DCS 1500-2500 and Taurus User Guide

A-D-042 12/2000
CUTTING EDGE DCS 1500/2500 MECHANICAL and TAURUS TLCS GERBERcutter
USERS GUIDE
COPYRIGHT NOTICE
Copyright 2000 by Gerber Technology, Inc., Cutting Edge division. This document may not be reproduced by any means, in whole or in part, without the written permission of the copyright owner. This document is part of the proprietary articles furnished to document the Cutting Edge software. In consideration of the furnishing of the information contained in this document, the party to whom it is given assumes control and custody and agrees to the following: 1. The information contained herein is given in confidence and any part thereof shall not be copied or reproduced without the written consent of Gerber Technology, Inc. 2. This document or the contents herein under no circumstances shall be used in the manufacture or reproduction of the article shown and the delivery shall not constitute any right or license to do so. This document contains information which is protected by copyright. All rights reserved. No part of this document may be photocopied or reproduced without the prior written consent of Gerber Technology, Inc. The information in this document is subject to change without notice. Gerber Technology, Inc., its subsidiaries and affiliates shall not be liable for errors in this documentation or for incidental or consequential damages in connection with furnishing, or use of this material. Document Number A-D-042 12/2000
TRADEMARKS
AccuMark, MicroMark, G (stylized logo) and Microdynamics are either registered trademarks, or trademarks of Gerber Technology, Inc. AutoCAD is a registered trademark of Autodesk, Inc. CADAM is a registered trademark of Dassault Systemes of America, Corp. CATIA is a registered trademark of Dassault Systemes, S.A. CorelDRAW is a trademark of Corel Corporation. Hewlett Packard is a registered trademark of the Hewlett Packard Company. In Focus and LP are trademarks or registered trademarks of In Focus, Inc. OptiTex is a registered trademark of Scanvec Garment Systems. PC is a registered trademark of International Business Machines Corporation. Pentium is a registered trademark of Intel Corporation. Trackball Pro is a trademark of CH Products. Virtek Leather Nesting software (AutoCut) is a registered trademark of Virtek Vision Corp. Windows 3.1, Windows 95 and Windows NT are registered trademarks of Microsoft Corporation.
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DCS 1500/2500 Mechanical and Taurus TLCS
TABLE OF CONTENTS
LIST OF FIGURES.................................................................................................................... XI LIST OF SCREENS ................................................................................................................ XIII LIST OF TABLES ....................................................................................................................XV 1.0 INTRODUCTION.............................................................................................................. 1-1 1.1 GENERAL .................................................................................................................... 1-3 1.2 SAFETY ....................................................................................................................... 1-3 1.2.1 PRECAUTIONS..................................................................................................... 1-3 1.2.2 SYMBOLS ............................................................................................................. 1-5 1.2.2.1 Control Panel.................................................................................................. 1-5 1.2.2.2 Keypad ........................................................................................................... 1-6 1.2.2.3 Labels............................................................................................................. 1-7 1.2.3 FORESEEN USES ................................................................................................ 1-8 1.2.4 NOISE EMISSIONS............................................................................................... 1-8 1.3 1.4 1.5 MANUAL DESCRIPTION ............................................................................................. 1-9 PARTS IDENTIFICATION .......................................................................................... 1-10 HOW TO CONTACT US ............................................................................................ 1-10
2.0 INSTALLATION ............................................................................................................... 2-1 2.1 GENERAL .................................................................................................................... 2-3 2.2 CUTTING SYSTEM SHIPPING WEIGHTS AND DIMENSIONS................................... 2-3 2.2.1 SHIPPING WEIGHTS AND DIMENSIONS DCS 1500........................................ 2-3 2.2.2 SHIPPING WEIGHTS AND DIMENSIONS DCS 2500........................................ 2-4 2.2.3 TAURUS TLCS SHIPPING WEIGHTS AND DIMENSIONS .................................. 2-4 2.3 MACHINE INSTALLATION REQUIREMENTS ............................................................. 2-5 2.3.1 TYPICAL CUTTING MACHINE INSTALLATION ................................................... 2-5 2.3.1.1 Cutting Machine Installation DCS 1500 ....................................................... 2-5 2.3.1.2 Cutting Machine Installation DCS 2500 ....................................................... 2-6 2.3.1.3 Cutting Machine Installation Taurus............................................................. 2-6 2.3.2 ENVIRONMENTAL TEMPERATURE AND HUMIDITY....................................... 2-7 2.3.3 AIR SUPPLY ......................................................................................................... 2-8 2.3.4 ELECTRICAL POWER.......................................................................................... 2-8 2.3.4.1 Electrical Requirements DCS 1500/2500..................................................... 2-8 2.3.4.2 Electrical Requirements Taurus................................................................... 2-8 2.3.4.3 Lightning Protection........................................................................................ 2-9 2.3.4.4 Machine/System Grounding ........................................................................... 2-9 2.4 INSTALLING THE CUTTING EDGE SOFTWARE ..................................................... 2-10 2.4.1 PC REQUIREMENTS DCS 1500/2500............................................................. 2-11 2.4.2 PC REQUIREMENTS TAURUS ....................................................................... 2-11
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2.5 HARDWARE LOCK.................................................................................................... 2-12 2.5.1 INSTALL HARDWARE LOCK ............................................................................. 2-12 2.5.1.1 Configure the Hardware Lock ....................................................................... 2-12 2.5.1.2 Remove Modules from the Lock ................................................................... 2-13 2.5.2 SET PC MONITOR RESOLUTION DCS 1500/2500......................................... 2-14 2.5.3 SET PC MONITOR RESOLUTION TAURUS ................................................... 2-14 2.5.4 START CUTTING EDGE SOFTWARE................................................................ 2-14 2.6 2.7 2.8 CONFIGURE MACHINE............................................................................................. 2-15 CAMERA CONFIGURATION ..................................................................................... 2-21 CHECK MACHINE CALIBRATION ............................................................................. 2-22
3.0 DESCRIPTION................................................................................................................. 3-1 3.1 3.2 3.3 GENERAL .................................................................................................................... 3-3 MACHINE DESCRIPTION DCS 1500/2500............................................................... 3-3 MACHINE DESCRIPTION TAURUS TLCS ............................................................... 3-4
3.4 TABLE AND CARRIAGE .............................................................................................. 3-6 3.4.1 VACUUM TABLE................................................................................................... 3-6 3.4.2 SERVO MOTORS ................................................................................................. 3-6 3.4.3 LIMIT SWITCHES ................................................................................................. 3-6 3.4.4 BUMPER ARM SWITCHES................................................................................... 3-7 3.4.5 EMERGENCY STOP BUTTONS (E-STOPS) ........................................................ 3-7 3.4.6 HOMING SENSORS ............................................................................................. 3-7 3.4.7 TOOL HOLDER SENSORS................................................................................... 3-7 3.4.8 KEYPAD................................................................................................................ 3-8 3.4.9 PEN AND CUTTER PNEUMATICS ....................................................................... 3-8 3.5 CONTROL CABINET.................................................................................................... 3-9 3.5.1 SAFETY INTERLOCK SYSTEM............................................................................ 3-9 3.5.2 CONTROL PANEL ................................................................................................ 3-9 3.5.2.1 AC Power Switch............................................................................................ 3-9 3.5.2.2 Reset Button................................................................................................. 3-10 3.5.2.3 Status Board................................................................................................. 3-10 3.5.2.4 Pressure Gauges and Regulators ................................................................ 3-10 3.5.3 EXTERNAL INTERLOCKS .................................................................................. 3-10 3.6 PERSONAL COMPUTER (PC)................................................................................... 3-11 3.6.1 REQUIRED SOFTWARE MODULE .................................................................... 3-11 3.6.2 HARDWARE LOCK............................................................................................. 3-11 3.6.3 SERVO MOTION CONTROLLER ....................................................................... 3-11
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3.7 OPTIONS ................................................................................................................... 3-12 3.7.1 SOFTWARE OPTIONS ....................................................................................... 3-12 3.7.1.1 Toolpath Module........................................................................................... 3-12 3.7.1.2 Nesting Modules........................................................................................... 3-12 3.7.1.3 Extended AutoNest Yield Enhancement Module........................................... 3-12 3.7.1.4 Matching modules ........................................................................................ 3-12 3.7.1.5 CIM (Database) Module................................................................................ 3-13 3.7.1.6 CIM Administrator Module ............................................................................ 3-13 3.7.1.7 Rights and Access (R&A) Module................................................................. 3-13 3.7.1.8 Imaging Module ............................................................................................ 3-13 3.7.2 HARDWARE OPTIONS ...................................................................................... 3-14 3.7.2.1 Laser Pointer ................................................................................................ 3-14 3.7.2.2 Spreader....................................................................................................... 3-14 3.7.2.3 Pneumatic Vacuum Shut Off System............................................................ 3-14 3.7.2.4 Pneumatic Reverse Air System .................................................................... 3-14 3.7.2.5 Pneumatic Dual Zone System ...................................................................... 3-14
4.0 OPERATING INSTRUCTIONS ........................................................................................ 4-1 4.1 4.2 GENERAL .................................................................................................................... 4-3 SAFETY ....................................................................................................................... 4-3
4.3 PRINCIPLES OF MACHINE OPERATION ................................................................... 4-4 4.3.1 CUTTING TOOL PRINCIPLES.............................................................................. 4-4 4.3.1.1 Wheel Cutter .................................................................................................. 4-4 4.3.1.2 Tangential Knife Cutter................................................................................... 4-4 4.3.1.3 Punch and Notcher Tools ............................................................................... 4-4 4.3.2 CUTTING PRESSURE .......................................................................................... 4-5 4.3.2.1 Wheel Cutter .................................................................................................. 4-5 4.3.2.2 Tangential Knife Cutter................................................................................... 4-5 4.3.3 INKING PRINCIPLES ............................................................................................ 4-5 4.3.4 MATERIAL PROPERTIES..................................................................................... 4-6 4.3.4.1 Material Set .................................................................................................... 4-6 4.3.5 VACUUM TABLE OPERATION ............................................................................. 4-7 4.3.6 PLASTIC OVERLAY.............................................................................................. 4-7 4.3.7 PAPER UNDERLAY .............................................................................................. 4-7 4.4 OPERATING CONTROLS............................................................................................ 4-8 4.4.1 KEYPAD OPERATION .......................................................................................... 4-8 4.4.1.1 Online Mode ................................................................................................... 4-9 4.4.1.2 Local Mode................................................................................................... 4-10 4.4.2 PC OPERATION ................................................................................................. 4-12 4.4.2.1 Basic Windows Concepts ............................................................................. 4-12 4.4.2.2 Basic Mouse Commands.............................................................................. 4-13
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4.5 SETTING UP FOR NEW JOB .................................................................................... 4-14 4.5.1 CUTTING MACHINE CONTROL SETTINGS ...................................................... 4-14 4.5.1.1 Set Pen Pressure ......................................................................................... 4-14 4.5.1.2 Set Cutter Pressure ...................................................................................... 4-15 4.5.1.3 Adjust the Focus of the (Optional) Laser Pointer .......................................... 4-15 4.5.1.4 Removal and Installation of Wheel Cutter..................................................... 4-16 4.5.1.5 Setting Depth of the Tangential Knife ........................................................... 4-17 4.6 STARTING THE CUTTING MACHINE ....................................................................... 4-19 4.6.1 LOCAL MODE ERROR MESSAGE ..................................................................... 4-20 4.7 SHUT DOWN THE CUTTING MACHINE ................................................................... 4-21
5.0 WORKING WITH JOBS................................................................................................... 5-1 5.1. GENERAL................................................................................................................. 5-3 5.2. OPENING A JOB FILE.............................................................................................. 5-3 5.2.1. OPENING A WORK ORDER................................................................................. 5-3 5.2.2. OPEN COMMAND................................................................................................. 5-4 5.2.2.1. Fast Open....................................................................................................... 5-5 5.3. JOB PARAMETERS.................................................................................................. 5-6 5.3.1. SETTING JOB PARAMETERS DIALOG BOX....................................................... 5-6 5.3.2. SPLIT TABLE OPERATION ................................................................................ 5-11 5.3.2.1. Job Origin in Split Table Mode...................................................................... 5-11 5.3.2.2. Mid-table Origins .......................................................................................... 5-12 5.3.3. NORMAL TABLE OPERATION DCS 1500/2500 .............................................. 5-13 5.3.3.1. Job Origin in Normal Mode ........................................................................... 5-13 5.4. PREPARE JOB ....................................................................................................... 5-14 5.4.1. SET TOOLS AND TOOL PARAMETERS............................................................ 5-14 5.4.2. CHECK TOOL CONFIGURATION ...................................................................... 5-15 5.4.3. CONFIGURE SMART TEXT................................................................................ 5-15 5.4.3.1. Automatic Text ............................................................................................. 5-15 5.4.3.2. Operator Text ............................................................................................... 5-16 5.5. RUNNING THE JOB ............................................................................................... 5-17 5.5.1. START CUT JOB ................................................................................................ 5-17 5.5.2. USING OPTIONAL STOPS AND SMART STOPS .............................................. 5-19 5.5.3. STOP AND CONTINUE THE JOB....................................................................... 5-20 5.5.4. PARTS OUT OF BOUNDS.................................................................................. 5-20 5.6. MATCHING ON A DCS 2500 .................................................................................. 5-21 5.6.1. SET MATCHING PARAMETERS ........................................................................ 5-21 5.6.2. MATCHING THE JOB ......................................................................................... 5-23 5.7. 5.8. DIGITIZE PARTS.................................................................................................... 5-24 EXIT........................................................................................................................ 5-26
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6.0 CALIBRATION................................................................................................................. 6-1 6.1 GENERAL .................................................................................................................... 6-3 6.2 CALIBRATE MACHINE ................................................................................................ 6-3 6.2.1 BASIC CALIBRATION ........................................................................................... 6-6 6.2.1.1 Square Carriage ............................................................................................. 6-6 6.2.1.2 Adjust Pneumatics.......................................................................................... 6-7 6.2.1.3 Set Scale Factor ............................................................................................. 6-9 6.2.1.4 Set Length .................................................................................................... 6-10 6.2.1.5 Set Stations .................................................................................................. 6-11 6.2.1.6 Check Y Belt................................................................................................. 6-12 6.2.1.7 Camera Calibration -- Taurus ....................................................................... 6-15 6.2.2 HOLDERS ........................................................................................................... 6-19 6.2.2.1 Align Cutter Angle......................................................................................... 6-19 6.2.2.2 Align Cutter Offsets ...................................................................................... 6-22 6.2.2.3 Align Punch Offsets...................................................................................... 6-25 6.2.2.4 Align Laser Pointer Offsets........................................................................... 6-26 6.2.2.5 Test Cut........................................................................................................ 6-27 6.2.3 TOOLS ................................................................................................................ 6-28
7.0 MAINTENANCE ............................................................................................................... 7-1 7.1 7.2 GENERAL .................................................................................................................... 7-3 PREVENTIVE MAINTENANCE SCHEDULE ................................................................ 7-3
7.3 MACHINE MAINTENANCE PROCEDURES................................................................. 7-9 7.3.1 CLEAN AND LUBRICATE RAILS AND BEARING DCS 1500/2500.................... 7-9 7.3.2 CLEAN THE RAILS TAURUS............................................................................. 7-9 7.3.3 CLEAN AND LUBRICATE THE LINEAR BEARINGS TAURUS.......................... 7-9 7.3.4 CHECK FOR LOOSE RAIL JOINTS...................................................................... 7-9 7.3.5 INSPECT THE LINEAR BEARINGS FOR DAMAGE ........................................... 7-10 7.3.6 CLEAN THE RACK AND PINIONS...................................................................... 7-10 7.3.7 CHECK THE LIGHT BULBS TAURUS ............................................................. 7-10 7.3.8 CHECK THE CUTTING BLADE .......................................................................... 7-10 7.3.9 CHECK THE WHEEL CUTTER BOLT ................................................................ 7-10 7.3.10 CLEAN THE TABLE SURFACE TAURUS .................................................... 7-11 7.3.10.1 Create the Table Cleaning File ..................................................................... 7-12 7.3.10.2 Clean the Table Surface............................................................................... 7-15 7.3.11 CHECK THE EMERGENCY STOP BUTTONS ................................................ 7-16 7.3.12 CHECK THE LOOP AND CHAIN FESTOONS................................................. 7-17 7.3.12.1 Check the X-axis Loop ................................................................................. 7-17 7.3.12.2 Check the Y-axis Chain Festoon .................................................................. 7-17 7.3.13 CHECK THE X-AXIS RACK AND PINIONS (ADJUST BACKLASH) ................ 7-20 7.3.14 CHECK THE RACK FOR DAMAGE OR ROUGH SPOTS ............................... 7-21 7.3.15 CHECK THE X-AXIS DRIVE HUB ................................................................... 7-21
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7.3.16 7.3.16.1 7.3.16.2 7.3.16.3 7.3.17 7.3.18 7.3.19 7.3.19.1 7.3.19.2 7.3.19.3 7.3.20 7.3.20.1 7.3.20.2 7.3.20.3 7.3.20.4 7.3.20.5 7.3.21 7.3.22 7.3.22.1 7.3.22.2 7.3.23 7.3.24 7.3.25 7.3.26 7.3.27 7.3.27.1 7.3.27.2 7.3.27.3 7.3.27.4 7.3.27.5
INSPECT THE MOTORS................................................................................. 7-23 Inspect the X-axis motors ............................................................................. 7-23 Inspect the Y-axis motor ............................................................................... 7-23 Inspect the Theta axis motor ........................................................................ 7-23 REPLACE THE WHEEL CUTTER BLADE BOLT ............................................ 7-24 CHECK AND LUBRICATE THE AIR CYLINDERS ........................................... 7-25 REPAIR THE CUTTING SURFACE DCS 1500/2500.................................... 7-26 Repair a Wear-Damaged Table Surface DCS 1500/2500 ......................... 7-26 Repair Delamination or High Temperature Damage DCS 1500/2500 ........ 7-27 Repair to Raised Seams between Plastic Panels DCS1500/2500 ............. 7-29 REPAIR THE CUTTING SURFACE TAURUS .............................................. 7-30 Install Table Panels- Standard Hole Pattern ................................................. 7-30 Install Table Panels- High Density Table Surface ......................................... 7-33 Remove the Table Surface Taurus ............................................................ 7-35 Replace One Table Surface Panel Taurus ................................................ 7-36 Repair Table Panel Glue Seam Taurus ..................................................... 7-37 CLEAN THE CONTROL CABINET FILTER ..................................................... 7-38 LUBRICATE THE DRIVE BELTS..................................................................... 7-38 Lubricate the X-axis Belts ............................................................................. 7-38 Lubricate the Y-axis Belt............................................................................... 7-38 REPLACE THE X-AXIS DRIVE PINIONS ........................................................ 7-39 REPLACE AND/OR ADJUST THE X-AXIS LINEAR BEARING ....................... 7-41 CHECK THE THETA AXIS HEIGHT DCS 1500/2500 ................................... 7-44 CHECK THE THETA AXIS HEIGHT TAURUS.............................................. 7-45 REPLACE AND ADJUST THE DRIVE BELTS ................................................. 7-46 Replace and Adjust the X-axis Belt DCS 1500/2500.................................. 7-47 Replace and Adjust the X-axis Belt Taurus................................................ 7-48 Replace and Adjust the Y-axis Belt DCS 1500/2500.................................. 7-49 Replace and Adjust the Y-axis Belt Taurus................................................ 7-51 Replace and Adjust the Theta Drive Belt ...................................................... 7-53
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8.0 TROUBLESHOOTING ..................................................................................................... 8-1 8.1 8.2 GENERAL .................................................................................................................... 8-3 INTRODUCTION .......................................................................................................... 8-3
8.3 SOFTWARE CHECKS ................................................................................................. 8-4 8.3.1 CHECK DIRECTORY FOR CUTTING EDGE SOFTWARE................................... 8-4 8.3.2 CHECK FOR RECENTLY LOADED SOFTWARE................................................. 8-5 8.4 8.5 HARDWARE CHECKS................................................................................................. 8-6 CHECK BASIC MACHINE OPERATION ...................................................................... 8-6
8.6 SYSTEM DIAGNOSTICS ........................................................................................... 8-13 8.6.1 OFFLINE TESTS................................................................................................. 8-15 8.6.1.1 Joystick Signal Test...................................................................................... 8-15 8.6.1.2 Input / Output Test........................................................................................ 8-16 8.6.1.3 Encoder Test ................................................................................................ 8-17 8.6.1.4 Keypad Test ................................................................................................. 8-17 8.6.1.5 Servo Motion Controller Info ......................................................................... 8-18 8.6.1.6 Index Pulse Test........................................................................................... 8-18 8.6.2 ONLINE TESTS................................................................................................... 8-19 8.6.2.1 Homing Sequence Tests .............................................................................. 8-19 8.6.2.2 X/Y Festoon Test.......................................................................................... 8-20 8.6.2.3 Theta Torque and Run Out........................................................................... 8-21 8.6.2.4 Servo Torque Values.................................................................................... 8-22
9.0 VENDOR DOCUMENTATION ......................................................................................... 9-1 9.1 9.2 9.3 GENERAL .................................................................................................................... 9-3 NEMATRON INSTRUCTION MANUAL ........................................................................ 9-3 IMATRONIC APPLICATION NOTE .............................................................................. 9-3
10.0 10.1
GLOSSARY ............................................................................................................... 10-1 LIST OF TERMS ........................................................................................................ 10-3
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LIST OF FIGURES
FIGURE 2-1 TYPICAL DCS 1500 INSTALLATION..................................................................................2-5 FIGURE 2-2 TYPICAL DCS 2500 INSTALLATION..................................................................................2-6 FIGURE 2-3 TYPICAL TAURUS INSTALLATION ...................................................................................2-6 FIGURE 3-1 TABLE LAYOUT ..................................................................................................................3-4 FIGURE 3-2 KEYPAD, JOYSTICK, AND EMERGENCY STOP ..............................................................3-8 FIGURE 3-3 CONTROL CABINET AND STATUS BOARD.....................................................................3-9 FIGURE 4-1 FIGURE 4-2 FIGURE 4-3 FIGURE 4-4 FIGURE 4-5 FIGURE 4-6 CROSS-SECTION OF AN OLFA BLADE............................................................................4-4 PROPER AND EXCESSIVE BLADE PENETRATION. .......................................................4-5 POSITION OF MATERIAL SET ..........................................................................................4-6 KEYPAD ..............................................................................................................................4-8 CUTTING EDGE SOFTWARE WINDOWS ICON ............................................................4-12 CONTROL CABINET PANEL............................................................................................4-14
FIGURE 5-1 SPLIT TABLE OPERATION ..............................................................................................5-11 FIGURE 5-2 MID-TABLE ORIGINS ON .................................................................................................5-12 FIGURE 5-3 NORMAL TABLE OPERATION.........................................................................................5-13 FIGURE 6-1 FIGURE 6-2 FIGURE 6-3 FIGURE 6-4 WHEEL BLADE AND SHOULDER BOLT .........................................................................6-19 POSITIVE X-AXIS CUTTER OFFSET ERROR ................................................................6-23 POSITIVE Y-AXIS CUTTER OFFSET ERROR ................................................................6-23 BLADE MISALIGNMENT CAUSING PROBLEMS WITH THE OFFSET TEST ................6-24
FIGURE 7-1 CABLE AND HOSE CONFIGURATION DCS 1500/2500 ..............................................7-18 FIGURE 7-2 CABLE AND HOSE CONFIGURATION TAURUS .........................................................7-19 FIGURE 7-3 DRIVE HUB ASSEMBLY (DCS1500/2500) .......................................................................7-22 FIGURE 7-4 MOTOR AND MOTOR BRUSH.........................................................................................7-23 FIGURE 7-5 WHEEL CUTTER BOLT....................................................................................................7-24 FIGURE 7-6 TABLE SURFACE .............................................................................................................7-31 FIGURE 7-7 PLACEMENT OF STANDARD TABLE PANEL SURFACE...............................................7-32 FIGURE 7-8 PLACEMENT OF HIGH DENSITY TABLE PANEL SURFACE.........................................7-34 FIGURE 7-9 X-AXIS DRIVE HUB ASSEMBLY ......................................................................................7-40 FIGURE 7-10 THETA AXIS ASSEMBLY HEIGHT...................................................................................7-44 FIGURE 7-11 ADJUST X AXIS BELT TENSION ....................................................................................7-47 FIGURE 7-12 THETA AXIS BELT ADJUSTMENT ..................................................................................7-53
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LIST OF SCREENS
SCREEN 2-1 SCREEN 2-2 SCREEN 2-3 SCREEN 2-4 SCREEN 2-5 SCREEN 2-6 SCREEN 2-7 SCREEN 2-8 SCREEN 2-9 SCREEN 4-1 SCREEN 4-2 SCREEN 4-3 SCREEN 5-1 SCREEN 5-2 SCREEN 5-3 SCREEN 5-4 SCREEN 5-5 SCREEN 5-6 SCREEN 5-7 SCREEN 5-8 SCREEN 5-9 SCREEN 5-10 SCREEN 5-11 SCREEN 5-12 SCREEN 5-13 SCREEN 6-1 SCREEN 6-2 SCREEN 6-3 SCREEN 6-4 SCREEN 6-5 SCREEN 6-6 SCREEN 6-7 SCREEN 6-8 SCREEN 6-9 SCREEN 6-10 SCREEN 6-11 SCREEN 6-12 SCREEN 6-13 SCREEN 6-14 SCREEN 7-1 SCREEN 7-2 SCREEN 7-3 SCREEN 7-4 HARDWARE LOCK CONFIGURATION DIALOG BOX..................................................2-14 HARDWARE LOCK REMOVE MODULE DIALOG BOX ................................................2-15 CONFIGURE MACHINE DIALOG BOX ..........................................................................2-17 TOOL OPERATIONS DIALOG BOX...............................................................................2-20 ADVANCED CONFIGURATION DIALOG BOX ..............................................................2-21 CONFIGURE/CALIBRATE PASSWORD DIALOG BOX ................................................2-22 PASSWORD VERIFICATION DIALOG BOX..................................................................2-22 CONFIGURE CAMERA DIALOG BOX ...........................................................................2-23 CALIBRATE MACHINE DIALOG BOX............................................................................2-24 SYSTEM STATUS DIALOG BOX ...................................................................................4-19 HOME MACHINE DIALOG BOX.....................................................................................4-20 LOCAL MODE ERROR MESSAGE ................................................................................4-20 SELECT WORK ORDER DIALOG BOX...........................................................................5-3 OPEN DIALOG BOX .........................................................................................................5-4 FAST OPEN DIALOG BOX...............................................................................................5-5 JOB PARAMETERS DIALOG BOX ..................................................................................5-6 GENERAL JOB PARAMETERS .......................................................................................5-8 CUT-OFF PARAMETERS.................................................................................................5-9 MAP LAYERS TO TOOLS ..............................................................................................5-14 SMART TEXT DIALOG BOX FOR AUTOMATIC TEXT .................................................5-15 SMART TEXT DIALOG BOX ..........................................................................................5-16 CUT JOB AND START OPTIONS DIALOG BOXES ......................................................5-17 PARTS OUT OF BOUNDS DIALOG BOX ......................................................................5-20 MATCHING PARAMETERS DIALOG BOX DCS 2500................................................5-21 DIGITIZE DIALOG BOX ..................................................................................................5-24 CALIBRATE MACHINE DIALOG BOX..............................................................................6-3 SQUARE CARRIAGE DIALOG BOX ................................................................................6-6 ADJUST PNEUMATICS DIALOG BOX.............................................................................6-7 SET Y SCALE FACTOR DIALOG BOX ............................................................................6-9 SET LENGTH DIALOG BOX...........................................................................................6-10 SET STATION DIALOG BOX .........................................................................................6-11 CHECK Y BELT DIALOG BOX .......................................................................................6-12 CAMERA CALIBRATION DIALOG BOX.........................................................................6-15 ALIGN ANGLE TOOL HOLDER DIALOG BOX ..............................................................6-20 ALIGN OFFSET TOOL HOLDER DIALOG BOX ............................................................6-22 ALIGN OFFSET: PUNCH HOLDER DIALOG BOX ........................................................6-25 LASER POINTER OFFSET CALIBRATION DIALOG BOX ............................................6-26 TEST CUT DIALOG BOX ...............................................................................................6-27 CALIBRATING TRAILER: NOTCHER DIALOG BOX .....................................................6-28 MACHINE TIMES DIALOG BOX.......................................................................................7-3 DIGITIZE TABLE SURFACE DIALOG BOX ...................................................................7-12 DIGITIZING A ROW OF VACUUM HOLES ....................................................................7-14 MAP LAYERS TO TOOL DIALOG BOX .........................................................................7-15
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SCREEN 8-1 FIND: ALL FILES DIALOG BOX ..........................................................................................8-4 SCREEN 8-2 FIND: ALL FILES DIALOG BOX WITH LOCATED FILES...................................................8-5 SCREEN 8-3 CUTTING EDGE ICON PROPERTIES................................................................................8-7 SCREEN 8-4 DCS 2500 DIAGNOSTIC MENU.......................................................................................8-13 SCREEN 8-5 JOYSTICK SIGNAL TEST DIALOG BOX .........................................................................8-15 SCREEN 8-6 INPUT / OUTPUT DIALOG BOX ......................................................................................8-16 SCREEN 8-7 ENCODER TESTS DIALOG BOX.....................................................................................8-17 SCREEN 8-8 KEYPAD TEST..................................................................................................................8-17 SCREEN 8-9 SERVO MOTION CONTROLLER INFO DIALOG BOX.....................................................8-18 SCREEN 8-10 INDEX PULSE TEST DIALOG BOX ...............................................................................8-18 SCREEN 8-11 HOMING SEQUENCE TESTS........................................................................................8-19 SCREEN 8-12 X/Y FESTOON TEST DIALOG BOX...............................................................................8-20 SCREEN 8-13 THETA TORQUE AND RUN OUT DIALOG BOX...........................................................8-21 SCREEN 8-14 SERVO TORQUE VALUES DIALOG BOX .....................................................................8-22
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LIST OF TABLES
TABLE 2-1 TABLE 2-2 TABLE 2-3 TABLE 2-4 TABLE 2-5 TABLE 2-6 TABLE 2-7 DCS 1500 SHIPPING CONTAINERS (5 TABLE) ..................................................................2-4 DCS 1500 SHIPPING CONTAINERS (6 TABLE) ..................................................................2-4 DCS 2500 SHIPPING CONTAINERS.....................................................................................2-5 NUMBER OF CONTAINERS FOR A DCS 2500 ....................................................................2-5 TAURUS TLCS SHIPPING CONTAINERS ............................................................................2-5 MINIMUM REQUIREMENTS FOR A DCS 1500 OR DCS 2500 MACHINE.........................2-13 MINIMUM REQUIREMENTS FOR A TAURUS MACHINE ..................................................2-13
TABLE 7-1 PREVENTATIVE MAINTENANCE SCHEDULE DCS 1500 AND DCS 2500 .......................7-5 TABLE 7-2 PREVENTATIVE MAINTENANCE SCHEDULE TAURUS ...................................................7-7
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Section
Introduction
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1.1 GENERAL This manual provides operation, maintenance and calibration instructions for the Cutting Edge DCS 1500, DCS 2500 and Taurus TLCS (Total Leather Cutting Solution) GERBERcutters. Most of the information in this manual applies to all of these machines. However, some information in this manual is machine-specific. The machine-specific information is noted with the machine type, with either DCS 1500/2500 or Taurus TLCS in the heading. For example, the minimum requirements for the PC used to run the Cutting Edge Software is divided into two sections: Paragraph 2.4.1 PC Requirements DCS 1500/2500 and Paragraph 2.4.2 PC Requirements Taurus. Paragraph 2.4.1 contains information specific to DCS 1500 and DCS 2500 machines; Paragraph 2.4.2 contains information specific to Taurus TLCS machines. The Cutting Edge Division of Gerber Technology has followed stringent production methods to produce a reliable and accurate machine that has been tested in our factory to verify its precision. Please read all of the following operating and service instructions so that you can realize the full potential of the cutter in daily plant operations. 1.2 SAFETY In addition to the following safety precautions, this section provides a brief description of the various sections that are included in this manual. 1.2.1 PRECAUTIONS Instruct machine operators and observers to stand clear of the table while it is in operation. In some cases, it may be desirable to install a guardrail to prevent access to the table. For added security, you may wish to add a safety interlock to stop machine motion. 1. Only competent and qualified operators who have been properly trained by Gerber Technology should operate this machine. 2. Only competent and qualified service technicians who have been properly trained by Gerber Technology should service this machine. 3. Do not operate machine with safeguards or interlocks suspended. 4. Use only the cutting tools that are called out in the parts list in the Cutting Edge DCS 1500/2500 GERBERcutter Engineering Drawings manual or the Cutting Edge Taurus TLCS GERBERcutter Engineering Drawings manual available from Gerber Technology, Cutting Edge Division. 5. Operating and maintenance people should read and understand the operating and service instructions before working on the machine. 6. When servicing or maintaining the machine, all machine control panels must be tagged in compliance with OSHA Lock out/Tag out procedures to indicate that the machine should not be operated. 7. Operators should not leave rolls of cloth or other material on the table surface in the path of the carriage. Damage may occur if the carriage hits an object at full speed.
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8. Do not attempt to move or interfere with fabric during cutting operation. 9. Never leave the machine unattended during cutting operation. 10. Turn electrical power off before opening any electrical enclosure. 11. Before performing any maintenance on the pneumatic system or parts moved by the pneumatic cylinders, disconnect the machine from the factory air supply. 12. Keep hands away from the carriage during machine operation or whenever the electrical power and air are on. 13. Do not operate the machine with the cover of any enclosure or the guard or covers over any mechanism removed. 14. Push the red E-stop button on the carriage or control cabinet to halt the machine operation should any question of malfunction arise. 15. Before operating the machine at the beginning of each shift, all covers, guards and safety devices should be checked for proper operation. 16. Due consideration should be given to any safety regulation applicable to the particular plant in which the machine is operating. 17. Do not turn on machine power when cable(s) and/or printed circuit board(s) are disconnected. 18. The machine must not be used for any purpose other than for what it has been designed and approved by Gerber Technology, Cutting Edge Division. 19. All electrical power switches including computer and vacuum blower power switches must be located 2 to 6 feet (0.6 to 1.9 meters) from the floor.
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1.2.2 SYMBOLS Machine operators should be familiar with the following symbols on the control panel and keypad. 1.2.2.1 Control Panel The following symbols are used on the status and control panels which are described in Section 3.0. Whenever these symbols are used in the manual, they will be shown as small caps with an initial large capital letter, which indicates that the symbol is defined in this paragraph. SYMBOL EMERGENCY STOP (E-STOP) DESCRIPTION The red mushroom switches that are located at various locations on the machine. When pressed, all power is removed from the servo system and the machine stops immediately.
SYSTEM ENERGIZED RESET AC POWER PEN TOOL HOLDER 1 TOOL HOLDER 2

CONTROL POWER
The green light on the control panel indicating that the system has been energized. The Reset button on the control panel that applies power to the control cabinet. The AC power switch that sets power on to the control cabinet. The pen pressure indicator and regulator on the control panel. The Tool Holder 1 pressure indicator and regulator on the control panel. The Tool Holder 2 pressure indicator and regulator on the control panel. The electrical power indicator light on the control panel. When lit, it indicates that the electrical power switch on the control panel is set to On and 24 volt control electrical power is available to the components in the control cabinet. The status board indicator that is lit when the servo motors are energized. The status board button that energizes the servo system The lights on the control panel that indicate the status of the servo motor amplifiers. The status board light for the festoon side X-axis servo motor status. The status board light for the keypad side X-axis servo motor status. The status board light for the Y-axis servo motor status. The status board light for the theta axis servo motor status. The status board light that indicates an open switch in the internal or external interlock switches. The status board lights for the homing sensors for the various servo axes. The status board light for the X-axis homing sensor status. The status board light for the Y-axis homing sensor status.
24 VDC READY SYSTEM ONLINE RESET MOTOR STATUS XF-AXIS XK-AXIS Y-AXIS T-AXIS E-STOP STATUS OPEN SWITCH HOMING SENSOR STATUS X-HOME Y- HOME
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1.2.2.2 Keypad The following symbols appear on the keypad. SYMBOL F1 F2 F3 F4 DESCRIPTION The keypad F1 button performs various functions depending on the machine operational mode. The keypad F2 button performs various functions depending on the machine operational mode. The keypad F3 button performs various functions depending on the machine operational mode. The keypad F4 button performs various functions depending on the machine operational mode. The keypad Up arrow button (!)performs various functions depending on the machine operational mode. The keypad Down arrow button(")performs various functions depending on the machine operational mode. The keypad Plus button ( ) performs various functions depending on the machine operational mode. The keypad Minus button ( ) performs various functions depending on the machine operational mode. The keypad CANCEL button (#) performs various functions depending on the machine operational mode. The keypad RETURN button ( machine operational mode.
! "
+ #
) performs various functions depending on the
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1.2.2.3 Labels The following safety labels are used on the various parts of the machine. Refer to the Cutting Edge DCS 1500/2500 GERBERcutter Engineering Drawings manual or the Cutting Edge Taurus TLCS GERBERcutter Engineering Drawings manual for illustrations that show the location of the following labels: SYMBOL DESCRIPTION REFER TO FOR LABEL LOCATION DCS 1500/2500 Electrical ground directly to machine frame Figure 2-4 and 2-5 (Theta Axis) Figure 2-26 and 2-24 (Carriage) CL-004-2 (Control Cabinet) Common reference ground Figure 2-25 (Carriage) CL-004-2 (Control Cabinet) CL-004-2 (Control Cabinet) TAURUS TLCS Figure 2-12 (Theta Axis) Figures 2-17 and 2-18 (Carriage) CL-005-3 CL-005-4 (Control Cabinet) Figure 2-18 Carriage Assembly CL-005-4 (Control Cabinet) CL-005-3 (Control Cabinet) CB2-120 L-101 L-100 PART NUMBER
Electrical Interference
Danger electrical shock potential Friction hazard
CL-004-2 (Control Cabinet)
CL-005-3 (Control Cabinet)
CB2-124
Figures 2-24 and 2-25 Carriage
Figure 2-16 Carriage Beam
CB2-127
Moving member
Figure 2-27 (Carriage)
Figure 2-14 (Carriage Assembly)
CB2-129
Pinch point
Figure 2-9 Carriage
Figure 2-11 (Festoon Cover)
CR2-183
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1.2.3 FORESEEN USES The cutting machine is designed to cut single layer fabrics or leather. We have test cut materials submitted by your company prior to machine sale, and have provided you with test cut results, including the tool parameters that were used in the cutting process. Do not cut any material or operate the machine in any manner other than for the purpose that it was designed and sold without prior consultation with Gerber Technology, Cutting Edge Division. 1.2.4 NOISE EMISSIONS Gerber Technology, Cutting Edge Division has tested a cutting machine that is similar to the machine that was delivered to you in an environment that is similar to a production environment. Actual noise levels can vary depending on the location of the blower and machine. An industrial hygienist should perform a noise level study after installation to determine actual noise levels. The following noise emissions have been measured during cutting machine operation with the vacuum blower located next to the machine. On a Cutting Edge DCS 1500/ 2500 GERBERcutter with a 3 horsepower blower installed next to the machine, the noise level is as follows: With tool cutting, average A-weighted noise emission at control cabinet approximately 3 feet (1 meters) from machine - 74 dB, Maximum C-weighted noise emission at control cabinet approximately 3 feet (1 meter) from machine -90 dB.
On a Taurus TLCS GERBERcutter with a 10 horsepower blower located underneath the machine: Average A-weighted noise emission in the work area around the cutter (3 feet or 1 meter) is 63 dB.
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1.3 MANUAL DESCRIPTION
Section 2.0, Installation, includes general installation requirements, instructions for installing the Cutting Edge Software and the hardware lock, and instructions for configuring the cutter. Section 3.0, Description, includes a description of the table and carriage, control cabinet, personal computer, and available hardware and software options. Section 4.0, Operating Instructions, includes a description of the principles of operation, a description of machine operating controls, cutting machine control settings, and instructions for opening the Cutting Edge software. Section 5.0, Working with Jobs, includes instructions for setting job parameters, opening a job file, preparing a job, and digitizing a new job. Specific instructions on how to use the other modules in the Cutting Edge Software (Base Module, Toolpath Module, the Limited and Extended Nesting and AutoNest Modules, the CIM Module database, and the Rights and Access Module) can be found in the Cutting Edge Software Users Guide. Section 6.0, Calibration, includes instructions for calibrating the cutting machine, tool holders, and tools. Section 7.0, Maintenance, includes a preventive maintenance schedule, and instructions for inspecting, lubricating, and maintaining the machine. Section 8.0, Troubleshooting, provides troubleshooting and diagnostic procedures that are useful for identifying and repairing machine malfunctions. Section 9.0, Vendor Documentation, includes all vendor documentation such as parts lists and maintenance instructions for vendor supplied equipment. Section 10.0, Glossary, defines terms that are unique to the Cutting Edge Software, and to the cutting systems.
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1.4 PARTS IDENTIFICATION Most machine parts mentioned in this manual are shown in schematic or exploded diagrams in the Cutting Edge DCS 1500/2500 GERBERcutter Engineering Drawings manual or the Cutting Edge Taurus TLCS GERBERcutter Engineering Drawings manual. In North America, parts should be ordered from Gerber Technology, Service Department at 1-800-3212448. Outside North America, call your local service office. If you have a service contract and are ordering replacement parts under warranty, call 1-800-999-1448. 1.5 HOW TO CONTACT US You can contact us by mail, telephone, fax, or electronic mail using the following information:
$ Mailing Address:
Gerber Technology, Inc. Cutting Edge Division 21 Lime Street Marblehead, MA 01945 781-631-1390 1-888-234-2887 781-631-3983 support@gerbertechnology.com
% Telephone number: % CEI Customer Service Number: &

Fax Number: Electronic Mail:
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Section
Installation
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2.1 GENERAL This section provides instructions for installing a Gerber Cutting Edge DCS 1500, DCS 2500, or Taurus TLCS GERBERcutters. This section includes general installation requirements, instructions for installing the Cutting Edge Software and the hardware lock, and instructions for configuring the cutter. A Cutting Edge DCS1500, DCS 2500 or Taurus TLCS cutter and any options must be installed or relocated by Gerber Technology personnel only. 2.2 CUTTING SYSTEM SHIPPING WEIGHTS AND DIMENSIONS The cutting machine is delivered in shipping containers. The following section describes the dimensions and weights of the shipping containers for a standard DCS 1500, DCS2500 and Taurus TLCS GERBERcutter. 2.2.1 SHIPPING WEIGHTS AND DIMENSIONS DCS 1500 The DCS 1505 Sample Cutter table is 8 feet (2.4 meters) long by 70 inches (1.8 meters) wide and the DCS 1506 Sample Cutter table is 8 feet (2.4 meters) long by 82 inches (2.1 meters) wide. Although disassembly is discouraged, by removing the table surface and tilting the base, the machine can fit through a doorway 30 inches (0.76 meters) wide if required. The computer and control cabinet are shipped on a separate skid. The dimensions of the table and carriage shipping boxes depend on the size of the table. TABLE 2-1 DCS 1500 SHIPPING CONTAINERS (5 TABLE) Item Computer and Control Cabinet Table (5 table) Carriage (5 table) Inches 22x70x 25 74x101x40 88x24x30 Centimeters 56x178x63 188x256x 102 224x61x76 Pounds 400 650 325 Kgs 182 295 148
TABLE 2-2 DCS 1500 SHIPPING CONTAINERS (6 TABLE) Item Computer and Control Cabinet Table (6 table) Carriage (6 table) Inches 22x70x 25 86x101x 40 100x24x 30 Centimeters 56x178x63 218x 256x 102 254x61x76 Pounds 400 700 350 Kgs 182 318 159
Section 2.0: Installation
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2.2.2 SHIPPING WEIGHTS AND DIMENSIONS DCS 2500 The dimensions and weights in Table 2-3 are for a standard DCS 2500 machine. A fork lift truck or hand dolly must be available to move the containers to the installation location. TABLE 2-3 DCS 2500 SHIPPING CONTAINERS Item Carriage Skid Computer Skid Vacuum Blower Skid Panels/Legs Skid ** Extrusion/Beam Skid ** Size L x W x H Inches Centimeters 100X24X30* 254X61X76 72X20X20 183X51X51 40X40X40 102X102X102 80X50X30 203X127X76 144X20X20 366X51X51 Weight Pounds Kgs 350 130.6 150 56 350 130.6 400 149.3 200 74.65
* Carriage Skid may be longer if carriage is 120 inches (305cm) or wider. ** See Table 2-4 below for quantity of skids for longer machines. TABLE 2-4 NUMBER OF CONTAINERS FOR A DCS 2500 Table Length 12 Feet (3.66m) 24 Feet (7.31m) 36 or 48 Feet (11 or 14.63m) 60 Feet (18.3m) 72 Feet (22m) to 108 Feet (33m) Quantity of Panels / Legs Skids 1 2 2 2 4 Quantity Extrusion -Beam Skids 1 2 3 4 4
A work area of approximately 40 inches (one meter) is required on all sides of the machine for access during operation and maintenance. 2.2.3 TAURUS TLCS SHIPPING WEIGHTS AND DIMENSIONS The dimensions and weights in Table 2-5 are for a standard Taurus TLCS machine. A fork lift truck or hand dolly must be available to move the containers to the installation location. TABLE 2-5 TAURUS TLCS SHIPPING CONTAINERS Item 9' TABLE CRATE (1) 9' TABLE CRATE (2) 9' PANEL CRATE 12' RAIL SKID COMPUTER SKID (1) COMPUTER SKID (2) BLOWER SKID CARRIAGE CRATE Size L x W x H Gross Weight Inches Centimeters Pounds Kgs 120 x 52 x 46 305 x 132 x 117 1450 658 120 x 52 x 46 305 x 132 x 117 1590 721 120 x 52 x 46 305 x 132 x 117 2020 916 145 x 20 x 12 368 x 51 x 30 333 151 72 x 20 x 30 183 x 51 x 76 223 101 72 x 20 x 30 183 x 51 x 76 127 57 72 X 36 X 30 183 X 92 X 76 1020 462 136 x 33 x 40 345 x 84 x 102 591 268 TOTAL 6334 2873 Net Weight Pounds Kgs 1021 463 1161 527 1591 722 261 118 190 86 94 43 850 385 274 124 4592 2083
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2.3 MACHINE INSTALLATION REQUIREMENTS The following sections describe floor space, environmental, electrical, and air supply requirements for DCS 1500, DCS 2500 and Taurus TLCS GERBERcutters. 2.3.1 TYPICAL CUTTING MACHINE INSTALLATION Refer to the preparation guide for area requirements for a particular application. 2.3.1.1 Cutting Machine Installation DCS 1500 Figure 2-1 is an example of a typical Cutting Edge DCS 1500 GERBERcutter installation.
FIGURE 2-1 TYPICAL DCS 1500 INSTALLATION
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2.3.1.2 Cutting Machine Installation DCS 2500 Figure 2-2 is an example of a typical Cutting Edge DCS 2500 GERBERcutter installation.
FIGURE 2-2 TYPICAL DCS 2500 INSTALLATION 2.3.1.3 Cutting Machine Installation Taurus Figure 2-3 is an example of a typical Cutting Edge Taurus TLCS GERBERcutters installation.
FIGURE 2-3 TYPICAL TAURUS INSTALLATION
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2.3.2 ENVIRONMENTAL TEMPERATURE AND HUMIDITY This machine must be operated in an environmentally controlled space to realize consistent accuracy and reliability. The temperature must always be between 55 and 80 degrees F (13 and 27 degrees C) and the humidity must always be between 20 and 95 percent (non-condensing). The electrical equipment used on the machine is capable of operating at altitudes up to 3500 feet (1067 meters). Although the machine is designed to operate over a wide environmental range, prolonged operation beyond extreme limits of temperature and humidity can have a substantial effect on the total reliability of the system. Environmental extremes will tend to shorten the useful life of both electrical and mechanical components and cause undesirable malfunctions. When Gerber Cutting Edge equipment is installed in geographic areas where environmental conditions will be beyond the limits for prolonged periods of time, it is recommended that the equipment be operated in a controlled environment. The effects of high temperature will tend to reduce component life. High relative humidity will cause insulation path breakdown and promote fungus growth while low relative humidity, on the other hand, will promote static discharge which can alter the memory and degrade or destroy electronic components within the system. For reliable operation, rapid changes in temperature should not occur during machine operation. Time should also be allowed for the equipment to stabilize at operating temperature after a non-operating period during which the temperature had departed from the specified range.
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2.3.3 AIR SUPPLY Compressed air is used for several functions on the machine. The machine is delivered with a 1/4-inch female NPT fitting to mate to your supply line. The compressed air system must be able to supply 0.5 SCFM (0.014 standard cubic meter/minute at 552 kPa) at 80 to 120 psi (552 - 828 kPa), and a filter/dryer should be installed somewhere between the compressor and the machine. The filter must remove 90-95 percent of all particles 40 microns or larger. 2.3.4 ELECTRICAL POWER The specific machine requirements are set in your Purchase Agreement and preparation guide. However, the machine is capable of operating with the voltage varying by up to +/-10 percent of the specified value. Also, the frequency can vary +/-1percent of the specified value. NOTE For European installations of DCS 1500/2500 and Taurus TLCS machines, all electrical components must meet European Norm requirements. On DCS 1500/2500 and Taurus TLCS machines, when the power switch is off, the carriage can be moved by hand without damage. Once the power is on, the motors are energized and the machine operator must not attempt to push the carriage by hand. 2.3.4.1 Electrical Requirements DCS 1500/2500 Wiring for the computer, control cabinet, and vacuum blower must conform to local electrical codes at the point of installation and is the responsibility of the customer. One dedicated grounded outlet is required at the location where you intend to install the computer and control cabinet. The control cabinet should be plugged directly into the wall socket, not an Universal Power Supply (UPS). The computers and monitors should be plugged into an appropriate UPS provided by you. Generally, the computer and control cabinet are installed at the origin end of the cutting table. Consult your Purchase Agreement and preparation guide for vacuum blower requirements, including blower configuration, power ratings, circuit breaker and slow-blow fuse needs and system grounding. 2.3.4.2 Electrical Requirements Taurus Wiring for the computer, control cabinet, and vacuum blowers must conform to local electrical codes at the point of installation and is the responsibility of the customer. Two dedicated grounded outlets are required at the location where you intend to install the computer and control cabinet. The control cabinet should be plugged directly into the wall socket, not an UPS. The computers and monitors should be plugged into an appropriate UPS provided by you. Generally, the computer and control cabinet are installed at the mid-point of the cutting table. Consult your Purchase Agreement and preparation guide for vacuum blower requirements, including blower configuration, power ratings, circuit breaker and slow-blow fuse needs and system grounding.
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2.3.4.3 Lightning Protection The power lines should be equipped with lightning protection. Consult your local electrician for details. 2.3.4.4 Machine/System Grounding Ground shall conform to local or national electrical code for the location of the installation. At the time of machine/system installation, it is strongly recommended that adequate grounding be done by the customer; this is to keep electrical noise and differential potentials under control in large systems. NOTE Consult local or national electrical code to determine the proper sizing and location of the electrical grounding connection. All of these ground connections are in addition to (not in place of) the ground leads carried through various signal cables and the ground conductors contained in the power cables. The ground wire in the power cable must also be connected to the ground, usually through the conduit of the electrical distribution system. This is a non-current carrying ground, not a neutral. The power cable conduit must not be used as the only ground connection. Whenever possible, the system's power panel should be grounded. Whatever grounding system is used, it should provide less than 10 ohms impedance to moist earth from DC to 10 MHz. The grounding system should also be isolated from electrical noise sources to prevent electrical noise being transmitted into the machine/system via the grounding system.
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2.4 INSTALLING THE CUTTING EDGE SOFTWARE The following paragraphs describe the minimum and the recommended requirements for a personal computer to run the Cutting Edge Software, and how to install the software using the Windows 95, Windows 98, or Windows NT 4.0 operating system. To install the software on a computer with Windows NT 4.0, Log on to Windows NT as the System Administrator. The software is supplied on a compact disk (CD). The installation program will prompt you as needed, and you should be able to install the Cutting Edge Software in a couple of minutes. When installing the new software over an existing installation of Cutting Edge Software, none of the data, including job files and machine operating parameters, in the existing software will be changed. If the software is being installed for the first time, do the following: Install hardware lock (see paragraph 2.5.1). Set display driver (see paragraph 2.5.2 or 2.5.3). Install the Cutting Edge Software (see below). Start the Cutting Edge Software (see paragraph 2.5.4). Check machine configuration (see paragraph 2.6). Check machine calibration (see paragraph 2.8).
To install the software in Windows 95, Windows 98, or Windows NT 4.0, do as follows: NOTE: Log on to Windows NT 4.0 as the System Administrator.
1. Place the Cutting Edge Software CD in the CD drive. The installation will begin automatically, unless the Autorun feature is disabled on the computer you are using. If the software installation program does not start automatically, click the Start button on the Windows taskbar, and then click Run. The Run dialog box is displayed. Type D:\autorun.exe (where D:\ is the CD drive, otherwise substitute the appropriate drive letter) then click OK. 2. Click Install Software. The Welcome screen appears. 3. Click the Next> button to begin the installation. Follow the instructions presented on the screen. NOTE: If your system have the optional CIM Module, refer to the Cutting Edge Software System Administration Guide for important installation information before installing the software.
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2.4.1 PC REQUIREMENTS DCS 1500/2500 Table 2-6 shows the minimum requirements, and Gerber Technologys recommendation for a personal computer running the Cutting Edge software: TABLE 2-6 MINIMUM REQUIREMENTS FOR A DCS 1500 OR DCS 2500 MACHINE MINIMUM REQUIREMENTS 133 MHz Pentium 16 Megabytes (MB) RAM 28 MB free hard disk space Windows 95, 98 or NT 4.0 Operating System RECOMMENDED 233 MHz Pentium 32 MB RAM 55 MB free hard disk space Windows 95, 98 or NT 4.0 Operating System
2.4.2 PC REQUIREMENTS TAURUS Table 2-7 shows the minimum and recommended requirements for the personal computers used with the Taurus TLCS, or with personal computers running the Cutting Edge Software that will be used as Network Nesters or Strategy Nesters. TABLE 2-7 MINIMUM REQUIREMENTS FOR A TAURUS MACHINE MINIMUM REQUIREMENTS 300 MHz Pentium 256 MB RAM 8 MB video card 200 Megabytes (MB) free hard disk space 2 Gigabytes (G) free network space Windows 95, 98 or NT 4.0 Operating System RECOMMENDED 450 MHz Pentium 256 MB RAM 8 MB video card 500 Megabytes (MB) free hard disk space 5 Gigabytes (G) free network space Windows 95, 98 or NT 4.0 Operating System
NOTE: The Cutting Edge software will not run on Windows 3.x operating system.
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2.5 HARDWARE LOCK A hardware lock, which is a small beige device, is included with the software and is needed for the software on the personal computer to operate the machine. The hardware lock has password-protected information that controls the features available to the user. Each working copy of the Cutting Edge Software requires its own lock. 2.5.1 INSTALL HARDWARE LOCK Install the hardware lock in the parallel printer port on the back of the personal computer. If a printer is already plugged into the computer, remove the printer connector from the computer, install the lock on the computer printer port, and then install the connector to the printer onto the lock. 2.5.1.1 Configure the Hardware Lock Gerber Technology configures each customers hardware lock(s) with the modules purchased. If, in the future, a customer wishes to purchase an additional module, Gerber Technology will issue a password for the new module along with instructions on how to install the module on their hardware lock. You can view the features installed on your hardware lock by clicking the Help menu, then Hardware Lock Configuration. The Hardware Lock Configuration dialog box (shown in Screen 2-1) will be displayed. This dialog box contains information, such as your hardware lock identification number, that will be helpful if you need to contact Gerber Technology Customer Service. Click OK to save any changes made in the Hardware Lock Configuration dialog box. Click Cancel to exit this dialog box without making changes. SCREEN 2-1 HARDWARE LOCK CONFIGURATION DIALOG BOX
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The fields in the Hardware Lock Configuration dialog box (shown in Screen 2-1) are as follows: Lock ID Lock Version The identification number for the hardware lock. You may need to refer to this number when speaking with Gerber Technology Customer Service. This number identifies the version of the Cutting Edge Software that can run on the lock. Lock Version 1 can run software version 2.21; Lock Version 2 can run software version 3.0; Lock Version 3 can run software version 4.0. This number cannot be changed. This section describes the features available using the current lock. Installed Features This list shows the Cutting Edge software modules that are currently installed on the hardware lock. All Features This list shows all the modules available in the version of Cutting Edge software that is currently installed on the PC. <<Install Click on the desired module in the All Features list, then click the <<Install button to add the module to the hardware lock. In the dialog box that appears, type in the password issued by Gerber Technology, then click OK. Extend>> Click on the desired module in the All Features list, then click the Extend>> button to add the module to the hardware lock as a timed feature. In the dialog box that appears, type in the password issued by Gerber Technology, then click OK. Features on Timer Displays features that are configured on the hardware lock for a timed trial basis. Time Remaining The time left for the trial mode. Click OK to save any changes made in the Hardware Lock Configuration dialog box. Click Cancel to exit this dialog box without making changes. 2.5.1.2 Remove Modules from the Lock When removing a module from the hardware lock, the software opens a dialog box that displays the Lock ID number, the Lock version, the name of the module you are removing, and the password used when adding the module. You should keep a record of this information to use if you need to replace the removed module. To remove a module, select the module in the Installed Modules list, and click Remove. The dialog box shown in Screen 2-2 is displayed. Click OK to remove the module from the software. The commands associated with that module cannot be used. SCREEN 2-2 HARDWARE LOCK REMOVE MODULE DIALOG BOX
Feature Lock
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2.5.2 SET PC MONITOR RESOLUTION DCS 1500/2500 On a DCS 1500 or DCS 2500 cutter, the Cutting Edge Software runs most optimally when you set the monitor resolution to at least 800 X 600, and set the display color to High Color (16-bit). To change the monitor display settings, follow the instructions in the User Guide for the PC operating system. 2.5.3 SET PC MONITOR RESOLUTION TAURUS On a Taurus TLCS cutter, the Cutting Edge Software runs most optimally when you set the monitor resolution to at least 1024 X 768, and set the display color to True Color (32-bit). To change the monitor display settings, follow the instructions in the User Guide for the PC operating system. 2.5.4 START CUTTING EDGE SOFTWARE You can start an application by using the mouse to double-click (or choose) the program-item icon. When you double-click (choose) the icon, the application appears in an application window. Sometimes you may have several Windows open; the active Window is usually the one in the foreground. You may make any Window the active Window by clicking anywhere in that Window. Start the Cutting Edge Software as follows: 1. Set the power switch at the control cabinet to ON. 2. If not already on, turn on the personal computer. 3. Double-click the Cutting Edge software icon .
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2.6 CONFIGURE MACHINE The Configure Machine dialog box includes basic machine setup, tool holder, and tool configuration information. Click the Machine menu, then select the Setup command to display the Setup dialog box. Then click Cutter in the Configure group to display the Configure Machine dialog box shown in Screen 2-3. Make changes to the setup parameters as described below. SCREEN 2-3 CONFIGURE MACHINE DIALOG BOX
Click OK to change the machine configuration after selecting the appropriate options. Click Cancel to exit this screen without changing the machine configuration.
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General Configuration
The general configuration parameters includes the following settings: Machine Type The choices are either Mechanical Cutter, Laser Cutter, and Taurus Cutter. If you change the type of cutter, a dialog box appears warning that you will lose the tool and tool holder calibrations if you accept the machine type change. Click Yes to change the machine type; click No to cancel without changing. Com Port Select the Com Port used for communications to the keypad. Generally Com Port 1 is used, however, this depends on your installation. Maximum Speed This is the maximum speed of the machine in units per second. Use the Map Layers to Tools dialog box described in the Cutting Edge Software Users Guide to set the speed of the individual cutters. Maximum Acceleration This is the maximum acceleration of the machine in units per second2. Local Mode Speed This speed is used for the keypad local mode moves. Y-Axis Travel (Inches) This sets the width of your table (Y-axis maximum movement). Select one of the available widths from the drop down list box or type in a different value. If you select a size that is larger than your table, the Y-axis assembly will hit the limit switch. X-Axis Offset (Inches) This determines the location of machine origin from the homing sensor position in the X-axis. All the available tools on the Y-axis assembly can be used at this location and the default value of -7.25 should not be changed unless instructed to by Gerber Technology. Y-Axis Offset (Inches) Movement of the Y-axis assembly in the negative direction from the homing sensor position. The default value of -3.875 should not be changed unless instructed to by Gerber Technology. Y-Axis Origin (Inches) Movement of Y-axis assembly in the positive direction to machine origin from Y-Axis Offset. All the available tools on the Y-axis assembly can be used at this location for machine origin. The sum of the Y-Axis Offset and Origin determine the location of the machine origin from the homing sensor in the Y-axis. Machine origin must be located such that the pointer is located on the cutting surface. Machine origin determines the allowable travel for all tools in the Y-axis. The default value of 1.125 should not be changed unless instructed to by Gerber Technology. However, if the Y offsets for one of the tool holders is greater than 1.125, the Y-Axis Origin will default to the Y offset for the tool holder. This may indicate an incorrect Y offset for the tool holder. Stations A drop down list box allows the user to specify between 1 and 100 stations to be used on the machine. After setting the number of stations, specify the position of each station using the Calibrate Machine dialog box described in Section 6. Split Table Dead Zone The length in units of the dead zone in the middle of the table when using split table operation described in Section 5 of this manual.
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Holders
Use the holder parameters to set the up and down delays for the various tool holders. Initially, default settings have been entered for the tool holders. These default settings can be modified as experience in machine operation is gained. Any increase in either the up or the down delay will slow machine operation and any decrease in delay will speed up machine operation. However, as you decrease the up delay, you increase the chance that the tool may not be clear of the material before the Y-axis assembly moves. Conversely, as you decrease the down delay, you increase the chance that the tool may not reach the material before the tool starts its cutting move. The pen has a default up and down delay of 0.150 seconds (150 milliseconds). Since the tool holders and the optional punch have sensors to detect when they are retracted, their up delay should be set to 0. Set the down delay on these tools to 0.010 seconds. Holder - The name of the tool holder. This field cannot be changed through the software. Up Delay - On tool holders without position sensors, such as the pen and punch, the up delay is the time the machine waits after the signal is sent to raise the tool and the Y-axis assembly starts to move. On tool holders with position sensors, the up delay is the time the machine waits between the sensor off signal and the Y-axis assembly starts to move. Down Delay - On tool holders without position sensors, the down delay is the time the machine waits after sending the tool down signal and the Y-axis assembly starts to move. On tool holders with position sensors, the down delay is the time the machine waits between the sensor on signal and the Y-axis assembly starts to move.
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Tools
Use the tool parameters to add or delete a tool and to set the tool trailer, tool operations, and default holders for each tool. Use the New command button to add a new tool and the Delete command button to remove a tool from the list. After clicking on New, a new Pen line is displayed in list (to change the name of the new tool, see Tool below). To delete a tool, click on the tool to highlight the tool and then click Delete. Make appropriate changes to the New Tool line or any tool line by right-clicking the entry. Type or select the changes in the text box and then press Enter. Tool - Change the tool name by clicking the right mouse button on the name and typing in the new name. The Edit Material Definitions dialog box described in the Cutting Edge Software Users Guide displays the tools called out in this list box. Trailer - The trailer of the tool is the amount of caster that is assigned to the tool. On some cutters the blade trails behind the center of the holder for stability. The trailer is the distance from the center of the cut to the center of the holder. On wheel cutters the default trailer setting is 0.085 inch (2.16 cm) and on knife cutters the default trailer setting is 0.0. Operations - This is the combination of operations that a particular tool can perform. Display the dialog box shown in Screen 2-4 by clicking the right mouse button on the operations entry. Use the dialog box to select the type of operations that the selected tool can perform. When assigning tool operations, make certain that the operations that are assigned to each tool are correct. For example, do not assign the knife to a drill operation or a punch to a tangential operation. SCREEN 2-4 TOOL OPERATIONS DIALOG BOX
Default Holder - The default tool holder defines the tool holder that is used when assigning tools to holders in the Tool Mappings list box described in the Cutting Edge Software Users Guide. As an example, if Tool Holder 1 is defined as the default holder for wheel cutter in the Configure Machine dialog box, the Map Layers to Tools dialog box defaults to Tool Holder 1 for the wheel cutter.
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Advanced
Use the Advanced configuration options to change the motion parameters and the pointer tool. Click Advanced to display the Advanced Configuration dialog box shown in Screen 2-5. SCREEN 2-5 ADVANCED CONFIGURATION DIALOG BOX
Click OK to change the advanced configuration after selecting the appropriate options. Click Cancel to exit this screen without changing the advanced configuration. Contouring This group controls the contouring of the machine when cutting a polyline. Contact Cutting Edge for additional information. Pointer Sets the pointer that is used on the machine when the machine is jogged to a location. Use the pointer to identify a point or position on the cutting table. For example, when starting a job, the operator jogs the pointer to the job origin and then starts the job. Also, when using op stops, the operator jogs the pointer to the op stop and then continues the job. To select the Pointer, click the scroll button and then click either Pen Holder or Laser Pointer depending on machine configuration and operator preference.
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Password
Use the password to prevent unauthorized changes to the machine configuration and calibration settings. Click Password in the Configure Machine dialog box to display the Configure/Calibrate Password dialog box shown in Screen 2-6. Use this dialog box to add, change, or delete the password used to access the Configure and Calibrate Machine dialog boxes. Type or delete the password and then click OK to add, change, or delete the password. Click Cancel to exit this screen without changing the password configuration. SCREEN 2-6 CONFIGURE/CALIBRATE PASSWORD DIALOG BOX
If a password has been set up, the Password Verification dialog box displays whenever the Configuration or Calibration dialog box is opened. Type the password and click OK. SCREEN 2-7 PASSWORD VERIFICATION DIALOG BOX
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2.7 CAMERA CONFIGURATION The Configure Camera dialog box includes basic camera orientation, image resolution, and COM port information. Click the Machine menu, then select the Setup command to display the Setup dialog box. Then click Cutter in the Configure group to display the Configure Machine dialog box. Click the Camera button to display the dialog box shown in Screen 2-8Error! Reference source not found.. Make changes to the setup parameters as described below. SCREEN 2-8 CONFIGURE CAMERA DIALOG BOX
Camera Orientation
Click the button that depicts how the camera is mounted on the cutter. Vertical Mirror. This option properly orients the view from the camera on the computer screen. This option is generally not selected for the DCS 1500, DCS 2500, or Taurus TLCS machine.
Corrected Image
The camera image will initially appear to be bowed on the computer screen. Adjust the pixel size to flatten the image. Type a value in the Pixel Size text box. The smaller the size typed in, the closer the image will be to the original. Specify the port used for the camera. The cutter uses the information in this group to help calibrate the camera. The pen on the cutter draws a grid that is used during the camera calibration. Horizontal Targets (Left/Right in Camera Image). Type the number of vertical lines to include in the calibration grid. Vertical Targets (Up/Down in Camera Image).Type the number of horizontal lines to include in the calibration grid. Target Spacing. Type the distance between the lines in each direction.
COM Port Calibration Grid
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2.8 CHECK MACHINE CALIBRATION After loading new software, and configuring the cutter, calibrate the machine as follows: 1. Click on Machine in the menu bar and then Setup. This will bring up the Setup dialog box. 2. In the Setup dialog box, click Cutter in the Calibrate group. This will bring up the Calibrate Machine dialog box. Note: It is possible to upgrade from Setup Utility (Green or Blue Screen) to the current version of software. To do so, please contact Gerber Technology, Cutting Edge Division for instructions on how to maintain the cutters current calibration. 3. For details on each calibration routine, refer to the on screen instructions and Section 6.0 of this manual. SCREEN 2-9 CALIBRATE MACHINE DIALOG BOX
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Section
Description
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3.1 GENERAL This section provides a description of the Cutting Edge DCS 1500, DCS 2500, and Taurus TLCS GERBERcutters. In general, this section includes a description of the table and carriage, control cabinet, personal computer, and available cutting machine options. 3.2 MACHINE DESCRIPTION DCS 1500/2500 The DCS 1500 and DCS 2500 GERBERcutters are designed to cut a wide selection of fabrics and materials efficiently and accurately for use in industrial, commercial, and consumer products. These fabrics and materials include, Fiberglass, composites, cloth, and leather. The DCS 1500/2500 is controlled by a servo motion control board installed in the PC that comes with the cutter. The PC also contains the Cutting Edge Software which is the interface used to control the cutter and setup jobs using customer developed files. Customer files can be loaded and stored on the personal computer floppy or hard disk drives. The system permits the machine to operate in either metric or English units. The machine consists of a table with a carriage and a control cabinet and PC located separately from the table. Figure 3-1 shows the points of reference used in this manual to describe the table. The sides of the table are referred to as the festoon side and the keypad side. The lower left-hand corner of the table is called the origin; from where the Y-axis assembly on the carriage usually starts. The other end of the table is referred to as the far end. The Y-axis is parallel to the carriage while the X-axis is parallel to the long dimension of the table. The carriage moves up and down the table riding along the X-axis of the table on the extrusion assembly. Located on both sides of the table is a linear rail to support the carriage and a steel rack to mate with the motor pinion at the keypad and festoon side of the carriage.
FIGURE 3-1 TABLE LAYOUT
Section 3.0: Description
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3.3 MACHINE DESCRIPTION TAURUS TLCS The Taurus Total Leather Cutting Solution (Taurus TLCS) is a high speed, modular leather cutting system which features automated color hide scanning, flaw recognition and multiple nesting packages. In addition, the system offers powerful tools to assist in scheduling and tracking production. The Taurus TLCS cutter is designed to automatically locate the hide perimeter and detect and identify any pre-marked flaw and grade zone information. Once this information has been captured, the hide will be nested to maximize material yield. The Taurus TLCS system supports fully automatic nesting as well as manual nesting. For added flexibility, the operator can choose to manually nest before and/or after automatic nesting. Once nesting is complete, the nest is sent to the cutter where the nested pieces will be cut with an accuracy of +/- 0.076cm (+/- 0.030 inches). A typical configuration of the Taurus TLCS will consist of two 9x24 static cutting tables, each equipped with dual high-flow vacuum systems and a full color digital scanning system mounted to the cutting beam. The color camera delivers high quality image resolution with a pixel size of approximately 0.051cm (0.020 inches). The Taurus TLCS cutter is equipped with two personal computers that are networked with a server. The cutting computer controls the hide scanning and cutting operations for the cutter. The nesting computer is used for the automatic nesting function, and can also act as the server for the Taurus TLCS if you do not want to connect the system to an existing network. The Cutting Edge Desktop with Base Module controls the machine through a servo motion control card that interfaces with the servo motors and switches through a control cabinet. In addition, the Base Module provides file editing and processing functions, and limited production information. Cut files can be loaded and stored on the server computer floppy or hard disk drives and accessed using the Local Area Network (LAN), which is required for this system installation. The system can operate in either metric or English units.
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3.4 TABLE AND CARRIAGE The carriage contains the bulk of the machinery of the Gerber Cutting Edge DCS 1500, DCS 2500 and Taurus TLCS GERBERcutters. The Y-axis assembly is a moveable platform mounted on the carriage span that carries the pen and the cutters. Some of the other major components are described below: 3.4.1 VACUUM TABLE The vacuum table is made entirely from aluminum and has a series of panels on its surface with holes for the vacuum hold-down. There are plastic surface panels on top of the aluminum surface. Valves enable the operator to supply vacuum to just those panels that are needed to hold down the job in process. Depending on the table size there is one or more vacuum blowers. 3.4.2 SERVO MOTORS The machine uses servo motors to move the carriage and the Y-axis assembly, and to rotate the cutters. The carriage is driven in the X-axis by two motors using a rack and pinion system on either side of the table. A single motor and a steel-reinforced timing belt drive the Y-axis assembly. There is a fourth motor on the Y-axis assembly that controls the angular direction of the cutting tools. The servo motors operate closed loop, which means that the servo motion controller always knows the position of the axes. When the motor is too heavily loaded, the controller will stop the machine. The system can be re-energized after the problem is fixed. 3.4.3 LIMIT SWITCHES A typical limit switch is a normally closed micro switch that detects machine component over-travel in both the X- and Y-axes. The X-axis has a limit switch that travels with the carriage and strikes a metal ramp at each end of the festoon side of the table when the carriage has traveled too far. The Y-axis has two limit switches, one at each end of the carriage, that detect travel of the Y-axis assembly beyond its normal limits.
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3.4.4 BUMPER ARM SWITCHES Bumper arm switches are located on the side of both the festoon and keyboard side covers of the carriage. Bumper switches are normally closed switches. When the bumper arm contacts an object, the arm opens the switch and stops the carriage. To re-set a bumper switch, move the switch back to the center position. 3.4.5 EMERGENCY STOP BUTTONS (E-STOPS) An Emergency Stop (E-STOP) button is a normally closed switch with a red mushroom head. When an operator presses an E-STOP, machine operation stops immediately, removing power from the motors. There are three E-STOPS located on the table. One E-STOP button is located on the control cabinet and the other two buttons are located on each end of the carriage. To release the E-STOP, rotate the red button clockwise. See Paragraph 3.5.3 for more information on the interlock system. 3.4.6 HOMING SENSORS Homing sensors are proximity switches that are used to find the physical origin of the machine to ensure that the machine is properly aligned before beginning the cutting operation. Two homing sensors are used, one on the X-axis and one on the Y-axis. The homing sensor for the X-axis is mounted on the festoon side of the carriage and senses the same metal ramp that is sensed by the limit switch. The homing sensor for the Y-axis is mounted on the carriage towards the keyboard side and senses the location of the Y-axis assembly. The status of these sensors is displayed on the control cabinet. 3.4.7 TOOL HOLDER SENSORS The tool holders that are mounted on the Y-axis assembly are equipped with sensors to detect the vertical position of the air cylinder. These sensors determine the location of the cutters on the upstroke. This enables cutter to move as quickly as possible in the X and Y-axis when the cutter is not in contact with the material being cut.
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3.4.8 KEYPAD The keypad on the carriage communicates with the control cabinet over a serial link, and enables the operator to control the machine from the carriage. Figure 3-2 shows the keypad mounted in the cover on the keypad side of the carriage. Next to the keypad is a joystick to enable the operator to manually move the machine and an emergency stop button to enable the operator to interrupt the cutting job.
*** DCS 2500 *** Online E-Stop
F1 F3
F2 F4
Joystick
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FIGURE 3-2 KEYPAD, JOYSTICK, AND EMERGENCY STOP 3.4.9 PEN AND CUTTER PNEUMATICS A double-acting pneumatic cylinder controls the vertical motion of the cutting tool. This cylinder is operated by compressed air routed through electric solenoid valves. By applying a voltage to the solenoid valve, the cylinder changes position. Pen. The pneumatic cylinder for the pen is fitted with flow control valves that restrict the passage of air out of the cylinder. These flow control valves enable the operator to control the up and down speeds of the pen. Tool holders. The pneumatic cylinders for the tool holders are fitted with a flow control valve that restricts the passage of air out of the cylinder on the down stroke. The passage of air on the up stroke is not restricted by a flow control valve.
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3.5 CONTROL CABINET The control cabinet, shown in Figure 3-3, is a separate housing that contains the servo motor amplifiers and power supply; the system interconnect circuitry; and the control panel, which includes the pen and tool holder pressure regulators and system controls, an E-STOP, a pneumatic shutoff valve, and the system status board. A festoon with air lines and electrical cables runs under the festoon side of the table and connects the carriage to the control cabinet. The motor amplifiers and power supply provide the motor current to move the machinery. The air lines provide the air pressure to move the cutters and pen up and down.
FIGURE 3-3 CONTROL CABINET AND STATUS BOARD 3.5.1 SAFETY INTERLOCK SYSTEM The system interconnect circuitry consists of an interlock loop that shuts off motor power if any of the system interlocks is open. These interlocks are the X-axis and Y-axis limit switches, the E-stop buttons on the carriage and the front of the control cabinet, the bumper arm switches on the side of the carriage covers, and the optional external interlock circuit. See Paragraph 3.5.3 for more information on the external interlock circuit. 3.5.2 CONTROL PANEL A control panel on the front of the cabinet includes an AC Power switch, a reset button and light, the status board, and the pressure gauges and regulators. 3.5.2.1 AC Power Switch The AC power switch is used to supply power to the system. When system power is turned on, the servo motors will not be energized. The servo motors are energized during software initialization.
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3.5.2.2 Reset Button The blue RESET button is used to energize the servo motor amplifiers and control circuit. When the button is pressed and the green SYSTEM ENERGIZED light is lit, 85 volts is supplied to the amplifiers and the 24 volt control circuit is energized. 3.5.2.3 Status Board The status board provides information about the machine's current operating status: The CONTROL POWER 24 VDC READY indicator is lit whenever the internal 24V-power supply is on. The SYSTEM ONLINE indicator is lit when the motors are energized. Because the motors are not energized when the system is first turned on, the SYSTEM ONLINE indicator will be off. Then, when the computer attempts to move the machine, it will detect that the motors have not been energized. At that time, you will be instructed to press the blue RESET button next to the SYSTEM ONLINE indicator. If all the interlocks are properly closed, the system will be energized. The MOTOR STATUS indicators tell the status of the four motor amplifiers. In normal operation, the motor status lights should be off. If one of the motor status lights come on, the operator should attempt to reset the system with the RESET button when prompted by the computer. If the MOTOR STATUS light does not go off, then power down the system (turn off the red AC POWER switch), and re-start the machine. The INTERLOCK STATUS indicators tell if any of the interlocks are open. In normal operation, all of the INTERLOCK STATUS indicators should be off. The SYSTEM ONLINE indicator will not come on if any of the interlocks are open. The HOMING SENSORS STATUS indicators are lit when the carriage is over the X-axis or Y-axis homing sensors. These indicators will go on and off during normal operation, depending on the position of the carriage. 3.5.2.4 Pressure Gauges and Regulators The three pressure gauges and regulators on the control panel are used to control the air pressure to the pen and cutters. See Section 4.0 of this manual for more information on setting the pressure for the pen and cutters. 3.5.3 EXTERNAL INTERLOCKS An optional external interlock connector is located in the junction plate on the side of the control cabinet to enable the addition of another emergency stop device, such as a light fence, door interlock, or emergency stop line. The external interlock connector is a male DB9. As shipped from the factory, the connector normally comes equipped with a shorting jumper from pin 1 to 2. If the connector is removed from the side of the control cabinet, the machine will not operate. To install another interlock, use the closed circuit of the interlock to connect pins 1 and 2. The interlock circuitry should be capable of handling 10 mA from the machine's internal 24 VDC supply and the resistance of the interlock circuit should not exceed 100 ohms. If there are any questions about interfacing a specific safety device to the external interlock, please contact Gerber Technology, Cutting Edge Division to verify proper connection.
Section 3.0: Description 12/2000 3-9
3.6 PERSONAL COMPUTER (PC) The Cutting Edge Software runs on a PC that is networked to the cutting machine. Taurus TLCS installations generally use two PCs, one for nesting and preparing files for cutting and one to run the cutting machine. The minimum requirements for any PCs running the Cutting Edge software are listed in Section 2.0. In addition to running the software, the PC can be used to store multiple job files and import jobs created on other computers. Job files can be loaded into the PC using floppy disks or compact discs (CDs) or across a network. NOTE: The Cutting Edge Software will not run on Windows 3.x operating system. Some of the more important aspects of the software are described below. 3.6.1 REQUIRED SOFTWARE MODULE The Base Module software is required to run a cutting machine. You use the Base Module to: control the cutting machine prepare job files for cutting store job files
Your machine comes with the Base Module loaded. You can also purchase any number of software modules to extend the functionality of the software and your machine. See Paragraph 3.7.1.
3.6.2 HARDWARE LOCK A hardware lock is needed on the PC to run the software and to operate the machine. The hardware lock is a small plastic device that attaches to the printer port on your PC. One lock is included with each seat of software. See Section 2.0 for more information on hardware locks. 3.6.3 SERVO MOTION CONTROLLER The servo motion control board is installed in the personal computer. The board receives motion commands from the software and generates electrical signals that are sent to the control cabinet. The servo motion controller also receives signals from the control cabinet indicating the status of the internal and external interlocks, the amplifiers, and the homing sensors.
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3.7 OPTIONS Several hardware and software options are available to enhance cutting system capabilities. These options are available from Gerber Technology, Cutting Edge Division and can be installed on the machine during machine fabrication or can be retrofitted at the customers facility. A brief description of the available options is provided in the following paragraphs. 3.7.1 SOFTWARE OPTIONS The following optional software modules build on the Base Module, adding functionality that can improve cutting, increase yields, and allow part matching. 3.7.1.1 Toolpath Module The Toolpath Module builds on the Base Module by adding the ability to automatically and/or interactively change the order that parts are cut to improve the cut quality and/or minimize the cutting time. 3.7.1.2 Nesting Modules Use the optional nesting modules to move parts around the material to obtain a better fabric yield. There are four nesting modules: Limited Nesting, Extended Nesting, Limited AutoNesting, and Extended AutoNesting. Refer to Section 5.0 for more information on using the nesting modules. 3.7.1.3 Extended AutoNest Yield Enhancement Module Use the optional Extended AutoNest Yield Enhancement Module to run a second AutoNesting computer. To save time, and to run additional nests, the Extended AutoNest module can run nests on more than one computer. The Yield Enhancement module can be installed on these additional dedicated nesting computers. 3.7.1.4 Matching modules Use the optional matching modules to match parts to the fabric or to other parts. There are two matching modules: Limited Matching and Extended Matching. The two matching modules are primarily used on the DCS 3500 cutting machines. See Section 5.0 of the DCS 3500 Conveyorized Mechanical Cutter Users Guide for information about the Limited and Extended Matching Modules.
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3.7.1.5 CIM (Database) Module The Rights and Access Module (R&A Module) provides features that allow you to control the access to and appearance of the software for each of their different users. Also, the shift and operator information provided during the user log on and log off through the Rights and Access module can be included in reports about the productivity of the cutting machine. 3.7.1.6 CIM Administrator Module This module is required with the CIM Module. This module is a licensing agreement that allows you to attach any number of computers to the network that the database is stored on. One seat of the CIM Administration Module is required per network.
3.7.1.7 Rights and Access (R&A) Module The CIM Module consists mainly of a database that keeps track of the important data relating to the production system, including: cutting machines in the plant; machine operators; materials being processed, styles and parts being processed. The goal of the CIM Module is to provide production supervisors and management with a tool to organize and track the operation of the cutting machinery. Over time, the database can provide valuable information to management, such as average yields, material used, effective output of the machinery, etc. 3.7.1.8 Imaging Module Use the imaging module to scan leather hides, locate markings on hides, perform camera calibrations, and other tasks that require a camera. The Imaging module is available only for machines with a camera installed.
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3.7.2 HARDWARE OPTIONS The following optional equipment is available to spread fabric onto the table more easily and to reverse the vacuum for easier fabric spreading. 3.7.2.1 Laser Pointer A laser pointer is available to use as a pointing tool when positioning cutters on the carriage assembly. The laser pointer projects a well defined light onto the cutting surface too more accurately position the cutters. 3.7.2.2 Spreader There are several types of spreaders available to layout material on the cutting table. 3.7.2.3 Pneumatic Vacuum Shut Off System A pneumatically operated shut off system is available to close off the vacuum system immediately without waiting for the vacuum blower to spool down. 3.7.2.4 Pneumatic Reverse Air System A reverse air system is available that can be used to float the material on to the cutting table during the spreading operation. The system, which includes a series of valves and a vacuum blower, can be used when spreading material by hand or using an optional material mover. This system is only applicable with non-porous or slightly porous materials. 3.7.2.5 Pneumatic Dual Zone System Dual Zoned vacuum control improves cutting quality and reduces electrical power consumption during split table operation. The table vacuum system consists of two zones one on each side of the center of the cutting table. The zones are controlled using pneumatically controlled shutoff valves. Vacuum can be turned on and off on the section of the table where the cut parts are being removed. This makes it easier to remove parts and increases the vacuum on the side being cut.
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Section
Operating Instructions
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4.1
GENERAL
This section provides operating instructions for a Gerber Cutting Edge DCS 1500, DCS 2500, or Taurus TLCS GERBERcutter. In general, this section contains important tool and cutting concepts, information on using the keypad, pressure control settings, and instructions for starting and shutting down a cutting machine. Additional information for setting up the machine parameters, preparing the job file for processing, and running the job can be found in Section 5.0 of this manual. Additional information for modifying the job file and changing tool parameters can be found in the Cutting Edge Software Users Guide. 4.2 SAFETY
Instruct machine operators and observers to stand clear of the table while it is in operation. In some cases, it may be desirable to install a guardrail to prevent access to the table. For added security, you may wish to add a safety interlock to stop machine motion. Refer to Section 1 of this manual for a complete description of safety precautions and symbols.
Section 4.0: Operating Instructions
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4.3
PRINCIPLES OF MACHINE OPERATION
The following paragraphs address pen inking, using the cutting tools, setting the cutting pressure, operating the table vacuum, and using the plastic overlay and paper underlay when cutting. 4.3.1 CUTTING TOOL PRINCIPLES
The following instructions provide a basic information on blade properties. See the Cutting Edge DCS 1500/2500 GERBERcutter Engineering Drawings manual or the Gerber Cutting Edge Taurus GERBERcutter Engineering Drawings manual for a list of approved cutting tools for each machine. 4.3.1.1 Wheel Cutter
The wheel cutter uses Olfa blades, which have an edge angle of roughly 25 degrees (see Figure 4-1).
FIGURE 4-1 CROSS-SECTION OF AN OLFA BLADE Refer to the parts lists in the Gerber Cutting Edge DCS 1500/2500 Mechanical Cutter Engineering Drawings manual for a list of approved cutting tools. Contact Gerber Technology if you are unable to find blades locally. 4.3.1.2 Tangential Knife Cutter
The most important feature of the tangential knife cutter blade is the blade entry angle. A blade with a shallow entry angle will slightly drag the fabric, and will cut with a large footprint. A blade with a steep entry angle will drag the fabric more, but it will also cut intricate shapes well. Gerber Technology, Cutting Edge Division supplies carbide blades with 30 and 45-degree entry angles. Refer to the parts lists in the Cutting Edge DCS 1500/2500 GERBERcutter Engineering Drawings manual for a list of approved cutting tools. 4.3.1.3 Punch and Notcher Tools
A variety of punch and notcher tools are available for use on the machine.
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4.3.2
CUTTING PRESSURE
The following sections address some important issues regarding cutting pressure for wheel cutters and knife cutters. 4.3.2.1 Wheel Cutter
Setting the correct cutting pressure will result in the best cuts and will ensure the longest life for the plastic table surface. Figure 4-2 shows the blade from the side with the correct cutting pressure and with too much pressure. As penetration into the surface of the table increases, the blade tends to start pushing the material forward instead of down. The blade also cuts into the plastic and causes unnecessary damage to the plastic table surface.
FIGURE 4-2 PROPER AND EXCESSIVE BLADE PENETRATION. As the cutting speed increases the cutting pressure must also be increased to keep the blade down in the fabric, and as a result, the blade will dull more rapidly. With some fabrics (like Kevlar) it is possible to chip the blade if the speed is too high. The amount of pressure necessary to cut with the wheel cutter is material dependent. It is best to set the minimum air pressure required to cut a particular material, and blades must be changed often. As the blade wears, do not increase the pressure of the cutter to compensate for a dull blade. Instead, install a new blade. 4.3.2.2 Tangential Knife Cutter
The tangential knife cutter should also be run at the minimum cutting pressure possible to prevent unwanted shifting of the material. Since the depth limiter rides on the fabric being cut, reducing the cutting pressure will reduce the drag exerted on the fabric. 4.3.3 INKING PRINCIPLES
The pen on the machine mounts in a standard Hewlett Packard plotter pen mount. A rubber "O" ring holds the pen in place, which, while quite secure, still allows the pen to deflect if it gets caught up in the fabric. Spring tension controls the downward pressure on the pen. Adjust the tension by changing to a stiffer or softer spring. The standard pen is a pressurized ballpoint with a replaceable ink cartridge. Only Hewlett Packard pens shown in the parts lists in the Cutting Edge DCS 1500/2500 GERBERcutter Engineering Drawings manual or the Cutting Edge Taurus GERBERcutter Engineering Drawings manual can be used. If a special writing implement is needed, contact Gerber technology, Cutting Edge Division for a custom adapter.
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4.3.4
MATERIAL PROPERTIES
Some important properties of fabrics that affect the way they cut are stiffness, porosity and the toughness and size of the fibers. Stiffness is a measure of the rigidity of the sheet of fabric. Fabric stiffness affects the tendency of the cutting blade to move the fabric, as well as the ability of the vacuum table to hold the material flat on the table. Dacron sailcloth is a good example of a stiff fabric. Dry carbon fiber or fiberglass woven fabric is a good example of a limp fabric (no stiffness). Porosity of the fabric is a measure of how easily air can pass through the fabric. Fabric porosity determines how well the vacuum table can hold the fabric in place. Fabrics like wool and cotton are very porous. Vinyl coated and polyester laminated products are not. In the middle of the range are many fabrics that are slightly porous, such as nylon fabric used to make sails and parachutes, acrylic fabric used to make outdoor covers and awnings, and Dacron. Fiber size and toughness determine how easily the cutting blade can break the fibers. Fibers that are both tough and very small can actually be pressed into the plastic table surface without breaking. The use of a paper underlay may be needed in this case and is explained later in this chapter. Please contact Gerber Technology, Cutting Edge Division before cutting any new materials on the cutting machine. 4.3.4.1 Material Set
Material set refers to the tendency of stiff fabrics to roll up. Because the vacuum table cannot prevent the material from peeling up off the table it is essential that materials with set are placed with the set down, as shown in Figure 4-3.
FIGURE 4-3 POSITION OF MATERIAL SET
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4.3.5
VACUUM TABLE OPERATION
The vacuum table is needed to keep the material in place during the cutting operation. To maximize the effectiveness of the vacuum it is important to properly set the valves and to curtain off open areas. The valves on the vacuum table connect each four-foot panel with the vacuum header. Any panel that has a part of the cutting job must be open, and all others must be closed. 4.3.6 PLASTIC OVERLAY
A plastic overlay is a very thin layer of plastic that is placed on top of the fabric being cut. This overlay serves two very useful purposes. One is to enhance the vacuum table effectiveness and the other is to provide a low friction surface for the foot of the tangential knife cutter. The plastic overly enables the vacuum table to firmly hold porous and semi-porous material that would otherwise not stay in place, because the overlay seals the table surface and allows the vacuum system to reach maximum vacuum holding strength. When using a plastic overlay, it is important to cover the whole table to eliminate unwanted leakage. The plastic overlay is also effective when using the tangential knife cutter to cut tacky fabrics. With tacky or sticky fabrics the cutter foot will not ride smoothly on the material. In this case, it is recommended to use a plastic overlay to provide a low friction barrier. 4.3.7 PAPER UNDERLAY
A paper underlay is useful when wheel cutting fabric with very fine fibers. The underlay consists of a sheet of paper placed between the plastic table surface and the fabric. When the blade presses against the cloth, the paper provides support to the fabric making it easier for the blade to completely sever all the fibers. Kraft paper works well as an underlay. When using cutting pressures above 20 psi (138 kPa) use heavy paper (40 lb.) whereas with cutting pressures below 20 psi (138 kPa) use lightweight paper (20 lb.).
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4.4
OPERATING CONTROLS
The following paragraphs describe how to operate the keypad, PC, and video projector. 4.4.1 KEYPAD OPERATION
This paragraph describes the keypad interface to the cutting machine. The keypad, Figure 4-4, simplifies operation by enabling the operator to move the machine and perform routine operating tasks at the carriage.
FIGURE 4-4 KEYPAD On the left of the keypad are the function buttons that are labeled F1 through F4. These buttons are used to execute specific options when needed. In the middle of the keypad are the Up () and Down () arrow buttons and the Plus (+) and Minus (-) buttons. The CANCEL ! and ENTER () buttons are located on the right of the keypad. The CANCEL button looks like a left arrowhead with a cross in it and the ENTER button has the same symbol as the ENTER key on a normal keyboard. See Figure 4-4. While the machine is operating, the control software monitors the keypad for operator input. If the Base Module on the personal computer is performing an intensive operation (reading in a new cutting job, or calculating the motion sequence, for example) the keypad may not respond right away to the operator. Also, when the operator exits the machine control software, the keypad display will go blank, and the keypad buttons will not respond to operator input. There are two modes of keypad operation: Online mode and Local mode. When the machine is in Online mode, the Base Module software has control of the machine. When the machine is in Local mode, the keypad has control and the operator can move the carriage with the joystick and execute commands from the keypad.
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4.4.1.1
Online Mode
When the machine is in Online mode, the Cutting Edge Software has control and Online is displayed in the bottom row of the keypad. In Online Mode, the keypad has the following functions: entering Local mode (explained in Paragraph 4.4.1.2), starting a job, and pausing (or aborting) in the middle of a job. Up and Down Arrows If the operator presses the Up () or Down () arrow button when the machine is in Online mode, the machine attempts to switch into Local mode. There are some cases where this may not be possible, such as if the machine is in the middle of a job. If the machine can go into Local mode, it will display the message Local in the bottom row of the keypad. ENTER button The ENTER () button is used to start a job from the keypad. When the Base Module software is ready to move the machine, it displays a message on the computer screen and waits for the operator to start the job from the keypad by pressing the ENTER () button. Pause / Abort Once the job begins and the machine starts to move, there are two ways to stop the machine. The first method uses an E-Stop; the second uses the keypad. To stop the machine immediately, press any E-Stop button or bumper. The machine stops cutting right away and lifts the pen and cutter. The servo motion controller discards any pending motion sequence so the rest of the parts on the table are not cut. To restart the job, press the Halt button then press the Restart Aborted Job button (or select Restart Aborted Job... from the Machine menu). Or, start the job using the Start At command explained in Section 5 of this manual. To execute a controlled pause using the keypad, press any one of the keys on the keypad. The machine stops and lifts the pen or cutter after completing the operation in progress. Once the machine has paused, the operator has the option to resume or abort the job. To resume, the operator presses the ENTER () button on the keypad; to abort, the operator presses the CANCEL ! button. This type of pause is known as a controlled pause.
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4.4.1.2
Local Mode
From Online mode, press the Up or Down arrow button to go into Local mode. Once the machine is in Local mode, Local is displayed on the keypad and the operator can control the carriage from the keypad. Use Local mode to enter Jogging mode (where you control the carriage with the joystick), return to Online mode, or perform a number of cutting functions. ENTER Press the ENTER () button to activate jogging with the joystick. Jogging is displayed on the keypad. In Jogging mode, you can move the carriage in both the X and Y direction using the joystick, with a top speed of about 15 inches (38 cm) per second. In Jogging mode, the machine has software limits to keep the operator from jogging into the limit switches. To lower the pen, press the Down arrow. To raise the pen press the Up arrow. CANCEL Press the CANCEL ! button when the machine is in Local mode to put the system back into Online mode. If successful, the message Online is displayed on the second row of the keypad. Up and Down Arrows Press either the Up or Down arrow button to scroll through functions on the second row of the keypad display. A new function appears each time the arrow button is pressed. To execute a function when it is displayed on the keypad press the ENTER () button. The available functions are: Move to Origin This function moves the carriage to the physical origin of the table. Move to Station This function moves the carriage to the selected station. The number of stations and their location is set in the Configure Machine and Calibrate Machine dialog boxes described in Section 6.0. After selecting this option, press the ENTER key on the keypad to display Station 1. Press the Plus (+) key until the station number to which you want to move is displayed. Then press the ENTER key on the keypad to move to the station. Move to Y Origin This function moves just the Y-axis assembly to its origin. The carriage is not moved in the X-axis. This option is very useful if you wish to move the Y-axis assembly to the edge of the cutting area without moving the machine from side to side.
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Move to Local Origin This function moves the carriage to the start position for the last job. This feature is especially useful if you need to cut in the same place several times, or if you need to restart a job and cut it in the exact same place. Move to Midpoint This function moves the carriage to the middle of the table. On systems that are set up for split table operation, this position corresponds to the origin for the right side of the table. Move to Far End This function moves the carriage to its maximum travel at the right end on the table. This is useful for loading cloth from a rack at the origin end of the machine or for clearing cut parts. Cut Off Material This function cuts a straight line across the Y-axis. This feature is useful for removing the jagged edge of material at the end of a job. To use this feature, jog the carriage to the location where you wish to cut, and then execute the Cut Off Material option. Use the Job Parameters dialog box found in the Machine menu to set your preferences for this option including the tool, speed and type of cut (full width or center cut). The Job Parameters dialog box is described in detail in Section 5.0 of this manual.
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4.4.2
PC OPERATION
The Cutting Edge Software is included with every machine, and allows you to read standard cut files. The software displays the job on the screen and provides information on relevant operational data such as the amount of time the machine has been running; the time spent cutting and slewing; and the amount material required to cut a job. It allows you to run the machine with a variety of different tools, and maintains calibration information on each tool so that tool changes are quick and easy. Each type of entity in a job (cut lines, text, notches, etc.) can be assigned to a different layer, and each layer can be assigned to a different tool or to the same tool using different calibration settings. Additionally, the Base Module allows you to modify the cut file by creating layers which allows the parameters of the tools that are being used to be customized for the individual functions. 4.4.2.1 Basic Windows Concepts
When working with windows, work is performed in rectangular areas of the screen called windows. These windows appear on the background called the desktop. The applications you work with (such as the Cutting Edge Software) are represented on the desktop by icons (small graphic symbols), such as Figure 4-5 for the Cutting Edge Software.
FIGURE 4-5 CUTTING EDGE SOFTWARE WINDOWS ICON Consult the Microsoft Windows Users Guide for information on basic Windows operation and a description of the various screens to learn more about revising data.
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4.4.2.2
Basic Mouse Commands
When working with windows, work is performed in rectangular areas of the screen called windows. These windows appear on the background called the desktop. The applications you work with (such as the Cutting Edge Base Module or other modules) are represented on the desktop by small graphical symbols called icons, such as the icon in Figure 4-5 for the Base Module. To learn more about Windows operation, consult the Microsoft Windows Users Guide. Consult the Cutting Edge Software Users Guide for information on basic Windows operation and a description of various screens. Following are some basic Windows mouse operations used with the Base Module.
For quick and easy access to frequent machine operations, use the toolbar. The toolbar includes buttons for common tasks such as opening a file, homing the machine, editing job files, setting the tool parameters, and running the job. Use the mouse to move the pointer or cursor. Click the left mouse button to select menus and commands and to position the cursor to insert text. In the following instructions, when instructed to click the mouse button, it is understood that you are to click the left button unless otherwise instructed. The arrow keys to cycle through the menus at the top of the screen. Use the tab key to move up and down within a displayed menu.
The following cursor and mouse operations are specific to the Base Module operation.
To select a group of entities, use the left mouse button to draw a rectangular box around the entities. Those entities that are completely within the box will be selected. Another method to select a group of entities is to press the CTRL key and press the left mouse button with the cursor on each entity you want to select. To select a particular entity, click the left mouse button. The entity covered by the cursor will be selected and all other selected entities will be deselected. Click the right mouse button on the selected data to modify existing data in some text boxes. To zoom in, position the cursor in one corner of the area you want to view. Then click and hold the right mouse button and drag the cursor diagonally to form a window in the area to be viewed. Release the right mouse button and the area enclosed by the rectangle is enlarged to full screen. Use this method to enlarge an area several times to view detailed entities of the job such as notches. After selecting one or more entities and performing an operation such as Move to Layer as described in and the Cutting Edge Software Users Guide, de-select all entities by clicking the left mouse button in an open area on the screen. When the mouse pointer passes over different parts of the job, it changes shape, indicating it will now perform.
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4.5
SETTING UP FOR NEW JOB
The following paragraphs describe the procedures for setting up the machine for a new job. 4.5.1 CUTTING MACHINE CONTROL SETTINGS
The following paragraphs discuss adjusting the pen and cutter pressures, focussing the optional laser pointer, removing and installing the wheel cutter, and setting the cutting depth of the tangential knife.
FIGURE 4-6 CONTROL CABINET PANEL 4.5.1.1 Set Pen Pressure
The downward pressure of the pen is controlled by a spring, and not by the PEN pressure regulator on the control panel (refer to Figure 4-6).The PEN pressure regulator only controls the upward movement or retraction pressure of the pen and the cutting tools. The PEN pressure regulator is also used to lower and raise Tool Holder 3. Set the pen pressure regulator labeled PEN on the control cabinet to 20-25 psi (138172.5 kPa). NOTE: Setting the pen pressure too low will inhibit the blade from retracting properly. Since the pen pressure is used to control both the retraction pressure of the tools, and to lower and raise Tool Holder 3, set the pressure to between 15 and 30 psi (104 and 208 kPa) depending on the pressure required to operate Tool Holder 3. Use only tools on Tool Holder 3 that can operate at the pressure range set for the pen.
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4.5.1.2
Set Cutter Pressure
The cutter pressure regulators labeled TOOL HOLDER 1 and TOOL HOLDER 2 control the downward pressure of the cutting tools (refer to Figure 4-6). Tool holder 1 is nearest the keypad, and tool holder 2 is nearest the festoon side of the machine. Tool holder 3 is located between tool holders 1 and 2. The downward force in pounds is roughly 4/10 ths (0.4 times) the cutter air pressure in psi. Therefore, a cutter setting of 30 psi corresponds to a downward cutter force of 12 pounds. For metric systems, 30 psi (208 kPa) would correspond to a downward cutter force of 5.45 kilos or 53.3 Newtons. Cutting pressures typically range from 10 to 40 psi (69 to 276 kPa). When setting the pressure for either a notching tool or a drilling tool, remember to loosen the lower flow control valves on the appropriate cutter cylinder first. This will ensure that the tool reaches maximum downward velocity to properly punch or notch the material. Refer to Section 6.0 for a detailed explanation of the flow control valve adjustments for the cutting tools. 4.5.1.3 Adjust the Focus of the (Optional) Laser Pointer
Focus the laser pointer using the special tool that is supplied. 1. Confirm that the laser pointer is mounted in its mount so that the nylon screw is bearing on the cutout in the body of the laser pointer. 2. Insert the adjustment tool into the bottom of the laser pointer. 3. Turn the tool until the light is focused properly. WARNING To prevent eye injury, never look directly at light emitting from laser pointer.
CAUTION Use the correct nylon screw provided to mount the laser pointer in the mount. Otherwise, the body of the pointer may be damaged.
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4.5.1.4
Removal and Installation of Wheel Cutter
The following procedure should be used to remove and install the wheel cutter on the tool holder. WARNING Blade on wheel cutter is very sharp. Use care when handling cutter. 1. Home the machine to gain access to the tool set screw. 2. Loosen the set screw and remove the tool holder from the tool mount. 3. Remove the cutter from the tool holder. 4. Change the blade as follows: a) Remove the nut from the screw that holds the blade and washers on the wheel cutter. b) Remove the old blade. c) Install a new blade between the two washers. Use the correct washers on the tool holder with the blade. Washers must be the correct thickness so that the blade is not offset improperly. If new washers are used, confirm the correct tool offset using Calibrate Machine dialog box described in Section 6.0. d) Install the screw with the proper locking nut so that the cutter blade does not loosen from the tool holder. 5. Install the tool holder on the cylinder tool mount as follows: a) Confirm that the ball bearing is soldered to tip of the set screw and that the tip protrudes slightly on the inside of the tool holder. b) Position the tool holder on the cylinder tool mount so that the set screw tip is located in the slot of tool mount. NOTE It might be easier to handle the wheel cutter by inserting the ball nut driver into the set screw and positioning the cutter using the ball nut driver to support the cutter. c) Raise the tool holder up to the flange on the tool mount and slightly tighten the set screw while loosely supporting the cutter. d) Loosen and then tighten the set screw on the tool holder so that the ball bearing on the set screw tip is seated in the dimple at the top of flat in the tool mount slot. This secures the upper surface of tool holder against the lower flange of the tool mount.
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4.5.1.5
Setting Depth of the Tangential Knife
Before cutting with the tangential knife, the depth, or penetration, of the blade, must first be set. The tangential knife cutting tool has a depth limiter (plastic foot) which rides on the material that is being cut. This depth limiter controls the penetration of the cutting knife into the material, and serves to improve the cut and reduce the wear on the plastic table surface. It is recommended that the tangential knife be set to a depth of approximately 0.005 to 0.015 inch (0.012 to 0.038 cm) more than the thickness of the material. The actual setting depends on the material that is being cut. Setting the depth too low may result in incomplete cuts and setting the depth too high may result in cutting too deeply into the table surface. It is best to start at 0.005 inch and increase the depth setting up to 0.015 inch or until it is certain that the material will be cut properly. To perform the depth adjustment use the following tools (which were supplied with the machine): dial calipers to measure material thickness, ball driver to move the set-screws, and dial indicator stand to verify the setting. 1. Home the machine to gain access to the tool holder set screw. 2. Loosen the set screw to remove the tool holder from the tool mount. 3. Measure the thickness of the material with the dial calipers and add approximately 0.005 to 0.015 inch (0.012 to 0.038 cm) to the material thickness to get the depth setting. 4. Loosen the set screw in side of the plastic depth limiter to free but not remove the depth limiter from the tool holder. 5. Locate the tool depth adjusting screw, which is accessed from the top of the tool holder through the mounting hole. 6. Place the tool and tool holder with depth limiter on the top of dial indicator and insert the 3/64 ball driver into the tool depth adjusting set-screw. Confirm that the dial indicator is set to zero prior to positioning the tool. 7. Turn the depth adjusting set-screw until the desired depth is achieved. 8. Tighten the plastic depth limiter set-screw to lock the setting in place. CAUTION Do not tighten the set screw on the depth limiter too tight. The limiter is made of a soft material and the threads might be stripped. 9. Confirm that the depth is set properly after the screw is tightened.
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10. Install the tool holder on the cylinder tool mount as follows: a) Confirm that the ball bearing is soldered to tip of the set screw and that the tip protrudes slightly on the inside of the tool holder. b) Position the tool holder on the cylinder tool mount so that the set screw tip is located in the slot of the tool mount. NOTE It may be easier to handle the wheel cutter by inserting the ball nut driver into the set screw and positioning the cutter using the ball nut driver to support the cutter. c) Raise the tool holder up to the flange on the tool mount and slightly tighten the set screw while loosely supporting the cutter. d) Loosen and then tighten the set screw on the tool holder so that the ball bearing on the set screw tip is seated in the dimple at top of the flat in the tool mount slot. This secures the upper surface of the tool holder against the lower flange of the tool mount.
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4.6
STARTING THE CUTTING MACHINE
Turning on a DCS 1500, DCS 2500, or Taurus TLCS machine involves turning on the power to the system, starting the software, and putting the cutter on-line. To start the cutter: 1. Set the power switch on the control cabinet to On. The machine and personal computer turn on and the Windows desktop is displayed on the computer. If the computer does not turn on, press the power button on the front of the PC. 2. Double-click the Cutting Edge Software icon should be on the Windows desktop. to start the Cutting Edge Software. The icon
3. The System Status Dialog Box shown in Screen 4-1 appears on the computer. This dialog box indicates that the system is not ready. SCREEN 4-1 SYSTEM STATUS DIALOG BOX
4. Press blue RESET button next to the AC Power switch on the control cabinet to energize the machine servo system. The green light on the control cabinet labeled SYSTEM ENERGIZED will be illuminated, indicating the amplifiers are energized and the 24V power supply in the control cabinet is powered on. The cutter keypad will display System not ready: Waiting for Reset. 5. Press the blue RESET button on status board to bring servo system motors online. When the system is online, the System Online light on the status board will be illuminated, and the cutter keypad will display DCS 1500/2500 Online or Taurus Online. The System Status dialog box will disappear from the computer screen when the system is online.
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6. If the machine will not reset, confirm the following: All E-stop buttons are in the unlocked position. Turn the E-Stops clockwise to release. All limit switches are not blocked. Move the carriage or the Y-axis assembly off the limit switch. All bumper arm switches are not blocked. Move the obstruction from bumper arm. The optional interlock is closed, or the interlock connector is not installed.
7. Press the RESET button on the control cabinet after correcting the problem. If the machine still does not reset, go to Troubleshooting, Section, 8.0. 8. Home the machine by clicking the Machine menu and then the Home Machine command). The Home Machine Dialog box shown in Screen 4-2 will be displayed. SCREEN 4-2 HOME MACHINE DIALOG BOX
To prevent the machine from making a clearing move in the X and/or Y direction, click the appropriate boxes in the Home Machine dialog box. You may want to skip the clearing move if it would make the carriage travel into a limit switch, causing the machine to go offline. NOTE: You should home the machine whenever power is shut off at the control cabinet. 9. Click OK to begin the homing process. 4.6.1 LOCAL MODE ERROR MESSAGE
The screen might display the Local Mode error message shown in Screen 4-3 when the software attempts to initiate communication with the machine, and the machine is in Local mode at the keypad. SCREEN 4-3 LOCAL MODE ERROR MESSAGE
Correct this error message by setting the keypad to Online mode instead of Local mode. Press the Cancel button ! on the keypad to return to Online mode.
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4.7
SHUT DOWN THE CUTTING MACHINE
Shutting down a DCS 1500, a DCS 2500 or Taurus TLCS machine involves closing the Cutting Edge Software, turning off the PC, and turning off power to the control cabinet. NOTE: Make sure an E-STOP is pressed before shutting down the cutter. 1. Before shutting down the software, close any open jobs. Close the job file by clicking the File menu, then selecting the Close command. Save the job as needed. 2. Shut down the software by clicking the File menu, then selecting the Exit command. The desktop closes. Close any other application that is open. 3. Exit Windows by clicking the Start button in the lower, left corner of the screen. 4. Select the Shut Down command on the menu that appears. The Shut Down Windows dialog box opens. 5. Select the Shut down the computer? option in the Shut Down Windows dialog box. 6. Click Yes to shut down Windows. Windows shuts down. After you shut down Windows, you need to turn off the computer and monitor, and shut off the Control Cabinet. Your system might be configured to shut down the computer automatically. If the monitor displays the message It is safe to turn off your computer and then goes black, then you do not need to shut down the computer. 7. Turn off the computer by pressing the power button on the front of the computer case. 8. Turn off the Monitor by pressing the power button. 9. Turn off the Control Cabinet by turning the power switch. When the 24 Volt button is not illuminated, the power is off.
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Section
Working with Jobs
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5.1.
GENERAL
This section provides instructions for using a Cutting Edge DCS 1500, DCS 2500, or Taurus TLCS GERBERcutter to cut jobs. This section includes instructions for opening a job file, setting job parameters, and preparing a job for cutting. This section also provides instructions for creating a new job file from a template (a process called digitizing). For instructions on any Cutting Edge Software commands not discussed in this manual, refer to the Cutting Edge Software Users Guide, or to the Cutting Edge Software On-line Help. 5.2. OPENING A JOB FILE
Before working on a job file, the job file must be opened. How you open a file depends on how your company stores job files. Users at companies that store the job files through the CIM database, and use work orders to organize jobs, should use the Open Work Order command on the Database menu. Companies that do not use the CIM database can use the Open commands on the File menu. If you do not have the CIM Module, the options on the Database menu are not available (they are grayed-out). 5.2.1. OPENING A WORK ORDER
The Open Work Order command opens an existing work order. To open a work order, the work order must exist in the CIM database. If the work order you need is not in the database, speak with your supervisor, the system administrator, or refer to Section 7.0 of the Cutting Edge Software Users Guide for more information on work orders. To open a work order, click the Open Work Order button (or click the Database menu, then select the Open Work Order command). The Select Work Order dialog box (shown in Screen 5-1) is displayed. SCREEN 5-1 SELECT WORK ORDER DIALOG BOX
Select the specific work order and click OK. You can sort the work order using the Work Order Status and Machine options. These options can be used to display specific types of work orders, such as only new work orders or work orders assigned to your machine. When the work order opens, the parts appear on the Cutting Edge Desktop.
Section 5.0: Working with Jobs
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5.2.2.
OPEN COMMAND
The Open command loads a file that has been processed in the Base Module or another application that is defined in the File Options dialog box (refer to the Cutting Edge Software Users Guide for more information). To open a job, click on the open toolbar button, or click the File menu, then the Open command to display the Open dialog box shown in Screen 5-2. Set the location and file type for the file you want to open and select the file from the list that appears. If you are not sure of the type of file you want to open, you can use the By Name file type to view all job files in the selected directory, regardless of type. Click OK to open the file. SCREEN 5-2 OPEN DIALOG BOX
Click Open to open a job file after selecting the appropriate options. Click Cancel to exit this screen without opening a job. File name The name of the file that is being opened. You can either select the name by double clicking a selection from the list displayed above the text box, or type the name in the text box. The type of files that can be opened. This box displays the file type that identifies the filter used to open the file. Click the arrow on the side of the box to display a list of the available file types. Click on the type of file to be opened to select it. The list of files type can be changed using the File Options dialog box described in the Cutting Edge Software Users Guide. The drive or folder that contains the job files. There are several ways to change the drive or folder listed in this box: To select a new drive, click the arrow on the side of the Look In box, and select the drive from the list. Double click on one of the folders displayed in the area below the Look In box to move down a level in the directory. Click the folder button the directory. next to the Look In box to move up a level in
Files of type:
Look in:
For additional information on opening, editing, modifying, saving, and closing a job, refer to the Cutting Edge Software Users Guide.
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5.2.2.1.
Fast Open
The Fast Open dialog box, shown in Screen 5-3, allows you to open files by typing in the directory path, the file name, and selecting the file type. Click OK to open the specified file. SCREEN 5-3 FAST OPEN DIALOG BOX
Path Name Type
Type the full path to the file in the Path text box or select the directory using the Browse button. Type the name of the job (including the extension) in the Name text box. Select the file type for the file from the Type menu. Click the down arrow to the right of the text box to display the menu.
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5.3.
JOB PARAMETERS
Use the Job Parameters dialog box to control some general machine cutting options, such as the location of job origin and material cut-off information. On DCS 1500 and DCS 2500 machines, you can also use the Job Parameters dialog box to operate in split table or normal table mode. These options do not change when a new job file is opened. This section begins with a detailed description of the Job Parameters dialog box, followed by an overview of split and normal table operation. 5.3.1. SETTING JOB PARAMETERS DIALOG BOX
The Job Parameters dialog box shown in Screen 5-4 controls the general machine behavior during cutting. Use the Job Parameters dialog box to set the job start and end locations and to set the cut-off parameters. SCREEN 5-4 JOB PARAMETERS DIALOG BOX
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Set the parameters in the Job Parameters dialog box as follows: General Parameters: Cutting Mode: This group sets up the machine starting and ending position. Edit the General Parameters as follows: The type of table used for cutting jobs, select either Normal Mode or Split Table Mode. Normal Mode This mode uses the full length of the table. This option is generally used with DCS 1500 and DCS 2500 machines only. See Paragraph 5.3.3 for more information on Normal Mode. Split Table Mode This mode divides the machine in the middle and creates a left side and a right side. Normally, you will also specify the Machine Midpoint in the At End Move To list box, see below. Refer to Paragraph 5.3.2 for more information on Split Table Mode. Job Origin: This group allows the user to select the start location for the jobs. The following start locations are available in the drop down list box. See Figure 5-1, Figure 5-2, and Figure 5-3 show the location of Local Origin and Machine Origin. Local Origin The machine starts to cut the material at a local position selected by the operator. Refer to the advanced group in the Configure Machine dialog box for details on setting the pointer tool. Machine Origin - The machine starts to cut the material at the machine origin. The Start in Jogging Mode option is not available when this option is selected. Lower-Right Origin - The machine starts to cut the material at a local position selected by the operator. When the operator presses the ENTER button on the keypad, the job is oriented so that the origin becomes the lower-right corner of the bounding rectangle.
Start in Jogging Mode - Select this check box to allow jogging to start point after Cut Job command is selected. After jogging to start point, press ENTER to start job. The Start in Jogging Mode option is not available when Machine Origin is selected. Mid-Table Origins - This check box is only available when using split table mode. When checked, the start location for the left side is at the lower right corner of the job. Rotate Left Side 180 - This check box is only available when using split table mode. When checked, the job for the left side of the table is rotated 180. This allows the user to cut material in split table mode when the orientation of the nap of the material is important. To start the job, move the pointer tool to the lower right corner of the left side of the mid table dead zone. The job is cut in the original order.
! !
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At End Move To:
After the job is cut, the cutter moves to the selected location in the drop down list box. Local Origin The cutter moves back to the local origin after completing the current job. Do Not Move The cutter stops at the end of the current job. Clear End of Job The cutter moves to a location just beyond the current job. The distance set in Clear Buffer controls how far beyond the end of the job to move. This option is typically selected when cutting several small jobs out of one long piece of fabric. Next Station The cutter moves to the next station when cutting with multiple stations. Machine Origin The cutter moves to the machine origin after completing the current job. Machine Midpoint The cutter moves to the midpoint on the machine table. Machine Far End The cutter moves to the far right on the machine table.
Clear Buffer: Randomize Origin:
The distance beyond the current job to place the cutter when using Clear End of Job. Randomly moves the origin to avoid starting a cut job in the same location every time. It prevents excessive wear when cutting with the mechanical cutter. The origin moves around the circumference of a circle. Diameter Type in the diameter of the circle for the randomized origin. Step Angle Type in the amount in degrees that the randomized origin increments around the circumference of the circle for each start. It is best to type a number that can not be evenly divided into 360 so that the origin does not start at the same spot after going around the circle. SCREEN 5-5 GENERAL JOB PARAMETERS
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Cut-Off Parameters:
Use the following group of parameters (shown in Screen 5-6) when cutting off the material from a roll. Edit the job Cut-Off Parameters as follows: Cut-Off Extensions - The cut-off extension extends the material cut-off both above and below the boundary to ensure complete cut-off. For material cut-off, the bottom of the cut-off in the Y-axis is the same as the start location of the job. If the material extends below the start of the job, type the amount of extension to complete the cut-off to the edge of the material. This dimension is added to the top and bottom of the cut-off. Cut-Off Buffer - The distance in the X-axis between the end of the job and the cut-off. Cut-Off Width - The cut-off distance in the Y-axis. Generally, this value is the width of the material. Use Material Settings When Cutting Jobs Use this option to cut off the material at the material width set in the Material Settings dialog box. Default Speed - The cut-off speed if the system is unable to find a cutting speed from the Use Layer or Use Holder (see below). Use Layer - Selecting Use Layer causes the software to search the current jobs layers. If one matches a name in the layer list, the cut-off parameters are taken from that layer in the job. Use Layer is especially useful if different tools are needed for different materials. The operator loads the layer settings from the material database, and the cut-offs are automatically done with the proper tool holder and speed. If the software is unable to make a match between the list of layers and the layers in the job, the software then defaults to Use Holder (see below). To add a new layer, position the cursor after the preceding layer name and press CTRL + ENTER: this will position the cursor at the beginning of a new line. Then type the new layer name. Pressing only the ENTER key will close the dialog box.
" Use Holder - Select this option to designate the default tool holder for the cut-off. Select the holder from the drop down list box adjacent to the button.
SCREEN 5-6 CUT-OFF PARAMETERS
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Cut-Offs:
Use this group to designate the cut-off parameters. Edit the cut off parameters as follows: Cut-Off Left - Select this check box to cut off the material at the left side of the job. Then select from the options described below. Before Job - Select this option to cut-off the material before cutting the job. After Job - Select this option to cut-off the material after cutting the job. Cut-Off Right - Select this check box to cut off the material at the right side of the job. Then select from the options described below. Before Job - Select this option to cut-off the material before cutting the job. After Job - Select this option to cut-off the material after cutting the job. On Fly - Select this option to cut-off the material after the last Op Stop is located. If there are no Op Stops in the job, the cut-off is done before cutting the job. Cut-Off Type - Select one of the cut-off types described below. Full Width - Select this option to make the cut-off from the bottom up or the top down depending on which is nearest to the end of the job. Center Cut - Select this option to make the cut-off outward from the center of the material. After cutting the job, the designated cut-off tool cuts the material from the center down and then the cutter lifts and moves to the center again and cuts the material upwards. This is particularly useful when using the tangential knife to cut material that may bunch up if the material cut-off is started from the bottom or the top.
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5.3.2.
SPLIT TABLE OPERATION
Split table operation allows you to divide the cutting area of the table into two halves, the left side and the right side. Split table operation can increase throughput because it is possible to keep the machine cutting almost all of the time. The disadvantage of operating in split table mode is that the maximum size of a cut job is only half of the available cutting area. In typical split table operation, the operator can control the carriage from the midpoint of the table and can instruct the carriage to cut on either the left or right side of the table. When cutting in Split Table Mode, place fabric onto the left side of the table and begin to cut the job. While the machine is cutting in the left side, place fabric onto the right side of the table. When the machine completes the left side, start the cutting job on the right side of the table. Then remove all the cut parts from the left side of the table while the machine is cutting on the right side. By the time the machine finishes cutting the job on the right side of the table, the left side of the table has been cleared of all the cut parts and new fabric has been pulled. Start the cut job on the left side again and clear the cut parts from the right side.
FIGURE 5-1 SPLIT TABLE OPERATION 5.3.2.1. Job Origin in Split Table Mode
Using the Local Origin option in Split Table Mode enables you to place the material anywhere on the table and jog the pointer tool to the beginning of the cut job. When selecting Local Origin with MidTable Origin On (see Paragraph 5.3.2.2), the operator jogs the pointer tool to the side of the table where the job will be cut. If you jog the pointer tool to the right of the dead zone, the carriage will cut the right side. If you jog the pointer tool to the left of the dead zone, the carriage will cut the left side. Using the Machine Origin option in Split Table Mode is the same as machine operation with the machine origin selected in normal mode.
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5.3.2.2.
Mid-table Origins
When operating in normal (full table) mode, you usually specify the lower left-hand corner of the material to start the current job. This can be time consuming when cutting the left side in the split table mode because you have to move the carriage from the middle of the table back to the physical origin of the table to start the job. Notice in Figure 5-1 the location of the machine origin for the left-side of the table. Using the mid-table origins option helps solve this problem by allowing you to move the origin to the midpoint of the table. Jobs for the left-hand side use the lower right-hand corner as the reference and jobs on the right-hand side use the lower left-hand corner as the reference. Refer to Figure 5-2 for an example of mid table origins
FIGURE 5-2 MID-TABLE ORIGINS ON
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5.3.3.
NORMAL TABLE OPERATION DCS 1500/2500
On a DCS 1500 or DCS 2500 machine, you can work in either normal table mode or in split table mode. When operating in normal (full table) mode, place the lower left-hand corner of the material at the table origin. This origin can be either the local origin or the machine origin as shown in Figure 5-3
FIGURE 5-3 NORMAL TABLE OPERATION 5.3.3.1. Job Origin in Normal Mode
When placing material, consider the bounding rectangle of the job relative to the origin. For instance, if starting the job along the edge of the material, consider the amount of buffer needed relative to the origin, then place the material accordingly. See paragraph 5.3.1 for more information on setting the job parameters. When Machine Origin is selected as the Job Origin, the cut job automatically starts at the same place, the zero coordinate in both the X and Y axes, each time the job is run. Starting the cut job at the machine origin saves time by eliminating the need to jog the cutter to a start location at the beginning of each job. The disadvantage of using the machine origin is that the fabric must be properly aligned on the table before each job. When Local Origin is selected as the Job Origin, the operator specifies the start location for each cut job. This simplifies fabric placement. The disadvantage is that the operator must take the time to jog the pointer tool to the start location before the start of each job. When Lower-Right Origin is selected as the Job Origin, the operator must jog the pointer tool on the carriage to the start of each job. However, unlike Local Origin, the origin will be the lower right corner of the bounding rectangle of the cut job. You might use the lower-right origin if the material is being fed from the origin end of the table. This would allow you to pull the material toward the far end of the table without having to pull it under the carriage, possibly damaging tools or tool holders.
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5.4.
PREPARE JOB
Use the following procedures to prepare the job for processing on the machine: Set tools and tool parameters Check tool configuration Configure smart text Set starting options SET TOOLS AND TOOL PARAMETERS
5.4.1.
Set tool and tool parameters for each type of material to be cut on the machine. The tool parameters are set as follows: Use the Edit Material Definitions dialog box under the Machine menu to create new material definitions and assign tool parameters to each type of material. Use the Map Layers to Tools dialog box under the Machine menu to edit tool parameters. Note: In the Map Layers to Tools dialog box, use the right mouse button and click on the parameter to be edited.
Refer to the Cutting Edge Software Users Guide for specific instructions on how to set the tool parameters using the Edit Material Definitions dialog box or the Map Layers to Tools dialog box. Once the material definition is set, it is filed in the database according to the material name. The material definition data then becomes available under Material Definitions in the Map Layers to Tools dialog to open the dialog box. box shown in Screen 5-7. Use the Map Layers to Tools icon SCREEN 5-7 MAP LAYERS TO TOOLS
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To load a material definition, select the material name in the Material Definition text box, then click Load. The tool settings assigned to the material definition selected will be set for the current job. If there is no corresponding layer name in the materials definition, the default layer information is used. To modify the tool settings, right-click on the setting then type the new value. Press the ENTER key on keyboard to accept the new setting. 5.4.2. CHECK TOOL CONFIGURATION
After assigning the material, visually check the tools installed on the carriage assembly against the tool list called out in the Tool Mappings list box of the Map Layers to Tools dialog box. The machine, the material, or the tools could be damaged if the tools called out in the Tool Mappings list box do not agree with the tools that are installed on the machine. 5.4.3. CONFIGURE SMART TEXT
There are two types of smart text, automatic text and operator text. Automatic text annotates the fabric with the current file name, date, and/or time. Operator text allows the operator to add text to the job prior to starting the job. Smart text commands must be inserted in the cut file when the cut file is designed. The cut file must be a file type that supports text, such as NC or DXF. In the following instructions for inserting automatic text or operator text, the ^ (caret), | (pipe) and @ (at) symbols are interchangeable. Use one of these symbols to indicate smart text annotation in the file. 5.4.3.1. Automatic Text
Automatic text for the file name, date and/ or time can be inserted into a cut file by adding desired information into the file. The text string must be all capital letters preceded by the ^, |, or @ symbol. 1. At the location where the annotations are to be inked, type: ^FILE ^DATE ^TIME |FILE |DATE |TIME -or@FILE @DATE @TIME 2. Before processing the job on the machine, open the Map Layers to Tools dialog box to confirm that the smart text layer is mapped to the pen. When the cut file is opened in the Base Module, the file name, current date, and current time are inserted and annotated on the fabric when the job is processed. 3. Use the Print Labels command to print the annotation on a label along with a picture of the perimeter of the part. SCREEN 5-8 SMART TEXT DIALOG BOX FOR AUTOMATIC TEXT
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5.4.3.2.
Operator Text
Operator text, such as the operators name or badge number, can be inserted into a cut file by adding the desired information to the cut file, preceded by a ^, | or @ symbol as follows: 1. At the location on where the annotations are to be inked, type the following: ^OPERATOR NAME |OPERATOR NAME or@OPERATOR NAME When the operator starts to cut the job, the Smart Text dialog box shown in Screen 5-9 is displayed. SCREEN 5-9 SMART TEXT DIALOG BOX
2. Click the right mouse button on ENTER TEXT HERE. 3. Type the annotation that must be made when the job is processed. Then press ENTER and click OK to accept the annotation. 4. Before processing the job on the machine, open the Map Layers to Tools dialog box to confirm that the smart text layer is mapped to the pen.
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5.5.
RUNNING THE JOB
The following paragraphs discuss how to cut a job, use Op Stops and Smart Stops while cutting, stop and restart a cut job, and what to do if parts in the job are out of bounds. 5.5.1. START CUT JOB
After opening the job file and setting the tool parameters and material definition, the job is ready to run. Use the following procedure to start cutting the job. 1. Position material on table. NOTE: Material location is not critical if using local origin. However, it is critical if using machine origin. Refer to the discussion in the Section 5.3 for more information on machine origins and local origins with normal and split table operation. 2. Turn on the blower for the table and open the valves needed to provide vacuum to the cut job. 3. Click the cut job button (or click on Machine menu then Cut Job) to start job.
4. If the machine is not homed, the Machine Not Homed dialog box appears. Click OK in that dialog box, and in the Home Machine dialog box to begin the homing process. 5. If applicable, the Smart Text dialog box appears. Click the right mouse button on ENTER TEXT HERE window. Type desired annotation text. 6. The Cut Job and Start Options dialog boxes shown in Screen 5-10 will be displayed. SCREEN 5-10 CUT JOB AND START OPTIONS DIALOG BOXES
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7. In the Cut Job dialog box, enter the following information: a. Either type number of Runs Needed or check Run Continuously to run each job from the keypad. The Cut Job dialog box will track the number of Runs Done (the number of times the job has been cut) as long as the file remains open. If you have more than one file open, the Cut Job dialog box will separately track the Runs Done for each file as long as it remains open. Click the square button next to Runs Done to reset the counter. b. To start multiple runs of same job automatically, click Auto-Start. For the first cut job, press the ENTER button on the keypad. All successive runs will start automatically after the previous run until the carriage reaches the end of the table. Whether you choose Run Continuously or Auto-Start, the machine will cut the number of jobs requested in Runs Needed box. When the cutter has finished cutting the Runs Needed, the machine will stop and wait for further input. 8. In the Starting Options dialog box, select an applicable Starting Option. If starting a normal job, do not select any Starting Options. The available Starting Options are: Shift Entities to Job Origin: When this box is checked, the Cutting Edge Software offsets the job bounding rectangle in the X and Y direction so that the lower left corner is set at the origin. The job bounding rectangle includes all parts in the job from the Start At (green light button) up to and including the Stop At (red light button). See Paragraph for more information on stopping and continuing a job. Front/Back Cutting: Check this box to indicate that the front/back mode is used during job processing. This option instructs the machine to cut only those layers that are labeled on the selected side. Restart the job to process the other side of the fabric. Use this option when processing a job that includes inking or annotation layers on both sides of the fabric. Front is Next - Select this option to process the front side of the fabric. When this option is selected, the machine will first process all layers of a job that are identified as Front in the Side entry of the Layer Settings dialog box described in the Cutting Edge Software Users Guide. Restart the job to process all layers of the job that are identified as Back. Prior to processing the front layers, the operator must turn over the fabric. The fabric should be turned over top to bottom. Back - Select this option to process the back side of the fabric. When this option is selected, the machine process all layers of a job that are identified as Back in the Side entry of the Layer Settings dialog box. Prior to starting the cut job, position the fabric upside down on the table and the mirror image of all layers identified as Back will be processed. After the back side is processed, flip the material top to bottom and restart the machine to process the Front side. 9. Click the Job Parameters button to display the Job Parameters dialog box (see Section 5.3) 10. Click the Matching Parameters button to open the Matching Parameters dialog box (see paragraph 5.5.6). 11. Press ENTER button at keypad on carriage to start the job.
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5.5.2.
SET MATCHING PARAMETERS
If you are matching the parts in the job to the fabric, use the Matching Parameters dialog box to determine how that matching job will proceed. For specific information on matching refer to Paragraph 5.5.6 and to the Cutting Edge Software On-line Help. To set the matching parameters, click the Machine menu, then select the Cut Job command. The Starting Options dialog box, shown in Screen 5-10, appears. Click the Matching Parameters button to open the Matching Parameters dialog box shown in shown in Screen 5-11. SCREEN 5-11 MATCHING PARAMETERS DIALOG BOX DCS 2500
Set the parameters, as follows: Shift Op Stops to Edge of Stripe Use these option when working with stripes. If your match point is in the middle of a stripe, it can be difficult to locate the exact match point. These options allow you to align the laser pointer with the edge of the stripe, rather than the center. The software will then cut the parts correctly, using the center of the stripe. Shift Left / Right. Check this box to indicate that the stripe runs in the Y-axis from the top to the bottom of the fabric. Then select the left or right edge of the stripe as the point you want to align the pointer to and enter the width of the stripe. Left - Select this option to align the pointer to the left side of the stripe. Right - Select this option to align the pointer to the right side of the stripe. Shift Up / Down. Check this box to indicate that the stripe runs in the X-axis down the roll on the fabric. Then select the top or bottom edge of the stripe as the point you want to align the pointer to, and enter the width of the stripe. Bottom - Select this option to align the pointer to the bottom side of the stripe. Top - Select this option to align the pointer to the top side of the stripe. Op Stop Control Select the Offset Part Following Op Stop Only option to move only the part that directly follows the Op Stop.
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5.5.3.
USING OPTIONAL STOPS AND SMART STOPS
An Optional Stop (Op Stop) is an entity in a cutting file that allows the operator to re-index the cutting machine, or use the joystick to move the pointer to another point on the fabric. For example, Op Stops are used when matching the parts in a job to the fabric. When the machine comes to an Op Stop in a file, the cutter stops allowing the operator to move the pointer to an specific point in a plaid or floral fabric to align the part with the fabric pattern. For more specific information on matching refer to Paragraph 5.5.6 and to Cutting Edge Software On-line Help. Smart Stops are a special kind of Op Stop that remember the part they are associated with. See the Cutting Edge Software Users Guide for information on how to change the Op Stops in a job to Smart Stops (using the Synchronize Smart Stops command. Op Stops and Smart Stops are placed in a file when the file is generated in AutoCAD or a similar marker making program. When a job is first opened in the Cutting Edge software, an Optional Stop appears as a box with a plus in it, and a Smart Stop as a box with both a plus and an X in it. If the program comes to an Op Stop or a Smart Stop while the machine is cutting the job, the machine will stop cutting and wait for re-indexing. There are several ways to re-index: To continue cutting without re-indexing: 1. Press F1 on the keypad. To re-index using the joystick: 1. Use the joystick to move your pointer to the location where your Op Stop or Smart Stop should be located. 2. Press the ENTER button to continue cutting the job. To rotate parts associated with an Op Stop (or Smart Stop): If you have a printed material that is not laid out straight on the cutting table, you may want to use the Op Stop (or Smart Stop) as a point for rotating the parts associated with it so that they will be cut correctly from the fabric. To rotate parts, you first need to index the Op Stop (or Smart Stop) and then index a second point, from which Base Module will determine the angle of rotation for the parts. Use the following procedure: 1. Use the joystick to re-index the pointer to where your Op Stop or Smart Stop should be located. 2. Press F3 on keypad. This will index the Smart Stop (or Op Stop) as the first point of rotation. 3. The pointer will then move about an inch to right. 4. Use the joystick to jog the pointer to the second point to define the angle of rotation. You can move the pointing device in any direction-- up, down, or to the left or right. NOTE The second point cannot create an angle of rotation greater than 30. The second point must be at least an inch away from the Op Stop (or Smart Stop). 5. Press ENTER to enter second point and continue cutting the job. The parts associated with the Op Stop (or Smart Stop) will be rotated.
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5.5.4.
STOP AND CONTINUE THE JOB
The following commands are available to start and stop the job at a particular location on the job file. Position the green light and red light buttons on the appropriate parts or entities in the cut job displayed on the screen prior to starting the job. You can use the buttons when starting a new job or an interrupted job. To start the cut job at a particular part, click the Start At button (or click on Machine and Start At) to enable the function. Then click on the part that you want to be first in the cutting sequence. To stop the cut job at a particular part, click the Stop At button (or click on Machine and Stop At) to enable the function. Then click on the part that you want to be the last part in the cut sequence. Start At This button shows a white light over a green light, and duplicates the Start At command in the Machine menu. Use this button to designate the first part or entity to be cut in a job. This button shows a red light over a white light, and duplicates the Stop At command in the Machine menu. Use this button to designate the last part or entity to be cut in a job. The halt marker appears on the screen whenever a cut job is stopped unexpectedly (for example, due to an E-stop or bumper stop activation). The program automatically places the halt marker at the start of the part or entity that the machine was cutting when it stopped. After determining and correcting the situation that caused the machine to stop, click once on the halt marker located on the toolbar at the top of the computer screen. The halt marker changes to the Start At command. Click the Restart Aborted Job command located on the toolbar at the top of the computer screen to continue cutting the job.
Stop At Halt Marker
5.5.5.
PARTS OUT OF BOUNDS
The Parts Out Of Bounds error message shown in Screen 5-12 will display if you try to cut a job with parts that are out of bounds. To specify a new start location, press the ENTER button on the keypad and move the carriage to a new start location and restart the job. If some of the parts are still out of bounds, you can press ENTER again for another start location, or you can start the job with F1. Starting the job with F1 will cut those parts that are in bounds and ignore those parts that are out of bounds. Pressing CANCEL button on keypad at any time will cancel the operation. For information on separating the job that is too long into smaller sections, use the Manual Feed feature described in the Cutting Edge Software Users Guide. SCREEN 5-12 PARTS OUT OF BOUNDS DIALOG BOX
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5.5.6.
MATCHING ON A DCS 2500
Matching is the process of placing a part on the fabric so that the part is cut on a particular location on the fabric. The goal of matching is to ensure that a fabric pattern flows seamlessly throughout the finished product; matching can also be used to make sure a certain aspect of the pattern falls in the same place on each part. For example, the furniture industry could use matching to make stripes flow from the top of a sofa to the bottom, or to place a flower in the center of each cushion. The apparel industry could use matching to make the stripe pattern flow properly down the front of a shirt, including the pocket and the sleeves. When matching on a DCS 2500 machine, the software uses the pointer to align the Op Stops in a job with the fabric match points. The match point, or repeat, is based on the matching information entered in the Material Settings dialog box. When the software comes to an Op Stop, the pointer should be located at or near the match point for that Op Stop. If the pointer is not exactly on the match point, use the joystick to move the laser pointer to the correct location. If necessary, you can rotate the parts slightly (see Paragraph 5.5.3 for information on rotating parts). When cut, the part match point will fall on the fabric at the point the laser pointer was reindexed. The basic process for matching on a DCS 2500 machine involves: Opening the file. There are a number of important options that should be selected when matching a job. Measuring the fabric. Measure the length and width of the material, and determine the fabric repeat. Entering the measurements. Enter the fabric measurements into the Material Settings dialog box. Setting Matching Parameters. Before cutting the job, open the Matching Parameters dialog box and enter the parameter, as described in Paragraph 5.5.6 Running the Job. Press the ENTER key on the keypad to start the job. When the software comes to an Op Stop or a Smart Stop, the machine stops and waits for input.
For more specific information on matching refer to the Cutting Edge Software On-line Help.
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5.7.
DIGITIZE PARTS
The following paragraphs describe how to use the cutting machine to digitize parts for cutting. Digitizing is a process by which you can transfer a template or drawing shape from the table to the computer using the carriage and joystick to trace the shape. The data from the digitizing process can be saved as a CEI, DXF, or NC file type that can be imported into other programs for editing or nesting. Only polylines and points can be digitized using the machine. Use the Digitize dialog box shown in Screen 5-13 to digitize a job. 1. Click the Machine menu, then select the Digitize command to open the Digitize dialog box. Instructions are displayed in the dialog box on the screen and on the keypad display. SCREEN 5-13 DIGITIZE DIALOG BOX
2. Click Proceed to begin the digitizing process. 3. Place the job to be digitized on the table and go to the keypad. The keypad displays information: Entity=1 This is the line or vertex currently being digitized. Vertex=1 This is the next vertex to be defined. Vertex 1 is always the start vertex. X=0.000 and Y=0.000 These are the coordinates of the pointer. The coordinates are based on the pointer, either the laser pointer or pen pointer, which is selected in the Configure Machine dialog box.
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4. To digitize lines to form an outline of a part: a. Use the joystick to move the pointer to the point where you want to start digitizing. Notice that the X and Y coordinates on the keypad change according to the location of the pointer. b. Press the F1 button on the keypad to digitize the first point. The keypad display changes to read Vertex=2. This means the machine is waiting to be informed of the location of the second vertex, or point. c. Use the joystick to move the pointer to the next point. d. Press either the F2 or F3 button on the keypad, depending on whether the point is to be a midpoint (a point along a polyline with more points to follow) or the end point of the polyline (the last point in the polyline). F2 Press this key if the point is a mid-point. The display will change to read Entity=1, Vertex=3. The machine is waiting to be informed of the location of the third vertex. F3 Press this key to end the polyline. It is important to note that pressing F3 will not close the entity. This button should only be used when ending a stand-alone polyline. CANCEL Press this button on the keypad to undo points in the polyline currently being digitized. When the CANCEL button is pressed, the carriage and theta assembly travel back to the previous position. The vertices can be undone all the way back to the starting point for the current entity. Points cannot be undone once the F1 button has been pressed to complete an entity. Minus Key (-) Press the minus key to toggle the conveyor belt to jogbelt mode. Then use the joystick to move the belt forward or backward to reposition the digitizing job. Plus Key (+) Press the plus key to return to jogging mode and continue digitizing. e. Continue digitizing the shape by jogging the pointer to the next desired point. Press F2 to enter the location. f. Press F1 to complete a closed polyline entity. Pressing F1 will cause the program to draw a straight line back to the beginning vertex to close the entity.
g. When the shape is completely digitized, click the Done command on the computer screen. Use the Save As command in the File menu to save the file. The file can now be edited using the Base Module Software. 5. To digitize points on the part: a. Use the joystick to move the pointer to the coordinates where you want to place the point. Notice that the X and Y coordinates on the keypad change according to the location of the pointer. F4 Press this button on the keypad to enter the coordinates as a point. Note that the CANCEL button will not undo points. Plus Key (+) Press the plus key to toggle the conveyor belt to jogbelt mode. Then use the joystick to move the belt forward or backward to reposition the digitizing job. Minus Key (-) Press the minus key to return to jogging mode and continue digitizing b. When all points are digitized, click the Done command on the computer screen. Use the Save As command in the File menu to save the file. The file can now be edited using the Base Module Software.
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5.8.
EXIT
Use the Exit command in the File menu to exit the Cutting Edge Software.
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Section
Calibration
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6.1 GENERAL This section provides the instructions for calibrating a Cutting Edge DCS 1500, DCS 2500, or Taurus TLCS GERBERcutter. In general, this section includes instructions for calibrating the cutting machine, tool holders, and tools. 6.2 CALIBRATE MACHINE Use the Calibrate Machine dialog box to calibrate the various components of the machine. Click the Setup command in the Machine menu to display the Setup dialog box. Then click Cutter in the Calibrate group to display the Calibrate Machine dialog box shown in Screen 6-1. The paragraphs below describe the use of the various Machine, Holder and Tool calibration procedures that are available to the user. The pen is used as the pointer in most of the following calibration procedures. SCREEN 6-1 CALIBRATE MACHINE DIALOG BOX
The Camera calibration is for Taurus only. There are three option groups in the Calibrate Machine dialog box: Basic Calibration, Holders, and Tools.
Section 6.0 Calibration
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6-3
Basic Calibration
For Basic Calibration, the order of calibration is important. Start at the top and work your way down the calibration dialog box in the following order. Square Carriage - Use the Square Carriage dialog box to square the carriage. Squaring the carriage ensures that both the festoon and keypad side of the carriage drive are even with one another and that the carriage is square to the X-axis when the carriage is moving. Adjust Pneumatics - Use the Adjust Pneumatics dialog box to set the flow control valves on the tool holders and pen cylinders. Use the buttons on the keypad to cycle the tools up and down and set the flow control by turning the screw on the flow control valve. Set X Scale Factor - Use the X-Axis Scale Factor dialog box to set the number of motor counts for a 1 inch (2.54 cm) move in the X-axis. Determine the X-axis scale factor by making a move over a known distance and then jog the carriage to the correct location. Press ENTER button on keypad to enter and accept the scale factor. Set Y Scale Factor - Use the Y-Axis Scale Factor dialog box to set the number of motor counts for a 1-inch (2.54 cm) move in the Y-axis. Determine the Y-axis scale factor by making a move over a known distance and then jog the carriage to the correct location. Press ENTER button on keypad to enter and accept the scale factor. Set Length - Use the Set Length dialog box to set the available X-axis travel. Mark the location of the beginning of the ramp on the top of the table prior to jogging the carriage. Then jog the carriage to the end of the table until the edge of the festoon cover is even with the mark on the table. Visually confirm the location of the limit switch on the carriage relative to the ramp. Then press the ENTER button on the keypad. Set Stations - Use the Set Stations dialog box to set the position of the stations used when operating the machine with multiple stations. Before setting the position, the number of stations that will be used must be set in the Configure Machine dialog box. Check Y Belt - Use the Check Y Belt dialog box to check the alignment of the Y-axis belt. The belt will cycle the Y-axis assembly approximately five feet back and forth across the carriage when using the procedure in the dialog box. Camera Use the Calibrate Camera dialog box to properly adjust the camera hardware, correct the camera image, and set the appropriate brightness of the image. This calibration is used with Taurus machines only.
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Holders
Use the Holders group to align the angle of the Tool Holders 1 and 2 and to adjust the offsets in the X-axis and Y-axis for all the tool holders. Also, use this group to test cut materials to establish cutting speeds and tool pressures. Since the Pen does not steer and is the default origin tool, it is not calibrated. The command buttons Align Angle, Align Offsets, and Test Cut are dimmed unless one of the tool holders is selected. To use the commands, select one of the tool holders and then click one of the align commands or the Test Cut command. Align Angle - Use the Align Angle dialog box to check the angular alignment of the tool holders. The Align Angle procedure moves the cutter approximately 12 inches (30.48) in the X-axis along masking tape that is placed on the table surface. Raise and lower the wheel at the end of the cut to determine if the wheel cutter tracked at an angle rather than a straight line. If the angle of the tool holder is not correct, input corrections at the keypad as instructed in the dialog box. Align Offset -Use the Align Offset dialog box to check the offset of each of the tool holders including the optional punch holder and Laser pointer. The Align Offset procedure draws a cross inside a box with the pen and then cuts along each line with the wheel cutter. Compare the offset of the cut from the pen line and type the amount of error as described in the dialog box. The Laser Pointer Offset Calibration procedure draws a cross hair inside a selected box size on the material on the table. The operator then centers the laser light over the center of the cross hair. The software compares the center of the cross hair with the location of the light and enters the amount of error in the software when the operator presses the Enter button on the keypad. The Punch Holder Offset Calibration procedure draws cross hairs inside a selected box size on the material on the table and then punches a hole in the center of the cross hairs. Compare the location of punched hole with the location of the center of the cross in the material. Type the amount of error as described in the dialog box. Test Cut -Use the Test Cut dialog box to determine the best speed and tool pressure to use when cutting a particular material. The dialog box allows you to cut several parallel lines while varying the speed, at a set angle and length of cut. After typing the slowest and fastest speeds and the size of speed increments, type the length, spacing, and angle and then proceed with test cutting the material.
Tools
Use the Tools group to set the notch depth of the Notcher. The procedure draws a box on the material on the table and then the notcher tool notches the four sides of the box. Compare the location of the notch relative to the line on the material and type the amount of error as described in the dialog box.
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6.2.1 BASIC CALIBRATION Select the command button for the machine calibration that you want to perform and follow the instructions in the dialog box. 6.2.1.1 Square Carriage Use the instructions in the Square Carriage dialog box shown in Screen 6-2 to set the carriage square to the X-axis on both the festoon and keypad side of the table. Click the Square Carriage command button in the Calibrate Machine dialog box to display the Square Carriage dialog box. The carriage must be square to the X-axis of the table to ensure cutting accuracy. This calibration will draw the corners of a large box on the table, and allow you to check the diagonals. If the diagonals are not the same, the routine enables you to enter a correction to properly square the carriage. Repeat the calibration until you are satisfied with the results. SCREEN 6-2 SQUARE CARRIAGE DIALOG BOX
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6.2.1.2 Adjust Pneumatics The machine uses air pressure to move the pen and the cutters up and down. The pneumatic cylinders on the carriage have flow control valves that enable you to individually tune the speed at which the pen and cutters move up and down. The flow control valves are located in the fittings at the top and bottom of each cylinder. To locate the fittings, follow the air hose to the cylinder. The fitting at the bottom of the cylinder controls the down speed, while the fitting at the top controls the up speed. Set the speed of the cylinder actuation by adjusting the airflow on the exhaust side of the cylinder. The settings described below are for initial setup of the airflow. Set the control valve exhaust on the down stroke as wide open as possible to improve the speed of the machine after the initial set up. Close the valve to avoid excessive noise or force. Sensors on the tool holders detect the tool position on the upstroke. Therefore, when a sensor detects that the tool is clear of the material, the computer allows the carriage to move. In this manner, the speed of the machine is not as affected by the speed of the cylinder up stroke. SCREEN 6-3 ADJUST PNEUMATICS DIALOG BOX
To perform this calibration, click the Adjust Pneumatics button in the Calibrate Machine dialog box to display the Adjust Pneumatics dialog box shown in Screen 6-3. Press Proceed. Adjust the pen pressure to 20 psi and the tool holder pressures to typical cutting pressures or 15 psi before setting the flow controls. The setting of the pen pressure also controls the pressure used to raise the tool holders. Jog the Y-axis assembly so that you can easily access the flow control valves on the pneumatic cylinders with the screwdriver. Speeds are adjusted by turning the small screw in the fitting: Rotate screw clockwise to decrease speed Rotate screw counter-clockwise to increase speed
While adjusting the flow control valves, use the up and down arrow keys on the keypad to move the cylinder up and down. Press the plus + and minus - keys to change to the next device. After all tool holder pneumatics have been adjusted, press CANCEL button on keypad. Do not press Enter button on keypad.
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6.2.1.2.1 Adjust the Tool Holders In addition to the pressure controls, the flow control valves on the tool holder cylinders control the how quickly the tool lowers. The setting of tool holder flow control valves depends on the type of tool that is installed on the tool holder. 1. With a wheel cutter or a knife installed, the bottom flow control on cylinder controls the speed of tool holder when it is being lowered. As an initial setting, set the bottom flow control adjusting screw fully open by turning the adjusting screw fully counterclockwise. If you experience excessive over-cutting on the plunge, turn the lower adjusting screw clockwise until you achieve the desired motion. You might give up some throughput if you slow the plunge somewhat. 1. With a notching tool installed in one of the tool holders set the bottom flow control fully open so that notching tool will adequately penetrate material being cut. Then adjust the bottom flow control so that the notching tool plunges into the conveyor belt about the same depth as a cutting blade. 6.2.1.2.2 Adjust the Pen Holder In addition to the pressure controls, the flow control valves on the pen holder control the how quickly the pen raises and lowers. Note that the Pen pressure control affects the speed that the pen rises, and does not affect the speed that the pen lowers. Turn the control valve clockwise to decrease the rise or plunge speed, or counter-clockwise to increase the rise or plunge speed. To change the speed of the pen when it is being lowered, adjust the bottom flow control valve on the flow cylinder controls. Ideally, the down speed of the pen is fast enough to get to the surface as quickly as possible without bouncing or damaging the pen tip. To change the speed of pen when it is being raised, set the top flow control valve on the cylinder controls. The up speed of the pen should be about the same as the down speed. 6.2.1.2.3 Adjust the Punch Assembly The optional punch assembly cylinder does not have flow control valves.
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6.2.1.3 Set Scale Factor The scale factors are used to convert servo motor encoder counts to physical units of movement. This routine will place marks on the table separated by a given distance, and allow you to verify that the machine calibration produces this distance correctly. After selecting the desired scale factor test from the Calibrate Machine dialog box, you are prompted for the physical test distance. (Remember that long tape measures may not be very accurate: the machine was calibrated at the factory, so do not recalibrate the scale factor unless you have an accurate tape measure). If the default test distance is not acceptable then type in a new value. Place a small piece of tape on the table near the origin. Jog the machine to the tape, and make a small mark with the pen to indicate the start point. Press ENTER button on the keypad to move the machine the requested distance in the X-axis or Y-axis. Place a small piece of tape on the table under the pen and make another mark. Measure the distance between the marks to verify the length of the move. If the error is not acceptable, draw a line at the correct location and jog the machine to match the line. Then press ENTER button on the keypad to accept the change. Press CANCEL on the keypad to abort the calibration. Except for the X and Y designations, the dialog boxes for both axes are the same as shown in Screen 6-4. SCREEN 6-4 SET Y SCALE FACTOR DIALOG BOX
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6.2.1.4 Set Length Use the instructions in the Set Length dialog box to set the available X-axis travel. Click the Set Length command button in the Calibrate Machine dialog box to display the Set Length dialog box shown in Screen 6-5. SCREEN 6-5 SET LENGTH DIALOG BOX
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6.2.1.5 Set Stations Use the instructions in the Set Stations dialog box to specify the position of each station. Click the Set Stations command button in the Calibrate Machine dialog box to display the Set Stations dialog box shown in Screen 6-6. Before setting the position of the stations, set the number of stations in the Configure Machine dialog box. SCREEN 6-6 SET STATION DIALOG BOX
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6.2.1.6 Check Y Belt Use the instructions in the Check Y Belt dialog box to set the tension of the Y-axis drive belt. Click the Check Y Belt command button in the Calibrate Machine dialog box to display the Check Y Belt dialog box shown in Screen 6-7. Perform the Y-axis belt tension preliminary adjustment whenever the idler pulley has been loosened for any reason, such as when changing the belt. SCREEN 6-7 CHECK Y BELT DIALOG BOX
To perform this calibration on a DCS 1500 or a DCS 2500 machine, refer to paragraph 6.2.1.6.1. To perform this calibration on a Taurus machine, refer to paragraph 6.2.1.6.2.
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6.2.1.6.1 Check Y-Belt DCS 1500/2500 Before performing the Check Y Belt calibration on a DCS 1500 or a DCS 2500 machine make sure that the belt is not sagging on the pulleys. To check for and correct a sagging belt, refer to the Carriage Drive, Festoon Side exploded view in the Gerber Cutting Edge DCS 1500/2500 Mechanical Cutter Engineering Drawings manual and do as follows: 1. Set the machine power to OFF on the control cabinet. 2. Remove the Festoon Cover Assembly, A-CR2-130, from the Right End Plate, CR2-049. a. Remove the six screws, F-1480, from the right end plate that attaches the festoon cover assembly. b. Remove the festoon cover. c. If the E-stop override jumper is available, unplug the cover connector from the connector on the pigtail that plugs into the JFEST connector on the carriage interconnect board and plug the jumper connector into the override jumper. d. If the override jumper is not available, do not disconnect the cover connector, just lay the cover on the table next to the machine. Do not run the Y-axis plate into the cover. 3. Tighten the lower and upper adjustment screws, F-1425, on the Y-Axis Drive Idler Assembly, A-CR2-117, by alternating between the upper and lower screws, one full turn at a time. 4. After you are certain that the belt is not sagging, use the following procedure to set the final Y-axis belt tension.
To set the final belt tension, again refer to the Carriage Drive, Festoon Side exploded view in the Cutting Edge DCS 1500/2500 GERBERcutter Engineering Drawings manual and do as follows: 1. Set the machine power to ON at the control cabinet. 2. Bring the machine on-line as described in Section 4.0. 3. Alternately tighten the upper and lower adjustment screws as tight as possible or until the Y-axis motor starts to hum. Touch the Y-axis belt occasionally to start the motor humming. 4. When the Y-axis motor hums constantly, back off on the adjustment screws. 5. Click the Machine menu, then select the Calibrate Machine command to open the Calibrate Machine dialog box (shown in Screen 6-7 above). 6. Click the Check Y-Axis Belt command button in the Calibrate Machine dialog box to display the Adjust Y-Axis Belt Tension dialog box. 7. Click Proceed. 8. Press the ENTER key on keypad to the start Y-axis assembly moving. 9. Make minor adjustments to the screws on the Y-axis drive idler assembly until the belt is centered on the pulley. The belt should ride evenly between the two flanges, and not favor either side. When adjusting the two screws, turning one screw one half turn, then turning the other screw one half turn. This will ensure the tension is maintained equally. 10. Click Cancel in the dialog box, or press the CANCEL key on the keypad when the belt is in the correct position and tension.
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6.2.1.6.2 Check Y Belt Taurus Use the instructions in the Check Y Belt dialog box to set the tension of the Y-axis drive belt. Click the Check Y Belt command button in the Calibrate Machine dialog box to display the Check Y Belt dialog box shown in Screen 6-7. To perform the Check Y Belt calibration, refer to the Carriage Drive, Festoon Side exploded view in the Cutting Edge Taurus GERBERcutter Engineering Drawings manual and do as follows: 1. Set the machine power OFF on the control cabinet. 2. Remove the Festoon Cover Assembly, A-CRL2-108, from the X-axis End Plate, CR2L-137. a. Remove the six screws, F-1480, from the right end plate that attaches the festoon cover assembly. b. Remove the festoon cover. c. If the E-stop override jumper is available, unplug the cover connector from the connector on the pigtail that plugs into the JFEST connector on the carriage interconnect board and plug the jumper connector into the override jumper. d. If the override jumper is not available, do not disconnect the cover connector, just lay the cover on the table next to the machine. Do not run the Y-axis plate into the cover. 3. Tighten the lower and upper adjustment screws, F-1425, on the Y-Axis Tensioner Assembly, A-CR3-141, by alternating between the upper and lower screws, one full turn at a time, until the Y-axis belt is vertical inside the cross tube. 4. Set the machine power ON at the control cabinet. 5. Bring the machine on-line as described in Section 4.0. 6. Click the Machine menu, then select the Calibrate Machine command to open the Calibrate Machine dialog box. 7. Click the Check Y-Axis Belt command button in the Calibrate Machine dialog box to display the Adjust Y-Axis Belt Tension dialog box. 8. Click Proceed. 9. Press the ENTER key on keypad to the start Y-axis assembly moving. 10. Make minor adjustments to the screws on the Y-axis drive idler assembly until the belt is centered on the pulley. The belt should ride evenly between the two flanges, and not favor either side. When adjusting the two screws, turning one screw one half turn, then turning the other screw one half turn. This will ensure the tension is maintained equally. Listen for the sound of the Y-axis motor to change. This can indicate too much tension is applied to the belt. 11. Click Cancel in the dialog box, or press the CANCEL key on the keypad when the belt is in the correct position and tension.
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6.2.1.7 Camera Calibration -- Taurus Use the Camera Calibration dialog box to properly calibrate the camera on your cutting machine. The camera scans the hide on the table and creates a representation on the material in the software. In order to obtain an accurate representation, you must ensure that the camera is properly calibrated. Use the instructions in the Calibrate Camera dialog box to calibrate the camera. Click the Camera command button in the Calibrate Machine dialog box to display the Calibrate Camera dialog box. The Camera calibration procedure involves the following tasks: Adjust the hardware Calibrate the camera image Calibrate the image brightness SCREEN 6-8 CAMERA CALIBRATION DIALOG BOX
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6.2.1.7.1 Adjust Hardware Use this calibration to adjust the camera and mirror mounting hardware. After performing this calibration, you should calibrate the camera image. Refer to the Leather Carriage Assembly exploded views in Cutting Edge Taurus TLCS GERBERcutter Engineering Drawings manual. Use these steps to adjust the camera hardware. 1. Click the Machine menu, then select the Setup command. The Setup dialog box opens. 2. Click the Calibrate button in the Cutter section of the dialog box. 3. Click the Camera button. 4. Click the Adjust Hardware button. 5. Place a piece of white plotter paper that measures approximately 16" x 24" on the table surface. 6. Turn the vacuum on to the side of the machine where the white plotter paper is located. 7. Place the machine in jogging mode and jog the pen tool so that it is over the lower lefthand corner of the paper. 8. Press the Cancel button on the cutter keypad two times to exit jogging mode. 9. Click Draw Template. The Starting Options dialog appears and the keypad displays: Waiting for Start Online 10. Press the ENTER key on the keypad. Three boxes inside a larger box are be drawn on the paper. 11. Place the machine in jogging mode and jog the carriage until camera\light hood lines up with the outer box drawn on the template. Use a framing square to verify the camera\light hood is directly over the outer box. The template is displayed in the Adjust Hardware dialog box. The three inner boxes should be roughly centered under the hood. Click the Show Image button in the Adjust Hardware dialog box to view the image, if necessary. 12. Remove the lower hood from the camera\light hood. If needed, click Camera Settings to adjust color of image. 13. Look at the image displayed in the dialog box. The image may need to be rotated or centered inside the dialog box. To shift the image, make adjustments to the surface mirror, CR2L-192. The mirror is located between the lights in front of the camera. Make adjustments as follows: a. Correct for image rotation by adjusting the bottom screw on the keypad side of the mirror. b. Center the image vertically by adjusting the top screw on the festoon side of the mirror. To access this screw, feed a screwdriver through the hole in the camera mount, CR2L-222, on the festoon side of the camera. If needed, open the door on the top of the light hood. c. Center the image horizontally by rotating the camera itself. To rotate the camera, slightly loosen the four Phillips Head screws, F-0095, that hold the camera to the mount. d. Tighten the screws when done. 14. Click Done when image is centered in dialog box.
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6.2.1.7.2 Calibrate Image This calibration should be performed after adjusting the camera mounting hardware. Each time you perform the Calibrate Image routine, you should also perform the Calibrate Brightness routine. Use the following procedure to calibrate the image: 1. Click the Machine menu, then select the Setup command. The Setup dialog box opens. 2. Click the Calibrate button in the Cutter section of the dialog box. 3. Click the Camera button. 4. Click the Calibrate Image button. 5. Place a piece of white plotter paper that measures approximately 16" x 24" on the table surface. 6. Place the machine in jogging mode and jog the pen tool so that it is about two inches away from the lower left hand corner of the paper. 7. Click the Register Grid button. 8. Click Proceed in the Register Target dialog box. 9. The Starting Options dialog is displayed and the cutter keypad displays the following message: Waiting for Start Online 10. Press the ENTER button on the cutter keypad. An 8" x 10" grid is drawn on the paper. The Calibrate Image box displays the grid. 11. Click Camera Settings in the Calibrate Image dialog box. Move the slider bars next to Gain, Red Gain, Blue Gain, and Color Saturation until the color of the image on the screen matches the actual color of the area the camera is over. 12. Click Done in the Camera Settings dialog box. 13. Click Center Image in the Calibrate Image dialog box. The machine is now in jogging mode. Move the carriage so that the image of the 8 x 10 grid is centered in on the computer screen. Use the blue box that is drawn in the dialog box to help center the grid image. Do not try to center the image on the computer monitor by moving the paper. Move the joystick left and right to make the image on the computer monitor move up and down. Move the joystick up and down to make the image on the computer monitor move left and right. 14. Press ENTER on the cutter keypad to exit jogging mode. The machine switches to Online mode. 15. Click Proceed in the Calibrate Image dialog box. The software automatically performs the image calibration routine. If you clicked CANCEL while still in jogging mode, an error message is displayed when you click Proceed. Click Yes, and the Starting Options dialog box is displayed. Press ENTER on the cutter keypad. The software will automatically perform the image calibration routine. 16. Click Test Map. The software draws blue lines on the screen. These blue lines should overlap the grid lines already displayed on the screen. If the blue lines do not overlap the grid lines, click Restart and perform the calibration again. Small deviations are acceptable, however, there should be no spikes in the grid lines. 17. Click Done.
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6.2.1.7.3 Calibrate Brightness Use the following procedure to calibrate the image brightness: 1. Click the Machine menu, then select the Setup command. The Setup dialog box opens. 2. Click the Calibrate button in the Cutter section of the dialog box. 3. Click the Camera button. 4. Click the Calibrate Brightness button. 5. Place the piece of material on the table surface so it is under the lighting/camera hood or place the machine in jogging mode and move the lighting hood over the leather. The material should be representative of the type that will be cut in production. The hide image will appear on the monitor. 6. Click the Camera Settings button. Move the slider bars next to Gain, Red Gain, Blue Gain, and Color Saturation until the color of the image on the screen matches the actual color of the area the camera is over. 7. Click Done in the Camera Settings dialog box. 8. Click Proceed. The software automatically calibrates the brightness of the image by mapping the brightness across the image. 9. Click Done.
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6.2.2 HOLDERS The Holders group allows you to calibrate the angle and offset for each tool holder. You can view the amount of offset in the X- and Y-axes and the angular correction in the Holders list box. You can also do test cuts on material to determine the optimum tool pressures and speed. Calibrate Tool Holder 1 first as follows: 1. In Local mode at the keypad, select Move to Origin to position the Tool Holder 1 so that the set screw is accessible. Insert the wheel cutter into the holder. 2. Click Tool Holder 1. Both the Align Angle and the Align Offsets buttons are active, indicating that both calibrations are required. Only the Align Offsets button will activate when selecting the optional Laser Pointer or Punch Holder. 6.2.2.1 Align Cutter Angle The following describes the alignment of the angle of the cutter for Tool Holder 1. After the completing the alignment of Tool Holder 1, align the other tool holders. When aligning the cutter, the head of the shoulder bolt holding the wheel blade must face the keypad side of the machine. Refer to Screen 6-1 for an illustration of the wheel blade and shoulder bolt. If the shoulder bolt is facing the festoon side of the machine, the cutter is 180 degrees out of alignment.
FIGURE 6-1 WHEEL BLADE AND SHOULDER BOLT
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To perform the Align Cutter Angle calibration: 1. Home the machine and install the wheel cutter tool on Tool Holder 1. 2. Click Tool Holder 1 in the Holders list box. 3. Click Align Angle, and the Align Angle: Tool Holder 1 dialog box is displayed. Refer to the Align Angle: dialog box shown in Screen 6-9. SCREEN 6-9 ALIGN ANGLE TOOL HOLDER DIALOG BOX
4. Set the cutting pressure to 15 psi. 5. Click Proceed to begin the calibration and go to the keypad. Tool Holder 1 rotates so that the head of blade bolt faces the keypad side of the machine. 6. The keypad displays: JOG Mode (0.50 Deg) Push Enter or Cancel 7. Visually check the knife in the holder to confirm that the blade is straight and parallel with the X-axis. If not, press the Up () and Down () buttons to turn the blade. Press the (+) and (-) buttons to control the step size. 8. Place a strip of masking tape on the table parallel to the X-axis. 9. Jog Tool Holder 1 over the start of the masking tape using the joystick. 10. Press the ENTER () button and keypad displays: CUT Mode Enter, Cancel, or F1 11. Press the down arrow () to lower the cutter to the table and jog Tool Holder 1 about 12 inches (30.48 cm) towards the right with the joystick. 12. With your eye on the blade of the wheel cutter, raise and lower the blade with the Up () and Down () arrows. Note the position of the blade when it is down on the table.
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13. If the blade goes into the same groove on the masking tape, the alignment is correct. Press the ENTER () button to accept any changes or press the Cancel button to clear the calibration box. 14. If the blade does not hit the groove in the tape, press the F1 button and the keypad displays: JOG Mode (0.50 Deg) Push Enter or Cancel 15. The Plus (+) button increases the angle of the step and the minus (-) button decreases the angle of the step each time the button is pressed. The range of step is 0.05, 0.1, 0.5, 1.0, 2.0, 5.0, and 10.0 degrees. NOTE: If the blade touches down on the festoon side of the cut line, use the arrow (Up) that points in that direction to correct the angle of cut. If the blade touches down on the keypad side of the cut line, use the down arrow to correct the angle of cut. 16. The Up arrow () button changes the angle by amount showing on the display in a counterclockwise direction. If the blade touches down on the festoon side of the line, use the Up arrow to correct. 17. The Down arrow () button changes the angle by the amount showing on the display in a clockwise direction. If the blade touches down on the keypad side of line, use the Down arrow to correct. 18. Adjust the angle and then repeat steps 7 through 13 above.
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6.2.2.2 Align Cutter Offsets The following describes the alignment of the offsets of the cutter for Tool Holder 1. Selecting Tool Holder 1 and clicking Align Offset displays the dialog box in Screen 6-10. Before aligning the cutter offsets, confirm that the wheel blade is installed correctly on the mount as shown in the wheel knife assembly exploded view in the Cutting Edge DCS 1500/2500 GERBERcutter Engineering Drawings manual. SCREEN 6-10 ALIGN OFFSET TOOL HOLDER DIALOG BOX
This test generates a box pattern consisting of both ink lines and cut lines, which should fall directly on top of each other. Comparing drawn and cut lines allows you to correct any cutter offset error. This calibration must be performed for all tool holders, even if the tool holder will be used for notching or drilling. CAUTION Do not perform this calibration with a notching or drilling tool installed. The tool would be dragged across the table and damage the surface and/or the tool holder.
NOTE: You must calibrate the cutter alignment before you calibrate the cutter offset.
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If you plan to use a drill tool, no other calibrations are required. If you plan to use a notch tool, then perform this calibration for all tool holders with a wheel cutter installed, and then refer to the instructions for setting notch tool trailer in Section 6.2.3. 1. Jog the pen to the start point and press the ENTER button on the keypad. The carriage draws and then cuts the pattern. After the test, the carriage returns to the origin. 2. Measure the X- and Y-axis offset errors and type the amount into the computer. Follow the instructions on the screen to make sure you type the correct sign (positive or negative). Refer to Figure 6-2 through Figure 6-4. Note: In the accompanying diagrams, inked lines are solid and cut lines as dashed.
FIGURE 6-2 POSITIVE X-AXIS CUTTER OFFSET ERROR Figure 6-2 shows an example of X-axis offset error. The cut (dashed) line is to the right of the drawn line, so a positive X-axis cutter offset error should be entered.
FIGURE 6-3 POSITIVE Y-AXIS CUTTER OFFSET ERROR Figure 6-3 shows an example of Y-axis offset error. The cut line is above the drawn line, again calling for a positive Y-axis cutter offset error. 3. Repeat the test to verify that the cutter offset is correct.
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The cutter offset test will be impacted by errors in the blade alignment. If the knife cutter is not aligned correctly, this calibration will give misleading results. Make sure the knife cutter has been properly aligned before calibrating the cutter offsets. Figure 6-4 shows a misleading cutter offset test:
FIGURE 6-4 BLADE MISALIGNMENT CAUSING PROBLEMS WITH THE OFFSET TEST In Figure 6-4, the inked line is the solid line and the cut line is dashed. In this example, the offset is properly set but the blade is not properly aligned. As a result, the cuts start in the right place (correct cutter offset) but they diverge from the intended cut line (knife cutter misalignment). Also, the washer used with the blade can affect this calibration as follows: If the cutter line is on the outside of the pen line on all sides of the box, the thickness of the inner washer must be reduced. Check to confirm that the correct washer is installed. If the correct washer is installed, use some emery cloth to reduce the thickness. It may help to switch the inner washer with the outer washer. Check the thickness of both inner and outer washers. If all else fails, contact Gerber Technology, Cutting Edge Division. If the cutter line is on the inside of the pen line on all sides of the box, increase the thickness of the inner washer. Do this by either switching to a thicker washer or adding a shim between the inner washer and the inside race of the bearing on the tool holder.
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6.2.2.3 Align Punch Offsets To calibrate the optional Punch offset, click Punch in the tool holder list. Note that the Align Angle button is deactivated, indicating that no angle calibration is needed for this tool. Click Align Offsets to display the Align Offset: Punch Holder dialog box shown in Screen 6-11 to correctly calibrate the punch. Follow the instructions in the dialog box. SCREEN 6-11 ALIGN OFFSET: PUNCH HOLDER DIALOG BOX
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6.2.2.4 Align Laser Pointer Offsets To calibrate the optional Laser Pointer offset, click Laser Pointer in the tool holder list. Note that the Align Angle button is deactivated, indicating that no angle calibration is needed for this tool. Click Align Offsets to display the Laser Pointer Offset Calibration dialog box shown in Screen 6-12 and calibrate the Laser pointer. Follow the instructions in the dialog box. SCREEN 6-12 LASER POINTER OFFSET CALIBRATION DIALOG BOX
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6.2.2.5 Test Cut With the Test Cut dialog box shown in Screen 6-13, you can perform several test cuts on material while varying the tool pressure and the cutting speed. The experienced gained from making these test cuts can be used to set up the tool parameters used in the material definition. SCREEN 6-13 TEST CUT DIALOG BOX
In step one of the dialog box the following information should be typed into the text boxes prior to doing the test cut procedure. Slowest Speed Fastest Speed Type the slowest speed in units per second that will be used during the cutting. Type the fastest speed in units per second that will be used during the cutting.
Speed Increments Type the amount of change in speed for each cut that will be made from the slowest to the fastest. For each parallel straight line cut, the speed will increase this amount in units per second. This also determines the number of lines that will be cut. In the example in the Test Cut dialog box, the machine will start cutting at 4 inches (10.16cm) per second. The speed will increase 2 inches (5.08cm) per second for every line cut up to 40 inches (101.6cm) per second. The procedure will not increment over the fastest speed of 41 inches (104cm) per second. Test Cut Length Cut Spacing Angle of Cuts Type the length of each cut. Type the distance between each line. Type the angle in degrees between vertical and horizontal for the cuts in this test cut. Type zero (0) for vertical cuts and 90 for horizontal cuts.
Step two displays the size of the bounding rectangle for the test cut. This will help the user in determining the size of material that is required for the test cut. As changes are made in the step one text boxes, the size of the bounding rectangle changes. Click Proceed to continue the procedure. After the material is placed on the table and the pointer is jogged to the lower left corner of the test cut area, turn on the table vacuum and press the ENTER button on the keypad to start the test cut.
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6.2.3 TOOLS Use the Set Notch Depth calibration to determine how far into a part notches should be placed, based on company preference. The depth of the notch in the material is determined by the trailer of the tool. The trailer that is used for each notching tool is specific to that notching tool and depends on the location of the notch cutter on the tool. Use the Tools group to calibrate the notch trailer on those holders that do notches as follows: 1. Select the Notcher tool in the Tools list box. 2. Click the Set Notch Depth button to display Calibrating Trailer: Notcher dialog box (shown in Screen 6-14) and perform calibration as follows: a. Type a size for the calibration box. b. Select the appropriate tool holder. c. Press the Enter button on the keypad. The machine draws a box with notches on four sides. d. Measure the amount of error. The error is the distance that the notches need to be moved so that they are at the correct depth. The error is positive if the notch needs to be moved into the part; negative if the motch needs to be moved out of the part. e. Type the amount of correction required as described dialog box. NOTE: The trailer can also be modified using the Tools group in the Configure Machine dialog box. SCREEN 6-14 CALIBRATING TRAILER: NOTCHER DIALOG BOX
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Section
Maintenance
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7.1
GENERAL
This section provides the instructions for maintaining a Cutting Edge DCS 1500, DCS 2500, or Taurus TLCS GERBERcutter. In general, this section includes a preventive maintenance schedule, and instructions for inspecting, lubricating, and maintaining the machine. Operator maintenance is limited to the cleaning procedures listed in Paragraph 7.2, routine preventive maintenance schedule. In addition, the operator should inspect the machine to ensure that there are no broken or loose machine parts before starting the machine. Only qualified service technicians who have been properly trained in the servicing of the computer-controlled mechanical, electrical, and pneumatic systems incorporated in the machines should perform the lubrication and adjustment procedures included in this section. Unless otherwise stated, perform maintenance procedures in their entirety starting with the first step. 7.2 PREVENTIVE MAINTENANCE SCHEDULE
Table 7-1 provides a preventive maintenance schedule for DCS 1500 and DCS 2500 machines. Table 7-2 provides a preventive maintenance schedule for Taurus machines. Both tables include references to the paragraphs that include the instructions to do the preventive maintenance. The hours shown are for normal operating conditions. If the machine is operated in a dirty or dusty environment, perform the recommended procedures more often. It may be helpful to make a copy of the table and attach it near the machine as a reference. The Cutting Edge Software tracks various software and cutting machine running times. It may be useful to refer to these times in order to adhere to the recommended maintenance schedule. To display the Machine Times dialog box shown in Screen 7-1, click on Machine menu, Statistics, then Machine Times. SCREEN 7-1 MACHINE TIMES DIALOG BOX
Section 7.0: Maintenance
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The following information is provided in the Machine Times dialog box: System On Time System Running Time The amount of time the software has been running (hours:minutes:seconds). The amount of time the machine has actually spent cutting jobs (hours:minutes:seconds). The System Running Time does not include time spent on calibrations, tool changes, etc. The distance in units (in., mm, etc.) that the machine has traveled. The cumulative distance in units (in., mm, etc.) that have been cut on the machine. The average cutting speed in units per second. This number is the result of dividing the Effective Distance by the System Running Time. The Machine Times dialog maintains measurements for the distance traveled, time cutting, and number of cycles for each tool holder. Choose one of the following to display either the current information, or cumulative information for the tool holders box. Since Last Reset - Click this button to display the current measurements for each tool holder. Overall Totals - Click this button to display the cumulative measurements for each tool holder, regardless of how often the tool holder has been reset. The Reset All button will set all numbers back to zero. Travel - Indicates how far the tool holder has traveled while cutting. Time - Indicates how long the tool holder has been cutting. Cycles - Indicates how many times the Tool Holder went down and back up. Reset Holder Highlight the tool holder that you wish to reset and click the Reset Holder button to change the measurements for the tool holder back to zero. The tool holder is usually reset to zero after changing a blade to track the number of inches cut. Click this button to change all the measurements in the Machine Times dialog box back to zero. The measurements should usually be reset to zero after the recommended 2000-hour maintenance has been performed. Click this button to exit the Machine Times dialog box.
Machine Travel Effective Distance Effective Speed Show Holder Times
Reset All
Close
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TABLE 7-1 PREVENTATIVE MAINTENANCE SCHEDULE DCS 1500 AND DCS 2500 PREVENTIVE MAINTENANCE SCHEDULEDCS 1500 AND DCS 2500 ITEM 8 Hours 40 Hours 200 Hours 2000 Hours
Rails Clean and Lubricate per paragraph 7.3.1 Clean and Lubricate per paragraph 7.3.1 Check for loose rails; repair or replace as needed per paragraph 7.3.4 Check for damage; per paragraph 7.3.5 Adjust Inspect; repair or replace as needed per paragraph 7.3.24
X- and Y-axis Linear Bearings
Rack
Clean per paragraph 7.3.6
Check rack for damage or tight spots; repair or replace as needed per paragraph 7.3.14
Cutting Blade
Check per paragraph 7.3.8 Check per paragraph 7.3.9 Check per paragraph 7.3.11 Check per paragraph 7.3.12 ! Align cutter ! Set cutter offset ! Square carriage Refer to Section 6 for calibration procedures. ! ! ! ! ! ! Adjust pneumatics Set X scale factor Set Y scale factor Check length Check belt Set notch depth Check; repair or replace as needed per paragraph
Wheel Cutter Bolt
7.3.17
Emergency Stop
X- and Y-axis Festoons Calibration
Refer to Section 6 for calibration procedures. X-axis Pinions Clean per paragraph 7.3.6 Check backlash and adjust if needed per paragraph 7.3.13 Check, Clean, and Lubricate per paragraph 7.3.18 Replace per paragraph 7.3.23
Air Cylinders
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PREVENTIVE MAINTENANCE SCHEDULEDCS 1500 AND DCS 2500 ITEM 8 Hours 40 Hours 200 Hours 2000 Hours
Cutting Surface Check and repair per paragraph 7.3.19 Clean per paragraph 7.3.21 Lubricate per paragraph 7.3.22 Check per paragraph 7.3.25 Replace per paragraph 7.3.27.5 Inspect per paragraph 7.3.14 Replace as needed X- and Y-axis Motors Inspect per paragraph 7.3.16 Replace as needed Theta Axis Motor Inspect per paragraph 7.3.16 Replace as needed Replace per paragraph 7.3.27 Replace per paragraph 7.3.19.2.1
Control Cabinet Filter X, Y Drive Belts
Theta Axis Height
Theta Drive Belt
X-axis Drive Hub
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TABLE 7-2 PREVENTATIVE MAINTENANCE SCHEDULE TAURUS PREVENTIVE MAINTENANCE SCHEDULE: TAURUS ITEM
Rails
8 Hours
Clean and Lubricate per paragraph 7.3.2 Clean and Lubricate per paragraph 7.3.3
80 Hours
Check for loose rails; repair or replace as needed per paragraph 7.3.4 Check for damage per paragraph 7.3.5
2000 Hours
X- and Y-axis Linear Bearings
Adjust Inspect; repair or replace as needed per paragraph 7.3.24
Rack
Check rack for damage or tight spots; repair or replace as needed per paragraph 7.3.14
Cutting Blade
Check per paragraph 7.3.8 Check per paragraph 7.3.9 Check per paragraph 7.3.11 Check per paragraph 7.3.12 ! ! ! ! Align cutter Set cutter offset Square carriage Calibrate Camera Refer to Section 6 for calibration procedures. ! ! ! ! ! ! Adjust pneumatics Set X scale factor Set Y scale factor Check length Check belt Set notch depth Refer to Section 6 for calibration procedures. Check; repair or replace as needed per paragraph
Wheel Cutter Bolt
7.3.17
Emergency Stop
Festoon
Calibration
X-axis Pinions
Check backlash and adjust if needed per paragraph 7.3.13 Check, Clean, and Lubricate per paragraph 7.3.18
Replace per paragraph 7.3.23
Air Cylinders
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PREVENTIVE MAINTENANCE SCHEDULE: TAURUS ITEM

Light Bulbs
8 Hours
80 Hours
Check; replace as needed per paragraph 7.3.7
2000 Hours
Cutting Surface
Check; repair if needed per paragraph 7.3.20 Clean per paragraph 7.3.21 Lubricate per paragraph 7.3.22 Replace per paragraph 7.3.27 Check per paragraph 7.3.26 Inspect per paragraph 7.3.14 Replace as needed
Control Cabinet Filter X-, Y- and Theta Axis Drive Belts Theta Axis Height
X-axis Drive Hub
X- and Y-axis Motors
Inspect per paragraph 7.3.16 Replace as needed
Theta Axis Motor
Inspect per paragraph 7.3.16 Replace as needed
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7.3
MACHINE MAINTENANCE PROCEDURES
Perform the following procedures (as recommended in Table 7-1 and Table 7-2) to keep the machine running efficiently and safely. Unless a machine type is specified in the heading, these procedures apply to all cutter. 7.3.1 CLEAN AND LUBRICATE RAILS AND BEARING DCS 1500/2500
Remove any dust, lint or plastic from the X-axis and Y-axis bearing wipers. The wipers are rubber seals on either end of the bearings that prevent debris from entering the ball bearing system. Remember to clean all eight blocks (four on X-axis and four on Y-axis). Spray a very small cloth with Tri-Flow with Teflon or equivalent. Run the cloth over both the X-axis and Y-axis rails to remove any dust and ensure that the rails have a light film of lubricant. 7.3.2 CLEAN THE RAILS TAURUS
To clean the rails first use compressed air or a rag to remove the leather and plastic bits from the top surface of the carriage (Y-axis) and from behind the railway on the extrusion (X-axis). Then, use a lint-free cotton rag with a small amount of Tri-Flow lubricant to remove any debris built up on the rails. Shake the Tri-Flow bottle well, it contains Teflon that will settle over time. Finally, wipe the rails dry with a clean lint free rag. When the rails are properly cleaned they will appear shiny, smooth, and dry. 7.3.3 CLEAN AND LUBRICATE THE LINEAR BEARINGS TAURUS
Clean and lubricate the linear bearings, CR2-053, every 8 hours of machine operation. Contamination of the bearings, which can be caused by excessive lubrication on the rail, can result in the bearings failing prematurely. The lubrication attracts debris and builds up in the bearing raceway, increasing the rolling resistance of the ball bearings until they can no longer track properly. To clean the bearings, use a clean rag or a swab to clean the bearing seals (or wipers) of any debris build up. Remove any dust, lint, or plastic from the X-axis and Y-axis bearing seals. The bearings have rubber seals on either end to prevent debris from entering the ball bearing system. To lubricate the linear bearings, apply a liberal amount of Tri-Flow to a two foot section of the rail on both sides of the carriage. Then jog the machine back and forth over the oiled area. Finally, wipe the rails and bearings dry with a clean rag. 7.3.4 CHECK FOR LOOSE RAIL JOINTS
Check that the X-axis rails are not loose by pressing hard against the rail with your thumb and watching for movement (as recommended in Table 7-1 and Table 7-2). The movement can be seen best at the seam between the rail and extrusion. Be sure to check each rail joint where the bearing has to pass from one rail section to another. Repair the rail if there is any movement.
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7.3.5
INSPECT THE LINEAR BEARINGS FOR DAMAGE
Visually inspect the linear bearings, CR2-053, for damage as recommended in Table 7-1 or Table 7-2. Make sure the seals are intact and the pillow block is not broken or damaged. Set the cutter offline and push the carriage along both the X- and Y-axis The carriage should move without excessive resistance or noise from the bearings. Replace the bearings as necessary (refer to Paragraph 7.3.24). 7.3.6 CLEAN THE RACK AND PINIONS
To maximize the life of the rack, remove any dust, fabric fibers, small pieces of leather, or bits of plastic from the rack and pinion system every 8 hours of use. Use a compressed air nozzle for best results. A stiff brush might be required to remove debris stuck between the rack teeth. Do not oil the X-axis rack and pinion. 7.3.7 CHECK THE LIGHT BULBS TAURUS
The light bulbs in the camera should be checked every 80 hours of machine use. Check that both light bulbs are working and both glow at the same intensity. To check the light bulbs, remove the lower hood from the camera/light cover by unfastening the black plastic latches that secure the lower hood to the camera/light cover. Replace the bulbs, if necessary. 7.3.8 CHECK THE CUTTING BLADE
Check condition of cutting blade before beginning the shift and change if required. 7.3.9 CHECK THE WHEEL CUTTER BOLT
While checking the blade, also check the wheel cutter shoulder bolt, F-0101, for grooves in the shank. Replace the bolt if it shows any sign of wear. Refer to Paragraph 7.3.17 for information on replacing the bolt.
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7.3.10 CLEAN THE TABLE SURFACE TAURUS Clean the table vacuum holes every other day or after every 8 hours of machine operation. As operators gain experience with the machine, the frequency of this procedure can be altered depending on the type of material that is being cut. It is important to keep the table surface of the Taurus TLCS clean. This helps ensure that the camera can correctly distinguish the hide from the table surface. In order to keep the table surface clean, sweep the surface clean from the midpoint out. Sweep the debris from the surface into the tray on the end cap cover and remove the debris. The clean the vacuum holes on the table using the cleaning tool. The cleaning tool uses a file, taurcln.cei, that identifies where the holes are located on the table surface, then uses air from cleaning tool to force residue from the holes. The Digitize Table Surface command creates the taurcln.cei file. The Digitize Table Surface feature has two modes: Automatic and Manual. In general, use the Automatic mode when the table surface is new, and use the Manual mode if the table surface is dirty. Ideally, you should create the cleaning file when the table surface is installed. That file can then be used to clean the table surface until the surface needs to be replaced. A new cleaning file will need to be created when the table surface is replaced. To create the table cleaning file, refer to Paragraph 7.3.10.1. To clean the table using the file, refer to Paragraph 7.3.10.2.
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7.3.10.1
Create the Table Cleaning File
Before cleaning the vacuum holes on the table, first create the job file that the software will use during the cleaning process. To create the file, you digitize a number of rows of vacuum holes using the mouse buttons. The camera scans the table, and displays the surface in the Digitize Table Surface dialog box. You place the cursor at the beginning of a row and click to register that point. The camera moves to the middle of the table. Again, click the mouse to register a second point in the same row. The software digitizes the row based on the two points entered. You do not need to digitize every row of holes on the table. The software skips rows, then extrapolates the location of the skipped rows based on the rows you digitize and on the settings in the Digitize Table Surface dialog box. To use the Digitize Table Surface command: 1. Open the Cutting Edge Software. 2. Click the Machine menu, then select the Digitize Table Surface command. The Digitize Table Surface dialog box, shown in Figure 7-2, is displayed. If the machine is not on line, or needs to be homed, a dialog box prompts you to correct the situation before the Digitize Table Surface dialog box is displayed. SCREEN 7-2 DIGITIZE TABLE SURFACE DIALOG BOX
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3. Enter the following information in the dialog box: Hole Spacing The distance between the rows of holes on the table surface. Most often the distance will be 0.75 inches; however, there may be exceptions. Measure this distance exactly. The software uses this figure to determine the location of rows skipped during this process. Rotation Offset The distance that the camera will move from the first reference point to the second reference point on one line of holes. The default setting is 30 inches, which means that the camera will move 30 inches in the Y direction. The digitizing is more accurate if you use a longer distance, but the process takes longer. Location Mode Select one of the following: Manual Select Manual mode if the table surface is used or dirty to the point that the camera will not be able to easily locate the lines of holes. Automatic Select Automatic mode if the table surface is new or clean. Type a speed in the Search Speed field. Note that the digitizing is more accurate using a slower speed. 4. Click Camera Settings. Adjust the gain so that the rows of holes are clearly distinguished. Click Done to close the Camera Settings dialog box. 5. Jog the pointer to the desired start point. This is usually the machine origin, although you might chose to create a separate cleaning file for one half of the table or one for each station. To jog, press the Down arrow key to enter Local mode, then press the ENTER key to enter jogging mode. After jogging, press the CANCEL button twice to return to Online mode. 6. Press ENTER on the cutter keypad to begin the digitizing process. If you selected Automatic Mode in Step 3, proceed with Step 7. If you selected Manual Mode in Step 3, proceed with Step 8. 7. If you selected Automatic mode in Step 3, the camera begins to scan the rows of holes on the table surface and digitizes the rows to create a cleaning file. The software marks a reference point at the beginning of a row of holes then the camera moves a selected distance from that point to mark a second point on that line. This process continues until: the entire table surface is digitized you press the CANCEL button on the keypad one time to pause scanning, two times to cancel the job the camera encounters a problem that causes it to stop scanning.
If the camera is not able to complete the scanning process, the software will switch to Manual mode. Proceed with Step 8. Once the scanning of the table is complete, proceed to Step 9.
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8. If you selected Manual mode in Step 3, use the mouse to mark the beginning and middle of each row of vacuum holes. Use a row of holes on the right side of the screen the software will fill in the lines to the left. To digitize the first point of the first row after a table seam, use the left mouse button. To digitize all other points use the right mouse button. Digitize as follows: a. Position the cursor over the first row of holes and click the left mouse button to digitize the first point in the first row. The camera moves in the Y-axis the distance specified in the Rotation Offset field. The cursor is where the two red lines meet (see Screen 7-3). b. Position the cursor over the same row as in Step a and click the right mouse button to digitize a second point on that line. The camera moves back to the keypad side of the table, a few rows closer to the far end. The cursor is a small red X (see Screen 7-3). Make sure the cursor is over the same row. Use the blue X at the bottom of the screen to locate the correct row. c. Position the cursor on a row of holes on the right side of the screen. Click the right mouse button to digitize the first point on the line. The camera moves to the middle of the table. d. Click the right mouse button again to digitize a second point on the line. Continue to digitize the lines this way until you get to a seam between panels on the table surface. Seams appear on screen as thicker lines. e. Digitize both points on the last row of holes to the left of the seam. f. Move the cursor to the first point on the first row of holes to the right of the seam, and click the left mouse button to digitize. The camera again moves to the middle of the table.
g. Click the right mouse button to digitize a second point on the same row. The camera moves back to the keypad side of the table, a few rows closer to the far end. h. Repeat Steps c through g until the entire table surface is digitized. The carriage will return to the start point when done. i. Proceed with Step 9. SCREEN 7-3 DIGITIZING A ROW OF VACUUM HOLES
Place the cursor directly over a row of holes. Click to mark the beginning of the row.
Place the cursor on a second point in the row and click. The software fills in the rest of the row.
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9. Click the Machine menu, then select the Map Layers to Tools command. The Map Layers to Tools dialog box opens. 10. In the Tool Mappings group, select the Knife Cutter on Tool holder 2. 11. In the Tool Settings group, set the Cut Length to 0, and the Speed to 1. SCREEN 7-4 MAP LAYERS TO TOOL DIALOG BOX
12. Click OK to close the Map Layers to Tools dialog box. 13. Click the File menu, then the Save command to save the cleaning file you just created. Although the filename Taurcln.cei is displayed in the title bar of the file, you need to type that name in the Save dialog box when you save it. 7.3.10.2 Clean the Table Surface
After creating a cleaning file, use the file to clean the vacuum holes in the table. To clean the Taurus table surface: 1. Remove the tool from Tool Holder 2 and install the cleaning head assembly on the tool mount same way any other tool is installed. 2. Plug the air line into the quick disconnect fitting on the theta axis assembly. 3. Set the air pressure for Tool Holder 2 to 60 psi. 4. Turn the vacuum blowers on. 5. Open the Taurcln.cei file and run it as a cut job.
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7.3.11 CHECK THE EMERGENCY STOP BUTTONS Functionally check the emergency stop buttons on the machine every 8 hours of machine operation as follows: 1. Set the power switch on the control cabinet to On. The machine and the personal computer turn on and the Windows desktop is displayed on the computer. If the computer does not turn on, press the power button on the front of the PC. 2. Double click the Cutting Edge Software icon to start the software. The icon should be on the Windows desktop. 3. The System Status dialog box is displayed. This dialog box indicates that the system is not ready. 4. Press the blue RESET button next to the AC Power switch on the control cabinet to energize the machine servo system. The green light on the control cabinet labeled SYSTEM ENERGIZED illuminates, indicating the amplifiers are energized and the 24V power supply in the control cabinet is powered on. The cutter keypad displays System not ready: Waiting for Reset. 5. Press the blue RESET button on status board to bring servo system motors online. When the system is online, the SYSTEM ONLINE light on the status board illuminates, and the cutter keypad will display DCS 1500/2500 Online or Taurus Online. The System Status dialog box will disappear from the computer screen when the system is online. 6. Confirm that the servos are on-line by gently pushing on the carriage. There should be a resistance when trying to move the carriage, and you will hear servo growl. 7. Push the E-stop on the control panel. The SYSTEM ENERGIZED light on the control cabinet and the SYSTEM ONLINE light on the control panel turns off. The OPEN SWITCH light on the control panel illuminates. 9. Gently push the carriage to confirm that the servos are now off-line. The carriage should move with no resistance and you should hear no servo growl. 10. Turn the E-stop clockwise to release the button. 11. Press the RESET button on the control cabinet. Confirm that the SYSTEM ENERGIZED light on the control cabinet is illuminated. 12. Press any one of the buttons on the keypad to make the System Status dialog box appear on the computer screen. 13. Press the RESET button on control panel. CAUTION Do not press the RESET button on the control panel unless the System Status dialog box is displayed on the computer screen. Pressing RESET without ensuring the System Status dialog box is displayed will cause the carriage to move and may injure the operator if they are in the path of the carriage. 14. Repeat steps 7 through 12 for each E-stop. 15. Home the machine by pressing the Home Machine button.
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7.3.12 CHECK THE LOOP AND CHAIN FESTOONS Check the X-axis Loop Festoons and the Y-axis Chain Festoons as recommended in Table 7-1 and Table 7-2. 7.3.12.1 Check the X-axis Loop
Check the X-axis loop festoon for the following by moving the carriage along the length of the table and watching that: the festoon moves freely along the entire length of table there are no obstructions in the path the Loops are not dragging on the floor
7.3.12.2
Check the Y-axis Chain Festoon
Check the Y-axis chain festoon for the following: there are no broken links cables and hoses are not twisted or intertwined there are no obstructions in channel the air hoses under the proper tension the cables are floating in the chain
The object of setting the tension of the festoon is that the air hoses are tight and the power and signal cables are loose enough to float in the chain festoon. Check cables at the bend in chain festoon to confirm that they are floating and not in contact with chain festoon or air lines. Doing this will cause minimum abrasion between the hoses and cables because the hoses will be suspended above the cables when the Yaxis assembly is moving back and forth across the carriage. If the tension is not correct, use one of the following procedures to set the tension: to set the Y-axis chain festoon for a DCS 1500 or DCS 2500 machine, refer to 7.3.12.2.1 to set the Y-axis chain festoon for a Taurus machine, refer to 7.3.12.2.2.
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7.3.12.2.1
Set the Y-axis Chain Festoon DCS 1500/2500
To set the Y-axis chain festoon for a DCS 1500 or DCS 2500 machine, do as follows: 1. Move the carriage to origin and set the machine power to OFF. 2. Remove the keypad cover using a 9/64-inch ball driver. 3. Push the Y-axis assembly to the festoon side of the carriage and inspect the air hoses to ensure there are no crossed hoses. If any crossed hoses are found, straighten them. Be careful not to use any sharp tools that could damage the hoses or cables. 4. Confirm that the cable and hose configuration is as shown in Figure 7-1.
FIGURE 7-1 CABLE AND HOSE CONFIGURATION DCS 1500/2500 5. Manually pull the Y-axis assembly to the keypad side of the carriage. 6. Set the tension of the cables and hoses as follows: a. Loosen the four screws on the Y-axis Festoon Clamp, CR2-197. b. Pull on each air hose and the ground wire individually to apply tension to the hoses and wire. c. Clamp the air hoses and ground wire in place by tightening the two inside screws on top of the festoon clamp. d. Push and pull on the Motor Power Cable and the Signal Cable to determine the range of movement inside the chain festoon. e. Set the cables to the midpoint of their range. f. Clamp the cables in place by tightening the two outside screws on top of the festoon clamp. NOTE: The hoses should be tight and cables should be relaxed so they float in chain. Check the cables at the bend in the chain festoon to confirm that they are floating and not in contact with the chain festoon or air lines. 7. Push the Y-axis assembly to the festoon side of the carriage and check the cables and air hoses for proper tension. Adjust the hoses or cables, if necessary. 8. Tie wrap all cables and air hoses where they are not protected by the chain. Place tie wraps around the hoses and cables at each cross member.
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7.3.12.2.2
Set the Y-axis Chain Festoon Taurus
To set the Y-axis chain festoon for a Taurus machine, do as follows: 1. Move the carriage to origin. 2. Turn the power to OFF at the control cabinet. 3. Remove the keypad cover using a 9/64-inch ball driver. 4. Push the Y-axis assembly to the festoon side of the carriage and inspect the air hoses and cables to ensure there are none are crossed. If any crossed hoses are found, straighten them. Be careful not to use any sharp tools that could damage the hoses or cables. 5. Confirm that the cable and hose configuration is as shown in Figure 7-2.
FIGURE 7-2 CABLE AND HOSE CONFIGURATION TAURUS 6. Manually pull the Y-axis assembly to the midpoint of the carriage where the chain festoon ends. 7. Cut and discard the tie wires. 8. Push and pull on each cable to determine the range of movement inside the chain festoon. 9. Set the cables to the midpoint of their range and tie in place with two tie wires for each cable. 10. Manually push the Y-axis assembly to the keypad side, then push back to the festoon side while observing the cables. 11. Make sure the cables float within the chain festoon across the entire carriage. If the cables do not float, make adjustments to the cables as required. 12. Gently pull on the air hoses and tie them in place with tie wraps. 13. Again, manually push the Y-axis assembly to the keypad side, then push back to the festoon side while observing the hoses. 14. Make sure the air hoses remain under tension and the cables float across the entire carriage. If the hoses do not maintain tension or the cables do not float, make adjustments as required.
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7.3.13 CHECK THE X-AXIS RACK AND PINIONS (ADJUST BACKLASH) During the course of normal use, the X-axis pinions will wear and thereby change the backlash of the carriage. Check the backlash of the carriage in the X-axis (as recommended in Table 7-1 and Table 7-2) to verify that it is less than 0.005 inch (0.0127 cm) on both sides. If the backlash is more than 0.005 inch (0.0127 cm), adjust the X-axis drive hub assemblies to correct the problem. Refer to Carriage Drive, Keypad Side and Carriage Drive, Festoon Side exploded views in the Cutting Edge DCS 1500/2500 GERBERcutter Engineering Drawings manual or Cutting Edge Taurus TLCS GERBERcutter Engineering Drawings manual. Check and adjust the X-axis pinions on the ends of the carriage as follows: 1. Set the machine power to ON at the control cabinet. 2. Bring the machine on-line as described in Section 4.0. 3. Check backlash as follows: a. Position the dial indicator against the side of the table so that the probe rests against the endplate or cover of the carriage and clamp in place. b. Gently move the carriage back and forth. A slight click is heard as the pinion gear hits the rack. Do not move the carriage enough to hear the servo growl. c. Observe the deviation on the dial indicator. The backlash must be less than 0.005 inch (0.0127 cm). 4. If the backlash is greater than 0.005 inch (0.0127 cm), make the following adjustment: a. Set the machine and computer power to OFF. b. On the side of the carriage that requires adjustment, remove either the keypad or festoon end cover by removing the six retaining screws, F-1480. c. Loosen the four motor mounting screws, F-0602, or the nuts, F-1000, that hold the X-Axis Motor, A-CR2-150 (DCS 1500/2500) or A-CR2L-103 (Taurus), to the end-plate. d. Loosen the four mounting screws, F-0602, that hold the X-Axis Drive Hub Assembly, A-CR2-104 (DCS 1500/2500) or A-CR2L-200 (Taurus), to the end-plate. e. Gently move the drive hub assembly upwards and tighten the four drive hub assembly mounting screws. f. Check the backlash and repeat this adjustment until the backlash is a maximum of 0.005 inch (0.0127 cm). Move the carriage length of the table to confirm that the backlash is within 0.005 inch (0.0127 cm) the entire length of the table.
g. When the backlash is correct, remove each drive hub mounting screw one at a time and apply Loctite 242 or equivalent to the threads. Tighten the screw before removing the next screw. h. If the backlash cannot be set to less than .005 inches, replace the pinion as described in Paragraph 7.3.23. i. j. Lift the motor to tension the drive belt as described in Paragraph 7.3.27.1. Tighten the four motor screws or nuts.
k. Move the carriage the length of the table to confirm that the carriage moves without binding. 5. Install the keypad or festoon end cover on the carriage end plate. 6. Square the carriage after completing the backlash adjustment.
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7.3.14 CHECK THE RACK FOR DAMAGE OR ROUGH SPOTS Check the Rack for Damage or Rough Spots as recommended in Table 7-1 and Table 7-2. With the machine off line, push the carriage along the length of the table. Listen and feel for tight spots or rough spots. Repair as necessary.
7.3.15 CHECK THE X-AXIS DRIVE HUB Inspect the X-axis drive hub every 2000 hours of operation. Replace the hub is there are any signs of wear, or if the hub does not spin smoothly. Check the X-axis hub as follows: 1. 2. Set the machine power to OFF at the control cabinet. Remove the festoon end cover from the carriage end plate by removing the six screws and unplug the connector on the cover to remove the cover. CAUTION Do not damage cable connections at interconnect board. 3. Remove the hub assembly, A-CR2-104 (DCS 1500/2500) or A-CR2L-200 (Taurus), from the rack as follows: a. Loosen the four motor mounting screws, F-0602, or the nuts, F-1000, that hold the X-axis motor drive assembly, A-CR2-193 (DCS 1500/2500) or A-CR2L-103 (Taurus), to the Xaxis end plate. The part number for the end plate are: DCS 1500/2500: CR2-185 (festoon side) and CR2-186 (keypad side) Taurus: CR2L-137 (festoon side) or CR2L-136 (keypad side). b. c. d. 4. Support the X-axis drive hub assembly and remove the four mounting screws that mount the drive hub to the end-plate. Remove the X-axis drive belt from the motor and drive hub. Remove the drive hub assembly.
While holding the drive hub, CR2-060, spin the pulley by hand. The pulley, CR2-058 (DCS 1500/2500) or CR2L-125 (Taurus), should spin without excessive resistance or rough spots. The pulley and pinion should run true (not warped). Refer to Figure 7-3.
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5.
Check that the pulley and pinion, CR2-059, are tight on the shaft by trying to spin them in opposite directions and feeling for slippage (see to Figure 7-3).
FIGURE 7-3 DRIVE HUB ASSEMBLY (DCS1500/2500)
6. 7. 8.
Clean the mounting holes in the hub. Install the hub. Set backlash for the drive hub as follows: a. b. Loosely tighten the four mounting screws to secure the drive hub to the end plate. Place a small piece of paper, 1 by 4, between the pinion gear and the rack. Manually spin the drive hub to pull the paper into, but not through, the space between the pinion gear and rack. Lift the drive hub and tighten the screws. Remove the piece of paper by manually spinning the drive hub until the paper is free of the pinion and rack.
c. d. 9.
Install the X-axis drive belt removed in Step 3.
10. Tighten the motor mounting screws loosened in Step 3. 11. Adjust the X-axis drive belt as described in Paragraph 7.3.27. 12. Install the festoon side or keypad side cover. 13. Set the machine power ON at the control cabinet. 14. Check the backlash by rocking both ends of the carriage back and forth. It should be less than 0.005 inch. If the backlash is not correct, adjust the backlash using the procedure in Paragraph 7.3.13. 15. Square the machine using the Calibrate Machine dialog box described in Section 6.0.
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7.3.16 INSPECT THE MOTORS Inspect the X-axis, Y-axis, and theta axis motors every 2000 hours of operation. The process for inspecting each of these motors involves removing the motor brush and measuring the length, as shown in Figure 7-4. New brushes measure .360. If the brush measures less than .200, the brush is worn out and the motor should be rebuilt. To remove a brush from a motor, insert a screwdriver in the slot in the brush retaining cap and gently twist counter-clockwise. Applying too much pressure with the screwdriver can damage the slot. To replace the brush, manually insert the brush in the motor, taking care not to damage the spring. Replace the cap and gently tighten with a screwdriver. 7.3.16.1 Inspect the X-axis motors
To inspect the X-axis motors, remove both the keypad and festoon side Crosstube Covers from the cross tube by squeezing the bottom of the legs on the covers to clear the mounting slots in cross tube. Slide the covers from the cross tube to expose the Y-axis assembly and gain access to the X-axis motors. There are two X-axis motors inside the crosstube, one on either end of the carriage. Remove the motor brush and measure. 7.3.16.2 Inspect the Y-axis motor
To inspect the Y-axis motor, remove the keypad cover. Remove the motor brush and measure. 7.3.16.3 Inspect the Theta axis motor
To inspect the Theta motor, remove the safety cover. Use a wrench to hold the thumbscrew nuts in place and twist the thumbscrews. Remove the motor brush and measure.
FIGURE 7-4 MOTOR AND MOTOR BRUSH
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7.3.17 REPLACE THE WHEEL CUTTER BLADE BOLT Replace the wheel cutter bolt as recommended in Table 7-1 and Table 7-2. You should check the wheel cutter bolt every shift per Paragraph 7.3.9. If a wheel blade needs to be changed during a job, pause the job using an E-stop. You can also wait until there is a controlled pause, such as an Op Stop or a Smart Stop in the job before changing the blade. To change the wheel cutter bolt: 1. Jog the carriage to a spot on the table where you can reach the wheel cutter. 2. Press the E-stop to take the system off line. 3. Remove the wheel cutter from the tool holder by loosening the set screw using the T-handle hex key. The tool should slide down off the holder. 4. Use the T-handle hex key and the nut driver to remove the 7mm nut, F-1001. 5. Slide the shoulder bolt, F-0101, out from the main body with the washers and blade. 6. Replace the old bolt with the new bolt. 7. Reassemble the cutter as pictured in Figure 7-5. The bolt passes through the washer and blade. 8. Tighten the 7mm nut to the bolt. Use a with a firm twist to make sure the nut is tight. 9. Verify that you can see the blade when you look through the hole of main body (where the assembled tool mounts on the tool holder). 10. Reattach wheel cutter to tool holder. Be sure to line up the set screw with the indentation on the tool holder. 11. Verify that the top of the wheel cutter is up tight against the tool holder and there is no gap. 12. Tighten the set screw with a firm twist of the hex key.
FIGURE 7-5 WHEEL CUTTER BOLT
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7.3.18 CHECK AND LUBRICATE THE AIR CYLINDERS The maintenance for the cutter system requires that the cutter drive mechanism be checked, cleaned, and lubricated and that the air cylinders be lubricated, as recommended in Table 7-1 and Table 7-2. Refer to Theta Axis Assembly exploded views in the Cutting Edge DCS 1500/2500 GERBERcutter Engineering Drawings manual or Cutting Edge Taurus TLCS GERBERcutter Engineering Drawings manual and do as follows: 1. Perform the Theta Torque Run Out diagnostic test before performing this procedure (see Section 8.0). This diagnostic test checks for bent tool shafts. 2. Set the machine power to OFF at the control cabinet. 3. Lower the air pressure to the PEN, TOOL HOLDER 1, and TOOL HOLDER 2 to 0 psi. 4. Remove the Y-axis Cover, CR2L-119, to gain access to knife cutter mechanism by removing eight screws, F-1495. 5. Check the cutter drive from the top for signs of dirt and excessive wear. 6. Lubricate the cutter drive as follows: a. Move the cutters up and down by hand and remove any dirt from the splines. b. Apply a small amount of lithium grease and work the grease into the spline by moving the cutters up and down again by hand. c. Check the small drive belt that couples the motor to the tool holders for signs of wear. 7. Lubricate the air cylinders as follows: a. Remove the three clear plastic air hoses for tool holders 1, 2, and 3 that are on top of the Y-axis assembly. The three air hoses are located on the input side of the cylinders. The input air hoses for tool holders 1 and 2 are connected to the elbow, CR-051, leading to the solenoid input EA. The input air hoses for tool holder 3 is connected to the elbow leading to the solenoid input P. b. Once the hoses are out of valve elbow, place a few drops of oil into the elbow. c. Replace the plastic hose. 8. Clean all tool holder, pen cylinder, and optional punch cylinder shafts as follows: a. Lower the tool to expose shaft. b. Spray a solvent such as Tri-Flow on a rag. c. Wipe the cylinder shaft to remove any contaminants. 9. Set the cutter pressures to normal levels. 10. Check for leaks and replace the cover on the Y-axis assembly using eight screws removed in the previous step.
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7.3.19 REPAIR THE CUTTING SURFACE DCS 1500/2500 There are three types of repairs that can be made to the plastic cutting surface. small and large repairs to the surface caused by wear (see Paragraph 7.3.19.1) repairs to the surface due to damage caused by surface delamination or by extremes in temperature (see Paragraph 7.3.19.2) repairs to the seams between the surface sections caused by delamination (see Paragraph 7.3.19.3)
The following paragraphs discuss these repairs. 7.3.19.1 Repair a Wear-Damaged Table Surface DCS 1500/2500
The plastic cutting surface will wear over time from routine cutting. The amount of wear depends on the patterns, time, and tool pressure used. Although the entire surface should be replaced from time to time, it is possible to repair portions of the table. Damaged spots and areas on the table will degrade performance levels. To make small or large repairs to the plastic, do as follows: 1. For small spot repairs such as gouges less than a pencil width, repair as follows: a. Sand or chisel flat and fill the holes with hot melt glue. Use white glue sticks. b. Use a sharp chisel to trim off the excess glue. 2. To repair larger areas, replace just a portion of the plastic surface as follows: a. Use a sharp knife to cut out the damaged area and peel the old plastic up off the table. b. Scrape the exposed aluminum table to remove any excess spray adhesive and prepare the new plastic for patch. c. Use a 5/64-inch diameter drill bit or similar diameter object to clean the holes in the aluminum surface. Remove any burrs from the holes by lightly sanding with medium sandpaper. After cleaning the holes, turn on the vacuum without any material on top of the table for a short period to flush the debris. WARNING Do not use a solvent to clean the aluminum table surface. d. Mask off the existing table surface around the patch to protect the existing surface from the overspray. Apply 3M Spray 77 on both the table and patch.
e. Wait until the adhesive is slightly tacky (approximately 5 minutes).
f.
Carefully place the patch and roll it out with a roller.
g. Use hot melt glue to fill the gap around patch. h. Use a chisel to trim the excess glue and leave a flush smooth surface.
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7.3.19.2
Repair Delamination or High Temperature Damage DCS 1500/2500
The following procedure provides instructions for partial table surface repair to damage caused by extremes in temperature. These temperature extremes cause delamination, which happens when the porous plastic table surface comes un-glued from the aluminum panel surface and creates bubbles or high spots on the cutting surface. Delamination is generally caused by excessive expansion and contraction caused by extreme temperature swings. The coefficient of expansion of the plastic surface is considerably higher than that of the aluminum panel on which it sits. If temperature swings are greater than those explained in the installation preparation guide and/or if the seam between panels is too small, or if the hot melt glue does not completely fill the seams, the edges of the panels will be forced against each other and will eventually buckle. WARNING Set machine and vacuum system power to OFF before removing and installing the table surface material.
7.3.19.2.1
Replace Damaged Surface Area
The following table surface replacement procedure is the preferred method for repairing large bubbles or raised areas in the plastic table surface. 1. To remove a damaged section of table surface, use a utility knife or use a tangential knife mounted on the machine to make a rectangular cutout surrounding damaged area. Cut approximately four inches beyond damaged section. a. If using a utility knife, use a straight edge as a guide to cut around the damaged area. b. If using the tangential knife on the Y-axis assembly, do as follows: 1) Use any common CAD software to create a rectangle using the "draw box" command. 2) Export the box as a DXF file and treat it like any cut file. 3) Set the tangential knife to cut at a depth of 0.125 inch (0.317cm) below the surface of the table plastic. 4) Set the cut speed of 5 inches (12.7cm) per second and the tool pressure to 35 psi. 5) Jog start point to position on surface that represents lower left side of piece to be removed and cut it out. You may have to retrace the rectangle using the Move to Local Origin command to reset the start point. 2. Remove the cutout using a putty knife with a 6 inch (15.24cm) blade under sheet material. 3. Clear aluminum table surface of debris and scrap material, but do not attempt to remove residual glue on aluminum table surface.
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4. Make a patch by cutting a smaller rectangle from a new piece of plastic surface material. The patch should be smaller by 3/16 inch (0.476cm) in each dimension. Lay the new sheet to be cut on top of the table cutout in the surface, tape it in place, and cut the patch using either the utility knife or the tangential knife in same manner as the cutout. Do not cut the plastic surface below. 5. Mask the area around the cutout. 6. Holding a can of 3M Spray 77 adhesive about 10 to 12 inches (25.4 to 30.5cm) from the surface, apply a thin but even coat to both the table and the rough surface of the patch. Apply the adhesive at rate of 2/3 can per full sheet of the surface. 7. Wait until the adhesive is slightly tacky (approximately 5 minutes). 8. Turn the patch over. Place the patch within the cutout with an even margin around all four sides. 9. Burnish the patch firmly in place with a plastic laminating roller or similar device. 10. Fill 3/32 inch (0.24cm) seam with hot melt glue, leaving a bead of glue above the level of the plastic surface. Be sure to fill the seam from the bottom up so that the hot melt glue actually bonds to the aluminum table surface. 11. After gluing all the seams, trim excess glue from each seam with a finely honed 3/4 or 1 inch (1.9 or 25.4cm) wide chisel. The purpose is to dress each seam down to exactly the level of the surface of the plastic material without gouging the surface of the material. Use a sharp chisel and keep the bevel of the blade exactly even with the table surface. You can avoid gouging the table by slightly rounding off the corners of the blade. 7.3.19.2.2 Re-Glue Existing Surface
The following cutting and re-gluing procedure is considered a temporary repair and should only be performed as an interim repair and used until the surface can be replaced. 1. Cut an "X" in the raised surface of table surface, with a small circular saw, creating a groove of at least 1/16 inch (0.16cm). The "X" should bisect the affected area as symmetrically as possible. 2. Set the blade depth so that the cut goes entirely through the plastic surface and not the aluminum table surface. 3. Carefully lift the plastic surface, one flap at a time. Carefully spray 3M Spray 77 on the underside of the plastic surface. Wait until the adhesive is slightly tacky (approximately 5 minutes). Then lower the plastic to the aluminum surface. Note that the aluminum surface usually does not require additional glue. 4. If the aluminum surface appears to be free of glue when the plastic surface is raised, then surface must be cleaned before further glue is applied and glue re-applied. 5. Burnish the plastic firmly in place with a plastic laminating roller or similar device. 6. Fill the 1/16 inch (0.16cm) groove with hot melt glue, leaving a bead of glue above the level of the plastic surface. Be sure to fill the groove from the bottom up so that the hot melt glue actually bonds to the aluminum table surface. 7. After gluing all seams, trim any excess glue from each seam with a finely honed 3/4 or 1 inch (1.9 or 25.4cm) wide chisel. The purpose is to dress each seam down to exactly the level of the surface of the plastic material without gouging the surface of the material. Use a sharp chisel and keep the bevel of the blade exactly even with the table surface. You can avoid gouging the table by slightly rounding off the corners of the blade.
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7.3.19.3
Repair to Raised Seams between Plastic Panels DCS1500/2500
The following procedure should be used to repair delamination at the seams of the plastic table surface. See Paragraph 7.3.19.2 for a definition of delamination. To correct this condition, do as follows: 1. Carefully remove any hot melt from the affected seam. 2. Lift the edges of the surface carefully away from the aluminum panel. 3. Apply 3M Spray 77 adhesive to the underside of the panel, being careful not to spray the top surface of plastic. 4. Wait until the adhesive is tacky (approximately five minutes) before re-setting the surface. Burnish the plastic firmly in place with a plastic laminating roller or similar device. 5. Open the seam to approximately 1/8 inch and fill with hot melt glue. The hot melt glue acts as an expansion joint, permitting greater expansion and contraction of the plastic surface. a. Cut the seam of the table surface, preferably with a small circular saw, creating a groove of at least 1/8 inch (0.317cm). b. Set the blade depth so that cut goes entirely through the plastic surface, but not the aluminum table surface. NOTE Plastic panels that are too wide might get pushed against the extrusion on both sides and delaminate at the edges. To fix this problem, cut away enough plastic to allow for proper expansion. c. Fill the 1/8 inch (0.317cm) groove with hot melt glue, leaving a bead of glue plastic surface. Be sure to fill the seam from the bottom up so that the hot melt glue actually bonds to the aluminum table surface. d. After gluing all the seams, trim the excess glue from each seam with a finely honed 3/4 or 1 inch (1.9 or 25.4cm) wide chisel. The purpose is to dress each seam down to exactly the level of the surface of the plastic material without gouging the surface of the material. Use a sharp chisel and keep the bevel of the blade exactly even with the table surface. You can avoid gouging the table by slightly rounding off the corners of the blade.
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7.3.20 REPAIR THE CUTTING SURFACE TAURUS Use the following procedures to replace table surface panels that are damaged or worn. to replace all standard table surface panels, refer to Paragraph 7.3.20.1 to replace all high density table surface panels, refer to Paragraph 7.3.20.2 to remove an old table surface, refer to Paragraph 7.3.20.3 to replace a single table panel, refer to Paragraph 7.3.20.4 to repair a glue seam, refer to Paragraph 7.3.20.5 Install Table Panels- Standard Hole Pattern
7.3.20.1
Use the following procedure to replace standard table panels. Refer to Figure 7-6 and install table surface (A-WCL-105 or A-WCL-102). Leave the protective plastic on the table surface during installation. Insert table surface spacers (A-WCL-110) under the lip of the extrusion on both sides of the machine. The table spacers are bits of an o-ring cut into 1/2" pieces. Use three spacers per table panel on both sides of the machine. These spacers ensure that the table surface panels are properly spaced. When the table surface pieces are put in place, butt each table surface piece against the keypad side extrusion. This will allow enough space for expansion in the X axis. 1. Place all six pieces of table surface (protective plastic side down) on table panels. Clean all edges of the table surface with denatured alcohol. Check for beveled edges on the table surface, as shown in Figure 7-7. 2. Cut five 9 pieces of fiberglass carpet tape (WCL-152). Place one piece of carpet tape on the right hand side (when looking at the table from the keypad side) of each piece of table surface. a. Place the tape 1 1/2" from each end of the panel. b. Do not put the tape on the table surface piece on the far end of the table. c. Place the tape the entire length of the table surface, from the keypad side to the festoon side, with the protective plastic side of the tape facing up. d. Adhere the carpet tape to the table surface so that half of the tape hangs over the panel. 3. Start at the center of the table. Turn the third piece of table surface over so that the protective plastic side of the surface faces up. Place the panel half way across the center vacuum separator. The adhesive side of the carpet tape is facing the ceiling. Peel back a small amount of the protective plastic from the edge of the table surface then tuck the table surface under the lip of the extrusion. Butt the table surface piece against the keypad side extrusion. 4. Turn the fourth panel over so that the protective plastic side of surface faces up. Peel back a small amount of the protective plastic from the edge of the table surface then tuck the table surface under the lip of the extrusion. Butt the table surface piece against the keypad side extrusion. Mate the fourth panel to the exposed piece of tape on the third panel. Leave a gap of 1/16 in between each panel. Place a ty-wrap between the two panels to approximate the 1/16 gap. Use a roller across the seam to secure the panels to the tape.
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FIGURE 7-6 TABLE SURFACE

Section 7.0: Maintenance 12/2000 7-31
5. Turn the fifth panel over so that the protective plastic side of surface faces up. Peel back a small amount of the protective plastic from the edge of the table surface then tuck the table surface under the lip of the extrusion and butt the table surface piece against the keypad side extrusion. Mate the fifth panel to the exposed piece of tape on the fourth panel. Leave a gap of 1/16 in between each panel. Place a ty-wrap between the two panels to approximate the 1/16 gap. Use a roller across the seam to secure the panels to the tape. 6. Repeat the procedure for the remaining table surface panels. Make sure to butt the table surface against the keypad side extrusion, and leave the 1/16 gap between each panel. Use a roller across the seam to secure the panels to the carpet tape. 7. Fill seam between panels with hot glue as follows: a. Peel back a small amount of the protective plastic where the table surface panels meet. b. Turn the blowers on. c. Fill the 1/16 seam between each panel using a glue gun and glue sticks (WC-015). Insert tip of glue gun directly into the seam. Glue gun should be perpendicular to panel, not at an angle, so glue will run into beveled area between table surface and carpet tape. Refer to Figure 7-7. Make sure the area is completely filled, with no air bubbles. Fix any air bubbles before the glue dries. d. Let the glue dry, then use a chisel to shave off glue bead. Use a chisel with the short angled side down and the long side facing up. Push the chisel away from your body. Shave off the glue bead until the table surface is smooth. 8. Turn the blowers off.
FIGURE 7-7 PLACEMENT OF STANDARD TABLE PANEL SURFACE 9. Remove the protective plastic from the table surface.
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7.3.20.2
Install Table Panels- High Density Table Surface
Use the following procedure to replace a high density table surface panel. Refer to Figure 7-6 and install table surface (A-WCL-106 or A-WCL-107). Leave the protective plastic on the table surface during installation. Insert table surface spacers (A-WCL-110) under the lip of the extrusion on both sides of the machine. The table spacers are bits of an o-ring cut into 1/2" pieces. Use three spacers per table panel on both sides of the machine. These spacers ensure that the table surface panels are properly spaced. When the table surface pieces are put in place, butt each table surface piece against the keypad side extrusion. This will allow enough space for expansion in the X axis. 1. Place all six pieces of table surface (protective plastic side down) on table panels. Clean all edges of the table surface with denatured alcohol. Check for beveled edges on the table surface, as shown in Figure 7-7. 2. Cut five 9 pieces of polyester tape (WCL-153). Place one piece of tape on the right hand side (when looking at the table from the keypad side origin end) of each piece of table surface. a. Line up the tape along the last row of vacuum holes on each panel. Do not cover any vacuum holes. b. Do not put the tape on the table surface piece on the far end of the table. c. Place the tape the entire length of the table surface, from keypad side to festoon side, with the protective plastic side of the tape facing up. d. Adhere the tape to the table surface. 3. Start at the center of the table. Turn the third piece of table surface over so that the protective plastic side of the surface faces up. Place the panel half way across center vacuum separator. The adhesive side of the tape is facing the ceiling. Peel back a small amount of the protective plastic from the edge of the table surface then tuck the table surface under the lip of the extrusion. Butt the table surface piece against the keypad side extrusion. 4. Turn the fourth panel over so that the protective plastic side of surface faces up. Peel back a small amount of the protective plastic from the edge of the table surface then tuck the table surface under the lip of the extrusion. Butt the table surface piece against the keypad side extrusion. Mate the fourth panel to the exposed piece of tape on the third panel. Leave a gap of 1/16 in between each panel. Slip a ty-wrap between the two panels to approximate the 1/16 gap. Use a roller across the seam to secure the panels to the tape. 5. Turn the fifth panel over so that the protective plastic side of surface faces up. Peel back a small amount of the protective plastic from the edge of the table surface then tuck the table surface under the lip of the extrusion and butt the table surface piece against the keypad side extrusion. Mate the fifth panel to the exposed piece of tape on the fourth panel. Leave a gap of 1/16 in between each panel. Slip a ty-wrap between the two panels to approximate the 1/16 gap. Use a roller across the seam to secure the panels to the tape.
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6. Repeat the procedure for the remaining table surface panels. Make sure to butt the table surface against the keypad side extrusion, and leave the 1/16 gap between each panel. Use a roller across the seam to secure the panels to the carpet tape. 7. Fill the seam between the panels with hot glue as follows: a. Peel back a small amount of the protective plastic where the table surface panels meet. b. Turn the blowers on. c. Fill the 1/16 seam between each panel using a glue gun and glue sticks (WC-015). Insert the tip of glue gun directly into the seam. The glue gun should be perpendicular to the panel, not at an angle, so the glue will run into the beveled area between the table surface and the carpet tape. Refer to Figure 7-8. Make sure the area is completely filled, with no air bubbles. Fix any air bubbles before the glue dries.
FIGURE 7-8 PLACEMENT OF HIGH DENSITY TABLE PANEL SURFACE d. Let the glue dry, then use a chisel to shave off glue bead. Use chisel with the short-angled side down and the long side facing up. Push the chisel away from your body. Shave off the glue bead until the table surface is smooth. 8. Turn the blowers off. 9. Remove the protective plastic from the table surface.
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7.3.20.3
Remove the Table Surface Taurus
Use the following procedure to remove the table surface for a Taurus TLCS machine. The table surface should only be removed if the entire table surface needs to be replaced. To replace a single table panel, refer to Paragraph 7.3.20.4. To remove the surface, start at one end of the table and do as follows: 1. Hold the first panel at a point about two feet from the extrusion and lift upward until the panel comes free from the extrusion lip. 2. Continue to free the panel from under the extrusion until the entire panel is out from under the extrusion. 3. Peel the panel along the glue seam between the first and second panels. 4. When the panel is free from the table, discard the panel. 5. Repeat these steps until all the panels are removed. 6. Clean the extrusion under the lip using compressed air. 7. Remove and discard all old surface spacers, A-WCL-110. 8. Clean any debris on the table and extrusion.
To replace the table surface, refer to Paragraph 7.3.20.
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7.3.20.4
Replace One Table Surface Panel Taurus
Use the following procedure to replace a single panel of the table surface for a Taurus TLCS machine. The panels should only be removed if one needs to be replaced. If the entire table surface needs to be replaced, refer to Paragraph 7.3.20. To replace one surface sheet: 1. Cut along the glue seams with a utility knife on both sides of the panel. 2. Hold the panel at a point about two feet from the extrusion and lift upward until the surface comes free from the extrusion lip. 3. Remove the sheet from the table. 4. Peel the tape and glue from the from the panel(s) on either side of the removed panel. 5. Apply tape along the edges of the panel(s) on either side of the removed panel. 6. Clean edges on the new surface panel with denatured alcohol. 7. Confirm that there are three evenly spaced table surface spacers under the extrusion lip on each side of the table. 8. Install the new sheet by inserting one edge under the extrusion lip, centered in the space between the remaining panels. Hold the panel up about two feet in from the extrusion on the opposite edge. 9. Lower the panel onto the table and tuck it under the extrusion 10. Check the tape joints for proper spacing. See Figure 7-7 (standard table surface) or Figure 7-8 (high density table surface). 11. Fill the seam between the panels with hot glue as follows: a. Peel back a small amount of the protective plastic where the table surface panels meet. b. Turn the blowers on. c. Fill the 1/16 seam between each panel using a glue gun and glue sticks (WC-015). Insert the tip of glue gun directly into the seam. The glue gun should be perpendicular to the panel, not at an angle, so the glue will run into the beveled area between the table surface and the carpet tape. Refer to Figure 7-8. Make sure the area is completely filled, with no air bubbles. Fix any air bubbles before the glue dries. d. Let the glue dry, then use a chisel to shave off glue bead. Hold the chisel with the short-angled side down and the long side facing up. Push the chisel away from your body. Shave off the glue bead until the table surface is smooth.
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7.3.20.5
Repair Table Panel Glue Seam Taurus
When gluing the panels of a table together, the glue must make contact with the tape underneath the surface panels and fill the entire beveled cavity between table panels (see Figure 7-8 above). If the glue does not fully fill the seam, the wheel blade can get caught between table surface panels and break off. To prevent this problem, visually inspect all glue seams. Use your hand or the tip of a small flat head screwdriver to press on the glue seam. Check for the following: If no air pocket exists, the glue seam is O.K. If an air pocket or weak spot exists between the glue and the tape on top of the sub-surface, repair the glue seam by using the screwdriver to press the glue down until it makes contact with the tape. Fill seam with new glue following steps 4 through 8. If an air pocket exists along the entire length of a glue seam, remove the existing glue in the seam and re-glue the seam following steps 4 through 8.
Be careful not to push screwdriver through glue so that it presses on the tape that is below the seam between each table surface panel. Refer to Figure 7-8 above. To repair the problem, do the following: 1. Turn the vacuum blowers on. 2. Fill the seam between each panel using a glue gun and the glue sticks (WC-015) provided with the Taurus machine. Insert the tip of the glue gun directly into the seam. The glue gun should be perpendicular to panel, not at an angle, so glue will run into the beveled area between the table surface and tape. Fill the seam with hot glue until the glue rises above the table surface panels. NOTE: The hot glue must completely fill the beveled cavity and make contact with the tape on the sub-surface. There should be no air pockets between the glue and the tape. 3. Let the glue dry, then use a chisel to shave off the glue bead. Hold the chisel with the short-angled side down and the long-angled side facing up. Push the chisel away from your body. Shave off the glue bead until the table surface is smooth. 4. Check the strength of the seams by using a flat head screwdriver to push down on the glue seams. 5. Turn blowers off when done. For a clean looking table surface, cover the glue seam with the white flaw marking tape included with the Taurus Machine. Change the white tape as often as needed to keep the table surface looking clean.
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7.3.21 CLEAN THE CONTROL CABINET FILTER Inspect the cooling fan filter in the carriage control cabinet and clean as recommended in Table 7-1 and Table 7-2. To clean filter, remove filter from control cabinet and spray filter with compressed air. Do not spray compressed air on filter while installed in cabinet.
7.3.22 LUBRICATE THE DRIVE BELTS Lubricate the three drive belts used on the X and Y axes on the carriage with Elmers Slide-All Dry Spray Lubricant as recommended in Table 7-1 and Table 7-2. CAUTION Do not use a lubricant that conducts static electricity.
7.3.22.1
Lubricate the X-axis Belts
Spray the left and right X-Axis Drive Motor Belt, CR2-065, with Elmers Slide-All Dry Spray Lubricant or equivalent as follows: 1. Set the machine power OFF at the control cabinet. 2. Remove the keypad or festoon end cover from the carriage end plate by removing the six retaining screws, F-1480. 3. Spray lubricant on the inside of the belt as you move the carriage along the length of the table. Move the carriage as far as needed to cover the entire inside surface of the belt. 4. Move the carriage back and forth to evenly distribute the lubricant on the belt and the pulleys. 5. Install the keypad or festoon end cover on the carriage end plate using the six retaining screws, F-1480. 7.3.22.2 Lubricate the Y-axis Belt
Spray the Y-axis drive belt with Elmers Slide-All Dry Spray Lubricant or equivalent as follows: 1. Set the machine power OFF at the control cabinet. 2. Move the Y-axis assembly to one end of the carriage. 3. Turn the belt over by hand to expose the inside of the belt and spray with lubricant. 4. Move the Y-axis assembly to the other end of the carriage. 5. Turn the belt over by hand to expose the inside of the belt and spray with lubricant. 6. Move the Y-axis assembly back and forth to evenly distribute the lubricant on the belt and the pulleys.
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7.3.23 REPLACE THE X-AXIS DRIVE PINIONS Replace the X-Axis Drive Pinions, CR2-059, as recommended in Table 7-1 and Table 7-2. After replacing the pinions, adjust the position of the X-axis motor to achieve the correct backlash. Refer to the two Carriage Drive and the X Axis Drive Hub Assembly exploded views in the Cutting Edge DCS 1500/2500 GERBERcutter Engineering Drawings manual, or the two Leather Carriage Assembly and the X Axis Drive Hub Assembly exploded views in the Cutting Edge Taurus TLCS GERBERcutter Engineering Drawings manual and do as follows: 1. Set the machine power OFF at the control cabinet.. 2. Remove the keypad or festoon end cover from the carriage by removing six retaining screws, F-1480, from cover. Remove the cover from the end that needs a new drive pinion. 3. Loosen the four motor mounting screws, F-0602, or nuts, F-1000, that hold the X-Axis Motor, A-CR2-150 (DCS 1500/2500) or A-CR2L-103 (Taurus), to the end-plate. 4. Support the X-Axis Drive Hub Assembly, A-CR2-104 (DCS 1500/2500) or A-CR2L-200 (Taurus), and remove the four mounting screws, F-0602, that mount the drive hub to the end-plate. 5. Remove the X-axis drive belt from the motor and drive hub. 6. Remove the drive hub from the end plate. 7. Replace the drive pinion on the drive hub as follows: a. Remove the set screw from the X-Axis Drive Pinion, CR2-059. b. Remove and discard the drive pinion from the X-Axis Drive Shaft, CR2-057. c. Remove and discard the Woodruff key, CR2-070.
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d. Install a new drive pinion with a new Woodruff key as follows: 1) Install the new Woodruff key in the slot on the shaft. 2) Apply Loctite 242 or equivalent to the inside diameter of the gear. 3) Press the gear on the shaft so that the bottom of the gear is 3/4 inch (1.9cm) from the drive hub flange (see Figure 7-9). 4) Apply Loctite 242 or equivalent to the set screw threads. Install and tighten set screw to 30 inch-pounds (3.4 Newton-meters).
FIGURE 7-9 X-AXIS DRIVE HUB ASSEMBLY 8. Position the drive hub on the end plate. Loosely install the drive belt on the drive hub and the X-axis motor pulleys. 9. Install and tighten the four mounting screws or nuts to secure the drive hub to the end plate. 10. Tighten the motor mounting screws loosened in the previous step. 11. Adjust the backlash as described in Paragraph 7.3.13. 12. Adjust the X-axis drive belt as described in Paragraph 7.3.27.1. 13. If the backlash adjustment not required, do following: a. Confirm that the carriage moves the length of the table without binding. b. Install the keypad or festoon end cover on the carriage end plate using the screws removed in the previous step. Square the carriage as described in Section 6.
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7.3.24 REPLACE AND/OR ADJUST THE X-AXIS LINEAR BEARING The following procedure provides instructions for replacing and/or adjusting the X-axis Linear Bearing, CR2-053, or inserts, CR2-077, in the X-axis of the carriage on a DCS 2500 or Taurus machine. There are two sets of bearings on each side of the machine (festoon and keypad). Bearings should be adjusted every 2000 hours of machine use, and replaced as needed. As a general rule, the bearings should be replaced in pairs on the same side of the carriage. This is because a failure in one bearing can overstress the other bearing causing it to weaken. The damage may not be immediately apparent. When removing parts from the machine, save all fasteners, as they are used to reinstall removed and replaced parts. Replace or adjust the linear bearings in the X-axis as follows: 1. 2. 3. 4. 5. Set the machine power to OFF at the control cabinet. Move the carriage approximately three feet from the origin end of the table. On DCS 1500 and DCS 2500 machines, remove the Rail End Cap, R-009, from the table extrusion by removing the three screws. On Taurus machines, remove the end cap cover, T2L-243, by removing the four screws. Remove the first three Rack Bits, R-010. Rack bits are small rectangular blocks that pinch the rack against the extrusion. First remove the screws, then release the bits from the rail by inserting an Allen wrench into the screw hole in the bits and prying them out. Use the largest wrench that will fit into the hole. Push the rack sideways towards the center of the table to access the first two socket head cap screws that hold in the Thomson rail. Remove the first two rail screws. Lift up the rail and slide the bumper spring and washer off the end of the rail. If changing bearings on Festoon side of the machine, do as follows: a. b. Remove the festoon end cover from the carriage end plate by removing the six screws and unplug the connector on the cover to remove the cover. Remove the four screws and washers that fasten the Carriage Interconnect Board, CR2-079. Move the board out of the way by pushing on the edge of the board. The bearing screws are located behind the interconnect board. Proceed with Step 11. CAUTION Do not damage cable connections at interconnect board. 10. If changing bearings on the keypad side of the machine, do as follows: a. b. Remove the keypad end cover from the carriage by removing the six screws and unplugging the connector on the cover to remove the cover. Proceed with Step 11.
6. 7. 8. 9.
c.
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11. Remove the hub assembly, A-CR2-104 (DCS 1500/2500) or A-CR2L-200 (Taurus), from the rack as follows: a. Loosen the four motor mounting screws that hold the X-axis motor drive assembly, A-CR2-193 (DCS 1500/2500) or A-CR2L-103 (Taurus), to the X-axis end plate. The part numbers for the end plate are: DCS 1500/2500: CR2-185 (festoon side) and CR2-186 (keypad side) Taurus: CR2L-137 (festoon side) or CR2L-136 (keypad side). b. c. d. Support the X-axis drive hub assembly and remove the four mounting screws that mount the drive hub to the end plate. Remove the X-axis drive belt from the motor and drive hub. Remove the drive hub.
12. Place blocks under the carriage on top of the extrusion, on the side that bearings are being replaced, to support carriage during the bearing removal. 13. Remove the four screws and lock washers holding each linear bearing in position. Remove the bearing closest to the origin end first. 14. Slide the bearings out by using a long flat-head screwdriver to draw the bearing past the end plate. Slide the bearings off the rail. 15. Adjust the new or existing bearings to the rail prior to installation by installing the bearing backwards on the rail. The adjusting screw should be facing away from the table. Do as follows: NOTE: Use care when installing the new bearings on the rail. If you put the bearing on the rail at an angle, the ball bearings inside the bearing could be damaged or released. a. b. Loosen the adjusting screw in the bearing until the bearing spins freely around the rail (not along the rail). Slowly tighten the adjusting screw in the bearing until there is slight resistance while spinning the bearing around the rail. The bearing should still be able to spin slightly around the rail. Remove the bearing without loosening the adjusting screw.
c.
16. Slide the bearing on the rails with the adjusting screw facing toward the table. Install the bearing farthest from the origin first. 17. Install the four screws and lock washers removed in Step 13. The screws should be finger-tight. 18. Remove the blocks from between the carriage and the extrusion. 19. Move the carriage back and forth to align the bearing and then tighten the screws. 20. If removed, replace the carriage interconnect board using the four screws and washers removed in Step 9.b. Install the washer, F-0903, in the upper right corner of the board. Make the sure connectors are plugged in and not damaged.
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21. After installing the board, check for ground as follows: a. b. On the rev C interconnect board, remove the motor power connector, JXF, JXK, JY, or JT. Check and record the resistance from pin 1 of the 3-pin motor receptacle on the circuit board to the upper-most left-hand screw on the endplate, F-0908. The reading should be 0.5 Ohm or less. As with all meter measurements, lead resistance should be subtracted from the reading. Re-install the motor power connector, JXF, JXK, JY, or JT.
c.
22. Install the washer and then the bumper spring on rail. 23. Install the rail screws using a drop of Loctite on the threads of each screw. 24. Replace the rack bits with the taper facing up and parallel to the extrusion. Use a drop of Loctite on each screw before installing the screw. While tightening, hold or clamp the rack in place. Make sure that the rack is tightened into place. 25. Install the rail end cap (DCS 1500/2500) or the end cap cover (Taurus) on the end of the extrusion using the screws removed in Step 3 or Step 4. 26. Move the carriage back and forth and make sure it moves smoothly. 27. Set backlash for the drive hub as follows: a. b. c. Clean the mounting holes in the hub. Loosely tighten the four mounting screws to secure the drive hub to the end plate. Place a small piece of paper, 1 by 4, between the pinion gear and the rack. Manually spin the drive hub to pull the paper into, but not through, the space between the pinion gear and rack. Lift up the drive hub and tighten the screws. Remove the piece of paper by manually spinning the drive hub until the paper is free of the pinion and rack.
d. e.
28. Install the X-axis drive belt removed in Step 11. 29. Tighten the motor mounting screws loosened in Step 11. 30. Adjust the X-axis drive belt as described in Paragraph 7.3.27. 31. Install the festoon side or keypad side cover. 32. Set the machine power ON at the control cabinet. 33. Check the backlash by rocking both ends of the carriage back and forth (see Paragraph 7.3.13). It should be less than 0.005 inch. If the backlash is not correct, adjust the backlash using the procedure in Paragraph 7.3.13. 34. Square the machine using the Calibrate Machine dialog box described in Section 6.0.
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7.3.25 CHECK THE THETA AXIS HEIGHT DCS 1500/2500 Check the distance of the theta axis assembly from the table surface in several places using the wheel cutter as a guide. Use the lowest location on the table surface to set the height of the theta axis assembly. Check the theta axis height every 200 hours of machine operation. With tool and pen pressures set to normal operating pressures, check height of theta axis assembly using the Adjust Pneumatics dialog box and the wheel cutter as shown in Figure 7-10.
FIGURE 7-10 THETA AXIS ASSEMBLY HEIGHT 1. Click the Machine menu, then select the Calibrate Machine command. 2. In the Calibrate Machine dialog box, click the Adjust Pneumatics button. The Adjust Pneumatics dialog box opens. 3. Remove the tool from Tool Holder 1 on the Y-axis assembly. 4. Lower Tool Holder 1 using the Down arrow key on the keypad. 5. Check the height of the theta axis assembly: a. Jog the carriage to a position on the table. b. Turn the wheel cutter upside down on table surface. c. Check that the top of blade on the wheel cutter is flush with the top of the flange on the tool mount of Tool Holder 1. See Figure 7-10. d. If the top of the blade is not flush, record the deviation. e. Jog the theta axis to several other locations on the table and record any deviations in height. 6. Set the height of the theta axis assembly so that the top of the blade on the wheel cutter is flush with the top of the flange on the tool mount at lowest point on the table surface as follows: a. Remove the Y-Axis Assembly Cover, CR2-010 or CR2-150, by removing the eight mounting screws, F-1495. b. Loosen the four theta axis assembly mounting screws and shift the theta axis assembly as required to obtain the proper distance between the lowest position on the table surface and the tool mount. c. Confirm that the theta axis assembly is square with the frame assembly. d. Install the Y-axis assembly cover.
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7.3.26 CHECK THE THETA AXIS HEIGHT TAURUS Check that the theta axis assembly is at the lowest position and is square to the cutting surface, every 2000 hours under normal operating conditions. To check the theta axis height: 1. Lift the safety cover, CR2-196, to the highest position. To move the shield, loosen the thumbscrews, A-CR2-187, on either side of the cover. 2. Loosen the four theta mounting screws, F-0601. The screws are inside the motor assembly, one in each corner. Do not remove the screws. 3. Move the theta assembly to the lowest setting. Use some pressure to slide the assembly to the lowest position. 4. Tighten the four screws loosened in Step 1. 5. Check that the theta assembly is square to the cutting surface.
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7.3.27 REPLACE AND ADJUST THE DRIVE BELTS The drive belts in the X-, Y-, and theta axes should be replaced as recommended in Table 7-1 and Table 7-2. There are two X-axis drive belts (one on each side of the machine), one Y-axis drive belt (which runs across the width of the machine), and one theta axis drive belt (which runs around the tool holder heads). DCS 1500/2500. To change the X-axis drive belt on a DCS 1500 or DCS 2500 machine refer to Paragraph 7.3.27.1. To change the Y-axis drive belt, refer to Paragraph 7.3.27.3. To change the theta drive belt refer to Paragraph 7.3.27.5. Taurus. To change the X-axis drive belt on a Taurus machine refer to Paragraph 7.3.27.2. To change the Y-axis drive belt, refer to Paragraph 7.3.27.4. To change the theta drive belt refer to Paragraph 7.3.27.5.
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7.3.27.1
Replace and Adjust the X-axis Belt DCS 1500/2500
Replace and adjust the left and right X-axis drive belts as follows: 1. Set the machine and computer power to OFF. 2. Remove the keypad and festoon end cover from the carriage end plates by removing the six retaining screws, F-1480, from each cover. 3. Support the motor and remove the four mounting screws, F-0602; lock washers, F-1440; and flat washers, F-0903 from the X-axis motor. 4. Tilt the motor down and remove the drive belt from the motor and drive hub pulleys. 5. Install a new drive belt on the drive hub pulley and the motor pulley. 6. Loosely install the motor on the end plate using the fasteners removed in Step 3. 7. Adjust the X-axis drive belt so that it is tight on the pulleys, but does not cause excessive loads on the pulley and the motor bearings as follows: a. If not already done, loosen the screws that secure the motor plate to the end plate. The motor plate drops and the belt curve expands to a larger diameter around the motor pulley. b. Raise the motor up to tighten the belt by gently prying with a screw driver blade between the head of the screw, F-1430, that mounts the end plate to the cross tube and the X-Axis Motor Plate, CR2-050. See Figure 7-11. Note that as the motor plate is raised, belt tension increases until the belt curves tightly around the motor pulley and the belt run is straight between the upper and lower pulleys.
FIGURE 7-11 ADJUST X AXIS BELT TENSION c. At point that the belt is in a straight line between the pulleys, tighten the screws that secure the motor plate to the end plate. The object is to apply just enough tension to the belt so that it will not slip on the pulley teeth, but at same time it will not cause excessive loads on the pulley and motor bearings. d. Move the carriage back and forth in the X-axis and note the travel of the belt on the pulleys. The belt should move evenly back and forth between the flanges on pulleys. e. If the belt rides against the outer flange of the motor pulley, the belt is too tight. Loosen the belt. 8. Lubricate the belt using Elmers Slide-All Dry Spray Lubricant or equivalent as described in Paragraph 7.3.22. 9. Install keypad or festoon end cover on carriage end plate.
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7.3.27.2
Replace and Adjust the X-axis Belt Taurus
The belts should be replaced in pairs. For Taurus systems use replacement belt CR2L-247. The new belts must be tensioned, lubricated, and then maintained. NOTE: The X-axis belts should be lubricated and checked for proper tension every 80 hours of operation. The belts should be replaced every 2000 hours. 1. Remove the keypad and festoon end cover from the carriage end plates by removing the six retaining screws from each cover. 2. Loosen the four mounting screws, lock washers, and flat washers, from the X-axis motor mount plate. Some Taurus machines do not have mounting screws. On these machines, loosen the #10-32 serrated flange lock nut that secures the motor plate in place. 3. Slide the motor down and remove the drive belt from the motor and the drive hub pulleys. 4. Install a new drive belt on the drive hub pulley and the motor pulley. 5. Adjust the X-axis drive belt so that it is tight on pulleys, but does not cause excessive loads on the pulley and the motor bearings as follows: a. Raise the motor up to tighten the belt by gently prying with a flat screw driver blade under the motor and against the end plate. As the motor plate is raised, belt tension increases until the belt curves tightly around the motor pulley and the belt run is straight between upper and lower pulleys. b. At the point that the belt run is in a straight line between the pulleys, tighten the screws that secure the motor plate to the end plate. Apply just enough tension to the belt so that it will not slip on the pulley teeth, but at same time it will not cause excessive loads on the pulley and the motor bearings. c. Move the carriage back and forth in the X-axis and note the belt travel on pulleys. The belt should move evenly back and forth between the flanges on the pulleys. d. If the belt rides against the outer flange on the motor pulley, the belt is too tight. Loosen the belt.
6. Lubricate the belts by spraying Elmers Slide-All Dry Spray Lubricant on the inside of the belt as
you move the carriage along the length of the table. Move the carriage as far as is needed to cover entire inside surface of the belt and the outside of pulleys. Be careful to not spray any electronic components with the lubricant.
7. Move the carriage back and forth to evenly distribute the lubrication on the belt and pulleys. 8. Install the keypad or festoon end cover on the carriage end plate using the fasteners removed
earlier. NOTE: Check the X-axis linear bearings for damage from running out of square, replace as necessary.
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7.3.27.3
Replace and Adjust the Y-axis Belt DCS 1500/2500
Replace and adjust the Y-axis drive belt as follows: 1. Set the machine and computer power to OFF. 2. Remove the keypad and festoon end covers from the carriage end plates by the removing six screws, F-1480, from each cover. 3. Remove the Chain Guide, CR2-002, from the cross tube by squeezing the bottom of the legs on the guide to clear the mounting slots in the cross tube. Slide the cover from the cross tube to expose the area of Y-axis assembly and access to drive belt clamp. 4. Loosen the two Y-axis belt adjusting screws, F-1425, on the Y-Axis Drive Idler Assembly, A-CR2-117, located on the festoon side of the carriage. 5. Remove the two screws, F-0602, and washers, F-1440, from the carriage structural assembly that support the Y-Axis Belt Clamps, CR2-014 and CR2-015. 6. Move the carriage to expose the belt clamps. Remove the two screws, F-1525, from the belt clamps to release the ends of the belt. 7. Use tape to attach one end of the new belt to end of the old belt. Pull the old belt through the cross tube and off the motor and idler pulleys and at same time pull the new belt onto the pulleys and through the cross tube. Be sure that the teeth on the new belt are facing toward the teeth on the pulley. 8. Loosely install the clamp screws in the clamps. 9. Pull both ends of the new belt tightly together and slip the ends of the belt between the clamps so that the teeth in the clamp mesh with the teeth in the belt. Tighten the clamp screws. 10. Move the belt so that the clamped ends of the belt are inside the carriage structural assembly. 11. Install the two screws through the structural assembly into the belt clamps. Tighten the screws to secure the belt clamps to the structural assembly. It is possible to install the clamp backwards. If the clamp is installed backwards, it will stick out from behind the carriage structural assembly. When installed properly, you cannot see the clamp when looking at the carriage structural assembly. 12. Replace the chain guide in the cross tube by sliding the guide into the cross tube and then squeezing the legs of the cross tube into the slots on the cross tube. 13. Tighten the two Y-axis belt adjusting screws to tighten the belt. The belt should not sag, but the belt should not be so tight that it strains the motor. 14. Lubricate the belt using Elmers Slide-All Dry Spray Lubricant or equivalent as described in Paragraph 7.3.22.2. 15. Install the keypad and festoon end covers using the six screws removed in Step 2.
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16. Using Calibrate Machine dialog box described in Section 6, do as follows: a. Home the machine. b. Set the Y Scale Factor. c. Check the Y-axis Belt. 1) Click the Check Y-Axis Belt command button in the Calibrate Machine dialog box to display the Adjust Y-Axis Belt Tension dialog box. 2) Click Proceed. 3) Press the ENTER button on the keypad to start the Y-axis assembly moving. 4) As the belt is moving, adjust the screws on the Y-axis drive idler assembly until the belt moves smoothly between the flanges. The belt should ride evenly between the two flanges, and not favor either side. When adjusting the two screws, turning one screw one half turn, then turning the other screw one half turn. This will ensure the tension is maintained equally. Listen for the sound of the Y-axis motor to change. This can indicate that too much tension is applied to the belt.
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7.3.27.4
Replace and Adjust the Y-axis Belt Taurus
Replace and adjust the Y-axis drive belt as follows: 1. Set the machine and computer power to OFF. 2. Remove the keypad and festoon end covers from the carriage end plates by removing the six screws, F-1480, from each cover. 3. Remove the Cross Tube Cover, A-CR2L-115 (keypad side) and A-CR2L-116 (festoon side), from the cross tube by squeezing the bottom of the legs on the guide to clear the mounting slots in the cross tube. Slide the cover from the cross tube to expose the area of Y-axis assembly and to gain access to the drive belt clamp. 4. Loosen the two Y-axis belt adjusting screws, F-1425, on the Y-Axis Belt Tensioner, A-CR3-141, located on the festoon side of the carriage. 5. Remove the two screws, F-0602, and washers, F-1440, from the carriage structural assembly that supports the Y-Axis Belt Clamps, CR2L-179 and CR2L-180. 6. Move the carriage to expose the belt clamps. Remove the two screws, F-0500, from the belt clamps to release the ends of the belt. 7. Use tape to attach one end of the new belt to the end of old belt. Pull the old belt through the cross tube and off the motor and idler pulleys and at the same time pull the new belt onto the pulleys and through the cross tube. Be sure that the teeth on the new belt are facing towards the teeth on the pulley. 8. Loosely install the clamp screws in the clamps. 9. Pull both ends of the new belt tightly together and slip the ends of the belt between the clamps so that the teeth in the clamp mesh with the teeth in belt. Tighten the clamp screws. 10. Move the belt so that the clamped ends of the belt are inside the carriage structural assembly. 11. Install two screws through structural assembly into the belt clamps. Tighten the screws to secure the belt clamps to the structural assembly. It is possible to install the clamp backwards. If the clamp is installed backwards, it will stick out from behind the carriage structural assembly. When installed properly, you cannot see the clamp when looking at the carriage structural assembly. 12. Tighten the upper and lower Y-axis belt adjusting screws by alternating between the upper and lower screws, one full turn at a time, until the Y-axis belt is vertical in the cross tube. 13. Replace the chain guide in the cross tube by sliding the guide into the cross tube and then squeezing the legs of cross tube into the slots on the cross tube. 14. Lubricate the belt using Elmers Slide-All Dry Spray Lubricant or equivalent as described in Paragraph 7.3.22.2. 15. Install the keypad and festoon end covers using the six screws removed in Step 2.
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16. Using the Calibrate Machine dialog box described in Section 6, do as follows: a. Home the machine. b. Set the Y Scale Factor calibration. c. Check the Y-axis Belt. 1) Click the Check Y-Axis Belt command button in the Calibrate Machine dialog box to display the Adjust Y-Axis Belt Tension dialog box. 2) Click Proceed. 3) Press the ENTER button on the keypad to start the Y-axis assembly moving. 4) As the belt is moving, turn the adjustment screws on the Y-axis drive idler assembly until the belt moves smoothly between the flanges. The belt should ride evenly between the two flanges, and not favor either side. When adjusting the two screws, turning one screw one half turn, then turning the other screw one half turn. This will ensure the tension is maintained equally. Listen for the sound of the Y-axis motor to change. This can indicate too much tension is applied to the belt.
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7.3.27.5
Replace and Adjust the Theta Drive Belt
Use the following procedure to replace and adjust the theta axis drive belt on both the two-headed and three-headed Theta Axis Assemblies, A-CR2-202 and A-CR2-188 (DCS 1500/2500), A-CR2L-215 (Taurus). The belt should be replaced as recommended in Table 7-1 and Table 7-2 Refer to the Theta Axis Assembly exploded views in the Cutting Edge DCS 1500/2500 GERBERcutter Engineering Drawings manual or Cutting Edge Taurus TLCS GERBERcutter Engineering Drawings manual and do as follows: 1. Set the machine power OFF at the control cabinet. 2. Remove the cover from the Y-axis assembly to gain access to the theta axis drive belt by removing the eight screws, F-1495. 3. Support the Theta Axis Motor Assembly, A-CR2-194 and remove the four mounting screws, F-1435; lock washers, F-1435; and flat washers, F-0901. 4. Tilt the motor and remove the old theta axis drive belt. 5. Confirm that the tool holders are oriented as follows when looking down on assembly as shown in Figure 7-12: a. Tool holder 2 should be oriented so that the dimple on tool mount faces 7:30 oclock. b. Tool holder 1 should be oriented so that the dimple on tool mount faces 4:30 oclock. c. On three-headed theta axis assemblies tool holder 3 should be oriented so that the flat on the tool mount faces 6:00 oclock. 6. Install the new theta axis drive belt. 7. Install the theta axis motor using the fasteners removed in step 3.
FIGURE 7-12 THETA AXIS BELT ADJUSTMENT
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8. With the fasteners loose, refer to Figure 7-12 and tighten the drive belt as follows: a. Insert the hex end of the blue T handle 2.5 mm hex key wrench from the keypad side of the theta axis assembly as described in following paragraphs. b. Insert the wrench under the belt, in front of hoses and wires, behind the Motor Pulley, CR2-033, above the motor support screw head and rest the tool tip on the Theta Axis Bearing Hub, A-CR2-300, for Tool Holder 2. c. Keep the wrench above the theta motor screws and just below the pulley flange. Do not rest the wrench against the pulley teeth. d. Pull the hex wrench back against the bottom of the motor pulley to tighten the belt until the hex tool shaft is even with the right rear corner (keypad side, origin end) of the theta axis motor bracket. e. While pulling back with the tool, slightly lift up on the tool to keep the tip of the tool on the bearing hub. f. Tighten the motor mount fasteners.
9. Install the Y-axis assembly cover using the eight screws removed in step 2.
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Section
Troubleshooting
8-2
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8.1
GENERAL
This section provides the instructions for troubleshooting a Cutting Edge DCS 1500, DCS 2500, or Taurus TLCS GERBERcutter. In general, this section provides troubleshooting and diagnostic procedures that are useful for identifying and repairing machine malfunctions. 8.2 INTRODUCTION
A thorough working knowledge of the Cutting Edge Software and the machine operational characteristics are the most important aids to troubleshooting. Also, maintenance personnel should be properly trained in and be familiar with personal computer operation and cutting machine theory. If a problem occurs on the DCS 1500/2500, the service technician should first check the most recent history of the machine. If there have been no unusual procedures performed on the machine the technician should follow the procedures called out in the following check of basic machine operation and specific system diagnostic tests. The following troubleshooting procedures are included: General software and hardware check, Check of basic machine operation, Specific system diagnostic tests. Prior to performing a diagnostic procedure on the machine, the following software and hardware checks should be made. If there have been recent changes made to the system, call your Gerber Technology Customer Support Representative. Some of the things to consider before starting the troubleshooting procedures are the following: When was the last successful cut job performed, overnight, the previous shift? Did anyone see the machine fail, and if so, what was it doing? What was the software doing and where were the tools? Did the machine hit something? When was the last complete calibration performed? Was there a recent installation of heavy equipment, and if so, when?
Section 8.0: Troubleshooting
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8.3
SOFTWARE CHECKS
If the Cutting Edge Software can be opened on computer, check the software configuration as follow: 1. Click Base Module Help menu. 2. Click on About Cutting Edge Software. 3. Confirm that latest software configuration is being used by checking with your Gerber Technology Customer Support Representative. 8.3.1 CHECK DIRECTORY FOR CUTTING EDGE SOFTWARE
In Windows Explorer, confirm that the Cutting Edge Software is loaded into the C:\CEI directory and that only one version of the Cutting Edge Software is loaded. Also, confirm that there is only one version of the CEI.INI file on the personal computer. Use the following procedure to check for the locations of files and directories. Consult your Windows Users Guide for additional information on the use of Explorer to search for and delete files and directories. 1. From the Windows desktop, click the Start button on the taskbar, then Find, then select the Files or Folders command. The Find: All Files dialog box opens. The Find: All Files dialog boxes for Windows 95, Windows NT, and Windows 98 are shown in Screen 8-1. This dialog box is used to search for files on your computer. SCREEN 8-1 FIND: ALL FILES DIALOG BOX
Windows 95/NT 2. Type CEIBASE.EXE in the Named text box.
Windows 98
3. In the Look in text box, type C:\ to search the root directory. To search for the file on another drive, click the arrow to the right of the text box and select that drive. 4. Select the Include subfolders check box.
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5. Click Find Now to search. The Find: Files named ceibase.exe dialog box is displayed with directories for filename listed. Refer to Screen 8-2. SCREEN 8-2 FIND: ALL FILES DIALOG BOX WITH LOCATED FILES
6. Confirm that CEIBASE.EXE is only in the CEI directory and the CEI\backup directory. If not, delete all versions of CEIBASE.EXE that are not in the CEI and CEI\backup directories. 7. Click New Search to reset Find: dialog box. 8. Type CEI.INI in the Named text box. 9. Tab down to the Look in: text box and type C:\ to set root directory. 10. Select the Include subfolders check box. 11. Click Find Now to search. 12. Confirm that the CEI.INI file is only in the C:\ CEI and CEI\backup directories. If not, delete all versions of CEI.INI that are not in the CEI and CEI\backup directories. If you want to save a copy of the CEI.INI file, save to a separate floppy disk. 13. Click File and Close to exit Windows Explorer.
8.3.2
CHECK FOR RECENTLY LOADED SOFTWARE
Confirm that new software of any type was not recently loaded on the personal computer that controls the Cutting Edge machine.
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8.4
HARDWARE CHECKS
Check that new add-on cards or other hardware has not been recently installed on the personal computer. Also, check that any previously installed add-on cards, such as a network card, are operating properly. If not sure, remove card from computer to confirm that the card is not creating a system conflict. Call your Gerber Technology Customer Support Representative if this system conflict exists. Check that equipment, personal computer, control cabinet, or table and carriage assembly, have not been moved recently or that the operating environment has not changed appreciably. 8.5 CHECK BASIC MACHINE OPERATION
Use the following diagnostic procedures after confirming that there have not been any recent changes to the machine software and hardware. If a more detailed procedure is required, call your Gerber Technology Customer Support Representative for additional information. Use the following checklist to check the basic cutting machine system operation. ! Exit all applications including Windows by clicking Start and Shut Down commands ! Select Shut down to shut down. ! Set the power to OFF at the control cabinet and personal computer. ! Set the power to ON at the control cabinet. Check that the SYSTEM ENERGIZED light on the control cabinet and fan are on. If the fan and the light do not turn on, check for power to the control cabinet. ! Turn the computer on. The computer might turn on when you turned on the power at the control cabinet.
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Double click the Cutting Edge Software icon on the desktop. Confirm that software starts, and the System Status dialog box appears. If not, check that the program is loaded and that icon (shortcut) Properties are correct. Right-click the Cutting Edge Software icon to display menu and left click on Properties to display dialog box shown below. Properties in Target should read C:\CEI\CEIBASE.EXE. SCREEN 8-3 CUTTING EDGE ICON PROPERTIES
! Press the E-stop button on the carriage to confirm that the servo motors are offline. Turn the E-stop button clockwise to release the button. ! Move the carriage back and forth manually to confirm that the linear bearings are not binding and that the carriage moves freely. Racking or twisting is caused by moving one end of the carriage in the X-axis more than the other. Move the carriage approximately three feet from the origin end of the table by pushing the middle of carriage beam. Push the carriage in the middle of the beam to avoid racking or twisting the carriage. ! Move the Y-axis assembly back and forth manually to confirm that the linear bearings are not binding and that the assembly moves freely. Move the Y-axis assembly approximately two feet from the origin end of the table. ! Rotate the Theta axis turn to confirm that the axis moves freely. ! Only the POWER ENGERGIZED status light should be illuminated on the control cabinet at this point. If one or more of the MOTOR STATUS lights are illuminated, check the signal circuit between the servo motion controller and the motor using additional troubleshooting procedures or contact your Gerber Technology Customer Support Representative.
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! When the System Status dialog box is displayed, do as follows: Press RESET on control panel and then press RESET on status board. The System Status dialog box closes and the SYSTEM ENERGIZED light on the control cabinet and the SYSTEM ONLINE light on status board lights are on. If not, check on the control cabinet status board for E-STOP STATUS lights. If the E-STOP STATUS light is on, 1. Check the E-stop buttons. Turn all buttons clockwise to release the button. 2. Check the limit switches. Clear the limit switches by moving the Y-axis assembly to the center of the carriage and moving the carriage three feet from the origin end of the table. Push the carriage in the middle of beam to avoid racking the carriage by moving one end of the X-axis more than other. Do not push the bumper arms on the keypad and festoon covers. 3. Confirm that the bumper arms are not in contact with another object. 4. Confirm that any optional interlock is not actuated. If an optional interlock is not used, confirm that the external interlock connector, DB9 with a shorting jumper from pin 1 to 2, is installed on the back of the control cabinet. See the Wiring Diagram, in the Cutting Edge DCS 1500/2500 GERBERcutter Engineering Drawings or Cutting Edge Taurus TLCS GERBERcutter Engineering Drawings manual. ! With the machine on line, check that all servos are on line as follows: 1. Check the X-axis by gently pushing on the festoon and the keypad covers to confirm that the servos respond by pushing back and making a low growl. Do not push on the cover bumpers. 2. Check the Y-axis by gently pushing on the Y-axis assembly to confirm that the servo motor responds by pushing back and making a low growl. 3. Check the theta axis by turning one of the tool holders to confirm that the servo motor responds by turning back and making a low growl.
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! Home the machine by clicking the Machine menu, then selecting the Home Machine command. After machine is at home position, verify that the pointer is at the machine origin position as marked on table. The carriage should move as follows: NOTE If the machine drops offline prior to completing the following procedure, note the step in the sequence and contact your Gerber Technology Customer Support Representative. 1. Both in the X-axis and the Y-axis in the positive direction to clear homing sensors. 2. In the X-axis in negative direction, stopping at the X-axis homing sensor signal. 3. In the X-axis slowly in positive direction until the X-axis festoon side index pulse signal is sensed. The carriage continues moving slowly along the X-axis in positive direction, stopping at the X-axis keypad side index pulse signal. 4. In the Y-axis negative direction, stopping at the Y-axis homing sensor signal. 5. In the Y-axis slowly in the positive direction, stopping when clear of home sensor. 6. If the theta axis is not already located on the index pulse (home position), the theta axis will turn and stop on the index pulse. 7. In the X-axis on keypad side in either the positive or negative direction to square the carriage. If the keypad side X-axis servo moves a noticeable amount (more than 1/8 th inch/0.32cm) or the servos go off line during the squaring move, square the carriage in accordance with procedure in step 1 of next paragraph. 8. In both the X-axis and Y-axis in negative direction amount of offset shown in the Configure Machine dialog box, plus the previous move to find X-axis index pulses. (The Local Mode Speed setting in the Configure Machine dialog box determines the axes speed.) Then the carriage moves along the Y-axis in positive direction approximately 1.1 inches (2.8cm) so that the pointer is at machine origin. The carriage is then at machine origin.
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! Press the E-stop button on keypad cover to turn servo system off line. Observe the carriage movement when pressing the button to see if the carriage beam racks or twists when the servo power is turned off. If the carriage racks, square the carriage as follows: 1. Turn the E-stop button on the keypad cover clockwise to release the button. 2. Exit all applications including Windows. 3. Set the power OFF at the control cabinet and the personal computer. 4. Move the carriage approximately three feet (1 meter) from the origin end of the table by pushing in the middle of the carriage beam. 5. Set the power ON at the control cabinet. 6. Set the power ON at the computer including the display terminal. 7. Double-click the Cutting Edge Software icon. Confirm that the software starts and the System Status dialog box appears. 8. Press the blue RESET button on the control cabinet to energize the servo system amplifiers and the control system circuit. The SYSTEM ENERGIZED light on the Control Panel goes on to indicate that the system is energized. Then press blue the RESET button on the status board to bring the servo system motors online. The SYSTEM ONLINE light on the status board turns on. 9. Click the Machine menu then select click the Setup command to display the Setup dialog box. 10. Click the Cutter button in Calibrate group to display the Calibrate Machine dialog box. 11. Click the Square Carriage button to display the Square Carriage dialog box. 12. Follow the procedure in the Square Carriage dialog box, except at end of procedure press the Enter key on keyboard to make a correction of zero (0). The machine follows the homing procedure and then goes to home position. NOTE Making a correction of zero in the Square Carriage calibration sets the initial value of the offset between the keypad side and festoon side X-axis encoder index pulse. 13. Click Square Carriage to display Square Carriage dialog box again. 14. Follow the procedure in the Square Carriage dialog box. This time measure and type the correction. Press Enter on keyboard. 15. Observe that the machine moves to home position correctly. If the machine does not home correctly, call your Gerber Technology Customer Support Representative. 16. Press the E-stop on keypad cover to see if the beam racks or twists. If there is racking, repeat steps 1 through 15. After the third attempt, call your Gerber Technology Customer Support Representative.
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! Check theta axis as follows: 1. Set all pressures to 15 psi. 2. Remove the cover from the Y-axis assembly by removing the eight screws (DCS 1500 and DCS 2500) or the ten screws (Taurus). See the Y-Axis Carriage Parts figure in the Cutting Edge DCS 1500/2500 GERBERcutter Engineering Drawings manual or the Leather Carriage Assembly Cutter/Camera Head figure in the Cutting Edge Taurus TLCS GERBERcutter Engineering Drawings manual. 3. Home the machine and note the position of the keyway on the Theta axis. Place a reference mark on the tool holder bracket corresponding to the keyway location. 4. With the machine power ON, press the E-stop button on the control cabinet. 5. Turn the E-stop button on the control cabinet clockwise to release the button. 6. Turn the Theta axis approximately turn. 7. Press the blue RESET button on the control cabinet to energize the servo system amplifiers and control system circuit. The SYSTEM ENERGIZED light on the control cabinet goes on to indicate that system is energized. 8. Press any one of the buttons on the keypad to make the System Status dialog box appear on the computer screen. 9. Press the blue RESET button on status board to bring servo system motors online. CAUTION Do not press the RESET button on the control panel unless the System Status dialog box is displayed on the computer screen. Pressing RESET without ensuring the System Status dialog box is displayed will cause the carriage to move and may injure an operator in the path of the carriage. 10. Home the machine by clicking the Machine menu, then selecting the Home Machine command. 11. Confirm that the Theta axis returns to the same position noted at the beginning of the procedure. 12. Repeat steps 3 through 10 to make re-check the Theta axis. 13. If there is a problem with the theta axis, check the theta axis encoder circuit or call your Gerber Technology Customer Support Representative.
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! Go into jogging mode and move the carriage as follows: 1. At the keypad, go into Jogging mode as follows: a. Press the Up or Down arrow button to go into Local mode. b. Press the ENTER () button to go into Jogging mode. 2. Jog the carriage along the X-axis in the positive and negative direction by moving the joystick side to side. 3. Confirm that the carriage moves smoothly and stops when joystick returns to the neutral position (centered in rubber bellows). 4. Jog the carriage along the Y-axis in the positive and negative direction by moving the joystick up and down. 5. Confirm that the carriage moves smoothly and stops when the joystick returns to neutral position (centered in rubber bellows). 6. If the carriage moves along either axis when the joystick is in the neutral position, check the joystick system using additional troubleshooting procedures or call your Gerber Technology Customer Support Representative.
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8.6
SYSTEM DIAGNOSTICS
The following procedures describe the system diagnostics, which are a series of dialog boxes to check various electrical and mechanical components on the machine. To start the system diagnostics and display the menu shown in Screen 8-4 , do as follows: 1. Close the Cutting Edge Software. 2. Click the Start menu, select Programs, then select the Cutting Edge Software command. The Cutting Edge menu appears. 3. Click the Diagnostics command. The screen shown in Screen 8-4 appears. SCREEN 8-4 DCS 2500 DIAGNOSTIC MENU
The following is a list of the available Offline Tests: Joystick Signal Test - Checks the voltage readings with the joystick in the neutral and extreme positions. Input / Output Test - Checks the input and output signals to and from the servo motion controller in the computer. Encoder Test - Checks the encoder signals to the servo motion controller in the computer. Keypad Test - Checks the operation of the keypad keys. Servo Motion Controller Info - Checks and displays the model number and revision level of the board. Index Pulse Test - Checks that the servo motors find the location of the index pulse.
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The following is a list of the available Online Tests: Homing Sequence Tests Checks the homing sequence by stepping through the procedure. X/Y Festoon Test - Checks the integrity of the cables in the X and Y-axis festoons. Theta Torque and Run Out - Measures and displays the servo motor torque required to move the theta axis. Also, rotates the tool holders in the extended position to locate a tool holder with a bent shaft. Servo Torque Values - Measures and displays the servo motor torque required to move the X, Y, and theta axes. In addition to the diagnostic menus, the TALK2BUS troubleshooting commands are available and can be typed starting at the white square at the bottom left side of the screen. The following paragraphs include a short description of the available dialog boxes. Consult your Gerber Technology Customer Support Representative for additional information on the use of the diagnostics dialog boxes. Click Exit to close DCS 2500 Diagnostic Menu.
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8.6.1
OFFLINE TESTS
Use the following offline tests available in the Offline Tests menu. 8.6.1.1 Joystick Signal Test Use the Joystick Signal Test dialog box in the Offline Tests menu to check the signals from the joystick on the keypad to confirm that the circuit is operating properly. The purpose of this test is to measure the voltage signal from the joystick. The voltage is measured and displayed with the joystick in the neutral position and then with the joystick fully deflected. Refer to Screen 8-5. With the joystick in the neutral position, the cross hairs should be centered in the middle box. If not, the machine will creep or jog when in jog mode. With the joystick fully deflected, the cross hairs should be on the outside of the larger box. If not, the machine will move slower or erratically when jogging in that direction. SCREEN 8-5 JOYSTICK SIGNAL TEST DIALOG BOX
Joystick X or Y= Done
Voltage being output by joystick in X and Y axes. Click Done button to close dialog box.
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8.6.1.2 Input / Output Test Use the Input / Output Test dialog box in the Offline Tests to check the input and output signals to and from the servo motion controller in the computer. These signals are used to communicate between the Cutting Edge Software on the computer and the input and output devices on the cutting machine. When a faulty input or output device is suspected for stopping the machine, use the Input / Output Test dialog box to check for signal integrity. In the dialog box shown in Screen 8-6, indicators in white are inactive and indicators in black are active. SCREEN 8-6 INPUT / OUTPUT DIALOG BOX
Inputs
The Inputs group lists the inputs that are available from the machine to the servo motion controller. When an input is enabled (Active), the letters turn from white to black. The Outputs group lists the outputs that are available from the servo motion controller to the machine. When clicking the Cycle button activates an output, the output lettering changes from white to black. In the case of the tools, the corresponding Hall sensor should also become active when the tool is cycled. Click Done button to close dialog box.
Outputs
Done
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8.6.1.3 Encoder Test Use the Encoder Test dialog box in the Offline Tests to test the signal that is generated by the encoder back through the encoder circuit to the servo motion controller located in the computer. In the following procedure, the axis being tested is moved a known amount and the number of counts from the encoder is recorded in the dialog box. Compare the number of counts in the dialog box with the correct number of counts to determine if the offline encoder signal is correct. Refer to Screen 8-7. SCREEN 8-7 ENCODER TESTS DIALOG BOX
Motor XF, XK, Y, T Zero All Done 8.6.1.4 Keypad Test
Axis encoder count for axes being moved. Click Zero All button to set all encoders to (0) zero. Click Done button to close dialog box.
Use the Keypad Test dialog box in the Offline Tests to test the operation of the keypad keys. The keypad keys send a command to the computer. Press each key on keypad at machine and confirm that corresponding key on screen shown in Screen 8-8 illuminates. Also, confirm that machine Com Port is set to correct port in Configure Machine dialog box. SCREEN 8-8 KEYPAD TEST
Click Done button to close dialog box.
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8.6.1.5 Servo Motion Controller Info Use the Servo Motion Controller Info in the Offline Tests to confirm the model number and revision level of the servo motion controller located in the computer. Refer to Screen 8-9. SCREEN 8-9 SERVO MOTION CONTROLLER INFO DIALOG BOX
Click Done button to close dialog box. 8.6.1.6 Index Pulse Test Use the Index Pulse Test dialog box in the Offline Tests to confirm that the servo motor finds the location of the index pulse and that the signal is sent to the servo motion controller located in the computer. Refer to Screen 8-10. To find the index pulse, press the appropriate button and slowly move the axis being tested until the screen displays a message indicating that the index pulse is recognized by the servo motion controller. Then click the button for axis being tested again to zero Motor Position. Move the same axis until message for index pulse is again displayed. Reading should be approximately 4000. SCREEN 8-10 INDEX PULSE TEST DIALOG BOX
Find Axis Index Done
Click button for motor being tested. Buttons are grayed out and Motor Position is (0) zero. Click Done button to close dialog box.
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8.6.2
ONLINE TESTS
The following Online tests are available in the Online Tests menu. 8.6.2.1 Homing Sequence Tests Use the Homing Sequence Tests dialog box in the Online Tests to step through the homing sequence one step at a time. This procedure is used to test the homing sequence to confirm that all homing target inputs are being located properly. Refer to Screen 8-11. SCREEN 8-11 HOMING SEQUENCE TESTS
X Clearing Move Y Clearing Move
Click the X Clearing Move button. The carriage moves along the X-axis in the positive direction approximately 10 inches to clear the homing sensor. Click the Y Clearing Move button. The carriage moves along the Y-axis in the positive direction approximately 6.5 inches to clear the homing sensor.
Find X Home Sensor Click the Find X Home Sensor button. The carriage moves along the X-axis in negative direction and stops at the X-axis homing sensor signal. Find XF Index Click the Find XF Index button. The carriage moves along the X-axis slowly in positive direction not more than 1 inch until the X-axis festoon side index pulse signal is sensed. The carriage stops moving on the festoon side index pulse signal. Click the Find XK Index button. The carriage moves along the X-axis slowly in the positive direction not more than 1 inch until the X-axis keypad side index pulse signal is sensed. The carriage stops moving on the keypad side index pulse signal.
Find XK Index
Find Y Home Sensor Click the Find Y Home Sensor button. The carriage moves along the Y-axis in the negative direction and stops at the Y-axis homing sensor signal. Find Theta Index Click the Find Theta Index button. If theta axis is not already located on the index pulse (home position), the theta axis will turn not more than one revolution and stop on index pulse. Click the Done button to close the dialog box.
Done
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8.6.2.2 X/Y Festoon Test Use the X/Y Festoon Test dialog box in the Online Tests to test the integrity of the cables in the X and Y-axes festoons. The X/Y Festoon Test dialog box shown in Screen 8-12 allows the operator to actuate one or more of the tools. The machine may be jogged in the X or Y-axis direction, or jog the theta, to determine if there is an intermittent break in one of the festoon cables. Additionally, the X and Y-axes position can be set to zero at any time as a reference so that the machine can be returned to that same position. SCREEN 8-12 X/Y FESTOON TEST DIALOG BOX
Machine Status
Use the Machine Status group to zero and display the X and Y encoder counts for the Y-axis assembly. Click Zero button at any time to zero the X and Y encoder counts. Use the Tool Status group to cycle the tools and pen down and up. At the same time the tools are cycled using the Tool Down / Up buttons in the Outputs column, the appropriate Hall sensor in the Input column is cycled from white to black. Black indicates the Input is active. An active Hall sensor means that the sensor is enabled. Click the Tool Down button to cycle the tool down and click the Tool Up button to cycle tool up.
Tool Status
Jog Theta Jog Carriage
Click the Jog Theta button to rotate the theta axis motor clockwise at 500 counts per second. Click the Stop Theta button to stop the Theta rotation. Click the Jog Carriage button to enable the joystick. Move the joystick up or down to jog the Y-axis assembly along carriage. Move the joystick left or right to jog the carriage along the table. While jogging, observe the Y-axis assembly suspected input or output for intermittent operation. If the tool or the Hall sensor cable is suspect, the black active indication on the screen will flicker. If the theta motor is suspect, the theta axis will operate erratically or machine will drop off line. Click Done button to close dialog box.
Done
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8.6.2.3 Theta Torque and Run Out Use the Theta Torque and Run Out dialog box in the Online Tests to rotate the theta axis while each of the tool holders is in the retracted position and the extended position. Observe the torque readings while the theta axis is turning to determine the maximum torque. Set the theta to the home position and zero the Position reading, by clicking the Theta Home button. Torque is shown on the graph in Screen 8-13 using the following: Negative readings are counterclockwise, Positive readings are clockwise, Light red indicates the maximum reading, which can be reset to zero using the Reset Max button, Blue is the average torque reading for approximately the last second, Dark red is the instantaneous torque reading.
To locate the exact location of the shaft bend use a block and the dial indicator. While the tool holder is rotating, compare the location of the tool mount to a block placed on the table. After locating the peak of the tool mount bend, bend the shaft back in position using the procedure supplied by the Gerber Technology, Cutting Edge Division. SCREEN 8-13 THETA TORQUE AND RUN OUT DIALOG BOX
Theta Torque Position Tool Down/Up
The instantaneous torque reading for the theta axis. The indicated position in degrees from theta axis home position. Click the Tool Down/Up button to move the tool up or down. When the button reads Tool Up, the tool is in the lowered position. When the button reads Tool Down, the tool is in the raised position. Click the Theta Home button to move the theta axis to the home position. Click the Reset Max button to reset the maximum torque reading shown in light red to zero. Click the Done button to close dialog box.
Theta Home Reset Max Done
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8.6.2.4 Servo Torque Values Use the Servo Torque Values dialog box in the Online Tests to measure the torque required to move the X, Y, and theta axes along their complete length. If a faulty servo axis motor is causing the servo system to trip off due to excessive X, Y, or theta axis torque, the motor can be identified using the following test. When performing the test on the X-axis, jog the carriage along the length of the table. Jog the Y-axis assembly along the length of the carriage. The theta axis turns in a clockwise direction. During the moves, the machine measures and displays the torque required to move the axes by measuring the servo motion controller command voltage required to move the motor. Refer to Screen 8-14. SCREEN 8-14 SERVO TORQUE VALUES DIALOG BOX
Torque Values
The Torque Values group displays the maximum and instantaneous torque value as the axes are moving. The dark red line indicates the instantaneous torque and the light red line indicates the maximum torque. The instantaneous value is also displayed on the right side of the graph. The Torque Limits group is used to reset the limits of the maximum torque that is allowed during the troubleshooting process. After setting the maximum limit for the axis being tested, click Set Limits button. The Jog group includes buttons to start and stop jogging the carriage and theta axes. The Carriage and Stop buttons are used to jog the carriage axis. Click the Carriage button to enable the joystick on the control panel. The Carriage button is grayed out and the Stop button is in black. The X or Y-axis can then be jogged using the joystick. The torque values for the axis being jogged are displayed in the graph on the screen. Additionally, LCDs on the keypad display a graph of the torque reading with one bar representing one volt. The Theta and Stop buttons are used to start and stop jogging the theta axis. Click the Theta button to jog the theta axis. Theta axis turns clockwise continuously at 500 counts per second until Stop button is clicked. To reset the maximum torque readings to zero, click Reset Max button. Click the Done button to close dialog box.
Torque Limits
Jog Carriage
Theta
Reset Max Done
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Section
Vendor Documentation
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9.1
GENERAL
The vendor documentation section contains selected pages from vendor manuals which describe vendor supplied assemblies that are used on the Gerber Cutting Edge DCS 2500. The vendor manuals are included to provide operator and service personnel with additional information to be used for both maintenance and part replacement. 9.2 NEMATRON INSTRUCTION MANUAL
The installation and service guide for the Nematron keypad is included. 9.3 IMATRONIC APPLICATION NOTE
The Imatronic application note for the Diode Laser is included.
Section 9.0: Vendor Documentation
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DCS 1500-2500 and Taurus User Guide

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A-D-042 12/2000

CUTTING EDGE DCS 1500/2500 MECHANICAL and TAURUS TLCS GERBERcutter

DCS 1500/2500 Mechanical and Taurus TLCS

DCS 1500/2500 Mechanical and Taurus TLCS

DCS 1500/2500 Mechanical and Taurus TLCS

DCS 1500/2500 Mechanical and Taurus TLCS

GLOSSARY ............................................................................................................... 10-1 LIST OF TERMS ........................................................................................................ 10-3

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DCS 1500/2500 Mechanical and Taurus TLCS

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DCS 1500/2500 Mechanical and Taurus TLCS

DCS 1500/2500 Mechanical and Taurus TLCS

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DCS 1500/2500 Mechanical and Taurus TLCS

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DCS 1500/2500 Mechanical and Taurus TLCS

Section 1.0: Introduction

DCS 1500/2500 Mechanical and Taurus TLCS

SYSTEM ENERGIZED RESET AC POWER PEN TOOL HOLDER 1 TOOL HOLDER 2

Section 1.0: Introduction

) performs various functions depending on the

DCS 1500/2500 Mechanical and Taurus TLCS

Danger electrical shock potential Friction hazard

CL-004-2 (Control Cabinet)

CL-005-3 (Control Cabinet)

Figures 2-24 and 2-25 Carriage

Figure 2-16 Carriage Beam

Figure 2-27 (Carriage)

Figure 2-14 (Carriage Assembly)

Figure 2-9 Carriage

Figure 2-11 (Festoon Cover)

Section 1.0: Introduction

DCS 1500/2500 Mechanical and Taurus TLCS

1.3 MANUAL DESCRIPTION

Section 1.0: Introduction

% Telephone number: % CEI Customer Service Number: &

DCS 1500/2500 Mechanical and Taurus TLCS

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DCS 1500/2500 Mechanical and Taurus TLCS

Section 2.0: Installation

DCS 1500/2500 Mechanical and Taurus TLCS

FIGURE 2-1 TYPICAL DCS 1500 INSTALLATION

Section 2.0: Installation

FIGURE 2-3 TYPICAL TAURUS INSTALLATION

DCS 1500/2500 Mechanical and Taurus TLCS

Section 2.0: Installation

DCS 1500/2500 Mechanical and Taurus TLCS

Section 2.0: Installation

DCS 1500/2500 Mechanical and Taurus TLCS

Section 2.0: Installation

DCS 1500/2500 Mechanical and Taurus TLCS

Section 2.0: Installation

DCS 1500/2500 Mechanical and Taurus TLCS

Section 2.0: Installation

DCS 1500/2500 Mechanical and Taurus TLCS

Section 2.0: Installation

DCS 1500/2500 Mechanical and Taurus TLCS

Section 2.0: Installation

DCS 1500/2500 Mechanical and Taurus TLCS

COM Port Calibration Grid

Section 2.0: Installation

DCS 1500/2500 Mechanical and Taurus TLCS

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* DCS 2500 * Online E-Stop