JUKI PS800-8045 User manual

CAUTION :
This Instruction Manual describes the laser knife type. When you want to use your sewing ma-
chine with this product attached, refer to the “Safety precautions” in the Instruction Manual for
your sewing machine carefully until you fully understand the included precautions in prior.
Laser knife type
INSTRUCTION MANUAL

i
CONTENTS
1. SAFETY PRECAUTIONS........................................................................................................ 1
1-1. Precautions to be taken when installing or adjusting the laser...............................................4
1-2. Precautions to be taken when using the laser...........................................................................4
2. MAINTENANCE ......................................................................................................................5
3. ELECTRICAL SAFETY ........................................................................................................... 6
3-1. Circuit diagrams ...........................................................................................................................6
4. INSTALLATION ....................................................................................................................... 7
4-1. Installation of the laser after unpacking.....................................................................................7
5. OPERATION.......................................................................................................................... 10
5-1. Tune ON the power .....................................................................................................................10
5-2. Starting the air supply................................................................................................................10
5-3. Temporary measures..................................................................................................................11
5-4. Use of the cooling system .........................................................................................................12
5-5. Adjusting the laser......................................................................................................................13
5-6. Using the laser ............................................................................................................................17
5-7. Adjusting the air volume of the fan...........................................................................................19
5-8. Editing / setting the patterns, setting the layer, and setting the speed.................................20
6. PRECAUTIONS TO BE TAKEN WHEN USING THE EQUIPMENT IN WINTER OR AT A
COLD REGION .....................................................................................................................26
7. IDENTIFICATION AND HANDLING OF FAILURES IN GENERAL...................................... 27
7-1. High-tension ignition and electric discharge...........................................................................27
7-2. Breakage / rupture of the laser tube .........................................................................................27
7-3. Cause of occurrence of high-pressure discharge and breakdown phenomenon ...................... 28
7-4. Attenuation of output .................................................................................................................29
7-5. Power fault inspection while the laser is in use ......................................................................29
If any control device or program other than those specified in this Instruction Manual is
used, or if the adjustment method and usage specified in this Instruction Manual are not
followed, the maintenance person or user of this product can be exposed to hazardous
irradiation from the laser. If the human body or cornea is exposed to direct laser-irradia-
tion, health hazard such as burn of cornea, burn of retina, conjunctivitis, visual loss, burn
of skin, etc. and the fire can be caused.

– 1 –
1. This product cuts the material using the Level 4 no observation light continuous wave laser.
Wave length is 10.6 μm, maximum output is 100 W and the angle is 3.1 mrad. Only the per-
sons who have received professional training are allowed to use and handle this product.
Be sure to contact our After-Sale Service staff if you want to carry out maintenance and / or
repair of this product. Professional staff who has received professional training in JUKI to
gain experience of the relevant work will carry out maintenance / repair of your product.
1. SAFETY PRECAUTIONS
2. Whenever you use of this product or carry out maintenance / repair of it, be sure to wear
safety goggles. Use the safety goggles that satisfy the following criteria or that are provided
by the manufacturer.
Safety goggles selection criteria :
1. CE Marking is obtained
2. Visible light transmittance VLT>60%
3. Applicable wave length : 10.6μm
4. Protective characteristics : Light absorption type CO2 laser safety goggles or light reflec-
tion type CO2 laser safety goggles
5.Protection level : OD5+
3. Safety-mark attachment positions and meaning of icons and expressions
For the PS-800-8045 models
Avoid direct exposure or
disperse exposure of the
eyes and skin to radia-
tion.
Avoid direct exposure
or disperse exposure of
the eyes and skin to ra-
diation. This product is
a Class 4 laser product.
Be careful about the
laser.

– 2 –
DANGER label
If the cover is detached,
Class 4 no observation
laser beam will leak. Avoid
direct exposure or disperse
exposure of the eyes and
skin to radiation.
For the PS-800-12080, PS-800-13085 models
Avoid direct exposure or
disperse exposure of the
eyes and skin to radia-
tion.
Any person other
than the profes-
sional engineer
is not allowed to
detach the cover.
Parts that are common to the PS-800-
8045, PS-800-12080 and PS-800-13085
DANGER label
Avoid direct exposure or
disperse exposure of the
eyes and skin to radia-
tion. This product is a
Class 4 laser product.

– 3 –
DANGER label
This product causes
Class 4 laser beam ex-
posure. When you have
detached the cover, be
sure to avoid direct ex-
posure or disperse expo-
sure of the eyes and skin
to radiation.
Any person
who has not
received profes-
sional training
is not allowed to
touch the keys.
Twist counterclockwise:
Laser maintenance
mode
Twist clockwise:
Laser operation mode
Any person other than
the professional engi-
neer is allowed to carry
out adjustment. Do not
remove the cover while
the laser is in opera-
tion.
CAUTION label
This is the laser exit port.
Warning label against
pinching
This label indicates that
there is a risk of pinching
hands between the sew-
ing machine and the laser
device mechanism.

– 4 –
1-1. Precautions to be taken when installing or adjusting the laser
1) If the laser intensity is excessively high, take care not to directly look into the laser in order to protect
your eyes. Be sure to wear safety goggles during work.
2) Take care not to irradiate the mirror surface with laser light in order to prevent reflection.
3) Laser current during the adjustment: Adjustment of the laser current during adjustment is prohibited.
The factory-set value at the time of shipment must be used as the standard value.
4) Be sure to use the adjustment mode when you adjust this product. (Refer to "5-5. Adjusting the
laser" p.13.)
5) Visible angle during work or adjustment (See the figure given below)
No observation
25°
Cutting position
1-2. Precautions to be taken when using the laser
1) Be sure to check the head section of the laser to clean it up to remove the accumulated combustion
impurity every working day before commencing the work.
2) Check atmospheric pressure and adjust it to 0.4 - 0.6 MPa every working day before commending
the work.
3) Be sure to check whether the cooling water tank and suction fan of the equipment normally operate
every working day before commending the work.
4) Be sure to check the cooling water tank of the laser contains an adequate amount of crystal water
every working day before commencing the work.
5) Turn OFF the power switch every working day at the end of the work.
6) Turn OFF the pneumatic circuit switch every working day at the end of the work.
7) Be sure to place the exhaust pipe of the suction fan in an outdoor location and attach a combustion
deodorizing filter to its outer connector.
8) This product is a Level-4 no observation light laser product. Anybody who has not received the pro-
fessional training must remain away from this product to protect against injury.
9) Whenever you want to carry out maintenance / repair of the laser equipment of this product, be sure
to contact our After-Sale Service Department. The professional staff who has received professional
training in JUKI to gain experience of the relevant work will carry out maintenance / repair of your
product.
C: Reflecting mirror of the laser
D: Focusing lens of the laser
E: Laser tube
Schematic illustration of the laser optical path: (For the PS-800-12080 and -13085 models)
It is prohibited to observe the laser
tube with an optical telescope or
directly look at the optical path while
the laser is in operation, from the
locations as shown in the figure.

– 5 –
Schematic illustration of the laser optical path: (For the PS-800-8045 models)
2. MAINTENANCE
1) Observe the cooling water tank of the laser to check whether the water normally circulates in the
tank to ensure that the laser tube is not clogged inside.
2) Wipe the reflecting mirror surface with alcohol once every half month to keep it clean and to im-
prove its reflecting effect. Wipe the focusing lens inside the irradiation cylinder with alcohol from
time to time to keep it clean.
3) Carry out replacement of the laser tube according to the frequency to be used. If the laser tube fails
to satisfy the requirements for cutting the material, change the laser tube with an appropriate one.
4) For the cooling water tank of the laser tube, change the pure water (approximately 5L - 6L) in the
tank periodically once a week.
5) The water in the cooling water tank of the laser tube should be changed every time the laser tube is
changed together. Potable pure water of approximately 5L - 6L is used in the cooling water tank.
6) Check the hose of the tank and laser tube periodically once every three months and change it with
a new one if necessary in order to prevent a broken tube from negatively affecting smoking and
cooling.
7) Adjust / calibrate the laser path once every six months to ensure that the laser beam is focused
without distortion.
8) Clean up the drawer type dust sucking box located under the front stage of the laser every time you
have used the laser for four hours in order to prevent a fire from occurring.
9) Thoroughly inspect and carry out cleaning of the following parts every time you have used the laser
for eight hours to prevent accumulation of dust and deterioration of the tube, thereby preventing a
fire from occurring.
①Clean up litter in the upper smoking tube.
②Clean up litter in the lower smoking tube (Loosen the screw in the cover on the table. Clean up
litter at the tube opening and in the tube with a tool or small wooden stick).
③Clean up litter accumulated in the dust suction opening, outlet and exhaust pipe of the suction
fan.
10) Immediately carry out inspection and maintenance according to the instructions displayed on the
operation panel.
Service life of the laser tube: Approximately six months. Service life of the focusing lens and reflect-
ing mirror: Approximately one year. Periodical cleaning is required to prevent foreign matters from
attaching them.
C: Reflecting mirror of the laser
D: Focusing lens of the laser
E: Laser tube
It is prohibited to observe the laser
tube with an optical telescope or
directly look at the optical path while
the laser is in operation, from the
locations as shown in the figure.

– 6 –
3-1. Circuit diagrams
3. ELECTRICAL SAFETY
Note: Intersection of lead wires is not yet connected
Intersection of lead wires is connected
All of the base lines are connected on the same base.
Input voltage 220V
Neutral line (blue)
Ground wire
Ground wire
Air switch
24 VAC direct current
24 VAC direct current
24 VAC direct current
24 VAC direct
current
24 VAC direct current
24 VAC
direct
current
24 VAC
direct
current
Relay
Relay
24 VAC
direct
current
Relay
Fan
Bobbin
winder
Switch pow-
er supply
Rotary switch
Emergency
stop switch
Wiring
board
Key switch
Air switch
Fire wire (brown)
Fire wire
(brown)
Neutral line (blue)
Neutral line (blue)
Wiring
board
Ammeter
Electric wire
Water outlet
Laser tube
Water inlet
High-voltage wire
Silicon
tube
Silicon
tube
Water
outlet
Water
inlet
OUTLET
Water
cooler
Power
cord
(acces-
sory)
Wire-cut electromagnet
High-voltage wire Ammeter wire connector
Laser power source 100 W
5V IN G P L H AC AC FG
For normal
cutting
Potenti-
ometer
5V
IN G
For adjust-
ment
Potenti-
ometer
5V
IN G
Adjustment switch
Switch power
supply
Safety relay
Laser UP / DOWN sensor
OUT4 port for electrical
control connection
Electric control
Laser warning
Air blower
Air blower, three-
core power cord
Air blower, power
cord socket
Thyristor type
electronic voltage
regulator power cord
Ground wire
Ground wire
Thyristor type electronic
voltage regulator
OUT6 port for electrical
control connection
Laser UP / DOWN air tube
solenoid valve
Main shaft
motor
Servo presser
motor Control panel
(display)
X-direction
motor
Y-direction
motor
Fire wire (brown)

– 7 –
4-1. Installation of the laser after unpacking
4. INSTALLATION
Laser power supply manufacturer : JINAN ZHENYU ELECTRONIC CO.,LTD
Type: MYJG100W
Alternating current input voltage : 220V±10% Frequency : 50Hz
Maximum output voltage : 38KV Maximum current : 38mA
For the PS-8045 model, the laser power supply
and the thyristor type electronic voltage regulator
should not be removed. (Refer to the figure on the
left for their locations.)
For the PS-800-12080 and 13085 models:
1) Securing the laser power supply
To secure the laser power supply, align screws
❶(Fig. 1) with the tapped holes of the slider
nuts (Fig. 1) and tighten the two screws on the
right and left of the laser power supply.
2) To secure the thyristor type electronic voltage
regulator (Fig. 2), align screw ❸(Fig. 2) with
the tapped hole of slider nut ❹(Fig. 2) and
tighten the screw.
Fig. 1
Fig. 2
❷
❹
❸
❶

– 8 –
3) Connect laser power supply Ato the connec-
tion connector of the laser tube. Tighten laser
tube connection connector 1 Band laser pow-
er supply connection connector Cby turning
them clockwise. (See the figure.)
A: Laser power supply
B: Laser tube connection connector
C: Laser power supply connection connector 1
D: Laser tube connecting wire
E: Laser power supply connecting wire 1
A
B
C
D
E

– 9 –
J
F
G
H
I
4) Connect the current indication meter connec-
tor to the laser power supply cord connector.
Insert laser power supply connection connec-
tor 2 Ginto the current indication meter (See
the figure on the left).
F: Current indication meter connector (2P
male terminal)
G: Laser power supply connection connector
2 (2P female terminal)
H: Current indication meter connecting wire
I: Current indication meter
J: Laser power supply connecting wire 2
5) Put 2.5-L pure water or distilled water in the
cooling system. Use of tap water or mineral
water is prohibited. (Refer to "5-4-2. How to
feed water to the cooling system, and water
changing cycle" p.12 for how to put water
in the cooling system.)

– 10 –
5-1. Tune ON the power
5. OPERATION
Fig. 1
❶
Fig. 2
❷
1) Insert the power cord plug into the socket
(supply voltage: 220 V ± 20 %, 50 Hz). Be
sure to ground the power cord for the sake of
safety.
2) Among the power switches (air switches) in
the control panel cabinet, the switch that is
located at the left side of the control panel and
has the identical-color upper and lower cords
(red and red, and black and black) is the laser
power supply switch ❶. (See Fig. 1.) Another
air switch that is located at the upper right cor-
ner in the control panel and has different-color
upper and lower cords (red and brown, and
blue and black) is the sewing machine power
supply air switch ❷. (See Fig. 2.)
Put the compressed air from the air source (air
pressure: 0.5 - 0.6 MPa) to the air supply suction
inlet 64 by means of the air tube (specification: 8
× 5 mm).
5-2. Starting the air supply

– 11 –
5-3. Temporary measures
5-3-1. Emergency stop
In the case an accident occurs, press the white
pause button on the operation panel (Fig. 1 and
Fig. 2) to stop the current operation state (the
laser operation is stopped, but the power to the la-
ser is not turned OFF). Or, all of the power supply
to the equipment excluding the bobbin winder and
the control panel cabinet fan can be turned OFF
by pressing the red emergency stop button on the
four-button control panel (Fig. 2).
Fig. 1
Fig. 2
5-3-2. Re-start
Method 1: While the sewing machine is in the
temporary stop state, the background
LED lamp of "PAUSE" button ❶(Fig.
1) located at the lower portion of the
screen lights up in red.
When the accident is eliminated, press
"PAUSE" button ❶(Fig. 1). Then, the
background LED lamp of the pause
button changes its color to blue to
indicate that the laser is released from
the temporary stop state. Then, when
you press "START" button ❷(Fig.
1) located at the lower portion of the
screen, the sewing machine re-starts
automatic sewing.
❶❷
❺ ❸ ❹
Method 2: Press white "PAUSE" button ❸(Fig. 2) on the four-button control panel to release the laser
from the temporary stop state. When you press "START" button ❹(Fig. 2) on the four-button
control panel, the sewing machine continues automatic sewing.
Method 3: When the laser is placed in the temporary stop state with emergency stop button ❺(Fig. 2)
pressed, turn the emergency stop button ❺(Fig. 2) clockwise to release the laser from the
emergency stop state, before re-starting the sewing machine. After the aforementioned re-
setting, press "START" button ❹(Fig. 1) located at the lower portion of the screen or green
"START" button ❹(Fig. 1) on the four-button control panel to continue / re-start sewing.

– 12 –
5-4. Use of the cooling system
Fig. 1
Fig. 2
Open the water inlet of the cooling system of the
equipment. Put cooling water in the cooling sys-
tem (take care not to allow water to overflow).
5-4-1. Using the cooling system
1) Check to make sure that the drain pipe and water supplying pipe are securely connected to the
equipment.
2) At least 2.5-L water should be put in the cooling system. If the water in the cooling system runs
short, an alarm will sound from the cooling system. (Be sure to use pure water or distilled water.
Avoid the use of tap water or mineral water.)
3) After starting the cooling system for the first time after the purchase, immediately check the tubes
for leakage of water.
4) Plug in the power cord and turn ON the power switch. (Starting the cooling system without supplying
water is strictly prohibited.)
5-4-2. How to feed water to the cooling system, and water changing cycle
1) How to feed water : See Fig. 1. Be sure to wait until the water temperature becomes equal to the
room temperature before putting it in the cooling system.
2) Water changing cycle : It is recommended to change the water once every three months. When you
want to change the water in the cooling system, turn the power OFF, turn the
drain outlet (Fig. 2) to open it to allow the water to be discharged from inside
of the system for cleaning. Then, tighten the drain output and put new water
according to the instructions.
AWater inlet FRadiating fan
BAlarm signal output port GEquipment parameter
CPower supply connector (provided
with a fuse tube) HSerial number of the machine
DWater outlet IDischarge outlet
ECondensate inlet JAir inlet
I
A
B
C
H
G
F
E
D
J
I
I

– 13 –
5-4-3. Pilot lamp of the cooling
system
1) Pilot lamp: Fig. 3
* Refer to the "Explanations
about handling / installation of
industrial cooling system" for
the detailed description of how
to handle the cooling system.
Fig. 3
System indication
Operating status Green lamp Red lamp Buzzer
System is normally operat-
ing Light up Goes out Silent
Cooling water circulation
flow passage is clogged Goes out Light up Sound is
generated
Cooling water temperature
exceeds 60 degrees Goes out Light up Sound is
generated
Circulation pump has failed Goes out Light up Sound is
generated
Water shortage alarm Goes out Light up Sound is
generated
5-5. Adjusting the laser
If it is necessary to adjust the light path, be sure to contact our After-Sale Service staff
before carrying out the adjustment. The professional staff who has received professional
training in JUKI to gain experience of the relevant adjustment work will carry out the ad-
justment.
1) Laser switch key
Do not pull out the laser switch key.
When the switch is set to "1", the laser is energized and can be operated.
When the switch is set to "0", the power to the laser is disconnected and the laser cannot be operat-
ed. However, even in this case, the sewing machine is able to perform sewing.

– 14 –
2) Laser tube cover key
If it is necessary to adjust the light
path, be sure to contact our After-Sale
Service staff before carrying out the
adjustment. The professional staff
who has received professional train-
ing in JUKI to gain experience of the
relevant adjustment work will carry out
the adjustment.
3) Opening the laser adjustment mode
Turn the laser operation mode knob located
on the right side of the thyristor type electronic
voltage regulator counterclockwise to proceed
to the adjustment mode. (When the laser oper-
ation mode knob is turned counterclockwise,
the laser enters the laser adjustment mode.
When the knob is turned clockwise, the laser
enters the laser operation mode.)

– 15 –
5-5-1. Adjusting the laser reference
Adjust the laser reference following the below-stat-
ed steps of procedure. This procedure also ap-
plies to the PS-800-8045, PS-800-12080 and PS-
800-13085.
1) Place a piece of paper ❶at the upper left cor-
ner of the pattern.
❶
❷
2) Aligning the pattern with guide pin, adjust the
position of the paper in the X direction. Then,
click "PRESS" ❷located under the display.
3) Turn the pulley by hand to allow the needle to
penetrate into the paper at one point ❸.
❸
4 Click "Next" ❹on the electronic control main
screen.
❹
Fig. 1

– 16 –
❻
5) Click "Move Frame" ❺.
6) Click "Head Offset" ❼".
Fig. 2
Fig. 3
󱢳 󱢴
7) The values displayed beside the "Head 1" are
changed by clicking "Head 1" ❽.
8) Press button ❾on the screen, as shown in
Fig. 4, to move the head 1 up and down and
to the right and left until the needle-penetrat-
ed point of the paper is aligned with the laser
irradiation point. When you press "OUT4" ❻
as shown in Fig. 3, the paper is irradiated with
the light from the laser. Check to make sure
that the laser irradiation point is aligned with
the needle-penetrated point of the paper.
If the laser irradiation point is not aligned with
the needle-penetrated point of the paper, ad-
just the position of the head 1 with the arrow
buttons (up, down, right, left) ❾on the screen
as shown in Fig. 4 so that the aforementioned
two points are overlapped. Press the "Head
2". Then, press the "Confirm". (Rough image
of the aforementioned alignment adjustment is
as shown in Fig. 5.)
Fig. 4
❾
Fig. 5
Second time: Laser irradiation point is aligned
with the needle-penetrated point of the paper
First time: Laser irradiation point is not aligned
with the needle-penetrated point of the paper
❺
❼
❽

– 17 –
5-6. Using the laser
5-6-1. Electric control port for the laser for the regular use
1. Electric control port for the laser irradiation: OUT4
2. Electric control port for downward-direction operation of the laser head: OUT6
5-6-2. Reduction in the laser cutting range in comparison with the sewing range of the standard
model of sewing machine
PS-800-8045 : Reduction in the laser cutting range in the X direction : 153.5mm
Reduction in the laser cutting range in the Y direction : 23.5mm
PS-800-12080 : Reduction in the laser cutting range in the X direction : 153.5mm
Reduction in the laser cutting range in the Y direction : 23.5mm
PS-800-13085 : Reduction in the laser cutting range in the X direction : 153.5mm
Reduction in the laser cutting range in the Y direction : 23.5mm
5-6-3. Weight of the finished laser product
PS-800-8045 : Weight of the finished laser product : 355kg
PS-800-12080 : Weight of the finished laser product : 713kg
PS-800-13085 : Weight of the finished laser product : 558kg
5-6-4. Power consumption of the laser
PS-800-8045 : Standard : 500VA
Laser : 1350VA
Rotary knife : 750VA
PS-800-12080 : Standard : 470VA
Laser : 1320VA
Rotary knife : 720VA
PS-800-13085 : Standard : 640VA
Laser : 1490VA
Rotary knife : 890VA
5-6-5. Operation pilot lamp
1) The laser irradiation is enabled only when sen-
sor lamp ❶lights up. When the sensor lamp
goes out, the laser irradiation is disabled.
❶

– 18 –
2) While laser operation pilot lamp ❷located
above the head is in the ON state, the laser
receives the irradiation command. When it is
in the OFF state, the laser does not receive
the command. When the pilot lamp lights up,
the laser equipment is in the operation state or
in the stand-by state for irradiation.
❷
5-6-6. Operation pilot lamp
1) When the laser tube is lifted to its upper po-
sition, there is a distance of 18 mm between
the lowermost point of the laser head and the
table surface. When the laser tube is pushed
down to its lower position, the aforementioned
distance is reduced to 5 to 8 mm. The highest
position of the suction cover must be posi-
tioned 8 mm or lower than the pattern while
the laser is in operation.
5 to 8mm
The distance between the cover and the table
becomes 8 mm or less when the pattern is
pushed down while the laser is in operation.
2) Loosen the connection at the upper part of the
laser tube, and adjust the height of the laser
tube according to the material thickness.