User Manual - Arrow Digital
Contents
1. 35 Support information 2 Symptoms plotter adjustment 50 51 55 58 62 T Toner en ns 10 41 Tool force 19 20 adjustments co cocococonoconoconacononannccnnonono 20 logbook cirie a 20 A 19 27 Tool holders ereraa ideia 21 Tool rack molded 22 Tool storage 21 Trouble shooting guide 50 V Mi tostadas 15 45 W Wagon Wheel Test Plot 38 39 X X Axis backlash adjustment cece 55 X Y Theta axes lock diagnostic nn 38 lock time out nenen 42 X Y Z axes lock diagnostic nn 38 lock time out nneen 42 Y Y axis backlash adjustment 58 Z Z axis tool height adjustment 512. SWAP mode and cut a test plot If symptoms persist repeat the Adjustment Procedure Replace the front cover 57 58 GSx Y Ax s Backlash Adjustment SYMPTOMS Text cut in NORMAL mode has closure problems OBJECTIVE To adjust the mesh of the jack shaft gear with the Y motor pinion to produce good letter quality in NORMAL mode ADJUSTMENT PROCEDURE 1 Turn the plotter power off 2 Remove all tools and material from the plotter 3 To remove the front cover lay the GSx on its side and remove the 2 Phillips head screws on the bottom edge closest to the front of the plotter Then stand the plotter upright Plotter Adjustments 59 Pull the front cover upwards and at the same time pull one side away from the plotter frame Be careful not to lift the cover so high that the front panel cable disconnects Pivot the cover to the side of the plotter 60 GSx 6 Locate the jack shaft gear and the Y motor pinion These two gears are meshed together Gently attempt to rotate the jack shaft gear With one finger on the motor pinion notice ifthe jack shaft gear moves while the pinion remains stationary Ifthe pinion moves with the jack shaft gear so there is no backlash go to the section for Drum End Play Adjustment If the Y motor pinion remains stationary so there is backlash locate the two Phillips head screws Only one screw is visible Loosen these screws which hold the Y motor bracket against t
3. or keyway in the barrel of the knife holder ensures proper orientation If necessary rotate the knife holder until it drops completely into the carriage spindle When the knife holder is in place swing the tool force arm and snap it into place over the cone shaped cap Select a tool force setting appropriate for material and blade Approximate tool force settings for cutting other vinyl materials are listed in the chart below See Plotter User Reference Card Tools and Tool Handling 27 SUGGESTED TOOL FORCE SETTINGS Material Recommended GS Plotter Starting Tool Force Swivel Knife Controltac 180 Delux 210 Gold Silver Dusted Crystal 210 Florescent 210 Scotchcal 220 Translucent 230 Gerber Cal Gerber IP Plus Gerber Mask I amp II Heat Transfer Flock Hot Split Plastisol Metalized Polyester Screen Print 35 Static Cling Sandblast 521 Not recommended for use with GSx Sandblast 522 To determine if adjustment of the tool force setting is required consider that m The weed should peel off easily m There should be no cuts through the backing material Use the minimum tool force setting that cuts satisfactorily Too much force will reduce edge quality BLADE REPLACEMENT One carbide knife blade is included with the Gsx Additional knife blades can be ordered through your distributor For ordering information contact Gerber Customer Service at 800 222 7446 or 860 643 1515 WARNING The blade
4. spindle When the pen holder is in place swing the tool force arm and snap it over the cone shaped cap 5 For plotting start with a tool force setting of about 5 See Plotter User Reference Card If the pen does not make a clear dark line increase the tool force setting Tools and Tool Handling 23 PEN REPLACEMENT Spare pens in blue and red are included in the tool kit Additional pens are available through a Gerber distributor To replace a pen 1 Insert a flat tip screwdriver into the notch at the base of the cone shaped cap see below Pry out the cap 2 Use the Allen wrench supplied with the tool kit to loosen the hex screw located near the tip of the pen Remove the pen through the top of the holder 3 Insert a new pen tip first into the top of the holder 4 The pen height gage included with the tool kit is a washer 1 8 thick Place the pen height gage on a smooth hard surface like a table top Position the lower end of the pen holder on the gage 24 GSx 5 Push down on the upper end of the pen until the point just touches the table surface 6 Use the Allen wrench to tighten the set screw near the tip of the pen Do not over tighten the set screw or the pen could be crushed 7 Replace the cap in the barrel Tools and Tool Handling 25 Knife Holder and Blades Gerber blades are extremely wear resistant In testing over 10 000 one inch letters were cut using a single blade before testi
5. Ban 12 Delete Plotters a ae ee 12 Assign Default Plotter nn ennn nn 13 MATERIALS AND TOOLS anni tn ne ra ann Radar 15 Materials aa lio ale 15 SN satten 18 TOA A o 19 A A EA 19 Adjustments a N ni A ETE 20 TOOLS AND TOOL HANDLING occonccccnnnncnnncnnnnnnconncnoncnnonnnnonanonnnnoconanonnnnonn nn cana nccnnnconnos 21 SOLA da EE E T E AETA dd 21 Tool Holders iia aaa rr Aa a 21 Pen Holderand Ponar arae E E tow bod E E een 22 Pen Replacement ui ts a a en 23 Knife Holder and Blades oserei AE AEA 25 Blade Wear dinin ean mean RAD 25 Blad Damage rss ran aan 25 Knife Holder Installation 26 Suggested Tool Force Settings 27 JEAN nenn 28 OPERATION Re rn Ri Na ln AE LU 29 Power Up ras Rien tnt der ee 29 Front Paneline erensia iee tan 30 SAN C A EE asa 31 SLOW SLEW KOY leder en cents 31 INIT KNIFE Keys tea aa a ia 32 RUN SINGLE Key aaa ae 32 RUN CONT Key ee ek Re bein 33 RESET Key wen sa Hanser 35 SPECIAL DIAGNOSTIESE a nee 37 Diagnostic Op ici iii lies 37 Wagon Wheel Test Plot 38 Square Circle Test Plot 39 ERROR CONDITIONS a need 41 Error Codes tc iO ro 42 MAINTENANCE Eras nee 43 Cleaning and Lubrication ss 43 Tool Holders and Carriage Spindle Bore nneeeeneen 43 Carr
6. Double click on the Control Bar to exit the GSP Setup Menu The system will return to the GSP GRAPHIX ADVANTAGE program group and you can now access the GSx plotter Multiple plotters can be added to your system They must be added one by one 1 2 3 Click on the plotter you wish to add from the plotters list box Click on the port it will be connected to Click on Add The highlighted plotter is added to the Ready for Plotting list box Note For each plotter you add a number is added after the plotter model number for example GSx 1 for the first plotter added GSx 2 for the second Delete Plotters To remove plotters from the system 1 2 In the Ready for Plotting box click on the name of the plotter to be deleted Click on Delete Set Up 13 Assign Default Plotter A default plotter can be assigned if more than one plotter is connected to the GRAPHIX ADVANTAGE Note There must be two or more plotter names in the Ready for Plotting box to select a default plotter If only one plotter is installed to the GRAPHIX ADVANTAGE system that plotter will automatically be assigned as the default plotter 1 2 Highlight the name of the desired default plotter in the Plotters box Click on Preference Click on OK The name of the default plotter selected will appear below the words Default Plotter Click on Continue The screen returns to the GSP Setup menu Double click on the Control
7. Find the small notch at the right edge of the black plastic plate on the rear panel 4 Insert a flat tip screwdriver into the notch and flip the black plastic plate open Maintenance 47 5 Pull out the light gray fuse carriers one at a time Note that each carrier has a white arrow on it and that the arrow points downward as do the two arrows on the black plastic plate 6 Examine each fuse Remove any blown fuse Install a new fuse of the same type and rating in the same place 7 Reinsert each carrier with the arrow pointing downward Be sure the carriers are inserted all the way Close the black plastic plate firmly 8 Reinstall the power cord and the cable connector Turn the power on at the system and at the plotter 49 PLOTTER ADJUSTMENTS This section contains a troubleshooting guide to help identify possible error conditions according to the symptoms displayed and the recom mended adjustment procedures It also contains a brief description of plotter adjustment problems that should be handled by contacting Gerber Field Service Department at 800 828 5406 Note Gerber warranties do not cover unauthorized repair Some service procedures require delicate adjustment of plotter parts If damage to your GSx plotter results from improper unauthorized service repair will NOT be covered by any Gerber warranty 50 GSx Troubleshooting Guide This chart of symptoms is designed to help identify the possible
8. as well as keeping a logbook of the settings Refer to the Plotter User Reference Card for guidelines 21 TOOLS AND TOOL HANDLING Storage A tool rack is molded into the rear cover of the GSx The pen holder knife holder and pounce wheel holder may be removed from the tool kit and stored here for easy access Tool Holders For quick identification each tool holder has a different colored cap The cap helps lock the tool in place in the carriage spindle during operation In addition red sleeves protect tool tips from accidental damage during storage Remove the protective sleeve before installing a tool holder in the carriage spindle 22 GSx Pen Holder and Pens The pen holder is shipped with a black pen installed After loading the plotting paper install the pen holder in the carriage spindle as follows gt To install the pen holder 1 Select the pen holder with pen installed from the tool rack molded in the rear cover A plastic lift washer is used to reduce friction between the tool holder and the lift fork of the carriage spindle during operation There should be one installed on the pen holder If not slip a lift washer from the Tool Kit over the barrel and slide the washer to the top of the holder Drop the pen holder into the carriage spindle A slot or keyway in the barrel of the pen holder ensures proper orientation If necessary rotate the pen holder until it drops completely into the carriage
9. is very sharp Take care when handling the knife holder and blade CAUTION Blades are fragile and can break Do not use tools to handle new blades To replace and adjust the swivel knife blade Remove the plastic adjustment shoe from the base of the tool holder by rotating it counter clockwise until it comes completely off the tool holder Leave the rubber O ring in place With the shoe removed carefully remove the old blade by grasping it with needle nose pliers and pulling gently Install a new blade in the hole provided pushing the blade in gently until completely seated Carefully thread the shoe onto the knife holder turning it clockwise until it is fully seated This will fully expose the knife blade Rotate the shoe counter clockwise until approximately 005 inches about the thickness of two sheets of paper of the knife is showing FIN y Rubber O ring 1 42 Insert and adjust blade lt _ 1 Remove shoe Il 3 Thread shoe Lo Y u 4 Adjust for proper cut 29 OPERATION Power Up When the GSx is turned on the following sequence occurs 1 A short beep sounds the Power light comes on and the RUN CONT and RUN SINGLE lights blink 2 As the GSx performs self check tests the lights over the RUN keys flash and one additional beep sounds 3 When the self check is complete the lights blink and one beep sounds 4 The plo
10. 800 828 5406 or fax at 203 645 2448 Plotter Adjustments 55 X Axis Belt Adjustment SYMPTOMS Text cut in AXIS SWAP mode has closure problems OBJECTIVE To adjust the tension of the X motor belt to produce good letter quality in AXIS SWAP mode ADJUSTMENT PROCEDURE 1 2 Turn the plotter power off Remove all tools and material from the plotter Open the bail arms To remove the front cover lay the GSx on its left side and remove the 2 Phillips head screws on the bottom edge closest to the front of the plotter Then stand the plotter upright CAUTION Do not rest the plotter on its right side Do not use the way shaft to lift or turn the plotter 56 GSx 5 Pull the front cover upwards and at the same time pull one side away from the plotter frame Be careful not to lift the cover so high that the front cable disconnects Pivot the front cover to the side of the plotter 6 Locate the X belt Press gently on the belt There should be little or no spring If the belt is loose or springy go to Step 7 Plotter Adjustments If the X motor belt requires adjustment locate the four X motor mounting screws Phillips head screws Loosen these screws which hold the X motor bracket against the standoffs on the side plate Pull the motor up until the belt becomes tight Tighten the four screws Turn on power at the plotter Load vinyl in the plotter and install the knife holder Select AXIS
11. Adjustments includes a troubleshooting guide as well as symptoms of plotter adjustment problems A GSx Conventions The following conventions are used in this manual Note A note contains important information which could affect successful completion of a task CAUTION A caution statement contains information which if not observed could result in damage to the equipment WARNING A warning statement contains information which if not observed could result in personal injury PACKAGE CONTENTS This section lists the contents of the GSx shipping container As you unpack the GSx plotter inspect all items for damage that may have occurred during shipping Report any damage to your dealer at once Save all packaging materials in case it becomes necessary to transport the plotter at a future date The GSx package contains the following GSx plotter assembly Roll holder 10 yard roll vinyl US only Plotter power cord 10 foot RS 232 cable fuses Vinyl letter squeegee User s Manual Warranty card Service contract Tool Kit Paper sample International only aaa N E Contents Tool Kit Pen holder with pen Knife holder with knife Tool lift washers on tool holders Spare life washers Allen wrench Pair tweezers Pen height gage RR N Neme m INSTALLATION Please unpack the plotter boxes and inventory the contents before you begin to assemble the plotter Follow these ins
12. Bar to exit the GSP Setup menu The system will return to the GSP GRAPHIX ADVANTAGE program group MATERIALS AND TOOLS Materials The GSx uses the same plotting materials as all Gerber plotters Gerber vinyl products in high performance or intermediate grades are available in translucent reflective or metallic finishes and come in a wide range of colors Also available are direct cut screenprint stencil ruby photo film paint masking material rubber sandblast stencil material and heat transfer materials Consult your Gerber distributor for further information about available materials colors and prices Always insist on Gerber authorized materials for highest quality results b To load material CAUTION Gerber recommends that you load material without a tool in the carriage to prevent damaging the knife blade 1 Slide the roll of material to be used onto the roll holder Pull the end of the material away from and over the top of the roll holder toward the plotter CAUTION When power is on the carriage spindle must be moved only by using the slew keys Attempts to manually move the plotter drum rotate or force the tool up or down will damage the plotter CAUTION While power is off center the carriage by gently pushing toward the center of its travel Take care to move the carriage slowly and firmly by gripping the right end of the carriage housing not by gripping the carriage spindle CAUTION Do not use the way s
13. GSx plusru USER S MANUAL COPYRIGHT NOTICE COPYRIGHT 1995 Gerber Scientific Products Inc All Rights Reserved This document may not be reproduced by any means in whole or in part without written permission ofthe copyright owner This document is furnished to support the GSx In consideration of the furnishing of the information contained in this document the party to whom it is given assumes its custody and control and agrees to the following 1 The information herein contained is given in confidence and any part thereof shall not be copied or reproduced without written consent of Gerber Scientific Products Inc This document or the contents herein under no circumstances shall be used in the manufacture or reproduction of the article shown and the delivery of this document shall not constitute any right or license to do so PRINTED IN U S A GSx Knife Mode Switching Corner Correcting Technology IP Plus Gerber Mask and GERBER EDGE are trademarks of Gerber Scientific Products Inc GRAPHIX ADVANTAGE and GerberCal are registered trademarks of Gerber Scientific Products Inc 3 in 1 is a registered trademark of Boyle Midway Inc HP GL is a registered trademark of Hewlett Packard ScotchCal and Scotchlite are trademarks of 3M FCC NOTICE This equipment has been tested and found to comply with the limits for a Class A digital device pursuant to Part 15 of the FCC rules These limits are designed to provide reaso
14. NTAGE use the TABLET port to install a second plotter Communication Parameters If you are connecting the GS750 to a system other than the GRAPHIX ADVANTAGE the plotter uses these RS 232 communication parameters 9600 Baud 1 Stop Bit Xon Xoff Flow Control Installation 9 The plotter has a 25DB female connector with these pin assignments All other pins are not connected Power Cords plus 1 Insert the female connector of the GSx plotter power cord into the socket on the rear panel of the plotter 2 Connect the power cords for both the GRAPHIX ADVANTAGE system and the GSx to a multiple outlet strip The strip should be plugged into a standard grounded electrical outlet 115V 10 AC 60 Hz or 230V AC 50 Hz 3 Turn power on at the system and the plotter 10 GSx CAUTION When the power is on never try to manually move the carriage move the drum rotate the tool or force the tool up or down Attempting to manually move the GSx in any axis of movement while the power is on may damage the plotter Power Up Sequence When the GSx is turned on the following sequence occurs 1 A short beep sounds the Power light comes on and the RUN CONT and RUN SINGLE lights blink 2 As the GSx performs self check tests the lights over the RUN keys flash and one additional beep sounds 3 When the self check is complete the lights blink and the plotter beeps 4 The plotter b
15. and other debris can greatly affect tool performance and letter quality 44 GSx CARRIAGE AND BALL BUSHING 1 Use a lint free cloth and alcohol to clean any dust or debris from the front way drive shaft cam shaft and rear way Rotate the cam shaft and move the carriage assembly for access to the entire length of these shafts 2 Therear way and front way should be given a light coat of oil This is best done by applying with a lint free cloth Maintenance 45 SPROCKETS AND BAIL ARMS 1 Inspect the teeth of the drum sprockets for adhesive buildup from the use of vinyl films 2 Use a small stiff brush such as a toothbrush dipped in alcohol to clean the sprockets 3 After using alcohol to clean them immediately dry the sprockets and drum with a lint free cloth 4 Place one drop of oil in each pin of the sliding sprocket at the front of the plotter 5 Slide the sprocket back and forth to work the oil into the bushing 6 Oil the bail arm pins Do not oil excessively 46 GSx Fuse Replacement Two spare fuses are included with the GSx Plotter The fuse holder is located between the on off switch and the power cord connector on the rear panel of the plotter To replace the fuse WARNING Turn off power at the plotter and the system and disconnect from the power supply 1 Unscrew and remove the RS 232 cable from the rear panel of the GSx 2 Remove the plotter power cord from the socket 3
16. backlash n 58 Z axis tool height 51 Arrow Keys 31 B Bail arms cnnnnnenenenn 45 E E 10 41 A ice rer rm 25 28 Melia 20 damage cococococononoconcconoconocnnonanonnannnos 25 replacement ooooconnccnonccionccnnccnnncnnnoo 28 WEE iii 25 C Cleaning routine 44 45 Closure problems nene 62 Communication parameters 8 Control stop 34 Controlled stop 32 Cover plotter front removal 55 56 58 59 D Diagnostic OPH ONS En ee 38 RS 232 loop back 38 square circle test plot 38 wagon wheel test plot 38 DEAL ARS 38 Y theta aXeS tl da 38 Diagnostics ACCESS ii ta 35 access special 37 special OS 37 71 Drum end play adjustment 62 E Error COLES intel een 42 COnditiONS 41 SIONAL tre set 10 41 F Front panel 30 Fuse replacement neeneen 46 H Helpful hints issin ninani 18 I INIT KNIFE enian 32 Initial setting at power up 10 29 Installation pen holder eeneeeen 22 plot 7 K Key front panel nnnn 30 Arrow keys 31 39 INIT KNIFE enna aeee 32 RESET Mu sen 35 41 RUN CONT onioni latida 33 39 40 RUN SINGLE 32 39 40 41 slew keys Also see Arrow keys 31 SLOW ER tne iaa 31 38 40 KEWA oaaae G 22 Knife ho
17. cal electrical error conditions at power up or during operation When an error condition occurs the plotter will turn off power to the stepper motors flash the RUN lights and sound a steady tone To determine the error condition that stopped plotter operation follow these steps 1 Press the RESET key to clear the error signal flashing lights and steady tone 2 Press the RUN SINGLE key to display the error code number The RUN lights flash the same number of times as the error number once for Error 1 twice for Error 2 etc A short beep indicates the end of the error message Press the RUN SINGLE key again to repeat the message if desired 3 Press the RESET key to clear the error display mode and return to the initial off line status 42 GSx ERROR CODES The error code numbers and suggested operator responses are listed below Error code numbers are also listed on the User Reference Card Error Number Description Operator Response 1 Program checksum failure Try power up again RAM memory failure Try power up again RS 232 test failure Illegal plot data command Corrupt data UART error Z axes lock time out Z axis error Theta home failure ES Buffer overflow Try power up again Check plot data resubmit Job Check plot data resubmit job Contact Gerber Field Service Only occurs as part of self test try power up again Power up again holding RESET key Turn of
18. eeps and goes off line Only the power light remains on This is the initial setting at power up Note Rapid continuous beeping and flashing lights may signal a self check error See the Error Conditions section for more information SET UP After connecting the plotter to the GRAPHIX ADVANTAGE you will use the GSP Setup program in the GRAPHIX ADVANTAGE to make the GSx accessible Note When the GSX is used with sign design systems other than GRAPHIX ADVANTAGE contact the system manufacturer to obtain a driver for the GSX installation instructions and setup information Plotter Selection 1 Click on Setup The Setup drop down menu appears 2 Click on Plotter The Add or Delete Plotter s dialog box appears Add or Delete Plotter s Plotters Ready for Plotting GSxPLUS GS 750 PLUS HS 750 PLUS Default Plotter Preference Click on GSx in the Plotters list box to highlight it Click on the port to which the plotter is connected COM1 COM2 COM3 or COM4 in the Ports box Click on ADD GSx appears in the Ready for Plotting list box Your system is now set up to use the GSx plotter 12 GSx Add Plotters Note The Default Plotter note in the lower right corner of the dialog box tells you the name of the plotter your jobs will be sent to unless otherwise specified in the Plot program Click on Continue The screen will return to the GSP Setup Menu
19. efore shipment in addition to testing during the manufacturing process Customer support through Gerber Field Service Department Step by step user s manual If you require assistance installing or operating the GS plotter contact your distributor or GSP Field Service Department at 800 828 5406 in the USA or fax at 203 645 2448 Introduction 3 About This Manual This manual explains the installation and operation of the GSx plotter It assumes the operator is familiar with the GRAPHIX ADVANTAGE system It tells you how to assemble install operate and maintain your GSx as follows The Introduction provides information about the GSx of contents of the shipping crates and a list m Installation contains instructions for plotter assembly and connection to the GRAPHIX ADVANTAGE Set Up contains instructions for managing plotters m Materials and Tools gives information about material loading the vinyl and use of the tool force dial Tools and Tool Handling discusses procedures on using and replacing the pen knives and pounce wheel Operation provides information about plotter operation and slew key functions m Special Diagnostics presents examples and instructions for diagnostic tests m Error Conditions lists common error conditions and corrective procedures m Service and Maintenance provides cleaning lubricating and fuse replacement instructions Plotter
20. f power at the plotter Adjust the pen using the pen height gage See Pen Holder and Pens Install the pen holder in the carriage spindle Turn on the plotter Rotate the cam shaft by hand counter clockwise until the bottom of the lift fork touches the top of the carriage spindle See below 52 GSx 6 Locate the adjustment pad There should be a gap of 003 to 010 about the thickness of a piece of paper between the pad and the cam shaft If not go to step 12 7 Ifthe gap is correct remove the rear cover with molded tool rack Lay the plotter on its left side Remove 2 Phillips head screws from the bottom edge Stand the plotter upright Lift the rear cover straight up CAUTION Do not rest the plotter on its right side Do not use the way shaft to lift or turn the plotter 8 Locate the Z motor collar clamp between the sensor disk and the drive motor at the end of the cam shaft Use the Allen wrench to ensure that the set screw in the collar clamp is tightened securely 9 Replace the rear cover Plotter Adjustments 53 Load paper in the plotter Run a multiple line test plot If symptoms persist turn the plotter power off Rotate the cam shaft by hand until the lift fork is at its lowest position Continue to rotate the cam shaft in the same direction Do this until the lift fork starts to lift upward from the spindle Then rotate the cam shaft back until it is approximately halfway between the h
21. f system check connectors Turn off system check connectors Error code occurs in Special Diagnostic mode if axes remain locked more than 30 minutes If the plotter consistently fails the self check tests contact Gerber Field Service Department at 800 828 5406 or fax at 203 645 2448 43 MAINTENANCE This section includes instructions for routine cleaning and lubrication fuse replacement and adjustments to keep the GSx plotter in good working order Cleaning and Lubrication Routine cleaning and lubrication should be done monthly or after every 160 hours of use whichever occurs first Isopropyl alcohol should be used to clean dirty parts Note When alcohol is used lubricate the parts immediately to prevent corrosion Use a light oil such as 3 in 1 Oil for all lubrication except as noted TOOL HOLDERS AND CARRIAGE SPINDLE BORE Note The spindle bore should be cleaned daily CAUTION Do not use oil to lubricate tool holders or spindle bore There is a very close fit between the pen knife and pounce wheel holders and the carriage spindle bore Any dirt or build up in the bore or on the tool holder restricts motion and can produce inconsistent results 1 Once a day clean the spindle bore and tool holders with isopropyl alcohol using a clean dry lint free cloth on the tool holders and a clean dry cotton swab in the bore 2 Wipe the tool spindle with a soft lint free dry cloth Dust hair silicon
22. hafts to lift or turn the GSx This will damage the system and reduce plotting accuracy 16 GSx Center the carriage spindle preferably by using the slew keys see Front Panel section or manually with certain precautions as outlined here Be sure that the carriage spindle is not located at either extreme end of its travel and that both ends of the rubber drum can be reached easily Open the bail arms at either end of the drum by pulling them up and away from the drum Using the slew arrow keys rotate the drum until three closely spaced pins are visible These three sprocket pins are used to align the material Materials and Tools 17 To feed and align material 1 Feed material under the black cam shaft and over the rubber drum See the illustration below 2 Place the holes in the material over the sliding sprocket pins first Match the three closely spaced sprocket pins and holes 3 Slide the material and the sliding sprocket to reach the fixed sprocket and place the material over these sprocket pins 4 Center the bail arms over the sprockets Move the adjustable bail arm at the rear of the plotter slightly forward or backward to accommodate small differences in the material width Securely close the front bail arm first and then the rear bail arm 18 GSx HELPFUL HINTS When you change materials open the bail arms and roll the material back onto the roll Tape the ends securely to prevent the rol
23. he side plate Apply light pressure upward to tighten the mesh of the jack shaft gear and the Y motor pinion CAUTION Forcing the jack shaft gear and Y motor pinion to mesh too tightly can cause the jack shaft gear to wear prematurely If you adjust the mesh too loosely poor letter quality will result However it is safer to tighten the mesh gradually cut a test plot then tighten again than to adjust the mesh too tightly Plotter Adjustments 61 While holding the motor bracket in place tighten the two bracket screws Turn the plotter power on Load vinyl in the plotter install the knife holder and cut a test plot If symptoms persist return to step 1 Replace the front cover 62 GSx Drum End Play Adjustment SYMPTOMS Text cut in NORMAL mode has closure problems Y axis backlash check procedure shows no problem OBJECTIVE To slide the plotter drum and X Axis gear toward each other and clamp them in position to remove end play to make sure the drum still rotates without binding ADJUSTMENT PROCEDURE 1 Turn the plotter power off 2 Remove all tools and material from the plotter 3 Open the bail arms to free drum 4 There should be end play of about 003 to 005 inch see below This play exists because the ball bearing has a flexible race If the amount of play does not exceed 005 inch and all check procedures in this section have failed to reveal the cause of the plotter s symptoms contact Ge
24. iage and Ball Bushing 44 Sprockets and Bail Arms 45 Fuse Replacement semseiana ci 46 PLOTTER ADJUSTMENT poo nitrate ne 49 Troubleshooting Guide isena ne aee EEE anar nonn EEE E EEEo EEE 50 Z Axis Tool Height Adjustment 51 SYMPLOMS ni in eer msn VER EEE ox ER A td 51 OBJECHVE 4 A Ano R 51 Adjustment Procedure ss 51 X Axis Belt Adjustment en enne essen 55 SYMPTOMS nes ee ent ich dde tete des 55 ODIO CV RR esse ere ner tt ete en Dioni 55 Adjustment Procedure ss 55 Y Axis Backlash Adjustment 58 A 58 ODJOCUVE Li A A Lire nr rates Brei 58 Adjustment Procedure ss 58 Drum End Play Adjustment ooooonoccioncnonoconoconoconnconnnonnnnononan nono nennen 62 SYMPTOMS serein mate mere nas RER 62 Objectivern n nn ad re say weave lt use adas 62 Adjustment Procedure ss 62 INTRODUCTION Description The GSx TM is a state of the art 15 inch 38 1 cm plotter designed for use with the GRAPHIX ADVANTAGE system and other sign design systems Note When used with GRAPHIX ADVANTAGE systems the GS requires GRAPHIX ADVANTAGE 4 3 or higher When GSX is used with other sign design systems contact the system manufacturer to obtain a driver for the GS Performance The GSx is designed to precisely register gra
25. ighest and lowest positions At its lowest position the lift fork should touch the top of the spindle If the lift fork appears to be adjusted correctly go to step 17 If the lift fork does not touch the top of the spindle or if it does not lift up when the cam shaft is rotated to either side locate the screw in the center of the adjustment pad Loosen the screw in the center of the adjustment pad with a Phillips head screwdriver If the lift fork does not touch the top of the spindle slide the adjustment pad upward If the lift fork remains touching the spindle when you rotate the cam shaft in either direction from its lowest position slide the adjustment pad downward 54 GSx 20 21 22 23 Retighten the adjustment pad screw Turn off power at the plotter Power up the plotter while holding the RESET key Load paper and install pen holder Press the left arrow key to access the Wagon Wheel Test Plot Press either RUN key to plot Inspect your test plot by comparing to the Wagon Wheel Test Plot illustration Turn off power at the plotter Power up the plotter while holding the RESET key Load vinyl and install knife holder Press the SLOW key to access the Square Circle Test Plot Press either RUN key to plot Inspect your test plot by comparing to the Square Circle Test Plot illustration If symptoms persist return to step 1 or contact the Gerber Field Service Department at
26. l from unraveling Before unrolling vinyl for a job determine how much material you need Check the length of the longest line in the job or the width of an automatically laid out sign or digitized design Remember that if you are plotting in the Axis Swap mode you need to consider the height of the job rather than its width The most practical way to unroll material for a job is to use the slew keys on the plotter It is best to unroll more than enough material rather than just enough in case your estimate is not accurate You may also pull material from the roll by hand This may be the simplest method if you are plotting relatively small jobs When you have advanced enough material for the job feed it back through the plotter or otherwise position it appropriately according to the tool start position selected from GRAPHIX ADVANTAGE If you have a large quantity of material piling up on the table be sure to arrange the material in loose accordion folds so it can feed easily Make sure the material is positioned to feed straight into the plotter rather than at an angle Materials and Tools 19 Tool Force Dial SETTINGS The tool force dial on the front of the housing indicates the tool force setting and the amount of tool force or pressure that is applied to the tool during operation This pressure ensures uniform cuts and pen lines Tool force can be adjusted by turning the small knob on the end of the tool force housing as
27. l move continuously as long as the arrow keys are pressed To use the slow slew feature 1 Press the SLOW key to select slow slew mode You will hear a single beep indicating the plotter is in slow slew mode When you press an arrow key the platen or tool will move a single step at a time When you press an arrow key the drum or carriage will move at a very slow speed as long as you hold the key down 2 Press the SLOW key again to return to normal mode You will hear two beeps indicating the plotter is in normal slew mode When you press an arrow key the platen or tool will move continuously as long as you hold the key down Note The arrow and SLOW keys do not function during the following conditions m while a job is plotting m during an error condition m ifa RUN light is on even if the plotter is idle 32 GSx INIT KNIFE INIT KNIFE RUN SINGLE RUN SINGLE Plot Use the INIT KNIFE key to initialize the knife so that the blade faces 0 Press the INIT KNIFE key after loading the knife CAUTION Pressing INIT KNIFE lowers the knife into the vinyl and cuts very short line It is important to have material loaded in the plotter so that the knife does not cut the drum surface Note You should initialize the knife before every job if you have changed material or after a new tool has been installed Use RUN SINGLE to plot a single job This plot mode allows the operator to reposition material between jobs and
28. lder 25 installation 26 L Light s front panel 37 41 Lubrication routine ococcnnnnnonnnnnnos 44 72 Index M Maintenance carriage and ball bushing 44 carriage spindle bore 43 cleaning and lubrication 43 fuse replacement 46 sprockets and bail arms 45 tool holders 43 Materials 15 P Pen height Gauge ooooococococnnonncnonoconocinonono 23 replacement c oooooocnnccnonccionoconoconocanonos 23 Pen holder enanson nieas 22 installation 22 Plot continuous EXETC SE nennen 34 single exercise 33 Square Circle Test Plot 38 40 Wagon Wheel Test Plot 38 39 Plotter add plotter cneeseeneeeneene 12 adjustments 49 assign default 13 delete plotter 12 installation 7 selection nario 11 Power cord c cocccccnnnnononnonicicnonanannnnnss 8 9 Power Up ars nine 10 29 R RESET Swe Stic ha eens 35 Roll holder material 7 15 RUN CONT una 33 RUN SINGLE nn 32 S Slew key tail 31 32 SLOW SLEW 31 Sprockets renren diis 16 17 45 Square Circle Test Plot 38 40 Stop controlled 32 34 Stop EMETZENCY
29. lotting mode and maximize the plotter s productivity gt To plot in continuous mode 1 Press RUN CONT The light above the RUN CONT key comes on and the GSx plots one job after the other without waiting for user prompting between the jobs The GSx creates a waiting list or queue of jobs to be plotted When one job finishes plotting the next job waiting in the queue begins immediately When all jobs in the queue are plotted the GSx remains on line until the operator presses either RUN key or the RESET key to return to off line status 34 GSx Controlled Stop Use RUN CONT or RUN SINGLE to pause plotting and check the current job To stop a continuous mode plot 1 2 Press either RUN key The GSx stops the plot at the next logical break in the program Do not use slew keys or orientation for the current job will be lost Press either RUN key to resume plotting at the exact same point Continuous Plot Exercise 1 Turn on the GSx Load plotting paper install the pen holder and set the tool force to 5 Using the slew keys position the carriage spindle approximately 1 from the front edge of the plotting paper Be sure that there are several inches of paper extending past the carriage spindle and to the left of the plotter Prepare two plot files If using a GRAPHIX ADVANTAGE to prepare the files in the Plot Program choose a left Start Position and a right End Positio
30. n for both plots before sending them to the plotter This will prevent the files from plotting on top of each other If using another layout program be sure to position the files so they will not plot on top of each other Note Entering an X Y pre position in the Plot Program is another way to be sure that plots done in the RUN CONT mode will not plot on top of each other See GRAPHIX ADVANTAGE Reference Press the RUN CONT key Both jobs will plot without a pause between them RESET RESET Operation 35 Use the RESET key to stop plotter operation in case of emergency to clear error signals and to access Special Diagnostics b To cause an emergency stop Press the RESET key while a job is plotting The following sequence occurs 1 GSx operation stops immediately 2 The current job is cleared All other jobs in the queue remain intact 3 The GSx returns to off line status as at power up To clear an error signal Press the RESET key to clear an error signal steady tone and flashing lights after a power up or plotting failure See the Error Conditions section To access diagnostics Hold the RESET key at power up to access additional diagnostics See the Special Diagnostics section 37 SPECIAL DIAGNOSTICS In addition to the self check tests that are part of the power up sequence the GSx plotter can perform other special diagnostics The steps to access these diagnostics and their functio
31. nable protection against harmful interference when the equipment is operated in a commercial environment This equipment generates uses and can radiate radio frequency energy and if not installed and used in accordance with the instruction manual may cause harmful interference to radio communications Operation of this equipment in a residential area is likely to cause harmful interference in which case the user will be required to correct the interference at his own risk This digital apparatus does not exceed the Class B limits for radio noise emissions from digital apparatus set out in the Radio Interference Regulations of the Canadian Department of Communications Le present appareil numerique n emet pas de bruits radioelectriques depassant les limites applicables aux appareils numeriques de la classe B prescrites dans les Reglements sur le brouillage radioelectrique edicte par le Ministere des Communications du Canada Table of Contents INTRODUCTION mn dirt Re A cle ns batter Stn Attendee tient 1 D SCHIPHON Eu intimiste Ste AE se 1 Performance rs Nennen Nein 1 CONVENIENCE Ys ss sn idad 1 Support Information 2 PACKAGE CONTENTS 2 22 des iol can a 5 INSI ON 7 Plotter Work ATi toas 7 Connectto the Plotter ni Aus it nn 8 Communication Parameters eienn E AT 8 Power Cords sisi 9 Power UpSequ nce sn rast Mean A 10 SETUP 00 aa it sida ES 11 Plotter Selection 22 22 er te cti babes cabernet 11 Add Plot Si ei Bun RM In
32. ng was discontinued with the blade still cutting satisfactorily Other blade manufacturers have attempted unsuccessfully to duplicate this cutting precision and durability Gerber warrants cutting quality of the GSx only when Gerber blades are used BLADE WEAR The knife blade will dull slightly after cutting thousands of characters Blade wear is always a gradual change Adjusting tool force will extend blade life for a period of many days and even weeks of use BLADE DAMAGE CAUTION Carbide blades are brittle and can be ruined by the slightest chip of the cutting tip Because they are ground to a controlled length the blades cannot be resharpened A sudden decline in cutting quality indicates that the knife blade is chipped Replace and discard any chipped blade 26 GSx KNIFE HOLDER INSTALLATION Follow these instructions to install the knife holder To install a knife holder 1 2 Load vinyl or other material Select the knife holder that matches the knife mode you want to use A plastic lift washer is used to reduce friction between the tool holder and the lift fork of the carriage spindle during operation There should be one installed on the knife holder If not slip a lift washer from the Tool Kit over the barrel and slide the washer to the top of the holder CAUTION Carefully install the knife holder taking care not to strike the tip of the blade against the bore of the carriage spindle A slot
33. ns are outlined below To access special diagnostics 1 2 Hold down the RESET key during power up When a steady tone sounds release the RESET key There will be two beeps followed by three beeps as the self check tests are completed Then the lights above the RUN CONT and RUN SINGLE keys will alternate These alternating lights mean that RESET was held at power up and that a special diagnostic can now be performed Access one ofthe special diagnostics described next by pressing the slew key noted in the description Note Only one special diagnostic can be accessed at each power up sequence To access another diagnostic turn the plotter power off and then on again as described above Diagnostic Options The following diagnostics are available RS 232 Loop Back Press the up arrow key to access Used to check internal workings of the communications hardware Beeps indicate a communications error A special loop back test connector is needed for this test See your Gerber distributor Wagon Wheel Test Plot Press the left arrow key to access Used to check X Y Z axes in plot mode and to verify operation after adjustments are made 38 GSx m Square Circle Test Plot Press the SLOW key Used to check X Y Z theta axes in cut mode and to verify operation after adjustments are made X08 Cut Test Press the down arrow key to access Used to test cut quality If the plotter consistently fails a s
34. or to pen plot using paper before cutting vinyl 1 Press RUN SINGLE The light over the RUN SINGLE key comes on and the GSx plots a single job If other plot files are received from the GRAPHIX ADVANTAGE while the first job plots then a waiting list or queue of these jobs is created The GSx returns to the off line status after the job plots The GSx waits for the operator to press the RUN SINGLE key again to plot the next job If other jobs are lined up in the queue the green lights above the two RUN keys will flash Controlled Stop Use RUN SINGLE or RUN CONT to pause plotting 1 Press the currently selected RUN key during a job to pause the job The GSx stops the job at the next logical break in the program Note Do not use slew keys or orientation for the current job will be lost 2 Press either RUN key to resume plotting at the exact same point Operation 33 Single Plot Exercise RUN CONT RUN CONT 1 Turn on the GSx Load plotting paper test the pen manually install the pen holder and set the tool force to 5 2 Using the slew keys position the carriage spindle approximately 1 from the front edge of the plotting paper Also be sure that there are several inches of paper extending past the carriage spindle and to the left of the plotter 3 Send a plot file to the GSx plotter 4 Press the RUN SINGLE key to plot the test exercise Use RUN CONT to access the continuous p
35. pecial diagnostic contact Gerber Field Service Department at 800 828 5406 at 800 828 5406 or fax at 203 645 2448 WAGON WHEEL TEST PLOT To plot the Wagon Wheel test plot 1 To access the Wagon Wheel test plot hold the RESET key while powering up Load plotting paper and install the pen holder Press left arrow key to access diagnostic Press RUN SINGLE to plot once or RUN CONT to plot continuously Compare the test plot to the illustration below Ifthe plot is different contact Gerber Field Service Special Diagnostics 39 SQUARE CIRCLE TEST PLOT To plot the Square Circle test plot 1 To access the Square Circle test plot hold the RESET key while powering up Load vinyl and install the knife holder Press SLOW key to access diagnostic Press RUN SINGLE to plot once or RUN CONT to plot continuously Compare the test plot to the illustration below Ifthe plot is different contact Gerber Field Service 40 GSx X08 CUT TEST To plot the X08 Cut test 1 2 To access the X08 test plot hold the RESET key while powering up Load vinyl and install the knife holder Press the down arrow to access diagnostic Press RUN SINGLE to plot once or RUN CONT to plot continuously Compare the test plot to the illustration below Ifthe plot is different contact Gerber Field Service Sar qn an 12345381 KOS 41 ERROR CONDITIONS The GSx is programmed to detect several mechani
36. phics up to 50 yards 45 7 meters long using carbide blades for crisp sharp cuts It cuts up to 25 faster than comparable plotters for rapid cutting of all but the most demanding materials such as sandblast stencil Gerber s exclusive Corner Correcting Technology assures sharp easy to weed corners Able to handle complex jobs the GSx cuts at 4 7 inches 11 9 cm per second on a straight line When used with the GRAPHIX ADVANTAGE the GSx uses the Plot Spooler feature to receive and plot files while the operator continues to design at the system Convenience The GSx has many features that make it easy and convenient to use Accepts any standard Gerber materials in 15 inch wide rolls m Draws cuts and pounces up to 12 75 inches 32 4 cm high Using the GRAPHIX ADVANTAGE system Panel feature the GSx can cut text or graphics in strips up to 96 feet 29 3 meters long and 12 75 inches 32 4 cm wide Adjustable tool force for uniform cutting with the turn of a dial 2 GSx m Stepper motor drive for consistent performance and easy maintenance On board 4K buffer in addition to GRAPHIX ADVANTAGE buffers m Quick installation m Simple to use keypad requires minimum training Support Information Gerber pioneered plotter technology with quality engineering designs that consider operator convenience Performance of the GSx plotter is assured by 24 hours of finished product testing b
37. problem and the probable adjustment procedure CAUTION Turn off GSx plotter and GRAPHIX ADVANTAGE or other sign design system before checking connections or attempting to make any adjustments unless otherwise directed Symptom Recommended Procedure 1 Check power cable and plugs 2 Check on off switches 3 Check fuse Poor Performance Perform routine cleaning and lubrication Plotter Error Press Reset on the plotter Verify and resend the job Inconsistent Tool Clean spindle bore and tool holder Material Contact Change knife blade Check for proper Z home Perform Z Axis Adjustment for Tool Height Jagged or Serrated Replace the knife blade Cutting Edges Closure Problem Check in this order 1 Material alignment in sprockets 2 Blade position in knife holder If the condition still occurs in NORMAL mode see GRAPHIX ADVANTAGE Reference perform the Y Axis Adjustment If the condition occurs when AXIS SWAP in the GRAPHIX ADVANTAGE is on make adjustments in this order 1 X axis Adjustment 2 Drum End Play Adjustment Plotter Adjustments 51 Z Axis Tool Height Adjustment SYMPTOMS OBJECTIVE The tool does not touch the material or touches only between characters The knife does not cut deeply enough The tool height changes in the middle of a job To set the height of the lift fork for consistent contact of tool holder with material ADJUSTMENT PROCEDURE 1 2 Turn of
38. rber Field Service Department at 800 828 5406 or fax at 203 645 2448 Plotter Adjustments 63 If there is more than 003 to 005 inch of play remove the front cover Lay the GSx on its left side and remove the 2 Phillips head screws on the bottom edge closest to the front of the plotter Then stand the plotter upright CAUTION Do not rest the plotter on its right side Do not use the way shaft to lift or turn the plotter Pull the front cover upwards and at the same time pull one side away from the plotter frame Be careful not to lift the cover so high that the front panel cable disconnects Pivot the cover to the side of the plotter Locate connector R728 at the end of the X motor cable Disconnect connector R728 Locate the three Phillips head screws which hold the X motor bracket against the standoffs on the side plate Remove these screws Remove the X motor Locate the outside drum clamp on the X axis gear Use an Allen wrench to loosen the clamp 64 GSx 11 Locate the centerline of the frame Slide the plotter drum and the X axis gear toward the centerline of the frame and each other Tighten the X axis drum clamp 12 Slowly rotate the X axis gear two revolutions Then rotate the X axis gear a quarter turn in the opposite direction 13 Gently try to push the drum from end to end Ifthe adjustment is correct the play will be between 003 and 005 inch 14 Spin the drum If the adjustmen
39. shown in the illustration below The Plotter User Reference Card at the end of this manual lists approximate tool force settings Be sure to refer to this list of settings when changing materials or applications Below are some initial suggestions For drawing start with a tool force setting of about 5 If your pen does not make a clear dark line you may wish to increase the tool force setting When cutting regular vinyl set the tool force setting at 1 The knife will not pivot at corners and will begin to cut through the material if the pressure is set too high Heavier material such as reflective vinyl requires increased tool force settings Worn blades require increased tool force settings Before cutting refer to the Plotter User Reference Card at the back of this manual for suggested tool force settings for different tools and materials Set the tool force accordingly If you find that 20 GSx different tool force settings produce more satisfactory results with your particular system tools and materials be sure to mark the preferred settings on your card for future use ADJUSTMENTS Several factors affect tool force and require setting changes m Type of material See Plotter User Reference Card m Knife and tool Drawing cutting and and blade angle all affect the tool force setting m Blade wear Increase tool force after several thousand cuts Gerber recommends experimenting with tool force settings
40. t is correct the drum will spin without binding 15 If the tests in either step 13 or 14 fail repeat steps 10 through 13 until the drum spins without binding and there is no end play Note You may need to repeat this procedure several times to obtain correct adjustment 21 22 Plotter Adjustments 65 After the adjustment is correct reinstall the X motor To do so place the X motor on its standoff Make sure the cable extends upward toward the ceiling Loosely install the three screws removed in step 8 Each must have a 8 lock washer and 8 flat washer The lock washer must be closest to the screw head While applying pressure tighten the three screws Turn on power to the plotter Load vinyl in the plotter install the knife holder and cut a test plot If closure problems persist repeat the Adjustment Procedure from step 1 If no closure problem appears select AXIS SWAP mode Cut a test plot If closure problems persist repeat the X Axis Backlash Adjustment Procedure If no closure problem appears reinstall the front cover 66 GSx Gsx Plotter Assembly list 1 of 2 pages 2 drawings Plotter Adjustments 67 Gsx Plotter Assembly list 2 of 2 pages 2 drawings 68 GSx Gsx Plotter Assembly list 1 of 2 drawings Plotter Adjustments 69 Gsx Plotter Assembly list 20f 2 drawings Index A Adjustment drum end play 62 X axis backlash 55 Y axis
41. tructions to install the GSx plotter to any GRAPHIX ADVANTAGE Installation of the GSx to other sign design systems is described separately Note Should you experience difficulty during installation of the GSx to the GRAPHIX ADVANTAGE system contact Gerber Field Service Department at 800 828 5406 Plotter Work Area 1 Carefully remove the GSx from its packaging materials and place it near the GRAPHIX ADVANTAGE system The cable is 10 feet 3 1 meters long so the plotter need not be located immediately beside the console however it should be close enough so there will be no strain on the cable after installation 2 Place the material roll holder next to the plotter on the right side 8 GSx Connect to the Plotter CAUTION Be sure power is turned off and the power cord is unplugged at both the GRAPHIX ADVANTAGE and the plotter 1 Insert the 9 pin connector at the end of the RS 232 cable into the 9 pin RS 232 connector on the back of the GRAPHIX ADVANTAGE This connector is normally labeled Plotter or COM Port 2 2 Carefully align all pins Use the connector thumb screws to secure the cable to the system 3 Insert the 25 pin connector at the end of the RS 232 cable into the 25 pin RS 232 connector on the back of the plotter 4 Carefully align all pins Secure the cable to the plotter with the connector thumb screws Note Ifa plotter is already installed in the PLOTTER port on the GRAPHIX ADVA
42. tter beeps and goes off line Only the Power light remains on This is the initial setting at power up Note Rapid continuous beeping and flashing lights may signal a self check error See the Error Conditions section for more information 30 GSx Front Panel The GSx front panel keys shown below are used to perform all of the following operations Position the carriage and material Put the plotter on line for drawing cutting and pouncing m Select single or continuous job processing m Initialize the knife tool m Access diagnostic modes as needed See the Special Diagnostics and Error Conditions sections for more information e e INIT RUN RUN gt POWER A further explanation of key functions and several test exercises follow SLEW KEYS A lt gt v SLOW KEY SLOW Operation 31 Use the left and right slew keys to unroll material before plotting to position the tool for plotting and to position the carriage and material between jobs Press the up or down slew keys to move the carriage between the rear and the front of the plotter Press the left or right slew keys to rotate the drum and feed material through the plotter or back toward the roll holder Use the SLOW key to access slow slew mode Slow slew mode moves the platen or tool one step at a time which simplifies precise registration of artwork produced by the GERBER EDGE In normal or slow mode the platen or too
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