean-cut, thick plate, etc.) and managed by material name.
Ten cutting conditions, three pierce conditions, and five edge conditions are
stored in each cutting data file.
Up to 90 material names may be kept in the NC at one time.
You can override speed, output, frequency, duty, and gas pressure (option) while
executing the program.

Amada America, Inc.O perating the Pulsar 1212

1.06c, 13 November, 1996

Cutting Data Library

Overview

7 - 11

Example

The program segment in figure 3 shows an example of cutting data use.


The cutting data file O-CRS063" is selected for use by the M102 (cutting material select). This copies data from the cutting data file of O-CRS063 into active
memory for use.
The command E1" selects Condition number 1. This determines the feedrate,
power, default pulsing parameters, assist gas selection, and cutter offset to be used
while cutting.
The default PIERCE NO is set in the cutting data file for all cutting conditions. To
specify a different pierce number in the program, command E101 - E103.
For no piercing (just beam ON and proceed), specify A0 on your M103 command line. (M103 A0;)
The default EDGE and Approach (lead-in) data is set in the cutting data file for
each cutting condition.
To specify an EDGE or Approach number in the program, specify E201 - E203.

O1313 (CUTTING DATA DEMO);


G20;
G92 X49.12 Y49.12 Z9.7;
M100;
M102(O-CRS063);
E1;
G00 X12.5 Y24.8;
.
.
.

Figure 3: Material selection in program

Amada America, Inc.O perating the Pulsar 1212

1.06c, 13 November, 1996

7 - 12

Display Operation

CUTTING CONDITION Screen

CUTTING CONDITION Screen


This is the primary display of cutting data. All items displayed on this screen can
be edited, except for material name.

Display Operation
If an NC screen is active, press the CUSTOM key. This displays the most recent
Cutting Data Screen.
From the Material Table screen, press the Cut Cond soft key.
From the Pierce Condition screen or Edge Condition screen, press the Return
soft key.
Note:
While the laser information screen is displayed, press the Cut Cond soft key to
switch between full screen and split-screen views.

[Mtrl name] CRS-16


[Type] SPC [THICK] 0.063
[Mtrl info] Std/Thick/Clean/Alumi
[WACS] ON/OFF
Cut Feed Pwr Freq Duty Gas Gas Gas Def. Ofst Edge Appr. Focal Pulse
Cond Rate [S]
[%] prss. kind time
[inch]
data [inch] type
1. 12.0
2. 47.1
3. 98.43
4. 157.48

1200
1400
1400
1400

300
300
300
300

12
50
50
50

0
0
0
0

1
1
1
2

0.5
0.5
0.5
0.5

0.0
0.0
0.0
0.0

0.0040
0.0040
0.0040
0.0039

201
201
201
201

202
202
202
202

0.020
0.020
0.020
0.015

0
0
0
0

5. 180.0
6. 157.5
7. 120.1
8. 120.1
9. 120.1
[ Etch]

1400
1400
1400
1400
1400

300
300
300
300
300

50
50
50
50
50

0
0
0
0
0

1
1
1
1
1

0.5
0.5
0.5
0.5
0.5

0.0
0.0
0.0
0.0
0.0

0.0039
0.0039
0.0039
0.0039
0.0039

201
0
0
0
0

202
0
0
0
0

0.0
0.0
0.0
0.0
0.0

0
0
0
0
0

10 120.1

100 100

100

4.0

0.5

0.0 0.0000 0

0.0

<

Power

]>

Cut
Mtrl
Cond List

Pierc

Edge Select Edit

Figure 4: Cut Condition screen


Amada America, Inc.O perating the Pulsar 1212

1.06c, 13 November, 1996

Save +

CUTTING CONDITION Screen

Display Operation

7 - 13

Items on Cutting Condition screen


This information defines the type and characteristics of the material. It is repeated on the PIERCE and EDGE screens.
Header information

This information is the same for each cutting condition of a particular cutting data
file. It is repeated on the PIERCE and EDGE screens.
Mtrl name:
Displays the currently selected material name (cutting data file).
Type:
Displays currently selected material quality selected.
It is used for search/management on the Material List screen.
Setting range: Eight characters or less.
Allowable characters: English letters, -, .
Thick:
Displays material worksheet thickness for Z-axis positioning purposes.
Be sure to set it to the correct thickness of the material to be processed.
Setting range: 0.00 ~ 999.99
Setting unit: mm(inch)
Mtrl info.:
Displays the process category for this material. This affects certain behaviors of
the machine. The selected process category is highlighted in green.
Category

Includes
3
8

Standard

Soft steel plate less than 9.0mm ( inch), stainless cut with oxygen

Thick

Soft steel plate of over 9.0 mm ( inch and over)

Clean

Clean cut (stainless, etc)

Alumi

Aluminum

3
8

WACS
(option) Select water nozzle ON or OFF. Only applies to machines with water nozzle.
Pierce No.
It selects default piercing routine for selected material. ( 101 ~ 103 ) See the
Pierce Condition screen (page 18) for more information.
Head:
Only used with optional Automatic Head Changer.

Amada America, Inc.O perating the Pulsar 1212

1.06c, 13 November, 1996

7 - 14

Display Operation

CUTTING CONDITION Screen

Cut Conditions

This is set for each condition, E1 .. E10. Unlike the header information, it is not
repeated on the PIERCE and EDGE screens.
Feed Rate:
Sets a cut speed [F]
Setting range: 0 ~ 99999
Setting unit: mm/min.(in/min)
Pwr:
Sets laser power [S]
Setting range: 0 ~ 9999
Setting unit: W (CW: during oscillation)
Frequency
Sets laser pulse frequency [p]
Setting range: 0 ~ 99999
Setting unit: Hz
Duty
It sets a duty [q] of pulse
Setting range: 0 ~ 100
Setting unit: 0 ~ 100
Gas- prss:
It sets assist gas pressure while cutting. Applies to machines with NC controlled
gas pressure only. (option).
Setting range: 0~25.5
Setting unit: kgf/cm2
Gas kind
It selects type of assist gas to use while processing.
Kind

Description

Kind

Description

Oxygen low pressure

Nitrogen

Oxygen middle pressure

Air

Oxygen high pressure

For machines with NC gas pressure control, selections 2,3 are retained for compatibility.
Gas time
This is a a purge time for assist gas AFTER PIERCING and BEFORE CUTTING.
Setting range: 0 ~ 99
Setting unit: second
Def.
not used.

Amada America, Inc.O perating the Pulsar 1212

1.06c, 13 November, 1996

CUTTING CONDITION Screen

Display Operation

7 - 15

Ofst
It set an offset amount (cutter compensation) for the laser beam.
Setting range: 0 ~ 9.999
Setting unit: mm
Edge
It is used to select an EDGE Condition for sharp corners in a contour, to
avoid burnouts, etc.
Value
0
201~205

Meaning
No selection: edge data not used at any corner
Selected EDGE data used when conditions match
(corner sharper than specified angle)

Appr. data:
It is used to select an EDGE Condition for two situations:
a. Lead-in cut at the beginning of a contour.
b. Re-pierce and lead-in when doing a cutting restart
Value
0
201~205

Meaning
No selection: approach data not used at any approach
Selected data used when conditions match

Focal:
It sets the lens focus position. It sets a focus height (distance plus or minus from
standard position) except condition No. 1 based on the focus standard position of
the parameter screen.
Only applies to machines with NC focus control (option)
Setting range: -9.9 ~ 99.9
Setting unit: mm
Pulse type:
It selects type of pulse for the laser. (pulse shape)
Only applies to lasers having selectable pulse type. Current Fanuc lasers do not
have this feature.
Setting range: 0 ~ 99
Other
Other information about the display
Etch : visual separator to show that the last condition (E10) is for etching/scribing.
Use E 10 in the program to select scribing.
White reverse cursor: It displays the cursor position for data correction.
Green reverse cursor: Shows which cutting condition is selected.

Amada America, Inc.O perating the Pulsar 1212

1.06c, 13 November, 1996

7 - 16

Editing Cut Conditions

CUTTING CONDITION Screen

Editing Cut Conditions


You can edit cutting, piercing, and edge data anytime. (the system is always in material edit mode.)
The PROGRAM PROTECT key does not protect against cutting data editing.

) are used to select data items on the screen. A white reThe Cursor keys (
verse cursor shows where you are.
If you press Cursor key UP at condition No.1, the cursor moves to Type.
If you press cursor key DOWN at condition No. 10, the cursor moves to condition No. 1.

Selection of cut condition


A cutting condition can be selected manually for test or operation. Manual selections are superseded by selections within a running part-program, though.
Selection by means of cursor

1) Press soft key SELECT (begins Selection Mode)


) to move the white reverse cursor to the desired condi2) Use the cursor keys (
tion.
3) Press INPUT key (Selects that condition, as shown by the green full-width highlight bar. Returns to Correction Mode)

Selection by means of key input

1) Press the SELECT soft key (activates Selection Mode).


2) A white reverse cursor is displayed: Key in the desired cutting condition No.
3) Press INPUT (returns to Correction Mode)
NOTES
To return to Correction Mode without selecting a new condition, press the EDIT
soft key.
When a program is run, any material selection command will supersede manual
selection. Any E-code in that program will supersede the manually selected
value.

Batch conversion of data

To change data below the cursor position to match the data at the cursor position.
1. Move the cursor to an item you want to perform batch conversion with Cursor key
2. Press the + soft key.
3. Press the All Repla. soft key.
4. Data below the cursor position to No. 9 changes to the same data as the cursor position. However, [Etch] data (No 10) does not change.

Amada America, Inc.O perating the Pulsar 1212

1.06c, 13 November, 1996

CUTTING CONDITION Screen

Editing Cut Conditions

Editing Data
1) Move the cursor to the data you want to correct by pressing the cursor keys
)
(
2) Key in the desired value .
)
3) Press INPUT or any of the Cursor keys (

Notes
If a value input is outside the valid range, Data error message is displayed
and the cursor does not move.
Press the CAN key to remove erroneous characters from the input key buffer.

Data storage
To save changes in cutting, edge, or piercing data.
1) Press soft key Save
2) Storage is completed with a message Has been saved
WARNING
Edited data remains on the screen, but the original data does not change until
you SAVE the new data.
Any unsaved changes are lost when:
(1) a different material is selected manually
(2) ANY material is selected by part-program using M102().

Amada America, Inc.O perating the Pulsar 1212

1.06c, 13 November, 1996

7 - 17

7 - 18

Editing Cut Conditions

PIERCE CONDITION Screen

PIERCE CONDITION Screen


This screen permits correction and storage of pierce data. The following items are
displayed:

Material name

12

(Step) time

Type

13

(Step) number

Thick

14

Pierce time

Mtrl info (Std/Thick/Clean/Alumi)

15

Gas pressure

[WACS]

16

Gas type

Pirc No.

17

Purge time

Pwr

18

Def.

(Initial) frequency

19

Focus

(Initial) duty

20

Pulse type

10

(Increment) frequency

21

Pwr

11

(Increment) duty

[Mtrl name] SS400-19.0


[Type] SS400
[Thick] 19.0
[Mtrl info] Std/Thick/Clean/Alumi
[WACS] ON/OFF
Pirc
No.

Pwr
(S)

[ Initial ]
freq. duty

[ Increm. ] [ Step ]
freq. duty time cnt

Pirc.
time

[ Assist gas ]
prss.
kind

101

1400

10

20

0.5

17

30.0

0.5

2.1

0.0

102

1500

10

20

0.5

17

21.5

0.5

1.5

0.0

103

1500

10

20

0.5

17

21.0

0.5

1.0

0.0

Pirc
No.

Focal Pulse
(mm) Type

101

3.0

102

3.00

103

3.0

[ Power

<

]>

EDIT ***** **** ****

Cut
Cond

Mtrl
List

Return

Figure 5: Piercing screen


Amada America, Inc.O perating the Pulsar 1212

1.06c, 13 November, 1996

Purge def
time

13:25:01

Edit

Save +

PIERCE CONDITION Screen

Display Operation

7 - 19

Display Operation
1) If an NC screen is active, press the CUSTOM key to display the Cutting Data
Screens.
The most recent Cutting Data Screen is displayed again.
2) Press the Cut cond soft key on the material table screen. (The cutting condition screen is displayed).
Press the Pierce soft key on the cutting condition screen. (The pierce condition
screen is displayed).
Press soft key Return soft key on the edge condition screen. (The cut condition
screen is displayed).
Note
While the laser information screen is being displayed, it is switched to a full
screen if you press the Cut Cond soft key. If you press the Cut Cond soft key
again, it displays the laser information screen.

Display items
Header Information

This is information about the material. It is the same as shown on the Cutting Condition screen. (Mtrl name, Thick, Mtrl info, [WACS])
See page 13 for description of header information.
Piercing Data Table

The following items may be set for each pierce condition (101~103)
pwr
It sets Laser power [S]
Setting range: 0 ~9999
Setting unit : Watts (CW : during oscillation)
freq [Initial value]
It sets a frequency [P] of pulse
It sets a initial value of frequency if it is a high speed pierce for Thick..
Setting range: 0 ~ 9999
Setting unit: Hz
duty:
It sets a duty [Q] of pulse
It sets an initial value of duty (only for high speed pierce of thick worksheet).
Setting range: 0 ~ 100
Setting unit: %

Amada America, Inc.O perating the Pulsar 1212

1.06c, 13 November, 1996

7 - 20

Display Operation

PIERCE CONDITION Screen

freq [Increment value]


It sets an increment value of frequency. (only for high speed pierce of thick worksheet).
Set it 0 if it is not a high speed pierce
Setting range: 0 ~ 9999
Setting unit: Hz
Step time:
It sets step time for increase of frequency and duty. (Only for high speed pierce of
thick worksheet).
Set it 0 if it is not a high speed pierce
Setting range: 0 ~ 9.9
Setting unit: second
Step number:
It sets step number for increase of frequency and duty. (Only for high speed pierce
of thick worksheet).
Set if 0 if it is not a high speed pierce.
Setting range: 0 ~ 9.9
Setting unit: times
Pierce time:
It sets pierce time (second)
Setting range: 0.1 ~ 99.9
Setting unit: second
Gas pressure:
It sets pressure of assist gas. It is not applicable to the machine without gas pressure NC control (option).
Setting range: 0~25.5
Setting unit: kgf/cm2
Gas type:
It selects assist gas type for piercing. See page 14 for a listing of gas types.
purge time:
It sets a purge time of assist gas. When it is switched to assist gas for cut, it waits
for a period time set.
Setting range: 0 ~ 99
Setting unit: second
Def. amount:
not used.

Amada America, Inc.O perating the Pulsar 1212

1.06c, 13 November, 1996

PIERCE CONDITION Screen

Setting Operation

Focus:
It sets a focus position of lens. Applies only to machines with NC focus control
(option).
Setting range: -9.9 ~ 99.9
Setting unit: mm (inch)
Pulse type:
It sets a type of pulse.
It is not applicable to a machine w/o pulse type.
Setting range: 0 ~ 99
White reverse cursor: It displays the cursor position of data correction.
Green reverse cursor: It displays cut condition selected.

Setting Operation
Editing procedures are the same as for the Cutting Condition screen. You can edit
cutting, piercing, and edge data anytime. (the system is always in material edit
mode.)
The PROGRAM PROTECT key does not protect against cutting data editing.

Editing Data

1) Move the cursor to the data you want to correct with the cursor keys
2) Correct it to a value desired with the Alphanumeric keys.

3) Press INPUT or one of the cursor keys

If a value input is outside the valid numeric range, a Data error message is
displayed and the cursor does not move.
Press the CAN key to remove erroneous characters from the input key buffer.
Note
If you press Cursor key UP at the pierce No.1, the cursor moves to Type.
If you press Cursor key DOWN at the pierce No. 3, the cursor moves to pierce
No. 1.

Amada America, Inc.O perating the Pulsar 1212

1.06c, 13 November, 1996

7 - 21

7 - 22

Setting Operation

PIERCE CONDITION Screen

Batch Conversion of Data

Data below the cursor position changes to the same data as the cursor position.
1. Use the cursor keys to move the cursor to an item you want to perform batch
conversion .
2. Press the + soft key.
3. Press the All Repla. soft key.
4. Data below the cursor position changes to the same data as the cursor position.
Data storage

To save changes for future use.


1) Press the Save soft key .
2) Storage is completed with a message Saved
Caution
The revised data is displayed on the screen, but until changes are Saved, the original data (in storage) does not change. Any operation which calls up a material file
(either the same one or a different one) causes the revised data to be lost. This especially includes M102 ( ). The revised data is replaced by the data called from
storage.

Amada America, Inc.O perating the Pulsar 1212

1.06c, 13 November, 1996

PIERCE CONDITION Screen

Setting Operation

Notes

Amada America, Inc.O perating the Pulsar 1212

1.06c, 13 November, 1996

7 - 23

7 - 24

Setting Operation

EDGE CONDITION Screen

EDGE CONDITION Screen


This screen permits viewing and editing EDGE data for the selected material.
EDGE control provides automatic control of sharp corners during processing.
Each material cutting condition (E1~E9) can have a default EDGE condition. The
part-program can also select a specific EDGE condition from the active cutting
data.

1. Material name
2. Type
3. Thick
4. Mtrl info Std/Thick/Clean/Alumi
5. [WACS]
6. Edge No.
7. Work angle
8. Pierce pwr
9. Pierce frequency

10. Pierce duty


11. Pierce time
12. Pierce gas pressure
13. Pierce gas kind
14. Recover distance
15. Recover speed
16. Recover frequency
17. Recover duty

[Mtrl name]
[Type] HRS.187
[Thick] .187
[Mtrl info] Std/Thick/Clean/Alumi
[WACS] ON/OFF

<

Edge Work Pirc.


No.
ang. pwr.

Pirc.
freq.

Pirc
duty

Pirc.
time

Pirc.
gas
prss.

Pirc.
gas
kind

201

91

1500

200

20

2.1

1.0

10

200

200

20

202

91

1500

200

50

1.5

1.0

15

200

200

50

203

120

1500

100

80

1.0

2.0

15

100

100

80

204

00

1500

00

00

00

00

00

00

00

00

00

205

00

1500

00

00

00

00

00

00

00

00

00

[ Work ang

]>

Recover
dis- feed freq.
tance rate

EDIT ***** **** ****

Cut
Cond

Mtrl
List

Return

Figure 6: Edge Condition screen


Amada America, Inc.O perating the Pulsar 1212

1.06c, 13 November, 1996

]
duty

13:25:01

Edit

Save +

EDGE CONDITION Screen

Display Operation

7 - 25

Display Operation
1) If an NC screen is active, press the CUSTOM key.
The most recent Cutting Data Screen is displayed again.
2) From the material table screen, press the Cut Cond soft key.
From the pierce condition screen, press the Return soft key.
3) Press the EDGE soft key to show the edge condition screen.
Note:
Press the Cut Cond soft key to switch between full screen and split-screen
views.

Display items
This screen displays the material header information (same as Cutting Condition
and EDGE Condition screens) and the piercing data table.
Header Information

This is information about the material. It is the same as shown on the Cutting Condition screen. (Mtrl name, Thick, Mtrl info, [WACS])
See page 13 for description of header information.
EDGE Data Table

The following items may be set for each Edge condition (201~205).
Note that edge end point refers to the point at the corner detected as being
sharp. (see following)
Work Ang
It sets an angle to switch from active cutting condition to specified edge condition.
Setting range: 0 < angle < 180
Setting unit : degree
(see page 28 for illustration)
Pierce pwr
Sets laser power [S] when piercing at the edge end point.
Setting range: 0 ~ 9999
Setting unit: W

Amada America, Inc.O perating the Pulsar 1212

1.06c, 13 November, 1996

7 - 26

Display Operation

EDGE CONDITION Screen

Pierce freq
It sets a frequency of pulse [P] when piercing at the edge end point.
Setting range: 0 ~ 9999
Setting unit: Hz
Pierce duty
It sets a duty of pulse [Q] when piercing at the edge end point
Setting range: 0 ~ 100
Setting unit: 0/0
Pierce time
It sets pierce time (second) when piercing at the edge end position
Setting range: 0 ~ 99.9
Setting unit: second
Pierce gas pressure:
It sets assist gas pressure when piercing at the edge end point.
It is not applicable to a machine without gas pressure NC control.
Setting range: 0~25.5
Setting unit: kgf/cm2
Pierce gas type:
It sets an assist gas type when piercing at the edge end point
See page 14 for a listing of gas types.
Recover distance:
It determines the distance that Recover speed, Recover frequency, and Recover
duty are used.
Setting range: 0 ~ 99.999
Setting unit: mm (inch)
Recover speed:
It sets speed [F] during recovery from the edge end point.
It also sets speed for approach cut
Setting range: 0 ~ 9999
Setting range: mm/min.
Recover frequency:
It sets laser pulse frequency during recovery from the edge end point.
It also is used during approach cuts.
Setting range: 0 ~ 9999
Setting unit: Hz
Recover duty:
It sets a laser pulse duty during recovery from the edge end point.
It also sets a duty for approach cut.
Setting range: 0 ~ 100
Setting unit: %

Amada America, Inc.O perating the Pulsar 1212

1.06c, 13 November, 1996

EDGE CONDITION Screen

Editing EDGE conditions

7 - 27

Editing EDGE conditions


Editing procedures are the same as for the Cutting Condition screen. You can edit
cutting, piercing, and edge data anytime. (the system is always in material edit
mode.)
The PROGRAM PROTECT key does not protect against cutting data editing.

Navigation
If you press Cursor key UP at the edge No.1, the cursor moves to type.
If you press Cursor key DOWN at the edge No. 5, the cursor moves to condition
No. 1.
The White
A Green

reverse cursor
reverse cursor

indicates cursor position for editing.


shows which edge condition is selected.

Editing
1) Move the cursor to the data you want to correct with the cursor keys
2) Key in the desired value .
3) Press the INPUT key or any of the cursor keys

Notes
If the value corrected is outside the valid range, a Data error message is
displayed and the cursor does not move.
Batch conversion of data

Data below the cursor position changes to the same value as at the cursor position.
to place the cursor at the source item.
1. Use the cursor keys

2. Press the + soft key.


3. Press the All Repla. soft key.
4. Data below the cursor position changes to the same data as the cursor position.

Data storage
The Save soft key is used to save changes. It saves ALL changes made to Cutting,
Piercing, and Edge data.
1) Press the Save soft key.
2) Storage is completed with a message has been saved
Caution
The revised data is displayed on the screen, but until changes are Saved, the original data (in storage) does not change. Any operation which calls up a material file
(either the same one or a different one) causes the revised data to be lost. This especially includes M102 ( ). The revised data is replaced by the data called from
storage.

Amada America, Inc.O perating the Pulsar 1212

1.06c, 13 November, 1996

7 - 28

Using EDGE Control

EDGE CONDITION Screen

Using EDGE Control


The purpose of EDGE control is to avoid burning at sharp corners.
To use EDGE control, the following conditions must be met.
1

The program instructions that make up the corner must be two move instructions only. There may not be any other instructions between the two motion
instructions. This means no EOB characters, G00, G09, etc.

At least one of the instructions must be G01 linear interpolation. (Curvecurve wont work)

The intersecting angle must be at least as sharp as the angle specified in


the active cutting data and EDGE data.
Start and stop at EDGE point
at corner point

use Pierce data


(perform pierce at corner using specified power, etc.)

departing corner

use Recover data


(after piercing, use Recover feed, freq, duty for specified distance)

no pierce data

ignore stop condition- immediately go to Recover data

no recover data

ignore start condition


(continue cutting with active cutting data)

The smaller the Work ang value is, the sharper the corner must be before the
system will use edge control. For example: if the angle is set to 91, then edge control will be used on the corners of a square or rectangle. If the value is set to 89,
then edge control is not used on square or rectangles.

145

0
3

Figure 7: Measurement of EDGE angles

Amada America, Inc.O perating the Pulsar 1212

1.06c, 13 November, 1996

EDGE CONDITION Screen

Using EDGE Control

7 - 29

Approach Control
The purpose of approach control is to avoid burning at lead-ins.
Approach control is used whenever the active cutting data (selected by M102
(mtrl) and E-code ) includes a value for Appr. data. When approach control is active, the first portion of the cut is performed using data from the [Recover] section
of the EDGE table. This occurs only after a pierce, regradless of whether it is in
the program (in M103 mode, etc.) or in a Standard Hole macro (G112, etc.).
The Pirc. data is not used in Approach control, only for edge control.

specify handling of sharp


corners

specify handling of
approach

[Mtrl name] CRS-16


[Type] SPC [THICK] 0.063
[Mtrl info] Std/Thick/Clean/Alumi
[WACS] ON/OFF
Cut Feed Pwr Freq Duty Gas Gas Gas Def. Ofst Edge Appr. Focal Pulse
Cond Rate [S]
[%] prss. kind time
[inch]
data [inch] type
1. 12.0
2. 47.1
3. 98.43

1200 300
1400 300
1400 300

12
50
50

1
1
1

0
0
0

0.5
0.5
0.5

0.0 0.0040 201 202


0.0 0.0040 201 202
0.0 0.0040 201 202

0.020
0.020
0.020

0
0
0

Figure 9: EDGE setup

used at corner point (edge end


point) for re-pierce

used when departing edge end


point and for approach control.

[Mtrl name]
[Type] HRS.187
[Thick] .187
[Mtrl info] Std/Thick/Clean/Alumi
[WACS] ON/OFF
Edge Work Pirc.
No.
ang. pwr.

Pirc.
freq.

Pirc
duty

Pirc.
time

Pirc.
gas
prss.

Pirc.
gas
kind

201

200

20

2.1

1.0

10

91

1500

Recover
dis- feed freq.
tance rate
200

Figure 8: Edge screen

Amada America, Inc.O perating the Pulsar 1212

1.06c, 13 November, 1996

200

]
duty

20

7 - 30

Display Operation

MATERIAL LIST Screen

MATERIAL LIST Screen


The Material List screen permits creation, deletion, renaming, and copying of cutting data files. Editing of Cutting, Edge, or Piercing data is done from the Cutting
Data screens.

Display Operation
If an NC screen is active, press the CUSTOM key to display the Cutting Data
screen.
The most recent Cutting Data Screen is displayed again.
If a Cutting Condition screen is displayed, press the Mtrl List soft key.
Note
To show or hide the Laser Information screen, press the Mtrl List soft key again.

[Search]
ALL
SPC/SPH
Stain
A
Others
ThIckness
Std.
Thick
Clean
Alumi

[Mtrl name]

[Mtrl name]

1. A-1050AL0.040
2. A-1050AL0.060
3. A-1050AL0.075
4. A-5052AL0.040
5. A-5052AL0.060
6. A-5052AL0.075
7. A-5052AL0.125
8. A-SS0.036
9. A-SS0.075
10 C-SS0.024
11. C-SS0.036
12. C-SS0.060
13. C-SS0.075
14. C-SS0.105
15 C-SS0.120

16. C-SS0.120
17. C-SS0.135
18. C-SS0.187
19. O-CRS0.030
20. O-CRS0.048
21. O-CRS0.060
22. O-CRS0.075
23. O-CRS0.090
24. O-CRS0.105
25 O-CRS0.120
26. O-GALV0.040
27. O-GALV0.052
28. O-GALV0.064
29. O-GALV0.079
30 O-GALV0.093

Rem mtrl

Number

mtrl name A-SUS1.5


Open (Rename) Copy

EDIT ***** **** ****


<

Cut
Cond

Mtrl
List

OPEN

NEW

Figure 10: Material List screen

Amada America, Inc.O perating the Pulsar 1212

1.06c, 13 November, 1996

13:25:01
SEARCH +

MATERIAL LIST Screen

Display Operation

7 - 31

Display Items
The following information is shown on the Material List screen.

Material List screen items


ITEM

Meaning / Purpose

[Mtrl name]

Material names listing: only displays items matching current search criteria.
(two columns in full-screen view)

[Search]

Lists material classifications which can be searched for, displays current search
criteria in reverse

[ALL]

When highlighted, ALL materials in the NC are listed.

SPC/SPH

When highlighted, indicates that ONLY the materials labelled as SPC/SPH


(cold rolled/hot rolled) are listed.

Stain

When highlighted, indicates that ONLY the materials labelled as stainless are
listed.

When highlighted, indicates that ONLY the materials labelled with names
beginning with A are listed.

Others

When highlighted, indicates that ONLY materials not in any of the other
categories are listed.

Thickness

When highlighted, indicates that ONLY materials having a particular thickness


are listed.

Std.

When highlighted, indicates that ONLY the materials labelled as Std. are listed.

Thick

When highlighted, indicates that ONLY the materials labelled as Thick are
listed.

Clean

When highlighted, indicates that ONLY the materials labelled as Clean Cut
type are listed.

Alumi.

When highlighted, indicates that ONLY the materials labelled as Aluminum


are listed.

Rem. mtrl Number

Available space in database for new materials (number of material names


which can be added: total capacity of 90 materials)

Mtrl Name

Material name currently selected

Open(Rename)(Copy)

Options prompt - select using soft keys. It displays a material name input for
load new, rename, copy, and delete

White reverse cursor

It displays the cursors position

Green reverse cursor

It displays the material name currently loaded

<, + soft keys

To show the previous / next group of soft key assignments.

Amada America, Inc.O perating the Pulsar 1212

1.06c, 13 November, 1996

7 - 32

Cutting Data File Operations

MATERIAL LIST Screen

Cutting Data File Operations


Material files can be created, deleted, and renamed. When creating a new file, you
can copy from an existing file or start with a clean sheet.

) on the Fanuc keypad are used to select items on the


The cursor keys (
screen. Item selection is indicated by a white highlight on the selected item.
Data Input

When a new name is required, use the Fanuc keypad and key-in the material name
to load.
Press the CAN key to remove erroneous characters from the input key buffer.
Press the INPUT key to activate that material data file.
Name limitations

Length: up to 15 characters
Usable Characters: Alpha-numerics, -, .

Selecting a material
You can use the cursor keys to select a material, or just key the name in, using the
Fanuc keypad.
Selection

1) Move the white highlight (cursor) to a material name you want to load with the
).
cursor keys (
2) Press the INPUT key 2) Execute by pressing the Open soft key.

Caution
When a specified material name already exists in the NC, a message The
material name already exists is displayed. No two Cutting Data files can
have the same name.
When a specified material name does not exist, a message The material name
does not exist is displayed.
You cannot load during AUTO operation.

Amada America, Inc.O perating the Pulsar 1212

1.06c, 13 November, 1996

MATERIAL LIST Screen

Creating New Material Name

Cutting Data File Operations


.

This creates a new, blank Cutting Data file.


1) Key in the name you want use for the new material file.
Setting range: less than 16 characters
Character restriction: Alphanumerics, -, .
2) Press the INPUT key
3) Press the NEW soft key to create the material data file. The display is
changed to the cutting condition screen
4) Press the Save soft key to store the new file in memory. Once you set and
Save the cut condition on the cutting condition screen, the new registration is
over.
WARNING
You must Save the new file, as it is created in temporary storage only. Use
the Save soft key on the cutting condition screen to store the new data file.

If the specified material name already exists, a message The material name already exists is displayed, and the new operation fails.
Material names cant be newly created during auto operation. If attempted, the
message It cannot be used during operation is displayed.

Rename a material
This is to change the name of an existing material (cutting data file).
1) Load the material name you want to rename
If it is already loaded, you dont have to load it again.

2) Input the new material name.


Use the Fanuc keypad Address/numeric keys
Setting range: less than 16 characters
Character restriction: Alphanumerics, -, .
3) Press the INPUT key
4) Press the Rename soft key to execute.
Notes
If the new name is already in use, a message The material name already
exists is output and the rename operation fails.
Renaming is not permitted during machine operation. A message It cannot be
used during operation is output and the material name is not changed

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7 - 34

Cutting Data File Operations

MATERIAL LIST Screen

Copy to new file


Creates a new material file using data from an existing material file.
1) Load the material file to copy.
2) Input a new material name with Address/numeric key
Setting range: less than 16 characters
Character restriction: English numerals
3) Confirm the new material name by pressing the INPUT key.
4) Press the Copy soft key to create the new file as a copy of the original file.
NOTES
If it is already loaded, you dont have to load it again.
Press the CAN key to remove erroneous characters from the input key buffer.
If a material name designated exists, a message The material name already
exists is output. Select a name that is not already used.
Data files cant be copied during program execution.

Deleting a material name


This deletes the name (and associated information) of a material.
Select the data file to delete.
Press the Delete soft key to erase the material name and cutting data from the
database.
Even if you delete a material name, the number will stay in the table until sorting. When the file is sorted, empty numbers are removed. You can sort when you
designate ALL in the search of the material name.
Press the CAN key to remove erroneous characters from the input key buffer.

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MATERIAL LIST Screen

Cutting Data File Operations

7 - 35

Search of material name


This permits the display of only the materials meeting certain criteria.
1) Press the Search soft key. The soft keys then show the following legends:
LEGEND: PURPOSE:
SPC, SPH:
Display all material names whose type is SPC or SPH.
SUS:
Display all material names whose type is SUS.
A:
Display all material names whose type starts with A.
Others:
Display material names whose type is other than the above.
Thick:
Display a material name of a designated worksheet thickness.
Standard: Display all material names whose process category is Std..
Thick.:
Display all material names whose process category is Thick
Clean:
Display all material names whose process category is Clean.
Alumi:
Display all material names whose process category is aluminum.
All:
Displays ALL material names in memory, Permits sorting names.
<
returns soft key assignments to previous
2) Select a search condition by pressing the appropriate soft key.
Listing by thickness

Press the Thick soft key. Then key the numeric value in, press INPUT. Any material names having the designated thickness will be listed. If none match, a
message is displayed There are no data.
While designating worksheet thickness, to return to the previous screen , press the
< soft key twice.
Notes

Each search is through all data in the NC. Therefore, a complex search such as
Thick 2.0 mm and SUS cannot be performed.
Even if you delete a material name, its No. stays in the table until sorting.
When you sort, empty numbers are removed.
Sorting Names

Press the Search soft key. Then, press the ALL soft key. When you press All a
message Sort? Y/N is displayed.
Y: It alphabetically sorts material names and displays them.
N: It displays them without sorting.

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Cutting Data File Operations

PARAMETER SETTING Screen

PARAMETER SETTING Screen


This screen is accessed by pressing the Param. soft key. (normally must use the

< soft key to display the Param. soft key)

or

Laser Parameter
Follow start height

] mm

Z retract H

] mm

M00

] mm

M01

] mm

Chute

] mm

Assist gas open height [

] mm

Cl, Al, Pirc height

] mm

focal point base pos

] mm

no end

Figure 11: Laser Parameters screen


The following items are available on the Laser Parameter screen:
Meaning of Laser Parameter items.

Item

Purpose

Following start height

Z-axis moves to this point in rapid traverse before activating sensor and
approaching slowly.
Z axis return height
safe height for Z-axis under various conditions (1)
No end
program has none of the following conditions at program end .
M00
program has M00 (program stop) in it.
M01
Program has M01 (optional stop) in it.
Chute
Work chute is activated (M180, etc.)
Assist gas open height
On approach to material, how soon to begin assist gas flow.
Cl, Al, Pirc height
Z-height above material for piercing these materials.
focal point base pos
not used without NC controlled focus.
[WACS] ON time
not shown unless water assist system is installed on machine.
1. Incremental distance from the material surface.

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MACHINE ALARMS Screen

Setting Operation

7 - 37

NOTE
When worksheet thickness + Z axis return height + offset Z (G93 Z_ ) is larger
than the Z axis maximum travel range, an alarm will occur during program
execution.

Cl, Al pierce height:


To raise the nozzle when piercing with clean cut and aluminum cut.
NOTE
This sets an incremental distance from the cutting nozzle gap (0.3mm / 0.012
inch).

focal point base pos


Only applies to machines with (optional) NC focus control.
It sets the standard position of focus (focus lens). The focus moves to the position
where the focus of cut condition No. 1 is added to the focus standard position
when instructing M100 in the machine with NC focus control (option).

Setting Operation
reverse cursor

Move the White

Key-in the new value.

Press the INPUT key.

to the setting position.

Notes
Press the CAN key to remove erroneous characters from the input key buffer.
Values of 0" or minus" are accepted, but will cause problems in operations.

MACHINE ALARMS Screen


It displays machine alarms. See the ALARMS chapter for alarms listing and descriptions.

Display Operation
1) Press HELP key to toggle between the Alarms page and any other Cutting
Condition screen.
2) The EXIT soft key displays the most recent Cutting Condition screen.

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Setting Operation

CUTTING DATA TRANSFER

CUTTING DATA TRANSFER


The cutting data library, under certain circumstances, can be transferred between
the NC and floppy disk. Data contained within the Cutting Data Library is Amada
Proprietary information, and must not be disclosed or made available to competitors or non-Amada customers.
For this reason and others, the procedures for transfer of cutting data are in a separate document. Contact Amada if you feel that you need this information.

Amada America, Inc.O perating the Pulsar 1212

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Chapter 8

MAINTENANCE

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8-2

Daily Maintenance

Daily Maintenance
The following operations should be performed daily.

Cleaning
Cutting head, lens, and nozzle should be cleaned and/or inspected. See page 21
for procedures.
Check the machine table and material supports for condition.

Noise
Make sure that the drive system (servomotors, etc.) doesnt make any unusual
noises.

Chiller
Check coolant level in the sight glass. Check coolant flow when the system is running.

Laser Gas
Check pressure in laser gas cylinder. Change cylinder when pressure drops to 145
psi.

Assist Gas
Check assist gas supply pressure (for compressed gases) or liquid level (for liquid
Oxygen , etc.)

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8-3

Daily Maintenance

Air System
Minimum inlet pressure is 5.7 kgf/cm 2 (85 psi). Check that regulated pressure is 5
kgf/cm 2 (75 psi), and adjust regulator if necessary. Drain any trapped water from
the air filter. Check lubricator oil level, and refill it if necessary. (release air pressure from the system before attempting refill)
Air Filter

When water collects in the the air filter trap, open the drain cock at the bottom of
the reservoir to drain it.
Regulator

Set the main air pressure to 5 kgf/cm 2 by turning the adjustment knob of the regulator.
Lubricator

Make sure that the lubricator (air lubricator) has enough oil in it.
Designated oil for lubricator.
Amada pure oil - A.32 (or its equivalent)

1. Air filter,
water trap

2. Regulator
Lubricator adjustment
screw

3. Lubricator

Water drain

Mist
separator

Figure 1: Air, Gas Panel


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8-4

Daily Maintenance

Laser Oscillator
Prior to start-up, or when the laser oscillator has been shut off for at least five minutes, check the oil level in the blower. The sight glass is visible through the view
window in the laser side cover. To add oil, see the procedures on pages 13, 14 .

View window
(two provided for
C2000, C3000)
Permits checking
blower iol level.

Laser power
switch
covers

Figure 3: Laser Cabinet

Note that two blowers


are used in C2000,
C3000 lasers

fill bolt
sight glass

Figure 2: Laser Blower Oil Check

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Periodic Maintenance

Calendar Schedule

Periodic Maintenance
In addition to Daily Maintenance, two maintenance schedules must be followed.
The first is according to calendar intervals, and the second is according to run
time. When the same item is listed on both schedules, use the schedule occurring
first.

Calendar Schedule
These items are scheduled by calendar periods.
Weekly Maintenance
See lubrication chart for required lubrication items. (page 7)
Inspect the ballscrews for X, Y, and Z-axes. Use compressed air to clean them, and
oil lightly.
Grease X, Y-axis ball nuts. (see pages 7, 9 )
Important:
Pump enough grease into the fitting so that grease exits from both ends of the
ball screw nut. This will ensure that the job is done properly.

Warning:
Turn off the circuit breaker for five minutes prior to removing the laser cover for
the following operations.

Check level and appearance of oil in laser vacuum pump. The level should be between the Max. and Min. lines on the sight glass. If the oil is darkened, rather
than clear, it should be changed. See page 14 for oil change, fill procedures. Also,
check for signs of oil leakage. Leakage can indicate that the exhaust filter needs
changing. (contact Amada)
Monthly Maintenance
See lubrication chart for required lubrication items.(page 7 )
Inspect the Z-axis bend mirror, clean if necessary. (see page 27 for procedure)
Check the coolant flow rate and pressure drop. Change the coolant filter (at
chiller) if flow drops or pressure drop is excessive.
Every Two Months
Grease fittings on machine. (see pages 7, 9 )
Every Four Months
Change laser blower oil. (see page 13)
Every Six Months
Inspect main air inlet filter, change if necessary.
Change laser vacuum pump oil (see page 14 )
The following items should be performed by Amada service personnel:
Change laser vacuum pump exhaust filter.
Clean laser internal mirrors.

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8-6

Hourly Schedule

Periodic Maintenance

Every twelve Months


Change the NC memory back-up battery. (NC power must be ON- see page 17)
Fanuc external optics - service or replace
Fanuc internal optics - service or replace
Vacuum pump exhaust filter - replace
For systems with anti-scratch system, replace the cutting rollers and roller scrapers.
Every 24 Months
Fanuc laser: replace pressure controller gas filter
Fanuc laser: replace discharge tube O-rings.
Every 36 Months
Fanuc laser - overhaul vacuum pump.
Every 48 Months
Fanuc laser - overhaul gas blower.

Hourly Schedule
This set of maintenance operations is scheduled according to hours of machine operation.
Every 200 hours
Inspect Z-axis bend mirror, clean if necessary. (see page 27 for procedure)
clean air filters on NC cabinet.
check air lubricator for correct oil flow.
Inspect Fanuc external bend mirrors, clean if necessary.
Every 1000 hours
Inspect machine for loose nuts, bolts. Tighten as needed.
Change laser blower oil.
Every 1500 hours
(Laser run time)
Laser vacuum pump - change oil
Laser exhaust system filter - replace (contact Amada)
Every 3000 hours
Laser vacuum pump - replace exhaust filter. (contact Amada)
Laser oscillator warning light - replace
Every 10000 hours
Laser vacuum pump - overhaul (contact Amada)
Every 12000 hours
Laser blower - overhaul (contact Amada)

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Lubrication

Hourly Schedule

Lubrication
The following cart lists recommended lubrication and oil change intervals for the
system. The item numbers refer to the figures on following pages.

Lubricants

Key #

Part

Oil

Interval

X-axis ball nut

A (grease fitting)

one week

X-axis guides

A (grease fitting)

two months

Y-axis ball nut

A (grease fitting)

one week

Y-axis guides

A (grease fitting)

two months

Z-axis ball nut

A (grease fitting)

two months

Z-axis guides

A (grease fitting)

two months

Y-axis thrust
bearing

A (grease fitting)

two months

X-axis thrust
bearing

A (grease fitting)

two months

work clamps

B (oil manually)

daily

10

cutting roller
system

A (grease fitting)

two months

11

Air system
lubricator

B (reservoir)

as needed

12

Laser blower

C (oil bath)

Change every 1000


hours or four months

13

Laser vacuum
pump

D (oil bath)

Change every 1500


hours or six months

A: AMADA Grease No. 2, MOBIL Mobilux 2, SHELL Alvania 2


B: AMADA A-32, MOBIL DTE Oil light, SHELL Tellus Oil C32
C: FANUC A04B-0800-K326
D: FANUC A98L-0040-0085/20L

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8-8

Lubrication Points

Lubrication

Lubrication Points
See figures 4-8 on this and following pages for locations of lubrication points and
access covers for the machine.

11
12

Figure 4: Lube Points - from side

Figure 5: Detail - Lube Points

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Lubrication

Lubrication Points

5, 6

3, 4

10
Figure 6: Lubrication points - front view

5
6

3
4

Figure 7: Lube Points: Y, Z- Carriages


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8 - 10

Lubrication Points

Cleaning

Figure 8: Y-axis Thrust Bearing

Cleaning
This section covers cleaning procedures for the cutting nozzle, spark trap, scrap
trays, and NC cabinet air filters. For the focus lens, see page 21.

Cutting Nozzle
The nozzle opening should be round and clean. The bottom face of the nozzle
should be fairly flat, not deeply scratched. Remove any residual spatter from the
nozzle face or orifice. Replace the sensor and nozzle if they are cracked or damaged.
Check the 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.

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Cleaning

Lubrication Points

Nozzle replacement

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.

Spark Trap
Inspect the spark trap screen weekly, or when exhaust flow is reduced. Clean as
necessary.

Filter screen
Spark trap assembly
Exhaust hose

Figure 9: Spark trap

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8 - 11

8 - 12

Lubrication Points

Cleaning

Scrap Trays
A support rack is provided for either of the trays. the other tray goes in the bottom
ot the compartment. Empty trays daily or as needed.

support rack

scrap trays

Figure 10: Scrap tray locations


NC Cabinet Air Filters.
These filters are located under platic grilles on the side of the NC cabinet. Gently
disengage each grille to expose the filter pad. Remove the filter pads and blow
them out with compressed air, or wash them in mild soap. Do not wring them our
after washing.

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Replacements

Servicing the Laser Blower

Replacements
This section covers replacement of blower oil, vacuum pump oil, air systems air
filter, laser gas bottle, and NC memory backup cell.

Servicing the Laser Blower


Adding Oil
To add oil to the laser blower, follow steps 1, 2, 4, and 5 listed under Changing
Oil below. (all operations except draining old oil from blower)

Changing Oil
1. Turn the laser power switch OFF at least five minutes before removing the laser
side cover.
2. Remove the main side cover from the laser. (socket head cap screws). Remove
the filler bolt and O-ring.
3. Place the drain tube in a suitable container, and open the drain cock. After the
oil has drained completely, close the drain cock.
4. Fill the unit with specified oil (see page 7) to between the MAX. and MIN.
lines on the sight glass. The blower has a capacity of 150 ml (5.1 oz.).
DO NOT overfill the blower. This can damage it.

Clean the filler bolt and O-ring with a dry cloth.


Inspect the O-ring on the filler cap. If damage or wear is evident, replace it.

Re-install and tighten the filler bolt. Replace the laser side cover.
5. Power up the laser.

Note that two blowers


are used in C2000,
C3000 lasers

Sight glass
Fill plug
Drain cock
Laser blower

Figure 11: Blower service points


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8 - 13

8 - 14

Servicing the Laser Vacuum Pump

Replacements

Servicing the Laser Vacuum Pump


1. Remove the main side cover from the laser. (socket head cap screws)
2. Remove the filler cap, place the drain tube in a suitable container, and open the
drain cock.
3. After the oil has drained completely, close the drain cock.
Fill the unit with specified oil (see page 7) to just below the MAX. line on the sight
glass. The vacuum pump has a capacity of 1.8 liters (61 fl. oz.)
Inspect the O-ring on the filler cap. If damage or wear is evident, replace it.

Replace the side cover.


4. Power up the laser and allow it to run for three minutes, and turn it off again.
5. Repeat steps 1-3. This assures that all contamination has been removed from
the pump.
6. Log the service operation, and resume normal operations.

Figure 12: Laser Vacuum Pump

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Replacements

Air System

Air System
This section covers the compressed air system for the machine.

Adjusting lube rate


Adjust the amount of oil drop inside the lubricator so that it drops once every 15
times the work clamp operates consecutively.
Caution
Drain the filter and check the amount of oil in the lubricator regularly.

Beam Purge Air


Clean air is directed into the beam delivery system to help keep contamination
from the external optics and the top of the focus lens. A mist separator and external filter are used to assure the cleanliness of the purge air.
External Filter

This filter is installed in the beam purge line after the mist separator. It should be
changed every one or two years, depending on quality of the shop air.
Mist separator.

Exchange the element assembly of the mist separator every 6 ~ 12 months.


Mist separator type AFA-550568
If you dont exchange the element assembly, the life of the external filter will be
reduced. If both filters become overloaded, the lens and mirrors can get contaminated.

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8 - 15

8 - 16

Air System

Replacements

Compressed Air Filter


The filter replacement interval cant be predicted because the cleanliness of shop
air is so variable. Element life also depends on machine use patterns- piercing, cutting, and scribing operations, etc.
The filter element may be removed for inspection or replacement in the following
manner. (see figure 13 )
Turn off air to the machine, and make sure that pressure is drained from
the compressed air circuit.
Push the knob on the front of the filter down and turn the cover counterclockwise to remove it.
Remove the filter clamp screw and then the filter.
Inspect filter and replace it if necessary.
Reverse above steps to install.

Air filter

Mist separator

Figure 13: Air filter, Mist separator

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Replacements

Laser Gas bottle

8 - 17

Laser Gas bottle


CAUTION: Do not open the main valve if anyone is in front of the regulator or
gauge faces. If a regulator fails, the glass can shatter and cause injury.
Laser gas should be replaced when (or before) gas pressure drops to 145 psi.
To replace the bottle:
Make sure the laser is properly shut down.
Turn the gas cylinders main valve OFF.
Release the regulator/hose pressure by backing the regulator adjustment to zero.
Make sure that the replacement cylinder threads and sealing surfaces are clean
and dry.
Remove the regulator from the exhausted cylinder and install it on the replacement cylinder.
Stand to one side or to the rear of the regulator and gently open the main gas
valve on the cylinder.
Apply soap suds to the connection between the cylinder main valve and the regulator to confirm that there is no leakage.
Adjust the regulator for an output pressure of 21.4 to 28.4 psi (1.5 to 2 kgf/cm 2 )

NC Memory Backup Cell


This cell should be replaced every 12 months, or sooner if the NC signals an
alarm for low backup battery voltage.
NOTE: Make sure to turn the NC ON prior to disconnecting the cell. This
prevents loss of programs or data in memory during the operation.
Turn the NC ON.
Remove the cell holder cover.
Disconnect the old batterys cable connector from the circuit board.
Connect the cable of the new cell to the circuit board.
(FANUC A02B-0120-K106)
Replace the cover.
Press RESET on the NC keyboard.

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8 - 18

Description

Nozzle, Focus Lens

Nozzle, Focus Lens


This section covers nozzle alignment, focus lens cleaning, and focus adjustment. I

Description
The focus lens takes the laser beam as delivered from the laser and focuses it to a
spot at or near the material surface. The focussed spot must be well centered in
the nozzle and correctly positioned (with respect to the surface of the material)
for good cutting results.

Priorities
If cutting results vary according to X, Y position, then optics alighment should be
checked before focus depth or nozzle alignment. If cutting results are similar at
all locations on the table, then beam centering in the lens, focus depth, and nozzle
centering may be checked.
NOTE
The laser beam creates highly toxic gases when materials such as plastics and
woods are burned. Ventilation must be provided when making test burns.
Avoid breathing smoke or fumes.

Centering the Nozzle


The laser beam must be centered in the nozzle opening for proper cutting results.
Centering must be checked after any operation which might affect the reletive positions of the laser beam and the nozzle opening. These include any work on the
laser optics, any re-alignments of the external beam delivery optics, or replacement of the focus lens.
One way to check centering is to fire the laser beam onto a thin sheet of steel
(carbon or stainless) and observe the direction of the sparks. The sparks should
come out evenly around the head.
Note
Use assist gas which is suitable for the material. For steel, use low-pressure
Oxygen.

nozzle
opening
beam
spot

sparks

Figure 14: Un-centered nozzle


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Nozzle, Focus Lens

Centering the Nozzle

8 - 19

If sparks fly only in one direction, use the adjustment screws (4) to move the nozzle in
the direction that the sparks go.
Figure 14 shows an off-center nozzle, with sparks only flying to one side.
Figure 15 shows the direction of nozzle adjustment needed for figure 14.
Figure 16 shows a nozzle centered well, with sparks flying evenly all around the nozzle.
Dont expect every pierce to have all sparks flying perfectly evenly- that wont
happen. When the nozzle is well-aligned, the machine is not moving, and the material is uniform, the sparks will be generally even around the head.

Setup
Laser output: over 600W
Assist gas type: Oxygen
Assist gas pressure: 1.5 kg/cm 2
See page 37 for a program listing for Beam Out. This program may be used to
output a laser beam for nozzle centering.

Figure 15: Adjustment Direction

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8 - 20

Centering the Nozzle

Nozzle, Focus Lens

Procedure
Example: material CRS 18 GA or 16 GA
1) After setting up and/or selecting the program, move the Z axis to the surface of
the sheet.
Caution
The system is interlocked so that the beam wont fire at a Z-height of more
than one inch.

2) Select MEMORY operation and press START.


3) Observe the direction of sparks during the pierce.
4) If the sparks are not uniform around the head, adjust as follows:
a. Loosen the adjustment screw(s) (counterclockwise) on the side of the head that
the sparks flew.
b. Screw the opposing screw(s) in (CW) to adjust the nozzle position.
(Move the center of nozzle in the same direction that the sparks fly)
c. Make sure the scews are all snug, and re-test.
5) Repeat 2 ~ 4) until sparks fly in all directions (at least 2 directions).
In the example in figures 14 - 16 , you would loosen screws 2 & 3, and tighten
screws 1 & 4.
Note
After adjusting all the above, it is a good practice to check the actual cutting conditions (dross, cutting width, heat affect, etc.) by making some test cuts.
The same material that was used for the spark test may be used. Cut a few 2" circles and check edge finish, cut width, etc.

Figure 16: Sparks after centering

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Nozzle, Focus Lens

Focus Lens

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 above
or below the proper part of the head, and will not clear the nozzle opening. Damage 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 identified 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

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 techniques.
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 reduce 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, make
sure to turn it in until it seats.

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8 - 21

8 - 22

Adjusting Focus Position

Nozzle, Focus Lens

Adjusting Focus Position


When you install a new focus lens, you must determine where it actually focuses.
This varies from one lens to another, and requires physical testing. One technique
for finding focus is presented below.
The focus position of a lens may be determined by making a series of cuts in thin
steel (.030 - .063) at varying focus settings. The focus setting which gives the narrowest cut is deemed to be at the surface of the material.

Cutting Test Setup


For program sample: see page 22
Laser output 300 ~ 600W
Operation speed F1200~F2000
Assist gas type Oxygen
Assist gas pressure 2-3 kgf/cm.

5'

4'

3'

width of slot
(kerf width)

Figure 17: Focus Test

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2'

1'

Nozzle, Focus Lens

Adjusting Focus Position

Adjustment Procedure
1) Set the lens in the highest position
2) Create or select the test program.
3) Press Start.
The program will cut one slit and stop.
4) Lower the lens 0.5 mm by turning Focus adjustment ring of the head counterclockwise while watching the scale
5) Repeat steps 3-4, and check cutting width at each position of the lens.
Notes
1. The narrowest slot indicates a focus at the surface or slightly below.
2. The best focus position for cutting depends on material type and thickness. This
procedure just gives you an indication of the particular lenss focus position.
In figure 17, each cut is made with a deeper focus, starting from too high and
progressing to too low.
After finding zero focus for a particular lens, its a good idea to confirm cut quality on something like 16 GA CRS before going to difficult materials. This may be
done by cutting a few circles and examining the cut edges of both slug and hole.

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Description

Beam Delivery System

Beam Delivery System


This section describes the beam delivery system (optical system external to the laser resonator), and covers testing of beam mode and alignment of the external
optics.

Description
The optical system consists of the laser and its internal optics, five external beam
delivery mirrors, and a focus lens. The focus lens is not covered in this section.
(see page 18)
Systems with the 1500 Watt laser have two external mirrors in the Fanuc enclosure. With the 3000 Watt laser, all five beam delivery mirrors are outside the laser
enclosure. This document covers cleaning and alignment of the external optics
only.

Interlocks
The system is interlocked to prevent operation unless all optics are in place. Certain of these optics must be removed and the and the corresponding interlock
cheated or defeated to make test burns for alignment testing and adjustment.
Suitable precautions must be taken to block the beam completely at the burn target.
DANGER
When making test burns with the lens or any of the mirrors removed, the beam
will travel until it hits something.
It remains dangerous for hundreds of feet.
The laser beam creates highly toxic gases when materials such as plastics and
woods are burned. Ventilation must be provided when making test burns. Avoid
breathing smoke or fumes.

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Beam Delivery System

Beam Quality

Beam Quality
The laser beam must pass cleanly through all mirrors and passages en route to the
focus lens. It must be well aligned with the Y-axis so that the nozzle centering is
consistant throughout the Y-axis travel. This is the purpose of external alignment.

Before Taking a Mode Burn


CO2 laser beam is invisible and very dangerous. Since both direct and indirect
beam exposure can damage the eyes, be sure to wear protective glasses.
Caution: Operating with unprotected eyes can damage your eye sight. Avoid
staring directly into the red laser beam .
Set up guards around the workshop to keep people or objects out of the beam
path. Display a sign indicating that laser beam is being emitted.
Provide ventilation and avoid breathing fumes emitted by burning or vaporized
plastic.

(a)

(b)

Figure 18: Mode Burn Profiles

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Beam Quality

Beam Delivery System

Making Burns
To diagnose the quality and/or location (alignment) of the laser beam, a burn may
be made in acrylic plastic. A Mode Burn is used to visualize the power distribution of the laser beam. The beam is applied to the acrylic long enough to make a
print about as deep as the beam is wide. A crosshair burn is used to determine
the alignment of the beam within the beam delivery system. A crosshair burn is
made for just long enough to leave a clean print on the acrylic of the beam and
crosshairs. If the beam does not have a proper mode (power distribution) then the
system will not cut properly.
Type of Burn
Mode
Crosshair

Target thickness

Power (Watts)

3/4"
1/4"

1500 (1)
1500 (2)

Time
10 sec (1)
0.1 sec (2)

(1) As needed to make a burn the desired depth.


(2) Just enough to make a clear print

(b)

(a)

Figure 19: Mode Burns, top view


Burn (a) shows good symmetry, while (b) is misshapen.
Note eyebrow on burn (b).

bore of optic

shadow of
crosshair
burn pattern

Figure 20: Crosshair Burn


Note that the burn is not centered in the crosshairs.

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Beam Delivery System

Beam Quality

8 - 27

Start the oscillator and let it warm up (making power). Make sure that SHUTTER ENABLE is OFF. (Red laser should be visible)
For a crosshair burn, remove the appropriate mirror and insert the crosshair assembly.
Position an acrylic plate in the beam path. If using crosshairs, the target should be
be within 12 inches of the crosshairs for a clean image in the plastic.
The cutting head must be within one inch of the table, or the shutter wont
open.
Set mode to MEMORY
Select the Mode Burn program (see page 37 for listings)
Have an assistant hold a hair dryer or air gun to blow the flame during the burn.
Set SHUTTER ENABLE to ON.
Press START to run the program. It will emit the laser beam for the programmed
period and power.
Set SHUTTER ENABLE to OFF after emitting beam

External Bend Mirrors


Cleaning Procedure:
Unscrew and remove the retaining bolts and remove the mirror assembly for cleaning. To clean, use the same technique as on a focus lens.

mirror retaining
bolts

Figure 21: Bend Mirror


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Beam Alignment

Beam Delivery System

Beam Alignment
Beam Path
The laser beam passes out of the laser and strikes mirrors A, B, 1, 2, 3. The optics
must be adjusted so that the laser beam passes through all optics cleanly. It should
strike the focus lens in the middle regardless of machine motion.
If the lens/nozzle centering seems to change from Y+ to Y-mid to Y-minus, then
the external alignment must be checked.

General Procedure
The laser beam passes out of the laser and strikes mirror 1. Mirror 1 must be adjusted to place the beam (approximately)in the center of mirror 2. Mirror 2 must
be adjusted to make the beam centered in mirror 3 and parallel to the Y-axis
(up/down and side-side). Mirror 3 must be adjusted so that it directs the laser
beam into the center of the focus lens.

Main Air Unit


Solenoid Block
Assist Gas Connections
Chiller Connections

Rear Side

External
Bend Mirror #1
Fanuc Bend
Mirrors

NC
Cabinet

Beam Path

edi Sr ot ar ep O

Control
Box
Y-Axis Positive

Y-Axis Negative
#2

#3

Magnetics
Cabinet
Y-Axis
Locate PINS
X-Axis
Locate PINS

LC1212a
Top View

edi s si x A- X

CRT and
Machine Operators Panel

Front Side

Figure 22: Beam Delivery Path, Top View

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Beam Delivery System

Beam Alignment

Adjusting the RED Laser Beam


The red (diode) laser beam should be adjusted so that it is centered with the main
(CO 2 ) laser beam along the entire beam path. When the two lasers correspond,
then most of the external optics alignment can be done using the red beam. This is
much safer and easier than using the main laser.
To verify alignment between the two beams, the positions must be checked both
near to the laser (within one or two feet away) and far from the laser (ten or fifteen feet away).
Make a mode burn at a distance of 10-15 feet from the laser outlet. Confirm that
the burn is round and symmetric, and that the red beam falls in the center of the
Mode Burn. If the mode is good but the red beam isnt centered, then the diode laser must be adjusted. For this testing (once mode is verified OK), make shallow
burns without crosshairs.
If the mode quality is poor, have it corrected first. Often, the lasers aiming will
change when internal alignment is adjusted.
1. Laser beam outlet
2. He-Ne laser
3. He-Ne laser (V adjustment screw)
4. He-Ne laser (H adjustment screw)
5. He-Ne mirror (H adjustment screw)
6. He-Ne mirror (V adjustment screw)
7. Sub-mirror
Adjust it with He-Ne laser (V, H adjustment screws) and He-Ne mirror (H, V adjustment screws) so that the He-Ne laser beam corresponds to the center of the
Mode Burn

M3

Y-axis

Focus Lens
material surface

Figure 23: Beam Path from M2

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M2

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8 - 30

Beam Alignment

Beam Delivery System

Adjustment at the Oscillator Outlet


Confirm that He-Ne laser beam is on the center of mirror 1. If the main beam is
not centered in M1, you should check the two Fanuc external mirrors as well. If
the beamis not in the center of the first Fanuc external mirror, (on your Right as
you face the end of the laser) then adjust the position of the first bend mirror so
that He-Ne laser beam hits the center of the mirror.

Far Field
Y-Axis Positive

Near Field
Y-Axis Negative

Fig. 2.0

Fig. 2.1

Fig. 2.2

Figure 24: Crosshair Burns for External Alignment

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Beam Delivery System

Beam Alignment

Adjusting the first bend mirror


Place crosshair target in aperture of #1 bend mirror. Adjust the Fanuc mirror so
the red diode laser beam is centered on the crosshair, using a 2mm allen key in the
set screws.
With the help of someone do a crosshair burn on Plexiglas. Put the Plexiglas in
the beam path as close to the crosshairs as possible. Using a hair dryer to blow the
flame, run the BEAM OUT program. Note that the shutter must be enabled and
the cutting head below an inch, for the beam to come on.
Center the CO2 beam on the crosshair. Note the relative position of the diode
beam to the CO2 beam. This will help position the CO2 beam with fewer burns.
Once it is centered, remove the crosshair, clean the #1 bend mirror and put it back
on the mount.
(1) Remove 4 bolts as the diagram shows and remove the bend mirror holder.
Cover the mirror with Kleenex tissue to protect it.
Set LS limit switch for confirmation of bend mirror mounting to ON with tape.
4. Bend mirror holder
5. Limit switch
(3) Place an acrylic plate on the position in the diagram. Open the shutter for several seconds while spraying air with an air gun.
6. Oscillator
7. Oscillator front cover
8. Acrylic plate
9. Acrylic base
(4) Set He-Ne laser to ON and confirm that He-Ne laser beam is in correspondence with the center of the Mode Burn. Adjust He-Ne laser beam if there is a big
discrepancy (see page 29)
1. Mode Burn
2. He-Ne laser beam
(5) Mount a target to the bend mirror mount and adjust it so that a Mode Burn
taken gets to its center.
3. Bend mirror block
4. Target
5. Adjust up and down
6. Adjust right and left
7. Center of the target

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Beam Alignment

Beam Delivery System

Adjusting the Second Bend Mirror.


This is only an approximate adjustment, as both M1 and M2 are adjusted to get
the beam properly adjusted on M3.
-Place the crosshair in aperture of the #2 bend mirror. Loosen the adjustment
locks on #1 bend mirror, and adjust the mirror so the CO2 beam is centered on the
crosshair, doing it similarly as done for bend mirror #1. Remove the crosshair,
clean the optic and replace.
(1) Mount the first bend mirror and remove the second bend mirror with tape. Set
LS for confirmation of bend mirror mounting to ON with tape.
1. First bend mirror
2. Oscillator
3. Aluminum cut
4. Second bend mirror
(2) Mount a target to the second bend mirror.
5. Bend mirror block
6. Target
(3) Tighten set screws for lock and adjust with adjustment screw so that He-Ne laser beam gets to the center of the target.
1. Pivot. Do not move it
2. Adjustment screw
3. Adjustment screw
4. Set screw for lock
5. Set screw for lock
6. First bend mirror
Lock it by tightening set screws for lock after adjusting

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Beam Delivery System

Beam Alignment

Alignment of Y axis NEAR. FAR


The goal of this alignment is to have the laser beam(s) stay centered in M3 at all
Y-axis positions. This is to assure that the beam does not walk in the focus lens
as the Y-axis moves from near (Y-) to far (Y+).
In making these adjustments, use M1 to perform centering at Y- (near) and M2 to
adjust at Y+ (far).
(1) Mount the second bend mirror. Remove the third bend mirror.
Set LS to ON with tape as in the previous sections.
1. Third bend mirror
2. Second bend mirror
(2) Mount a target to the third bend mirror block.
3. Third bend mirror
4. Target
(3) Adjust it by NEAR & FAR so that He-Ne laser beam gets to the center of the
target
5. Opposite to the original of Y axis
6. Origin side of Y axis
(4) Adjustment of second bend mirror (Angle Adjustment).
It becomes parallel to Y axis by changing mirrors angle. Adjust it so that it
comes under the center of the target at NEAR and FAR. Refer to the adjustment
method in 4.1.5 (3)
(5) Confirmation by means of Mode Burn.
Take Mode Burn at NEAR and FAR and be sure that both are on the center of the
target.
*If there is a discrepancy, repeat (4)
1. Acrylic plate
2. Acrylic plate

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Beam Alignment

Beam Delivery System

Adjusing the Third Bend Mirror


This adjustment is to center the laser beam in the focus lens.
Preparation
(1) Remove the cutting head and focus lens, then mount the lens crosshair.
(2) Lower the head, and perform a burn.
If the burn is centered, youre done. If not, adjust M3 to center the beam in the
crosshair.
(3) Loosen the set screws and adjust it with the adjustment screw so that the center of the Mode Burn corresponds to the center of the target.
4. Pivot. Do not move it
5. Adjustment screw
6. Adjustment screw
7. Set screw for lock
8. Set screws for lock
9. Third bend mirror
10. Adjust the adjustment screw (X direction)
11. Adjust the adjustment screw (Y direction)
After adjustment
Lock M3 by tightening the set screws .
Remove the lens crosshair, and re-install the focus lens and cutting head.
After any optics alignment procedure, the lens centering must be checked.

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Origin Adjustment

Beam Alignment

Origin Adjustment
The center of the laser beam can change when adjusting internal alignment or external alignment of the oscillator or due to external causes such as vibration. If
the center of the laser beam changes, the positions of origin in the system are
shifted, which leads to the size error when manufacturing a sketch model or during complex operation such a NC T. Therefore, correct as follows:
(1) Measurement method of Discrepancy amount of the origin position.
Material SPCC t1.6 ~ 2.3
Cutting conditions:
feedrate 500 ~ 1000mm/min
Assist gas type oxygen (O2)
Assist gas pressure 3.0kgf/cm2

Program example
Caution
.........differs according to cutting material type. Set it from the manufacture condition file.
differs according to a manufacture position
Do not use a sheet that is not squared properly.
Use a material with good right angle
1. Material
2. Locate pin
3. Clamp

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8 - 36

Beam Alignment

Origin Adjustment

Adjustment Procedure
1) Cut 20 by the above program
2) Measure the size of 20 (x2, y2) with slide calipers and record it.
3) Measure the distance between the origin and 20 (x1, y1) by the above method
and record them.
4) Obtain Discrepancy amount by the Capacitive formulas:
Discrepancy amount of X axis: oX
oX = x1 + x2/2 - 150
Discrepancy amount of Y axis: oY
oY = y1 + y2/2 - 150
........indicates the value of the manufacture position.
5) Correct Discrepancy amount of Z axis and Y axis
(2) Correction is made by setting NC parameter
1) Set the cursor to the parameter (setting data) No. 1850 (X axis) and No. 1850
(Y-axis)
2) Change the value of parameter
The value of parameter is as follows
Setting value - the value written in the parameter + Discrepancy/0.001
Example
When discrepancy oY is -0.2mm and the present parameters value is 6000,
6000 + (0.2)/0.001 = 5800
Add -200" to the value written in the parameter
Caution
1. Refer to NC operation for the method of parameter change.
2. The compensation direction my be reversed from a certain value of parameter.
If so, move the position of dog of Y- axis.

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Maintenance Program Listings

Beam Alignment

Maintenance Program Listings


The following programs are for INCH mode.

O2001(BEAM OUT);
G31P3T5;

P is assist gas type, and T is pressure in KG/CM2

M760;

Shutter open

G24S1500P2000Q100R.1;

Pierce command, S is power and R is time

M762;

Shutter closed

M30;
O2002(FOCUS ADJUST);
G90G92X49.2126Y49.2126;
G93X___Y___;
G00X0Y0;
N1;
M102(MATRL);

Material designation from custom cutting condition table

M100;

Laser Mode/Shutter Enable

E_;

Specific cutting condition, 1 through 10 is available

M103;

Head down, assist gas on, beam on

G01Y2;

Straight line cutting, note that there is no need for feedrate

M104Z4;

Beam off, head up, assist gas off

M101;

Shutter disable

G00X.5Y0;
M00;
G90G92X0Y0;
GOTO1;
M99;
O2003(HOLE-N-SQUARE)
G90G92X49.2126Y49.2126
G93X___Y___
M102(MATRL)
M100
E_
G112X0Y0I.375

Hole cutting macro, note that X and Y are hole center


and positioning move

E_
G111X0Y0I2R.25
M80
M101
M30

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8 - 38

Beam Alignment

Maintenance Program Listings

O2004(REPO CHECK)
G90G92X49.2126Y49.2126
M102(MATL)
M100
E_
G00X-.050Y_
M103
G01X10
M104Z3
G25X10
M103G01 X(TO THE END OF THE SHEET)
M104
M101
G25X-10
G50
M30

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Maintenance Program Listings

Beam Alignment

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Chapter 9

ALARMS

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9-2

Alarms -

Notes

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Overview

Alarms 1 - 2

Overview
This chapter covers system alarms. These include NC (Fanuc) alarms and various
machine-side (Amada) alarms.
When an alarm occurs in the NC, the machine stops and ALM flashes on the lower edge
of the CRT screen. No indication appears on the NC operation panel.
When an alarm occurs in the machine, laser oscillator, dust collector, or cooling unit, the
machine stops and the MACHINE ALARM light and STOP switch on the NC operation
panel illuminate. No indication appears on the CRG unless one of the Cutting Conditions
screens is active.

ALARM DISPLAYS
The Fanuc alarm list display can be shown by pressing the FUNC and MESSAGE keys at
the same time. The active alarm number and message is shown.
A machine alarm condition can be identified by selecting the Cutting Conditions screens
(CUSTOM key) and pressing HELP to show the alarm list. The active alarm(s) will be
shown in red.

MACHINEALARMS
There are two types of machine alarms. One type allows the machine to resume its
operation as soon as the cause of the alarm is removed. The other type requires that the
NC be reset before the machine can resume its operation. When the NC is reset, return all
the axes to their origins, and restart the machine from the beginning.
1

EMG Stop (X, Y OT)


a. The Emergency Stop button on the NC operation panel or the Emergency button on the
table control panel has been pressed.
Confirm safety around the machine, unlock the pressed and locked button by turning it
clockwise, and return all the axes to their origins. When the Emergency Stop or
Emergency button is pressed while the laser oscillator is producing high-voltage
discharge, the high-voltage discharge will also be stopped. You need to start the
oscillator again.
b. The table or the laser head has overtraveled. Change to the MANUAL mode, press and
hold the O/T Release key, and press the jog key that will retract the overtraveled axis.
Press the RESET key to clear the alarm, and return all the axes to their origins.

Circuit Breaker Trip


The circuit protector has tripped in the NC unit because of an overload or short circuit in
the 100V AC or 24V DC control circuit. Contact AMADA.

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9-3

9-4

Alarms 3 - 14
3

MACHINE ALARMS

Air Pressure down


The main air inlet pressure has dropped below 3 kgf/cm2 (43 psi).
Check the inlet pressure and/or your shop air system. Return the pressure to 5.7 kgf/cm2
(82 psi) or more. Press the RESET key to clear the alarm.

Mirror interlock
a. One of the bend mirrors is overheated. Wait until the bend mirror cools off and the
alarm will clear. If the alarm condition does not clear or repeats, contact AMADA.
b. One of the bend mirrors is not correctly installed. Correctly reinstall the bend mirror.

Z Sensor malfunction
The nozzle has contacted the worksheet, or the gap between the tip of the nozzle and the
worksheet has fallen below 0.1mm. Press the Sensor ON/OFF button and return all the
axes to their origins. Inspect the nozzle and sensor for spatter, and the worksheet for
spatter or other foreign matter. Check the content of the program, and correct the program
if necessary. On the AHS control panel, press the RESET button to clear the alarm.

Chiller Alarm
A fault signal has been received form the cooling unit. Contact AMADA.

Chiller Abnormal
Contact AMADA.

Gage block up
Cant move or run machine with gage block (pins) in UP position.

10

Part didnt fall


(option) Part-drop sensor didnt detect part drop through work chute

11

Assist Gas Pressure Down


a. The assist gas pressure has dropped below 0.2 kgf/cm2 (2.8 psi). Inspect the residual
pressure in the assist gas cylinder, and if it is under 3-5 kgf/cm2 (128 psi), have the
cylinder changed by the supplier.
b. The main valve of the assist gas cylinder is closed, or the regulator knob on the assist
gas pressure setup panel is turned fully counterclockwise. Check the main valve or
regulator knob.
c. The assist gas that is not connected with the machine has been specified. Cheek the
type of the assist gas.

12

Laser H/V OFF

13

Al Cut cover open

14

Work Clamp Open


Clamps are open and machine is in MEMORY or MDI mode.

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MACHINE ALARMS
15

Alarms 15 - 28

NC Battery alarm
The NC memory backup cells have dropped in voltage. Replace the cells every 12 months
- refer to Maintenance section.

16

Al Cutting Fault
(option) The Laser beam reflected by the aluminum worksheet being cut has been detected
by the reflected laser beam sensor (optional). Check the laser cutting conditions, and
correct them if necessary.

17

Al Protector Prox. SW.


(option) The proximity switch of the reflected laser beam sensor (optional) used for the
laser cutting of aluminum worksheets has detected its dog. Press the Power Off button on
the NC operation panel, and turn the NC unit circuit breaker switch to OFF. Then, turn the
NC unit circuit breaker switch to ON, and press the Power ON button to turn on the
power of the machine again.

18

Dust Collector Thermal Trip


The dust collector thermal relay has tripped Contact AMADA.

19

Dust Collector Alarm


Check dust collector power, filters. If unable to clear, contact AMADA

20

Assist Gas Unselected Alarm


Beam ON commanded but no assist gas has been selected.

21

no cutting condition file

22

No material name registered


M102 (name) was commanded but the material name was not found in the Cutting Data
Library.

23

Extended memory not supported

24

Recovering data

25

PMC/CNC malfn

26

Z-axis interlock

27

No nozzle installed
Lower cutting head nor installed properly or problem with head detect interlock.
(microswitch)

28

Abnormal head

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9-5

9-6

Alarms 29 - Work Chute Crash


29

Scrap box front door open

30

Scrap box back door open

31

Maintenance Mode

32

Work Chute open

MACHINE ALARMS

Alarm condition in any but MEMORY or MDI mode. In MEMORY or MDI mode,
inhibits
33

Dead Zone alarm


Can occur if the machine does not have escaping workclamps or if the AVOID CANCEL
switch (on the NC Operation Panel) is ON.
The laser head has entered the workclamp dead zone where it may collide with the
workclamps. Change to Manual mode, raise the laser head clear of the workclamps, and
move it in the + Y direction out of the dead zone. To execute the same program, change
the clapm positions or shift the laser cutting position in the worksheet so that the laser
head does not enter the workclamp dead zone.

34

Safety mat alarm

35

Pierce alarm

36

M10 Watch Dog alarm

37

M11 Watch Dog alarm

38

M760 Watch Dog alarm

39

M762 Watch Dog alarm

40

M80 Watch Dog alarm

41

Front cover open

Work Chute Crash


This alarm is displayed when something keeps the work chute from closing properly.
RECOVERY:
1. Press STOP (latches ON) and clear the workchute area of any scrap or parts.
2. Press ALARM RESET (70 on the NC Operator Panel)
3. Release STOP.
4. Press START to resume operation.
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Height Sensor Alarms

Alarms -

Height Sensor Alarms


The AHS-100 height sensor has a self diagnosis function in the controller. When an alarm
occurs in the Height Sensor, the machine stops and the RESET button on the AHS control
panel lights up. Clear the alarm as described below.
Alarm during calibration.
1) Be sure that the SENSOR switch on the NC operation panel is on.
2) Be sure that OVERRIDE on NC operation panel is set to 100%.
3) Be sure that the nozzle and materials have no water, oil, and dust. Clean them as
needed.
4) Be sure that the worksheet is clamped.
After making sure of the above, cancel the alarm by pressing the Reset switch on the
AHS control and calibrate by running program 9000.
Alarm during laser processing:
Usual causes:
Either the nozzle touched the cutting material, or the gap became less than 0.1mm.
1) Make sure that the selected materials worksheet thickness value is correct. See
page 7-12 for more information.
2) Make sure that the nozzle and the sensor are clean and undamaged. Make sure that the
workpiece surface is clean.
3) As the material was being cut, a cut edge may have raised up enough to touch the
nozzle and cause the alarm. This may call for part-program revisions.
4) When slope cutting, if the feedrate is too high, the Z axis cannot follow and the nozzle
may touch the workpiece. Reduce the feedrate.
Refer to Alarm 6 in the previous section (page 4)and cancel the alarm. If you cannot,
contact AMADA.
Make sure of the above, cancel the alarm by pressing Reset switch and resume processing.
Other errors
When you cannot cancel the alarm by pressing Reset switch on the AHS control panel,
check the following.
1) Make sure that cables are properly connected.
2) Remove any water, oil, and spatters from the nozzle.
3) Try a sensor on the machine that is known to be ok.
If these steps dont restore normal operation, the AHS-100 system may be broken. Contact
AMADA.

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1.06c, 13 November, 1996

9-7

9-8

Alarms 2050 - 2057

AHC Alarms (Option, Altair only)

AHC Alarms (Option, Altair only)


The Auto Head Changer is not offered on Pulsar.
2050

Message No head

Contents Clamp command was made when there is no head.


(note) When turning on the power or an emergency stop, this message is is displayed if
there is no head.
Remarks This message does not cause the field hold, a normal operation can be
performed. Start to operate AHC system to erase this message.
2051

Head LS abnormal
LS for confirming clamp and unclamp is not working properly.
Contact AMADA.

2052

Head C/UC command mistakenly.


Clamp and unclamp were commanded outside AHC adjustment domain.
*It occurs during AHC adjustment.

2053

Magazine cover is closed.


A magazine cover is closed outside AHC adjustment domain.
*It occurs during AHC adjustment.

2054

Magazine cover is open.

NC start was commanded when the magazine cover was open.


Close the magazine cover.
2055

Magazine cover LS abnormal


LS for confirming to open or close magazine cover is not working properly.
Contact AMADA.

2056

AHC mode +X 0.T


It entered AHC adjustment domain when AHC is not being executed.
Move to -X side and reset.

2057

Power stop alarm during AHC.


When the power stops during AHC clamp operation, it occurs if you start the power again.
Contact AMADA.
(note) It occurs during AHC adjustment indicated with an asterisk is an alarm occurring
when a service man adjusts AHC. Usually it does not occur.

Amada America, Inc.

Operating the Pulsar 1212

1.06c, 13 November, 1996

NC Alarms

Alarms 000

- 015

NCAlarms
NC alarms may be cleared by pressing RESET.
If a program was in execution when the alarm occurred, it can not be continued. Return
the machine axes to the origins, and begin the program from the beginning.

Program Error (P/S alarms)


000

Turn off the power


A parameter has been changed which requires the NC to re-initialize. Turn the power off,
then on again.

001

TH parity alarm
TH alarm (an incorrect number of holes have been punched for a character in the tape).
Correct the tape.

002

TV parity alarm
TV parity alarm produced only when TV check is effective. An incorrect number of
characters have been punched for a block in the tape.

003

Data with an excessive number of digits has been found.


Data with an excessive number of digits has been found. (Refer to Max command value)

004

No address in the beginning of the block.


A word without address and starts with a numeral, minus sign, or decimal point has been
found at the beginning of the block. Example: 1.2 Y42.1;

005

No data after address


An address is not followed by data, but by the address of the next word or an
end-of-block code has been found. Example: X;

006

Sign input error


A word with a misplaced minus sign or two minus signs has been found.

007

Digit input error


A word with a misplaced decimal point or two decimal points has been found. Example:
X1..01;

009

Address input error


An address unable to be used for significant information has been input.

010

An invalid G-code has been found.


A G-code corresponding to a function not added (option not present) has been found.

011

Cutting feed rate not commanded.


The cutting feed rate has not been specified or is invalid.

014

Synchronous feed (G95) commanded and not available.


G95 (synchronous feed option) not present on NC.

015

Too many axes moved simultaneously


Cant move more than the number of simultaneously controlled axes at once.

Amada America, Inc.

Operating the Pulsar 1212

1.06c, 13 November, 1996

9-9

9 - 10

Alarms 021 - 038


021

Program Error (P/S alarms)

Axis command only available in designated plane.


Circular arc interpolation can only be performed in designated plane. Use G17, G18, G19
for plane selection.

025

F0 cannot be commanded with G02/G03.


In circular interpolation, F0 has been commanded.

027

No axis designation to G43/G44.


There is no axis designation in the block of G43 and G44 in the laser beam path
compensation type C. Other axis has been used without offset canceling in the laser beam
path compensation type C.

028

Error in a plane select command.


More than 2 axes in the same direction have been commanded in the plane select
command.

029

Offset amount out of range.


The offset amount value selected with H code is too large.

030

Offset number out of range.


The offset number commanded with D/H code of the laser beam path compensation is too
big.

031

P command error in G10.


P value designating an offset number in the offset amount program is missing or too big.

032

Offset amount out of range in G10.


The offset amount designated is too big in the offset amount program input (G10) or in
writing the offset amount with a system variable.

033

The point of intersection cannot be calculated.


The point of intersection cannot be calculated for the laser beam path compensation.

034

Cant Start or Cancel laser beam path compensation during G02/G03.


In the laser beam path compensation C, Start or Cancel during G02/G03 mode has been
found.

035

Unable to command G39.


G39 has been commanded in the laser beam compensation B cancel mode or outside the
offset plane.

036

Unable to command G31.


Skip cutting has been commanded during the laser beam compensation mode.

037

Unable to switch the compensation plane.


The compensation plane (G17, G18, G19) has been switched during the laser beam path
compensation C or G40 has been commanded in the laser beam path compensation B.

038

Overcutting at arc start or end point.


The radius at the arc start or end point is zero for the laser beam path compensation and
likely to cause overcutting.

Amada America, Inc.

Operating the Pulsar 1212

1.06c, 13 November, 1996

Program Error (P/S alarms)


041

Alarms 041 - 059

Overcutting in the laser beam path compensation.


The laser beam path compensation may result in overcutting. Blocks without move such
as interpolation function and dwell function have been commanded consecutively more
than 2 blocks in the laser beam path compensation mode.

042

Unable to command the laser beam position compensation.


The laser beam position compensation has been commanded during the laser beam path
mode.

044

No G27 ~ G30 during the canned cycle.


G27 ~ G30 has been commanded during the canned cycle mode.

046

Error in 2nd, 3rd, 4th, Zero Return command.


Commands other than P2, P3, P4 have been made in the 2nd, 3rd, and 4th reference point
return command.

050

Cut plane/corner has been commanded during cutting a screw.


Cut plane and corner R have been commanded during cutting screws.

051

Next move is inappropriate to cut plane/corner R.


The move or move amount of the block next to the block which cut plane w/ arbitrary
angle and corner R were commanded is inappropriate.

052

Next block command not G01.


The next block command to the block which cut plane with arbitrary angle and corner R
were commanded is not G01.

053

Excessive address commands.


More than two commands among I, J R have been commanded in the cut plane with
arbitrary angle and corner R or in the diagram size direct input, C or R.

054

Cut plane/corner R command is a taper command.


The block to which the cut plane with arbitrary angle and corner R are commanded is a
taper command.

055

Less move than the cut plane/corner R amount.


In the block to which the cut plane with arbitrary angle and corner R are commanded, the
move amount is less than the cut plane and corner R amount.

056

No end point and angle designation.


In the block command next to the block of angle designation only (A..), both end point
designation and angle designation have not been input. I(J) has been commanded to X
axis (Z axis) in the cut plane command.

057

The end point of the block cannot be calculated.


The end point of the block has not been calculated correctly in the diagram size direct
input.

058

End point of the block cannot be found.


The end point of the block has not been found in the diagram size direct input.

059

Program number not found.


The specified program number has not been found.

Amada America, Inc.

Operating the Pulsar 1212

1.06c, 13 November, 1996

9 - 11

9 - 12

Alarms 060 - 085


060

Program Error (P/S alarms)

Sequence number not found


The specified sequence number has not been found.

070

Not enough memory capacity.


The available memory is not sufficient.

071

Data for search not found.


The Specified address has not been found or the program number designated has not been
found in the program number search.

072

Too many programs


Cant store more than 400 programs in the control at one time.

073

The program number entered for registration is already used.


The program number entered for registration is already used.

074

Program number out of range


A program number other than 1 to 9999 has been specified.

076

Address P not set


The M98, G65, or G66 block has no P . (Program number) set.

077

Subprogram call error


Five levels of nested subprograms have been called.

078

Number designated not found.


The program or sequence number has not been designated by the address P for the M98,
M99, G65, or G66 block has not been found. The sequence number to which GOTO was
commanded cant be found.

079

Memory and program do not agree.


The programs in the memory do not agree in contents with those in the tape.

080

Measurement position reach signal not ON.


The measurement position reach signal has not turned on in the domain designated with
parameter. (Auto laser beam path compensation function).

081

No T code in G37
T code has not been commanded and the auto laser beam path compensation has been
commanded. (Auto laser beam path compensation).

082

T code commanded to the same block in G37.


T code and the auto laser beam path compensation have been commanded. (Auto laser
beam path compensation).

083

Error in axis designation in G37


In the auto laser beam path compensation, the axis designation was mistakenly made or
the command is an incremental command. (Auto laser beam path compensation).

085

Corresponding error
The over run, parity, or framing error have occurred, in reading-in with reader/puncher
interface. The bit number of the input data do not agree, or the baud rate setting is
incorrect.

Amada America, Inc.

Operating the Pulsar 1212

1.06c, 13 November, 1996

Program Error (P/S alarms)


086

Alarms 086 - 111

Data Ready signal OFF.


The DR signal (Data Ready) of selected I/O device (reader/puncher or computer) is OFF.

087

Buffer overflow
More than ten characters have been read following the DC3 stop code.

090 Unable Zero Return.


Signals have not been received from the pulse coder, and the axes cannot be returned to
the origins.
092 Has not returned to the origin.
In the reference point return check (G27) , the designated axis has not returned to the
reference point.
094 Coordinate system set after stop.
P type cannot be commanded when the program is resumed. (The coordinate system has
been set after auto operation stop).
095

Change of external work offset amount after stop.


P type cannot be commanded when the program is resumed. (The external work offset
amount has changed after the auto operation stop).

096

Change of work offset amount after stop.


P type cannot be commanded when the program is resumed. (The work offset amount
has changed after the auto operation stops).

097

No auto operation after turning on the power.


P type cannot be commanded when the program is resumed. (The auto operation has
never been performed after turning on the power, emergency stop, or P/94 ~ 99 reset).

098

G28 found during search.


After turning on the power and emergency stop, the program was commanded to resume
without returning to the reference point. G28 has been found during the search.

099

Movement command with MDI after search.


Movement command has been made with MDI after search in program restart.

100

Parameter writing is enabled.


Set Data PWE is 1 (parameter modification ENABLED). Turn off (0) and reset.

101

Memory clear
Power was lost during editing. When this alarm occurs, press RESET while holding
PROG. This will delete the program you were editing.

110

Data with too many digits.


The absolute value of the data displayed with fixed digits is excessive.

111

Overflow in computation.
A computed (or intermediate result) floating point value is too big or too small.
The valid range is (-232 to 232 -1).

Amada America, Inc.

Operating the Pulsar 1212

1.06c, 13 November, 1996

9 - 13

9 - 14

Alarms 112 - 126


112

Program Error (P/S alarms)

Zero divisor
Zero is entered as divisor. ( including tan (90)

113

Unable to use designated function.


A function has been commanded in the custom macro which is not permitted there.

114

Format error in macro


An error has been found in a format other than a <formula>.

115

Variable number error


Values which are not defined as a variable number were specified in a custom macro or
in high-speed machining.
The content of the header is inappropriate. This alarm occurs in the following cases.
1) There is no header corresponding to the calling manufacture cycle number commanded.
2) The value of the cycle connection information is out of the range (0 ~ 999)
3) The number of data in the header are out of the range ( 0 ~ 32767)
4) The storage start data variable number of the executable format data is out of range (#
20000 ~ 85535)
5) The last storage data variable number of the executable format data is out of the range
(# 85535)
6) The storage start data variable number of the executable format data and the variable
number used in the header overlap.

116

Illegal or write protected variable


Cant assign values to write-protected variable, or an illegal variable has been assigned in
the left statement.

118

Parentheses overflow.
The number of parentheses has exceeded the algebraic nesting limit of five levels.

119

Error in argument
A negative argument has been entered for SQRT or BCD. Or the argument for BCD
contains data other than 0 to 9.

122

Macro modal double command.


Nested macro programs have been called exceeding two levels.

123

Unable to use macro command.


A macro control command has been used for DNC operation.

124

No Do-End correspondence.
Do and End have been incorrectly specified, which must have a relationship of 1:1

125

Error in format
An error has been found in the format of an expression.

126

Error in DO sentence.
In DOn, n has been incorrectly specified, which must be 1 to 3.

Amada America, Inc.

Operating the Pulsar 1212

1.06c, 13 November, 1996

Program Error (P/S alarms)


127

Alarms 127

- 145

NC and Macro command exist together.


An NC command and a macro command are present in the same block.

128

Error in sequence No. of macro


In GOTO, n has been incorrectly specified, which must be 0 to 9999.
The sequence no. to which GOTO was commanded cannot be found.

129

Error in argument address


An invalid address has been used in an argument.

130

Error in axis control command.


The axis control command from PMC has been made to the axis CNC control. Or the
axis control command from CNC has been made to the axis PMC controls.

131

Alarm number is too large in the external alarm message.


More than 5 alarms have occurred in the external alarm message.

132

No. alarm number in the external alarm message.


There is no alarm number corresponding to the clear of the external alarm message.

133

Data error in the external alarm message.


There is an error in small separated data in the external alarm message or in the external
operator message.

135

Error in angle command.


The angle determining a position for index table calculation has been commanded
without integral multiplication of min. angle value.

136

Unable to command to the other axis simultaneously.


The other axes have been commanded with B axis.

139

Unable to select axis in PMC axis control.


The axis has been selected during PMC axis control.

141

Unable to command G51 during the laser beam compensation


G51 (scaling on) has been commanded during the laser beam compensation.

142

Error in scaling magnification


The scaling magnification has been instructed other than 1 ~ 999999 values.

143

Over max instruction value


As a result of scaling, values of movement amount, coordinate amount, or circle-arc
diameter are too big..

144

Different circle-arc and plane


The coordinate relation plane or circle and the laser beam path compensation plane have to
correspond.

145

Error in polar coordinate compensation.


The conditions when the polar coordinate compensation starts or is canceled are incorrect.
a. G21.1/G13.1 have been instructed other than in G40 mode.
b. There is an error in the plane selection (Parameter No. 5460, 5461 incorrect setting).

Amada America, Inc.

Operating the Pulsar 1212

1.06c, 13 November, 1996

9 - 15

9 - 16

Alarms 146
146

- 176

Program Error (P/S alarms)

G code unable to instruct.


G code which cannot be instructed has been instructed during the polar coordinate
compensation.

147

Error in a setting value.


The decelerate ratio and decision angle of the auto corner override is out of the setting
possible range.

150

Laser beam group number is out of the range.


The laser beam group number is over the max value.

151

Laser beam group not set.


The laser beam group designated in the manufacture program.

152

The number of laser beam is over the max value.


The number of laser beam within a group is over the possible registration max value.

153

Unable to find T code.


T code is not stored in the block where it is supposed to be stored.

154

No group instruction
When there is no group instruction, H99 or D99 were instructed.

155

T code is not corresponding to the group.


T code of the same block as M06 is not corresponding to the group used in the
manufacture group.

156

No P/L instruction for laser beam group setting.


The program for setting laser beam has no beginning P, L instruction.

157

The number of laser beam group is over the max.


The number of laser beam group is over the max value.

158

Durable value of laser beam is out of the range.


The durable value of laser beam to be set is too large.

159

The power was turned off during setting.


The power was turned off while executing the program for setting.

175

Error in cylinder interpolation.


The condition during the cylinder interpolation start or cancel is incorrect. Instruct G07.1
Rotation_axis_name cylinder_radius to activate Cylinder Interpolation mode.

176

G mode not available during cylinder interpolation mode.


The G mode commanded is not available during cylinder interpolation mode. The
following G modes cannot be instructed during the cylinder interpolation mode.
a. Position determination (including G28, G53, G73, G74, G76, G80 ~ G89 which create a
cycle of fast feed).
b. Work coordinate system (G92, G54 ~ G59).
c. Local coordinate system (G52).

Amada America, Inc.

Operating the Pulsar 1212

1.06c, 13 November, 1996

Program Error (P/S alarms)


177

Alarms 177 - 197

Checksum error (G05 mode)


Checksum error.

178

G05 has been instructed during G41/G42 mode.


G05 has been instructed during G41/G42 mode.

179

Error in parameter setting (No. 7510).


Too many controlled axes set with the parameter 7510

180

Correspondence error (remote buffer).


Circuit alarm of the remote buffer.

181

Format error in G81 block.


Format error in the G81 block (Hob panel).
a. T has not been instructed.
b. Data out of the command range has been commanded in T, L, Q, and P.

182

The same period has not been instructed.


G83 (axis servo delay amount compensation) has been instructed without the same period
instruction by means of G81 (Hob panel).

183

Duplicate G83
G83 (axis servo delay amount compensation) has been instructed without canceling the
previous G83 with G82.

184

Instruction cannot be given during the same period.


The command you cannot give has been given during the same period by G81 (Hob
panel).
a. The C axis has been commanded by G00, G27, G28 and G30.
b. The inch/metric conversion has not been commanded by G20 and G21.

185

G81 instructed without returning to the origins.


G81 has been instructed without reference point returning after turning on the power or the
emergency stop.

186

Error in parameter setting.


A parameter error regarding G81 (Hob panel).
a. C axis has not set to be the rotating axis.
b. There is an error in setting the gear ratio between the Hob axis and the position coder.

190

Error in axis designation.


The axis designation is incorrect in speed constant control (program error).

194

Main axis cannot be designated to the same-period axis.


The contouring mode and rigid mode have been instructed during the serial spindle same
period control mode. (Instruct after canceling the same period control mode.)

197

Move instruction cannot be given when CON is 0.


Move instruction was given from the program to (s axis serial contour control) when CON
signal was off.

Amada America, Inc.

Operating the Pulsar 1212

1.06c, 13 November, 1996

9 - 17

9 - 18

Alarms 199 - 213


199

Program Error (P/S alarms)

Undefined macro reserve words have been used.


Undefined macro reserve words have been used.

200

The main rotation instruction is out of the range.


The S value in the rigid tap is out of the range or has not been instructed.

201

No feed speed instruction.


F has not been designated in the rigid tap.

202

Distribution amount of the main axis is excessive.


The distribution amount of the main axis is excessive in the rigid tap

203

Error in the rigid tap instruction.


The instruction position of the rigid M code or S is incorrect in the rigid tap.

204

Axis move to between and the rigid M code and G84.


The axis move has been instructed between the rigid M code and G84 (G74) in the rigid
tap.

205

Rigid mode DI is OFF.


Although the rigid M code has been instructed, the rigid mode DI signal is ON during the
block execution of G84 (G74).

206

Switching planes is impossible during rigid tapping mode.


Cant switch planes in rigid tapping mode.

210

Unable to execute M198/M199


M198/M199 have been executed during the schedule operation. M198 has been executed
during the DNC operation.

211

G31 (high speed) is impossible during G99.


G31 has been instructed with the every rotation instruction when high speed skip option is
attached.

212

Error in the selected plane.


The diagram size direct input instruction has been given on the plane containing the added
axis.

213

Illegal command in synchronous mode


Any of the following has occurred during simple synchronous operation.
a. The move command has been given to the slave axis by the program.
b. Manual continuous feed/manual handle feed/incremental feed has been commanded to
the slave axis.
c. The auto reference point return has been commanded without manual reference point
return after turning on the power.
d. The difference of the position difference amount between the master axis and the slave
axis went over the parameter value. (No. 8313)

Amada America, Inc.

Operating the Pulsar 1212

1.06c, 13 November, 1996

Program Error (P/S alarms)


214

Alarms 214 - 5010

Coordinate setting and the laser beam path compensation impossible.


The coordinate system setting or the laser beam compensation of the shift type have been
executed during synchronous control.

222

You cannot operate with input and output at the same time.
You have tried to execute the input-out same time operation during the background editing.

223

Return to the origins.

224

Return to the origins.


Return to the reference point before automatic operation.

230

Cutting amount R has not been designated.


The cutting amount R has no been instructed to the block of G160, or the instruction
value of R is negative.

231

Format error in G10 and L50.


There are following errors in the instruction format in the programmable parameter input.
a. The address N or R has not been input.
b. The number unlisted among the parameters has been input.
c. The axis number is too big.
d. The axis number has not been instructed even though it is a axis type parameter.
d. The axis number has not been instructed even though it is a axis type parameter.

232

Too many helical axis commands.


Three or more axes (in the normal direction control mode two or more axes) have been
instructed as helical axes in helical interpolation mode.

5000

Incorrect instruction code (HPCC)

5003

Illegal parameter (HPCC)


Illegal parameter setting.

5004

HPCC preparation not completed..

The operation is not ready on HPCC side (only HPCC mode).


5006

Too many words in block

The number of word with one block is excessive (over 26 words). (Only HPCC mode).
5007

Distance too far.

Move amount is more than the max instruction value. (HPCC mode only).
5009

Feed speed = 0, (dry run).

The parameter setting values of the max feed speed (parameter No. 1422) or the dry run
speed parameter (no. 1410) has been 0. (HPCC mode only)
5010

Program is over.

EOR (End Of Record %) has been instructed.

Amada America, Inc.

Operating the Pulsar 1212

1.06c, 13 November, 1996

9 - 19

9 - 20

Alarms 5011 - 5062


5011

Program Error (P/S alarms)

Feed speed 0 (Maximum cut/slice feed).

The parameter setting value (No. 1422) of the max cut/slice feed has been 0. (HPCC
mode only).
5012

G05 P10000 illegal start up

G05 P10000 has been instructed to the mode where HPCC mode cannot go into. (Refer
to the conditions for going into HPCC mode).
5013

HPCC: CRC OFS remain at cancel.

G05 P0 has been instructed during G41/G42 mode or with the offset amount left.
5014

The rotation axis is not the axis in the laser beam axis direction.

5016

Inappropriate M code combination.

a.. Two or more M codes of the same group have been instructed on the same line
b. A single instruction M code was placed on a line with other instructions.
5043

G68 overflow

Three dimension coordinate transformation has been instructed more than three times.
5044

G68 format error.

There is a format error in the G68 block.


The following give this alarm. (1) When there is not any instruction among I, J, K of the
same block as G68. (When there no coordinate rotation option). (2) I, J, K of the same
block as G68 are all ). (3) When there is no R instruction in the same block as G68.
5060

Error in parameter (Exponential interpolation).

The parameter setting has an error. No. 5641 (straight line setting) has not been set. The
axis set to No. 5641 is not a straight line axis. No. 5642 (rotation axis setting) has not
been set. The axis set to No. 5642 is not a rotation axis. The straight axis and the rotation
axis cannot be controlled by CNC. (More than the setting values of No. 1010 has been
set).
5061

Format error (Exponential interpolation).

There is an error in the instruction (G02.3/G03.3) of exponential function interpolation).


The address I, J, K has not been instructed. The value of address, I, J, K is 0.
5062

Error in the instruction value (exponential interpolation).

The instruction value has an error in the instruction of exponential function interpolation.
(G02.3/G03.3). A value which the exponential function interpolation cannot be made has
been instructed (e.g., the value in In is negative). *HPCC is a high precision contour
control.

Amada America, Inc.

Operating the Pulsar 1212

1.06c, 13 November, 1996

Background Edit Alarms (BP/S)

Alarms 140 - 140

Background Edit Alarms (BP/S)


In addition to the following special alarms, the same alarms that can that normally appears
in the ALARM MESSAGE for P/S program management. (e.g., 070, 071, 072, 073, 074,
etc.) can occur during background editing.
140

BP/S alarm: Cant access same program in foreground and background.


An attempt has been made to select or delete a program in the background which is
currently selected in the foreground.
BP/S alarm will not appear in the regular alarm screen but on the same line as the entry
line of the background program management screen. Background alarms are reset when
another MDI key is pressed.

Amada America, Inc.

Operating the Pulsar 1212

1.06c, 13 November, 1996

9 - 21

9 - 22

Alarms 300 - 308

Absolute Pulse Code (APC) Alarms

Absolute Pulse Code (APC) Alarms


300
301

Zero-return: n-axis n-axis (1-8) needs to be Zero-returned manually.


APC alarm: axis communication
APC communication error has been found in n-axis (1-8).(Data transmission error )

302

APC alarm: n-axis overtime


APC overtime error has been found in n-axis (1-8).(Data transmission error)

303

APC alarm: n-axis framing


APC framing error has been found in n-axis (1-8).(Data transmission error)

304

APC alarm: n-axis parity


APC parity error has been found in n-axis (1-8).(Data transmission error)

305

APC alarm: n-axis pulse missing


APC pulse (missing) error has been found in n-axis (1-8).(APC alarm)

306

APC alarm: Zero (voltage) in n-axis battery


The voltage of the n-axis (1-8) APC battery has been insufficient (0 voltage) to retain data.
(APC alarm)

307

APC alarm: Low voltage in n-axis (1)


The voltage of n-axis (1-8) is currently low, requires battery replacement (APC alarm)

308

APC alarm: Low voltage in n-axis (2)


The voltage of n-axis (1-8) has been detected low (including when the power has been
turned off )
The battery needs replacement. (APC alarm)

Amada America, Inc.

Operating the Pulsar 1212

1.06c, 13 November, 1996

Serial Pulse Coder (SPC) alarms

Alarms 350 - 405

Serial Pulse Coder (SPC) alarms


350

SPC alarm: n-axis pulse coder


n-axis (1-8) serial pulse coder error. Use the DIAGNOSTICS display, item 202 for details
on alarm.

Diagnostic #202
Bit#

#7

#6

#5

#4

#3

#2

#1

#0

Item:

xx

CSAL

BLAL

PHAL

RCAL

BZAL

CKAL

SPHAL

SPHAL: Soft Phase Data error alarm has occurred.


CKAL: Clock alarm has occurred.
BZAL: Battery Zero alarm has occurred (not related to alarm No. 350)
RCAL: Revolving Count error alarm has occurred.
PHAL: Phase data error alarm has occurred.
BLAL: Battery Low alarm has occurred. (not related to alarm No. 350)
CSAL: Check Sum alarm has occurred.
351

SPC alarm: n-axis communication-axis (1-8)


Serial pulse coder communication error. Use the DIAGNOSTICS display, item 203 for
details on alarm.

Diagnostic #203
Bit#

#7

#6

#5

Item:

DTERR

CRCERR STBERR

#4

#3

#2

#1

#0

STBERR: Stop Bit error has occurred.


CRCERR: CRC error has occurred
DTERR: Date error has occurred.

Servosystem alarms
400

Servosystem alarm: n-axis overload


The overload signal has been raised for n-axis (1-8). DIAGNOSTIC No. 201 for details.
(see page 25)

401

Servosystem alarm: n-axis V ready off


The servo amplifier ready signal (DRDY) has been turned off for n-axis (1-8).

404

Servosystem alarm: n-axis V ready on


The DRDY signal has not bee turned off, although the MCON of n-axis (1-8) signal has
been turned off. Or the DRDY signal has been turned on, although the MCON signal has
not been turned on when the power has been turned on.

405

Servosystem alarm: Zero-return error

Amada America, Inc.

Operating the Pulsar 1212

1.06c, 13 November, 1996

9 - 23

9 - 24

Alarms 407

- 415

Servosystem alarms

A axes position control error has occurred. The axes may not have been properly returned
to the origins due to a fault in the Servosystem of NC. Zero-return the axes manually
once again.
407

Servosystem alarm: Position deviation error


The positional deviation of same period axis is larger than the preset data.

410

Servosystem alarm: Position deviation error of n-axis


The positional deviation of n-axis (1-8) when stopped is larger than the preset data.

411

Servosystem alarm: Position deviation error of n-axis


The positional deviation of n-axis during travel is larger than the preset data.

413

Servosystem alarm: n-axis LSI overflow


The positional deviation of n-axis has exceeded +231. (This alarm is normally produced
by a parameter setting error)

414

Servosystem alarm: n-axis digital servosystem error


An alarm condition has occurred in n-axis digital servosystem. Refer to No. 200 in the
alarm chart .

DIAGNOSTIC # 200
Bit#

#7

#6

#5

#4

#3

#2

#1

#0

Item:

OVL

VL

OVC

HCAL

HVAL

DCAL

FBAL

OFAL

OFAL: Overflow alarm has occurred.


OFBAL: Fiber alarm has occurred. (not related to alarm No. 414)
DCAL: Regenerative Discharge Circuit alarm has occurred.
HVAL: High Voltage alarm has occurred.
HCAL: High Current alarm has occurred.
OVC: Overcharged Current alarm has occurred.
LV: Low Voltage alarm has occurred.
OVL: Over Load alarm has occurred. (not related to alarm No. 414)

415

Servosystem alarm: n-axis velocity error


A velocity of over 511875 detection units per second has been instructed for n-axis (1-8).
(This alarm is produced by a CMR parameter setting error).

Amada America, Inc.

Operating the Pulsar 1212

1.06c, 13 November, 1996

Servosystem alarms
416

Alarms 416 - 417

Servosystem alarm: n-axis wire breakage


A fault (wire breakage, for example) has occurred in the position detection system of
n-axis (1-8) pulse coder.
The detail message of the servosystem alarm N0. 416 will be displayed in DIAGNOSTICS
No. 201.

DIAGNOSTIC # 201
Bit#

#7

Item:

ALDF

#6

#5

#4

#3

#2

#1

#0

EXPC

When servosystem alarm No. 400:


ALDF
1

Overheating of motor

Overheating of amplifier

When servosystem alarm No. 416


ALDF

417

EXPC

meaning

Wire breakage (hard) in the inner pulse coder.

Wire breakage (hard) in the attached pulse coder.

Wire breakage (soft) in pulse coder.

Servosystem alarm: Faulty n-axis parameter


One of the following parameter setting errors has been found in n-axis digital servosystem:
1) A faulty data has been set in parameter No. 2020 (motor model).
2) A correct data (111 or -111) has not been set in parameter No. 2022 (motor rotation
direction)
3) A faulty data ( 0) has been set in parameter No. 2023 (speed feedback pulse per motor
rotation )
4) A faulty data ( 0) has been set in parameter No. 2024 (location feedback pulse per
motor rotation)
5) Parameter No. 2084 and 2085 (flexible feed gear ratio) has not been set.
6) A faulty axis number (other than 1- n-axis or non-consecutive number) has been set in
parameter No. 1023 (servosystem axis number).

Amada America, Inc.

Operating the Pulsar 1212

1.06c, 13 November, 1996

9 - 25

9 - 26

Alarms 500 - 750

Overtravel alarms

Overtravel alarms
Overtravel alarms No. 504 and 505 occur only in type T.

500

Overtravel: +
axis (1-8) has traveled beyond the stored stroke limit I in the plus direction.

501

Overtravel: -nn-axis (1-8) has traveled beyond the stored stroke limit I in the minus direction.

502

Overtravel: +
axis (1-8) has traveled beyond the stored stroke limit II in the plus direction.

503

Overtravel: nn-axis (1-8) has traveled beyond the stored stroke limit II in the minus direction.

504

Overtravel: +
axis (1-8) has traveled beyond the stored stroke limit III in the plus direction.

505

Overtravel: axis (1-8) has traveled beyond the stored stroke limit III in the minus direction.

506

Overtravel: +
axis (1-8) has traveled beyond the hard OT in the plus direction.

507

Overtravel: axis (1-8) has traveled beyond the hard OT in the minus direction.

Overheat alarms
700

Overheat: control unit


The master printed circuit board is overheated.

704

Overheat: spindle
The spindle for main axis change detection is overheated.
(8) Spindle alarms

750

Main axis serial link start error


This alarm occurs when the main axis serial link unit of the system equipped with serial
spindle does not start when the power is turned on. The following are the typical cases of
this alarm:
1) Bad connection in lighting cable, or the power of the main axis control is not turned
on.
2) NC power is turned on when the LED alarm display of the main axis control unit is
other than SU-01 or AL-24.
3) Other (installation errors in the hardware)

Amada America, Inc.

Operating the Pulsar 1212

1.06c, 13 November, 1996

Overheat alarms

Alarms 751 - 762

4) When the second main axis (when the parameter No. 3701 /bit4 SP2=1) is in one of
the situations 1) through 3) above. Refer to the No. 409 in the alarm chart for detail.
2) can typically happen when the power of CNC is turned off while serial spindle is in
operation. In such case, turn off the power of the spindle amplifier once, and restart.
751

The 1st main alarm detection(AL-xx)


In the system equipped with serial spindle, detects the alarms of the main axis unit on the
NC screen. The alarms will be displayed as AL-xx (xx = number).
Refer to the manual for main control unit for the message of the alarms.

752

The 1st main alarm switchover error


The switchover of the contouring modes, main axis location setting, rigid tap modes, or
main axis control modes in the serial spindle control are not functioning properly.

761

The 2nd main alarm detection(AL-xx)


Refer to No. 751 in the alarm chart.

762

The 2nd main alarm switchover error


Refer to No. 752 in the alarm chart. The detail message of alarm No. 750 will be
displayed in DIAGNOSTIC No. 409.

DIAGNOSTIC # 409
Bit#

#7

#6

#5

#4

Item:

#3

#2

#1

#0

SPE

S2E

SIE

SHE

SHE
0

Serial communication module of CNC is normal.

Serial communication module of CNC is abnormal.

SIE
0

The 1st main axis is normal in the main axis serial control start up.

The 1st main axis is abnormal in the main axis serial control start up.

S2E
0

The 2nd main axis is normal in the main axis serial control start up.

The 2nd main axis is abnormal in the main axis serial control start up.

SPE
0
The serial spindle parameter of the main axis serial control
is satisfying the start up conditions of the main axis unit.
1
The serial spindle parameter of the main axis serial control
IS NOT satisfying the start up conditions of the main axis unit.

Amada America, Inc.

Operating the Pulsar 1212

1.06c, 13 November, 1996

9 - 27

9 - 28

Alarms 900 - 973

System alarms

System alarms
900

ROM PARITY
A battery error in the ROM (CNC/OMM/Servosystem)

910

RAM PARITY : (4n)


A parity error has occurred in the RAM in the tape memory RAM module. Clear memory
or change the module.

911

RAM PARITY : (4N+1)

912

RAM PARITY : (4N+2)

913

RAM PARITY : (4N+3)

920

Servo Alarm (1/2 axis)


A watchdog alarm or RAM parity error in the servo module has occurred.

921

Servo Alarm (3/4 axis)


A watchdog alarm or RAM parity error in the servo module has occurred.

922

Servo Alarm (5/6 axis)


A watchdog alarm or RAM parity error in the servo module has occurred.

923

Servo Alarm (7/8 axis)


A watchdog alarm or RAM parity error in the servo module has occurred.

924

SERVO MODULE SETTING ERROR


Digital Servo module has not been installed.

930

CPU INTERRUPT
An abnormal interrupt error has occurred in the CPU.

945

SERIAL SPINDLE COMMUNICATION ERROR


A communication error has been found in the serial spindle. Breakage or omission of the
lighting cable is a possible cause.

950

PMC SYSTEM ALARM


An error has occurred in the PMC.

951

PMC-RC WATCH DOG ALARM


An error has occurred in the PMC-RC. (A watchdog error)

970

NMI OCCURRED IN BOC


A RAM parity error or NMI has occurred in the PMC-RA2 or PMC-RB module.

971

NMI OCCURRED IN SLC


An LC communication error has occurred in the PMC-RA1or PMC-RA2.

972

NMI OCCURRED IN OTHER MODULE


NMI has occurred in a board other than main CPU board.

973

NON MASK INTERRUPT


An unidentified NMI has occurred.

Amada America, Inc.

Operating the Pulsar 1212

1.06c, 13 November, 1996

Laser alarms

Alarms 660 - 4068

Laser alarms
Contact Amada if any of the following alarms occur (except 670, 672, 673)
660

The allowance for clearence of Z-axis is excessive.

661

AD converter-1 irregularity

662

AD converter-2 irregularity

663

RF Power source problem

665

Shutter problem

666

Discharge tube problem

667

Resonator overtemp

669

Power Supply for laser interface PCB has problem

670

Chiller not ready

671

Low assist gas

672

low coolant flow rate - check chiller, filter, strainer

673

Laser gas pressure low. Check cylinder pressure

674

blower overtemp

675

cooling water too cold, condensation forming in RF power source

676

blower problem

677

beam dump absorber overtemp

678

discharge tube pressure abnormal

680

resonator vacuum leak

682

negative pressure sensor problem

683

A discharge tube is faulty, assist gas down, or shutter not open ??????

696

laser gas mixer overpressure

697

problem with gas mixer: bad power supply or mixer in E-stop condition or bad
interface cable/connection.

698

gas mixer vacuum system problem

699

gas mixer pressure switch

4060

Large error of the following axis.

4061

An abnormal interrupt in A/D converter 1.

4062

An abnormal interrupt in A/D converter 2.

4063

Abnormal RF power.

4065

Abnormal shutter movement.

4066

A disconnected power discharge tube has been found.

4067

Temperature too high in the laser cabinet.

4068

Laser beam has been reflected back to the resonator.

Amada America, Inc.

Operating the Pulsar 1212

1.06c, 13 November, 1996

9 - 29

9 - 30

Alarms 4069 -

Laser alarms

4069

Abnormality in the power of laser IF has been found.

4070

Chiller is not ready.

4071

Assist gas is not ready.

4072

Cooling water too low.

4073

Mixed gas pressure too low.

4074

Root blower has been burning.

4075

Temperature of cooling water too low.

4076

Laser power too low.

4077

Beam absorber has been burning.

4078

Abnormal mix gas pressure in the power cable.

4079

EMERGENCY STOP button has been pressed. Reset the machine.

4080

A leak has been found in the power discharge tube or gas pipe.

4081

Gas pressure control is working yet the pressure is not properly controlled
within the preset time period.

4082

Abnormality in the minus pressure sensor has been found.

4083

Shutter closed.

4084

Power source is not properly selected.

4085

Mirror is not clean.

4087

Shutter has been burning.

4088

Voltage in the power cable is getting low.

4089

Assist gas is not emitting.

4090

Laser is not working.

4091

Abnormality in the inverter has been found.

4094

Abnormality in the vacuum pump has been found

4095

Abnormality in the reading for the following displacement amount

Amada America, Inc.

Operating the Pulsar 1212

1.06c, 13 November, 1996

Amada Laser Systems

Index A - P

INDEX
A

F
Alarm display
NC, program
Aperture
Approach data

Focus lens
adapter
adjustment
cleaning
identification

9-3
1-3
7-15

4-12
8-23
4-10, 8-21
4-10

B
Battery, NC backup
Beam quality
aiming effects
Blank
CRT screen

8-17

3-10, 7-3

5-17
4-5
8-7

M
Machine alarms
to display
Material type
SEE Process category

5-9

9-3

N
Nozzle
centering
inspection

8-18
8-10

O
Optics
adjustment
Override switch
described
Overtravel
recovery

8-18
3-12
4-17

Amada America, Inc.

Laser Status
Laser Power screen
viewing
Lubrication

Cap Sensor
controls
3-23
nozzle
4-11, 8-10
Cutting conditions
override
3-12, 3-15
Cutting data
Create new file
7-33
deleting
7-34
editing
7-17
make copy
7-34
selecting from program
7-11
selecting manually
7-16
loading, saving
7-38
Cutting Data listing
by material type
7-35
Cutting head
identification
4-10
mounting
4-10

Edge condition
editing
Edge data
viewing

7-14

8-29

Diagnostics
selecting screen

Gas selection

7-27
7-15
7-24
Operating the Pulsar 1212

Parameters
selecting screen
Parts count
reset
Pierce
high-speed
1.06c, 13 November, 1996

5-9
5-8
7-20

10 - 1

10 - 2

Index P - W

Amada Laser Systems

lead-in
selecting manually
Process Category

7-24
7-11
7-10, 7-13

R
Relative coordinate system
preset
Run time
reset

Amada America, Inc.

5-8

Safety
Additional information
Screen selection

2-4
5-4

Work Chute
crash recovery

9-6

5-8

Operating the Pulsar 1212

1.06c, 13 November, 1996

ADDITIONAL INFORMATION

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