Cut Startup

This section will guide you through the process of setting up WAZER to cut your Design. Over time this process will be familiar to you, and the Control Panel prompts will likely be enough to walk you through the setup.

Insert the SD Card

Transferring Cut Files to WAZER is done through an SD Card. To transfer Cut Files onto the SD Card, connect the card to your computer, and drag-and-drop the Cut Files onto the SD Card. WAZER has a slot near the Control Panel that accommodates a standard sized SD Card. It is important that you insert the SD Card before turning WAZER on.

An SD Card is provided with your Setup Kit. This SD Card contains the Cut File for the Welcome Cut. Place it in WAZER now.

 

Turn On WAZER

WAZER has a single Power Switch located at the bottom right corner of the main unit. Flip this switch to turn WAZER on.

[NOTICE] When you first turn on WAZER, the Main Menu will be displayed on the Control Panel, and the Start/Stop Button will be flashing. If you remove the Right-Side Access Panel and observe the Control Box, all four of the LEDs on the left side will be on, the top and bottom lights of the middle column will be on, and the two middle LEDs of the middle column will be flashing. None of the LEDs on the right side will be on. WAZER will not be making any noise.

You will notice that there is no Power Switch for the Pump Box. This is because the Pump Box is controlled by WAZER Main Unit through the Signal Cable. Please ensure that the Pump Box is connected to power and that the Signal Cable is connected.

During initial startup, a water leveling error may occur . This is the first time the WAZER is switched on, so it is normal for the water level to be too high or too low. If your WAZER fails to turn on, check the high and low float switch on right side of the tank; if either of these switches are triggered, WAZER will not operate. Top up or siphon out water as needed. DO NOT use Reverse-Osmosis or Deionized water as this will destroy the machine.

 

Transfer Cut Files to WAZER

The next step is to transfer a Cut File to WAZER. A Cut File is a type of .gcode file with some WAZER-specific commands. This file includes all the parameters required to cut your Design. NOTE: USB connectivity is still under development but will be available at a later date.

Follow the Control Panel Prompts
You control WAZER via the onboard screen and keypad. The “>” symbol on the left indicates the current selectable field. The OK Button confirms a selection. Pressing the Left-Arrow key will take you back to the previous menu.

When WAZER is turned on, the Control Panel will present two options:
- Select Cut File: This allows you to select a Cut File and initiate a Cut.
- Setup & Maintenance: This allows you to choose from several setup and maintenance options that will aid in the upkeep of WAZER. (More on this later.)

Select a Cut File
Select Cut File on the Control Panel’s Main Menu brings up a file selection menu that lists all the .gcode Cut Files on the SD Card. Select the Cut File that you would like to cut.

Selecting a Cut File will not immediately start a Cut. The Control Panel will walk you through a series of prompts before cutting your file. WAZER will never start cutting without your explicit consent.

If you do not have an SD Card plugged in, the Control Panel will display the .gcode Cut Files that are located in WAZER’s onboard memory.

ControlPanelScreen-SelectCutFile.png
ControlPanelScreen-WelcomeCut.png
 

Initiate a Cut

If this is the first time using a new WAZER, select the Welcome Cut file. It is important to
run this Cut File to ensure that WAZER is fully functional. It will also familiarize you with the basic WAZER functionality before learning the Wam software, which we will cover in the next section. You will find this Cut File on the SD Card that is provided in the Setup Kit. Go ahead and plug it into WAZER and select Welcome Cut File.

 

Lift the Nozzle

After selecting a Cut File, you will be prompted to lift the Nozzle. This is to ensure that the Nozzle does not crash into anything in its next automated action. To lift the Nozzle, loosen the Nozzle Lock Knob, lift the Nozzle by pushing it up and then tighten the Nozzle Lock Knob. Confirm this action has been performed by pressing “OK” on the Control Panel. This will initiate a homing routine. NOTE: The Nozzle will start moving after you press “OK”.

ControlPanelScreen-CutPrep1.png
 

Home WAZER

Upon confirmation, the WAZER will automatically home the Nozzle to the top-left corner of the Cut Bed. Once completed, the Nozzle will move to the top-left corner of your Cut File’s Cut Extents (the Bounding Box around the Cut). This is the visual locater you will use to reference your Material’s position when placing it on the Cut Bed. We address this in detail later on in the User Manual. WAZER will also Analyze the Cut File while it is homing. This shouldn’t take more than a few moments.

 

Load Abrasive

After homing, WAZER will prompt you to check the Abrasive Level.
You must refill the Abrasive Hopper before running every Cut so that WAZER can pause when it starts to run low on Abrasive. The Abrasive Hopper will hold approximately 35 lbs of abrasive when full.

[NOTICE] Refilling the Abrasive Hopper completely is extremely important. Failing to fill the Abrasive Hopper sufficiently will result in a Failed Cut, and you will need to restart. WAZER does not have a sensor to read the Abrasive Level, so it assumes that it is filled prior to the start of every Cut. If this is done correctly, WAZER will pause the Cut when the Abrasive runs low, then prompt you to refill the Abrasive Hopper and continue cutting. WAZER will pause after one hour of run-time to allow you to refill the Abrasive Hopper and to empty the Used Abrasive Buckets.

[NOTICE] Using an Abrasive that is not specified by WAZER may lead to poor quality and damage to your machine. You must use the Abrasive suggested on the WAZER website. The WAZER is calibrated to run with the 80 HPA garnet available for purchase at www.wazer.com.

For very long Cuts, you may need to use more Abrasive than the Abrasive Hopper can hold. WAZER is set with a timer that will pause the Cut after a set amount of time and allow you to refill Abrasive and continue cutting.

Always use the screens for sifting abrasive into the machine. Even particles of 1.2mm can cause an abrasive clog and jam your cutting head, resulting in a very expensive fix and serious back-flow of water up the abrasive line.

To load Abrasive:

  • Pull out the Abrasive Hopper, located on the left side of WAZER.

  • We recommend using a large cup to pour the Abrasive through the two screens until the Abrasive Hopper is full. It is critical that you pour the Abrasive through the screens. If anything other than new, dry Abrasive falls into the Abrasive Hopper it can ruin your Cut and require time-intensive maintenance. The Abrasive should filter through the screens quickly. The filters will not clog as your pour.

  • Fill the Abrasive Hopper until you see some Abrasive above the level of the screen on both sides. A small void may remain between the two screens. Close the Abrasive Hopper and confirm task completion by selecting OK on the Control Panel.

It is okay if the Abrasive piles are a little uneven and begin to pile up in the center. Just add some Abrasive to the sides to help even things out.

 

Empty the Used Abrasive Buckets

Next, you will empty the Used Abrasive from the collection system. During cutting, Abrasive is constantly being introduced into the Jet. To prevent accumulation on the bottom of the Tank, the Used Abrasive is constantly collected and routed into two Used Abrasive Buckets located at the front of WAZER. You must empty both Used Abrasive Buckets before every Cut.

To empty the Used Abrasive Buckets:

  • Remove the Front Tank Cover.

  • Rotate the handles upwards and pull the Used Abrasive Buckets out of their retainers.

  • Dump the Used Abrasive into a container to await final disposal. We suggest you first pour excess water out of the Used Abrasive Buckets; the collected Used Abrasive will have settled at the bottom.

Not all the Used Abrasive will be collected from the Tank and there may be some that accumulates in the Tank. This is not a concern. Run a Tank Cleaning Cycle to collect the excess Used Abrasive. More on this in Maintenance > Used Abrasive Collection System. If you have any trouble with the Used Abrasive Collection System see Troubleshooting > Used Abrasive Collection.

Replacing the Used Abrasive Buckets is sometimes tricky, here are two techniques to help:(also see Troubleshooting > Trouble Getting Abrasive Buckets In)

     a. Push the Used Abrasive Buckets down into their retainers to fill with water, so they do not float. The metal handles double as a locking mechanism to hold the buckets down. Rotate the handles so that they are straight up, push the Used Abrasive Buckets all the way down, and rotate the handle forward. The hooks on the handle should engage with the Tank and keep it down while it fills.

     b. You may realize the Used Abrasive Buckets sometimes cannot be fully pushed down into their retainers. This is because Used Abrasive has collected in the area under them. Simply clear this out with your hand (using gloves as needed) and then replace the Used Abrasive Buckets. If this happens, it may be time to do an additional Tank Cleaning Cycle through the Setup & Maintenance menu after your next Cut.

ControlPanelScreen-CutPrep2.png
  • Replace the Front Tank Cover. You should feel it fall into place if installed correctly. You will also see the front of the handles sticking out beneath the front lip of the Front Tank Cover when correctly installed.

  • Confirm task completion by pressing “OK” on the Control Panel.

Failing to empty the Used Abrasive Buckets between Cuts will result in your Filtration System becoming clogged over time. The amount of time and work required to unclog the system is significantly greater than simply staying on top of regularly emptying your Used Abrasive Buckets.

Dispose of Used Abrasive properly. The abrasive is inert, so it can be handled as a non-hazardous material and thrown away as garbage waste. However, if you are cutting hazardous Materials or certain metals, be sure to check your local regulations and requirements.

[CAUTION] Bacteria can build up in the standing water of the Tank. Any injuries or cuts, even minor ones, should be treated with caution. If you have open wounds avoid contact with the water or wear gloves that do not expose you to the Tank water

 

[NOTICE] Confirm the Water Supply is On

Water is supplied to WAZER via the Pump Box so that it can cut. Double-check that the On/Off Valve is on. It is critical to not overlook this step, because WAZER does NOT know if the water supply is on or off. Running WAZER without the water supply turned on will damage the Pump Box.

If you do happen to attempt to cut a file without the water on, you will immediately notice that something is wrong, because the flow will be weak, and the Jet will not cut through. In this case, DO NOT panic. Simply pause WAZER, turn the water supply on and start your Cut.

 

Fasten the Material

Securely fastening the Material to the Cut Bed is critical to the accuracy of your desired Cut. If your Material moves during cutting, the results will be very poor, or the Cut may fail completely.

Be mindful if the shape you are cutting will be close to the edge of the stock Material in certain areas. Place the fasteners away from these areas. This will reduce the risk of the Nozzle crashing into those fasteners.

You can use any fasteners that are about 5 mm in diameter to secure your materials to the corrugated Cut Bed. The coarser the thread the better, hence wood and sheet metal screws are ideal. Be mindful of the Nozzle profile and the screw head size you choose to minimize Nozzle crashes and losing a Cut.

To fasten your Material:

  • Place several Fastening Screws around the Material and screw them directly into the Cut Bed. You can insert a screw into any of the holes in the Cut Bed.

  • Perform a quick check to make sure that the Material is large enough to accommodate the shape you want to cut.

  • Place the Material on the Cut Bed and line up the top left corner of the Material with the center of the Nozzle (if you have extra Material, you may place it past the Nozzle center - higher and more to the left).

  • Fasten the Material with the Fastening Screws in the Spare Parts bag, confirming that it cannot slide in any direction.

ControlPanelScreen-CutPrep3.png
  • Confirm task completion by pressing “OK” on the Control Panel.

  • If this is your Welcome Cut, we already did this for you, so you can move on!

 

Set Nozzle Height

[NOTICE] Setting the height of the Nozzle relative to the Material is critical. If the Nozzle Height is set improperly, WAZER may not cut through the Material or the Gantry may jam.

ControlPanelScreen-CutPrep4.png

To set the Nozzle Height:

  • First, the Control Panel will prompt you to set the Nozzle Height.

  • Grab the Nozzle Height Tool, which is the black cap on top of the Nozzle.

  • Place the Nozzle Height Tool on top of your Material and loosen the Nozzle Lock Knob on the Nozzle.

  • You may Jog the Nozzle over the Material using the keypad. This will not affect the starting position for the Cut.

  • Slide the Nozzle Height Tool up against the Nozzle Cover, and gently lower the Nozzle onto it. The flange of the Nozzle Height Tool should now be caught between the Material and the Nozzle, which is hidden under the grey Nozzle Cover. As long as the Nozzle Height Tool is between the Nozzle and the Material to becut, you can trust that it is set properly.

  • Tighten the Nozzle Lock Knob after the height is set properly.

  • Pull the Nozzle Height Tool out from under the Nozzle and replace it on top of the Nozzle.

  • Confirm task completion by pressing OK on the Control Panel.

Tips for setting Nozzle Height:

When setting the Nozzle Height, you should feel some resistance, but the Nozzle should not be so tight against the Nozzle Height Tool that you cannot easily slide it out. If the Nozzle Height is set too low, it might crash and ruin your Cut which would require significant maintenance. If the Nozzle height is set too high, you may notice a small effect on your Cut Quality. It is better to be slightly too high than to be too low.

If you lost your Nozzle Height Tool, simply slide a 0.098” (2.5 mm) piece of material between your Material and the Nozzle.

 

Perform a Final Check

A Cut can be costly. Take advantage of the Control Panel’s preview features to ensure that you positioned the Material correctly.

We highly recommend that you use one of these features before starting a Cut:

Check Cut Extents: Select this feature and the Nozzle will slowly trace a rectangle that will designate your Cut Extents (essentially the smallest rectangle that fully encompasses your Cut). As it moves, the center of the Nozzle should never cross the edge of the Material that you fastened to the Cut Bed.

Dry Run: Select this feature and the Nozzle will trace the path of the entire Cut File without releasing water. This is the more time-consuming option, but fully verifies the setup since it replicates the final Cut Path.

 

Finalize the Setup

Once you have checked your setup select “Cut Material” on the Control Panel. WAZER is now ready to cut.