GS15 Plus USER`S MANUAL - Gerber Scientific Products
Contents
1. sees wy wart a NAN MOTOR CONNECTOR X MOTOR X CABLE 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 Plotter Adjustment 75 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 X AXIS X MOTOR GEAR CLAMP DRUM aj FRAME FRAME CENTERLINE X AXIS GEAR 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 If the adjustment is correct the play will be between 003 and 005 inch 14 Spin the drum If the adjustment 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 76 GS15 Pus 16 17 18 19 20 21 22 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 r2. Tools and Tool Handling 31 To replace and adjust the swivel knife blade 1 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 Rubber O ring 2 Insert and adjust blade 1 Remove shoe ee M lt 3 Thread shoe Co 4 Adjust for proper cut and 33 OPERATION Power Up When the GS15 is turned on the following sequence occurs 1 A short beep sounds the Power light comes on and the RUN CONT RUN SING and SWIVEL KNIFE lights blink 2 As the GS15 performs self check tests the lights over the RUN and SWIVEL KNIFE keys flash and one additional beep sounds 3 When the self check is complete the lights blink and one beep sounds 4 The plotter goes off line in tangential knife mode Only the Power light remains on This is the initial s
3. ANA teccladenscoateeteceteaateaiadees 66 SYM weve ieee a ei ee 66 ADDIS E KN Se foods oeecec A A A E 66 Adjustment Procedure pesaire nna a 66 Y Axis Backlash Adjustment oooooonnccnocononcconnconnaconoconnconnconn conc nona non conan 69 Symptoms eitn eet EE EE eee Te tt 69 ODE CUE A td e 69 Adjustment Procedure ooonoocnoconococonoconoconnconncnnnnnnncrnn conocio nn ccoo cnica cra 69 Drum End Play AdjustMeNt ooooonnccnnccnocononcconnconnnnnnccnnncnnncnnncnna cono cra conan 73 SAMP A A 73 ODEVE a ia ade 73 Adjustment Procedure oooooccnnccnocononoconnconoconnconnnnnn nono nono nono nono n cra cnn 73 INTRODUCTION Description The GS15 P 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 GS15 ds requires GRAPHIX ADVANTAGE 4 3 or higher When GS15 us is used with other sign design systems contact the system manufacturer to obtain a driver for the GS15 ia The GS15 features Gerber s exclusive Knife Mode Switching Technology which offers the operator a choice of two cutting modes selectable from the plotter keypad Tangential Knife Mode keeps the blade aligned with the direction of plotting motion for cutting thick materials such as sandblast stencil and for pouncing patterns Swivel Knife Mode is used for rapid cutting of all but the most demanding materials such as san
4. dama geenit iore es 27 replacement 30 replacement oooconnnnncccnonnccccoso 31 WEAD a 27 Cap tool s cats 21 Carriage spindle DOLE ios 49 61 Cleaning routine s es 50 Closure problems 61 66 69 73 Communication parameters 8 CONVENTIONS cococccoccconcconoconcc nnacnnanns 4 Cover plotter front removal 66 69 74 rear removal 58 Customer Support eee eee 2 Cut test XOS reret 45 Delete plotter eee 12 Diagnostic Options cece 42 Diagnostics s es 40 41 Drum end play adjustment 73 Drum rubber ccecce 15 Error COS cui 48 Sion ali ces weet 33 47 Front panel eee eeeeeseeeseeeneee 34 Plotter Adjustment INIT KNIFE key 36 Initial setting at power up 10 33 Installation pen holder siinsetes 22 Plotter conan 7 pounce wheel holder 25 Jagged edges character 61 Key front panel eee eee 34 AITOW KEYS cocooococccocccocncnanananannss 35 INT is 36 RESET ici 40 RUN CONT eee 38 43 RUN SINGLE 37 38 43 SLEW Also see Arrow keys 35 SLOW inenen nenin 42 SEOW veerts eree isiin ite 35 SWIVEL cnc 36 Key Win o 22 Knife blades CHANGING usina sia 30 Knife blades changing 29 Knife holder ooooooonncnnnccnoconocccnnns 56 Lift washer tool cccccccccc 22 Light s front panel 38 Lubrication routine 50 51 Material incon
5. 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 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 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 holde
6. drive shaft cam shaft and rear way Rotate the cam shaft and rear way the front way does not turn and move the carriage spindle for access to the entire length of these shafts FRONT WAY CAM SHAFT REAR WAY 2 The rear way and front way should be given a light coat of oil This is best done by applying with a lint free cloth Service and Maintenance 51 3 Tip the plotter on its left side CAUTION Do not rest the plotter on its right side Do not use the way shaft to lift or turn the plotter 4 Place one or two drops of oil on each side of the ball bushing as indicated and in the oil hole CAUTION Do not place any oil on the tangential knife belt OIL OIL 52 GS15 Pus 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 f y js 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 Service and Maintenance 53 Fuse Replacement Two spare fuses are included with
7. height gage INSTALLATION Please unpack the plotter boxes and inventory the contents before you begin to assemble the plotter Follow these instructions to install the GS15 Pe plotter to any GRAPHIX ADVANTAGE Installation of the GS15 5 to other sign design systems is described separately Note Should you experience difficulty during installation of the GSI5P to the GRAPHIX ADVANTAGE system contact Gerber Field Service Department at 800 828 5406 Plotter Work Area 1 Carefully remove the GS15 US from its packaging materials and place it near the GRAPHIX ADVANTAGE system The cable is 10 feet 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 GS15 PMs 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 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 Carefully align all pins Use the connector thumb screws to secure the cable to the system 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 Carefully align all pins Secure the cable to t
8. 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 800 828 5406 or fax at 203 645 2448 Plotter Adjustment 61 Theta Axis Tool Rotation Adjustment SYMPTOMS Letters have jagged edges m Letters have closure problems of less than 1 32 m The tool loses position in the middle of a job OBJECTIVE To center lift fork over carriage spindle bore to align tool holder in carriage spindle ADJUSTMENT PROCEDURE 1 Remove any tool from the carriage spindle 2 Turn on power at the plotter 3 After the carriage spindle initializes look down at the lift fork and carriage spindle from directly above The half circle of the lift fork should be centered with respect to the carriage spindle If it is go to step 12 LIFT FORK SPINDLE 62 GS15 Pus 4 If the lift fork is not centered use the Allen wre
9. pounce wheel 1 Using the Allen wrench from the tool kit remove the hex screw that serves as the wheel s axle Remove the old wheel Position the new wheel in the holder Slide hex screw through holder and wheel as an axle and tighten Tools and Tool Handling 27 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 testing 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 GS15 me 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 28 GS15P KNIFE HOLDER INSTALLATION The GS15 P comes with two different types of knife holder Swivel Knife Used to cut all but the thickest materials such as sandblast stencil at high speed Tangential Knife Used to cut al
10. 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 shafts to lift or turn the GS15 This will damage the system and reduce plotting accuracy 16 GS15 Ps 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 BAIL ARMS BAIL ARMS Materials and Tools 17 To feed and align material Feed material under the black cam shaft and over the rubber drum See the illustration below BAIL ARMS BAIL ARMS Place the holes in the material over the sliding sprocket pins first Match the three closely spaced sprocket pins and holes Slide the material and the sliding sprocket to reach the fixed sprocket and place the material over these sprocket pins Center the bail arms over the sprockets Move the adjustable bail arm at the rear of the plotter slightly forward or backward
11. 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 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 m 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 For pouncing start with a setting between 5 and 6 When cutting regular vinyl in tangential knife mode try a tool force setting of 1 m When cutting regular vinyl in swivel knife mode set the tool force setting at 1 The swivel knife will not pivot at corners and will begin to cut through the material if the pressure is set too high m Heavier material such as reflective vinyl requires increased tool force settings 20 GS15P 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 different tool force settings produce more satisfactory results
12. two RUN keys will flash Controlled Stop Use RUN SINGLE or RUN CONT to pause plotting and check the current job 1 Press the currently selected RUN key during a job to pause the job The GS15 P 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 38 GS15 PMs Single Plot Exercise RUN CONT RUN CONT 1 Turn on the GS15 Load plotting paper test the pen manually 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 Also be sure that there are several inches of paper extending past the carriage spindle and to the left of the plotter Send a plot file to the GS15 ve plotter Press the RUN SINGLE key to plot the test exercise Use RUN CONT to access the continuous plotting mode and maximize the plotter s productivity To plot in continuous mode 1 Select either swivel or tangential knife mode by pressing the SWIVEL KNIFE key When swivel knife mode is selected the light above the SWIVEL KNIFE key is on Press RUN CONT The light above the RUN CONT key comes on and the GS15 S plots one job after the other without waiting for user prompting between the jobs The GS15 creates a waiting list or queue of jobs to be plotted When one job f
13. 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 mode and tool Drawing pouncing and cutting knife mode 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 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 GS15 P 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 GS15 Pus 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 To install the pen holder 1 Select the pen holder with pen installed from the tool rack molded in the rear
14. 00 828 5406 Note Gerber warranties do not cover unauthorized repair Some service procedures require delicate adjustment of plotter parts If damage to your GS15 P we plotter results from improper unauthorized service repair will NOT be covered by any Gerber warranty 56 GS15 Pus Troubleshooting Guide This chart of Z Axis Tool Height Adjustment symptoms is designed to help identify the possible problem and the probable adjustment procedure CAUTION Turn off GS15 plotter and GRAPHIX ADVANTAGE or other sign design system before checking connections or attempting to make any adjustments unless otherwise directed Symptom Recommended Procedure No power 1 Check power cable and plugs 2 Check on off switches 3 Check fuse 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 Check for proper theta home If improper do theta adjustment 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 make adjustments in this order Y Axis Backlash Adjustment Drum End Play Adjustment If the condition occurs w
15. 8 POWER COLAS TE A A PO eae E eae 9 Power Up Sequence 251 005 a etic rii Ale eee tie 10 SETUP ua raid iria vnseiseasabneee e 11 Plotter Select a ltda lidad 11 Add dada idad ae 12 Delete Plotters india TEE EE 12 Assign Default Plotter ss ne ailere eoret t e cotos iento ladies ide 13 MATERTAES AND TOOLS wisi cic e eten eere ee iet a ier oE ae EE E orai EAER eE 15 Material sis isane Teten anae e E E TE E EET 15 Helptul Hits aia A EEE AE OEE ENS 18 Tool Forc Dial a tota NEA 19 SCU IS A a Lee A EE E EA EE E RON 19 ACYUSUMENTS ee n E este NE E E R E E iE 20 TOOLS AND TOOL HANDLING rnanan a a a N aSa dea 21 A e aa e a E ete A E a A iA 21 Tool Holders virran a A EE 21 Pen Holderand Pensinio aee e e aaa TEONE EEEO Ei 22 Pen Replacements ito i i aa i c 23 Pounce Wheel Holdet ccccceceeesesssesesesssssssesesssssessseseseseseeeeeseseeeeees 25 Aligned Holes cui A Gee eee 25 Off Center A ON 25 Plotter Spesdiccioii il ii ee iio 25 Pounce Wheel Holder Installation oooooncccnccnnninoniccnnnnnnnnninccnnos 25 Pounce Wheel Replacement oooconccnoccnoncconnnonnnnnnnnnnnonanonancnnncrnn conan 26 Knife Holder and Blades ooooonconnccnncnnnnnnncnnnonconncnonnonncnnncnn nono a 27 Blade Wear iento EEEa 27 Blade Damaris is 27 Knife Holder Installation oooonnccnncnnnccnoccconaconoconncnnncconoconccnnccnnnanos 28 Blade Replacement rios ita 30 OPERATION ii A 33 Power UD AA Aa AA Rd 33 Front Panel iii
16. AA eee ees 34 SLEW Keys instintos dro 35 SLOW Keynes eet 35 SWIVEL KNIFE a Sores let tae tin A tenets 36 INIT KNIFE syntactic tee Sel AS 36 RUN SINGLE 37 RUN CONT cosas llista sir 38 RESE iii A A AEE 40 SPECIAL DIAGNOSTICS coito e e aa a ana a ae ieat 41 Diagnostic OPptONS citaciones 42 Wagon Wheel Test Plot cuota 43 Square Circle Test Plot occiococcoonnocon none osoicttan cisne ranita 44 KOS Cut TES iii adds plas ra ties 45 ERROR CONDITIONS ctrl ill tidad 47 Error Codes etica taa 48 SERVICE AND MATNTENANCE cortada ltda 49 Cleaning and Lubrication oooconoccnoncconnconnnonnnononannnnnnnnnnnnrnn nono n cnn ccrnncnnnno 49 Tool Holders and Carriage Spindle Bore 49 Carriage and Ball Bushing eee eeeeseeeeeeeeseeeeneeeeeeeseeeneeenaes 50 Sprockets and Bail Arms coooconnccnnccnocnnocnnonnnonnnono nono nonnncnn corn n nono ncnnnoon 52 Fuse Replacements sois 53 PLOTTER ADIUSTMENWS cursis iros a erica salu 55 Troubleshooting Guide cbc t 56 Z Axis Tool Height Adjustment ooooocnnncnnoconocononoconoconaconnoconoconccanccnnnannss 57 A E eee a 57 Objective inutil aiii add 57 Adjustment Procedure ooonoocnoccnocononoconnconoconncnnn conc nono nono nonnn conc cra conos 57 Theta Axis Tool Rotation Adjustment oooococnoccccnoncconnnccnnnaninanacnnncccnnnos 61 SYMPLOMS dic IA A A A 61 ODIO CUE Soe ed A At lt o 61 Adjustment Procedure ooonoccnnccnoconocononnconnconncnnnnnnn conan ono ccoo ccoo n cra cra 61
17. GS15 Plus USER S MANUAL ns eee eas ie Pe A ee AE 23 OS i oe 3 o AS o o g err 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 of the copyright owner This document is furnished to support the GS15 plus 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 USA I GS15 P oe Knife Mode Switching Corner Correcting Technology IP Plus Gerber Mask and GERBER EDGE are trademarks of Gerber Scientific Products Inc GRAPHIX ADVANTAGE is a registered trademark 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 3M ScotchCal and Scotchlite are trademarks of 3M FCC NOTICE This equipment has been tested a
18. II Heat Transfer Flock Hot Split Plastisol Metalized Polyester Screen Print Static Cling Sandblast 521 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 When in swivel knife mode use the minimum tool force setting that cuts satisfactorily Too much force will reduce edge quality 30 GS15 Ps BLADE REPLACEMENT Five carbide knife blades are included with the GS15 one installed in the tangential knife holder two tangential knife spares one installed in the swivel knife holder one swivel knife spare Extra blades and special angled blades for sandblast vinyls are available from your Gerber distributor WARNING The blade 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 The replacement procedures for the tangential and swivel knife blades are different To replace the tangential knife blade 1 2 3 Loosen the hex screw with the Allen wrench from the tool kit Carefully remove the old blade Install the replacement blade in the slot provided not riding up on either edge Gently seat the flat end of the blade against the pin stop with the blade point toward the center of the tool Retighten the hex screw SLOT BLADE a POINT ON CENTERLINE TOOLHOLDER
19. 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 if the jack shaft gear moves while the pinion remains stationary If the pinion moves with the jack shaft gear so there is no backlash go to the section for Drum End Play Adjustment Y MOTOR BRACKET MOUNTING SCREW JACKSHAFT GEAR gt ai Y Wii Y MOTOR gt Y MOTOR PINION 6 Ifthe 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 the side plate 7 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 72 GS15 Ps 10 11 12 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 Plotter Adjustment 73 Drum End Play Adjustment SYMP
20. TOMS m Text cut in NORMAL mode has closure problems m 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 Gerber Field Service Department at 800 828 5406 or fax at 203 645 2448 74 GS15 Pus 5 If there is more than 003 to 005 inch of play remove the front cover Lay the GS15 us 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 10 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
21. ady 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 1f desired 3 Press the RESET key to clear the error display mode and return to the initial off line status 48 GS15 PMs 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 Try power up again Illegal plot data command Check plot data resubmit job Corrupt data Check plot data resubmit job UART error Only occurs as part of self test try power up again Z axes lock time out Power up again holding RESET key Z axis error Turn off system check connectors Theta home failure Turn off system check connectors Buffer overflow Contact Gerber Field Service Error code occurs in Special Diagnostic mode if axes remain locked more than 30 minutes If the plotter consistently fails the self check tests co
22. and install knife holder Press the down arrow to run the X08 test cut Press either RUN key to cut Inspect your test cut If symptoms persist call Gerber Field Service Department at 800 828 5406 or fax at 203 645 2448 66 GS15 Pus 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 Turn the plotter power off 2 Remove all tools and material from the plotter 3 Open the bail arms 4 To remove the front cover lay the GS15 us 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 COVER SCREWS Plotter Adjustment 67 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 i wy l y ee e 6 Locate the X belt Press gently on the belt There should be little or no spring If the belt is l
23. dblast stencil Gerber s exclusive Corner Correcting Technology assures sharp easy to weed corners in swivel knife mode Performance The GS15 is designed to precisely register graphics up to 50 yards 45 7 meters long using carbide blades for crisp sharp cuts When used with the GRAPHIX ADVANTAGE the GS15 lus uses the Plot Spooler feature to receive and plot files while the operator continues to design at the system 2 G S15 Pus Convenience GS15 P has many features that make it easy and convenient to use Accepts any standard Gerber materials in 15 inch 38 1 cm wide rolls m Draws cuts and pounces up to 12 75 inches 32 4 cm high Using the GRAPHIX ADVANTAGE system Panel feature the GS15 S can cut text or graphics in strips up to 96 feet 29 3 meters long and 12 75 inches 32 4 cm wide m Adjustable tool force for uniform cutting with the turn of a dial 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 GS15 ee plotter is assured by m 24 hours of finished product testing before shipment in addition to testing during the manufacturing process Customer support through Gerber Field Se
24. e 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 CAM SHAFT Plotter Adjustment 59 8 Replace the rear cover 9 Load paper in the plotter 10 Turn on power Run a multiple line test plot 11 If symptoms persist turn the plotter power off 12 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 highest and lowest positions 13 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 14 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 PHILLIPS 15 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 60 GS15 Pus If the lift fork remains touching the spindle when you rotate the cam 16 17 18 19 20 21 22 23 shaft in either direction from its lowest position slide the adjustment pad downward Retighten the adjustment
25. e tool is not aligned correctly turn off the plotter power 17 Remove all tools and materials from the plotter 18 To 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 19 Locate the theta motor collar clamp Use the Allen wrench to ensure that the set screw in the collar clamp is tightened securely THETA MOTOR COLLAR CLAMP REAR WAY REAR WAY COLLAR CLAMP THETA TIMING BELT 20 21 22 23 24 Plotter Adjustment 65 Power on the plotter The Theta axis is locked for approximately 3 minutes Locate the rear way collar clamp Use the Allen wrench to loosen the collar clamp Rotate the knife holder by hand until the blade is properly aligned as explained in step 15 Tighten the clamp Turn the power off to unlock the theta axis Press and turn the knife holder out of alignment Power up the plotter to the normal off line state The blade in the knife holder must return to the correct alignment If not turn the plotter power off Return to step 20 Note You may need to repeat steps 20 through 24 several times to 25 26 obtain correct alignment When the blade is correctly adjusted power up the plotter while holding the RESET key Load paper
26. emoved 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 GS 15 Plotter Assembly Note The numbers refer to drawings on subsequent pages 14 15 16 17 18 20 23 24 Spacer Motor Bracket Y Axis Motor Connector and Pinion Y Axis Jackshaft Pulley and Bracket Assembly Bearing Pulley Modification Belt Timing X Axis Screw Motor and Pulley X Axis Motor Plate Assembly Standoff Bushing Spring Part of Right Bail Arm Assembly P39771C Bail Arm Screw Bail Arm Part of Bail Arm Assembly Paper Bail and Wheel Assembly Part of Right and Left Bail Arm Assembly Screw Part of Right Bail Arm Assembly Bushing Plotter Base and Side Plate Assembly Drum and 1st Sprocket Assembly Drum Shaft Part of item 23 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 45 46 47 Theta Motor Screw P25204A Washer Sensor Bracket Subassembly Screw Washer Washer Wired Photo Inter
27. etting at power up Note Rapid continuous beeping and flashing lights may signal a self check error See the Error Conditions section for more information 34 GS15 Pus Front Panel The GS15 front panel keys shown below are used to perform all of the following operations m Position the carriage and material m Put the plotter on line for drawing cutting and pouncing m Select single or continuous job processing m Select knife mode m Initialize the knife tool Access diagnostic modes as needed See the Special Diagnostics and Error Conditions sections for more information e e e RUN RUN SWIVEL 4 P INIT POWER KNIFE A further explanation of key functions and several test exercises follow SLEW KEYS lt q gt v SLOW KEY SLOW Operation 35 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 tool move continuously as long as the arrow keys are
28. gle jobs The GS15 S returns to the off line status as at power up after each job and waits for the operator to press RUN SINGLE key again to plot the next job Controlled Stop Press either RUN key to stop plotting at the next logical break in the program and check current job Do not use slew keys or the orientation for the current job will be lost RUN CONT Key Plot Press RUN CONT to plot two or more jobs continuously The GS15 P ue plots one job after the other without pausing between them and remains on line until either RUN key is pressed Controlled Stop Press either RUN key to stop plotting at the next logical break in the program and check current job Do not use slew keys or the orientation for current job will be lost Slew Keys Arrow Keys The arrow and SLOW keys do not function while a job is plotting during an error condition or while a RUN light is on even if the plotter is idle Press arrow keys to position carriage and material between jobs m Up and down arrow keys move the carriage spindle between the rear and the front of the plotter Left and right arrow keys rotate the drum and feed material through the plotter or back toward the roll holder Slow Key Hold the SLOW key while simultaneously pressing any Arrow key This slows carriage movement for exact positioning Reset Key Emergency Stop Press RESET key to stop GS15 sai operation clear the current job from the buffer and return the plotter
29. he plotter with the connector thumb screws Note If a plotter is already installed in the PLOTTER port on the GRAPHIX ADVANTAGE use the TABLET port to install a second plotter Communication Parameters If you are connecting the GS750 P Sto 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 The plotter has a 25DB female connector with these pin assignments All other pins are not connected Power Cords 1 Insert the female connector of the GS15 P 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 GS15 5 to the multiple outlet strip included with the GRAPHIX ADVANTAGE 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 9 10 GS15 Ps 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 GS15 in any axis of movement while the power is on may damage the plotter Power Up Sequence When the GS15 is turned on the following sequence occurs 1 A short beep sounds the Power light comes on and the RUN CONT RUN SING and SWIVEL KNIFE lights blink As the GS15 s perform
30. hen AXIS SWAP in the GRAPHIX ADVANTAGE is on perform the X Axis Adjustment Plotter Adjustment 57 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 Turn off power at the plotter 2 Adjust the pen using the pen height gage See Pen Holder and Pens Install the pen holder in the carriage spindle Rotate the cam shaft by hand counter clockwise until the bottom of the lift fork touches the top of the carriage spindle See below CAM SHAFT LIFT FORK CARRIAGE SPINDLE 58 GS15 PMs 5 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 11 ct i PHILLIPS y EAD SCREW SHAFT re o gt v ADJUST MENT PAD 6 If the 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 7 Locate the Z motor collar clamp between th
31. inishes plotting the next job waiting in the queue begins immediately When all jobs in the queue are plotted the GS15 us remains on line until the operator presses either RUN key or the RESET key to return to off line status Controlled Stop Operation 39 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 GS15 ce 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 GS15 Load plotting paper install the pen holder and set the tool force to 5 Select either swivel or tangential knife mode by pressing the SWIVEL KNIFE key When swivel knife mode is selected the light above the SWIVEL KNIFE key is on 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 Position 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 s
32. l knife 1 28 31 36 Tangential knife 1 28 36 Theta axis adjustment oo ee eect eeee ee 61 A A A EAE 33 Tool force adjustment oo eects 19 20 Gal esta ene eek Sih eects 19 HOUSING 2232505522 orere r oiez ieir 62 POUNCING oocococcconcconnnnnnncnnananannss 26 SENO S o aer ia eoet 29 Tool height adjustment 57 Tool rack molded 21 25 Tool rotation adjustment 61 Troubleshooting coooconocccoccnnononno 56 Milicic dcir 15 Wagon Wheel test plot 43 60 X axis backlash adjustment 69 X Y theta axes lock time out ee eee eeeeeee 48 X Y Z axes lock time out eee eee eeeeeees 48 Y axis backlash adjustment 69 Z axis tool height adjustment 56 tool height adjustment 57 Gerber Scientific Products B A Gerber Scientific Company 151 Batson Drive Manchester CT 06040 U SA P57347A Rev B
33. l materials including sandblast stencil The tangential knife can be used with either 30 45 or 60 blades To install a knife holder 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 or keyway in the barrel of the knife holder ensures proper orientation If necessary rotate the knife holder until 1t 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 following chart See Plotter User Reference Card Tools and Tool Handling 29 Suggested Tool Force Settings Material Recommended Tangential Swivel Knife Starting Tool Force Knife Blade Blade Controltac 180 Delux 210 Gold Silver Dusted Crystal 210 Florescent 210 Scotchcal 220 Translucent 230 Gerber Cal Gerber IP Plus GerberMask I amp
34. lick on Preference 3 Click on OK The name of the default plotter selected will appear below the words Default Plotter 4 Click on Continue The screen returns to the GSP Setup menu 5 Double click on the Control Bar to exit the GSP Setup menu The system will return to the GSP GRAPHIX ADVANTAGE program group 15 MATERIALS AND TOOLS Materials The GS15 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 To load material CAUTION it is recommended 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
35. lowed 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 3 Access one of the 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 42 GS15 Pus Diagnostic Options The following diagnostics are available RS 232 Loop Back Press the up arrow key to access Use 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 Square Circle Test Plot Press the SLOW key Use 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 Use to test cut quality If the plotter consistently fails a special diagnostic contact Gerber Field Service Department at 800 828 5406 or fax at 203 645 2448 Special Diagnostics 43 WAGON WHEEL TEST PLOT To plot the Wagon Wheel test plot 1 T
36. nch from the tool kit to remove the two screws shown below at the front of the tool force housing cover SCREWS 5 Use a Phillips head screwdriver to remove the cover screw at the rear of the tool force housing see below Remove the housing cover 10 11 12 13 Plotter Adjustment 63 Rotate the cam shaft by hand until the lift fork is at the point closest to the spindle Locate the two screws which hold the lift fork in place Loosen these screws but do not remove them LIFT FORK SCREWS Move the lift fork until it is correctly aligned with the half circle of the lift fork centered with respect to the carriage spindle Tighten the two screws After tightening the screws make sure the lift fork is correctly aligned If it is not return to step 7 If the lift fork is aligned correctly load vinyl in the plotter Select AXIS SWAP mode and cut a test plot If symptoms persist turn the plotter power off Install the knife in the carriage spindle 64 GS15 Pus 14 Turn on the plotter power After the spindle initializes look under the carriage to note the position of the blade as it sits in the carriage spindle m The blade should be parallel with the two forks of the lift fork m The tip of the blade should point toward the left side of the plotter m The spindle pin should be at 12 00 relative to the front of the plotter 15 If the tool is aligned correctly go to step 25 16 If th
37. nd 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 reasonable protection against harmful interference when the equipment is operated in a commercial environment This equipment generates uses and can radiate radio frequency energy and 1f 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 ita 1 Descriptiom een e E Oo Si 1 PEONES a oia edi 1 GN OR 2 Support IMformatiOn metrics ingeent chests aent EEE EE EEOAE REEE 2 PACKAGE CONTENES 00 A di A E e e a E Ri 5 INSTALLATION aan a 7 Plotter Work Arca is 7 Connectito the Plinio E a o EEE iaa 8 Communication ParameterS ooooononooooonononononononononnnnonononononononononononanononona
38. ntact Gerber Field Service Department at 800 828 5406 or fax at 203 645 2448 49 SERVICE AND MAINTENANCE This section includes instructions for routine cleaning and lubrication fuse replacement and adjustments to keep the GS15 la 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 and other debris can greatly affect tool performance and letter quality 50 GS15 PMs CARRIAGE AND BALL BUSHING 1 Use a lint free cloth and alcohol to clean any dust or debris from the front way
39. o 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 If the plot is different contact Gerber Field Service 44 GS15 Pus 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 If the plot is different contact Gerber Field Service i w O X08 CUT TEST Special Diagnostics 45 To plot the X08 cut test 1 To access the X08 cut test plot hold the RESET key while powering up Load vinyl and install the knife holder Press the down arrow Press RUN SINGLE to plot once or RUN CONT to plot continuously Compare the test plot to the illustration below If the plot is different contact Gerber Field Service Sar ran 123453M 81 KOS 47 ERROR CONDITIONS The GS15 is programmed to detect several mechanical 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 ste
40. o 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 40 GS15 PMs RESET RESET Use the RESET key to stop plotter operation in case of emergency to clear error signals and to access Special Diagnostics To cause an emergency stop Press the RESET key while a job is plotting The following sequence occurs 1 Gsis operation stops immediately 2 The current job is cleared All other jobs in the queue remain intact 3 The GS15 returns to off line status as at power up To clear an error signal Press the RESET key to clear an error 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 41 SPECIAL DIAGNOSTICS In addition to the self check tests that are part of the power up sequence the GS15 S plotter can perform other special diagnostics The steps to access these diagnostics and their functions are outlined below To access special diagnostics 1 Hold down the RESET key during power up 2 When a steady tone sounds release the RESET key There will be two beeps fol
41. oose or springy go to step 7 68 GS15 Pus Te 8 10 11 12 13 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 X MOTOR MOUNTING SCREWS MOUNTING SCREWS Tighten the four screws Turn on power at the plotter Load vinyl in the plotter and install the knife holder Select AXIS SWAP mode and cut a test plot If symptoms persist repeat the Adjustment Procedure Replace the front cover Plotter Adjustment 69 Y Axis 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 GS15 us 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 COVER SCREWS 70 GS15 Ps 4 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 i Plotter Adjustment 71 5
42. owing 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 GS15 S shipping container As you unpack the GS15 ne 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 GS15 P package contains the following Gs15P plotter assembly m Roll holder Small components consisting of 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 Swivel knife holder with blade Spare swivel knife blade Tool kit Paper sample International only Ra ee e NO 6 GS15 Pus Contents Tool Kit i e e W i i Pen holder with pen Tangential knife holder with blade Pounce wheel holder Tool lift washers on tool holders Allen wrench Pair tweezers Spare red pen Spare blue pen Envelope containing 2 spare lift washers Spare cone shaped tool caps Capsule containing 2 Spare knife blades 1 Spare pounce wheel 1 Pen
43. position produces distinct holes at any plotting rate up to full speed See the GRAPHIX ADVANTAGE Reference for more information on controlling the plotter speed POUNCE WHEEL HOLDER INSTALLATION To install the pounce wheel holder 1 Select the pounce wheel holder from the molded tool rack in the rear cover 26 GS15 Ps A plastic lift washer is used to reduce friction between the tool and the lift fork of the carriage spindle during operation There should be one installed on the pounce wheel holder If not slip a lift washer from the tool kit over the barrel and slide the washer to the top of the holder Hold the pounce wheel holder upright over the carriage spindle Rotate the barrel until the desired keyway is oriented above the protruding key inside the carriage spindle Lower the pounce wheel holder into the carriage spindle When the pounce wheel holder is in place swing the tool force arm and snap it over the cone shaped cap Check the pounce wheel position by looking under the carriage to make sure the wheel is oriented at the desired angle Pouncing generally requires higher tool force settings than drawing or cutting To begin set the tool force dial between 5 and 6 Adjust if necessary for paper thickness or desired hole size Reduce plotter speed if pouncing small holes POUNCE WHEEL REPLACEMENT One pounce wheel supplied is installed in the tool holder and a spare is included in the tool kit To replace the
44. 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 arrows 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 36 GS15 Ps SWIVEL KNIFE Press the SWIVEL KNIFE key to select knife mode SWIVEL KNIFE m When the swivel knife mode is selected the light over the SWIVEL KNIFE key is on m If the tangential knife mode is desired the light must be off m Press SWIVEL KNIFE to turn the light on and off Use swivel knife mode for most cutting except for demanding material such as sandblast stencil Use tangential knife mode for cutting thick materials such as sandblast stencil and for pouncing patterns Note You cannot change knife mode in the midst of a job the plotter must be between jobs You must take the plotter off line to switch knife modes INIT KNIFE INIT Use the INIT KNIFE ke
45. r on the gage 24 GS15 Pus 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 Pounce Wheel Holder Pouncing is a technique used to create an outline for a sign that will later be hand painted Pouncing can also be used to align vinyl letters on a large job The pounce wheel is designed to pounce perforate holes either perfectly aligned or off center to the direction of travel CAUTION The pounce wheel may be used only in tangential knife mode Pouncing in swivel knife mode will tear the paper ALIGNED HOLES There are two keyway slots on the barrel of the pounce wheel holder The standard keyway aligns the pounce with the drum axes Use this position to produce small holes in lightweight paper or for light dusting applications OFF CENTER HOLES The second keyway holds the tool at 11 degrees off center to the direction of tool travel Using the pounce wheel in the angled position causes the points to drag slightly as the wheel moves forward This produces larger slightly elongated holes suited for heavy or clay coated paper and for bold dusting applications PLOTTER SPEED In the straight aligned position the pounce wheel works best at reduced plotter speeds The angled off center
46. rupter Board Theta Pulley Clamp Screw Sprint Part of Left Bail Arm Assembly PP39772C Left Bail Arm Part of Left Bail Arm Assembly Shoulder Screw Long Front Way Carriage Stop Left Screw Bushing Clamp Belt Timing Theta Axis Rearway Pulley Motor Bracket Screw Bracket to Standoff Screw Washer Nut Special Motor to Bracket Motor Z Axis Cam Motor Bracket Assembly 48 49 50 51 52 53 54 55 56 57 58 59 61 62 63 64 65 66 67 68 69 70 71 72 73 Sensor Disk and Cam 74 Bearing Cap Part of item 82 Assembly 75 Spindle Assembly Standoff 76 Screw Idler Pulley Bracket 77 Lock Washer Assembly 78 Washer Belt Assembly Y Axis 79 Front Idler Pulley Assembly Rearway Grooved 80 Front Idler Sleeve Spacer 81 Nut Retainer 82 Vertical Lift Carriage and Bearing Bearing Cap Screws 83 Tool Force Housing Assembly Roller Assembly 84 Bail Arm Screw Same as Carriage Stop Right item 14 Sprocket Belt 85 Wired Photo Interrupter Board Ball Bushing Assembly Adjusting Screw Part of Ball Bushing Assembly Adjust Screw Ring Part of Ball Bushing Assembly Screw Dowel Pin Screw Adjusting Pad Screw Washer Screw Screw Flat Washer Lock Washer Lifter Bar Dowel Pin Same as item 64 Screw Same as item 65 Tool Lifter Pivot Plotter Adjustment 81 GS15 P PLOTTER USER REFERENCE CARD KEY FUNCTION DESCRIPTION RUN SINGLE Key Plot Press RUN SINGLE to plot sin
47. rvice Department m Step by step user s manual If you require assistance installing or operating the GS15 E contact your distributor or GSP Field Service Department at 800 828 5406 in the USA or fax at 203 645 2448 plotter Introduction 3 About This Manual This manual explains the installation and operation of the GS15 ve plotter It tells you how to assemble install operate and maintain your GS15 P as follows m The Introduction provides information about the GS15 us anda list of contents of the shipping crates m Installation contains instructions for plotter assembly installation and connection to the GRAPHIX ADVANTAGE Setup contains instructions for adding the plotter to the GRAPHIX ADVANTAGE m Materials and Tools gives information about materials loading the vinyl and using the tool force dial m Tools and Tool Handling discusses procedures on using and replacing the pens 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 m Plotter Adjustments includes a troubleshooting guide as well as symptoms of plotter adjustment problems 4 GS15 Pus Conventions The foll
48. s self check tests the lights over the RUN and SWIVEL KNIFE keys flash and one additional beep sounds When the self check is complete the lights blink and a beep sounds The plotter goes off line in tangential knife mode 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 11 SETUP After connecting the plotter to the GRAPHIX ADVANTAGE you will use the GSP Setup program in GRAPHIX ADVANTAGE to make the GS15 accessible Note When the GS15 is used with sign design systems other than GRAPHIX ADVANTAGE contact the system manufacturer to obtain a driver for the GS15 s and for setup information Plotter Selection 1 Double click on the GSP Setup icon to open GSP Setup 2 Click on Setup The Setup drop down menu appears 3 Click on Plotter The Add or Delete Plotter s dialog box appears Add or Delete Plotter s Plotters Ready for Plotting GS 15 PLUS GS 750 PLUS HS 750 PLUS Default Plotter 4 Click on GS15 P in the Plotters list box to highlight it 5 Click on the port to which the plotter is connected COM1 COM2 COM3 or COMA in the Ports box 6 Click on Add GS15 appears in the Ready for Plotting list box Your system is now set up to use the GS15 is plotter 12 G S15 Ps Note The Default Plotter note in the lo
49. sistent tool contact with 57 AAA 15 tool force settings eee 19 Package Contents 000 0 eeeeeeereee 5 Pen height gage eneee 23 replacement ooooonncnnnnnnnncnnnns 23 24 Pen holder oocccccccnnnnncncncnc 22 23 Pen Holder installation ooonconnnnnnnninocnnncnnnnos 22 Perforate See Pounce 25 Plot 3 Continuous exercise oocccccnccc 39 single exercise seese 38 Square Circle test plot42 44 45 60 Wagon Wheel test plot 43 60 Plotter A N 56 adding plotter eee 12 assign default plotter 13 delete plotter eee 12 Installation cc cece cece eeeees 7 Speedio meii hee ites ee 25 26 Plotter adjustment 57 61 66 69 73 Pounce wheel 25 holes aligned eects 25 holes Off center ococccccc 25 replacement eee 26 Pounce wheel holder 25 Pounce Wheel Holder Installation ccccceeeeeeeees 25 Power COLO occcnccnccicicicicinininons 9 53 POWer UPDoocccnocnnocnnocnnocnnonncnnncnnncnnnos 10 RESET key held at 40 RESET keyen ripiani 40 Roll holder material 15 RS 232 loop back sessen 42 RUN CONT key seese 38 RUN SINGLE key eee 37 SEW KEYS ccc enecivsndiiertetieceliens 35 39 SLOW key iii 35 Sprockets ossee 16 52 Square Circle test plot 42 44 60 Stop controlled 37 39 Stop EMETBENCY cocccocccconcnancnannnnnnss 40 Swive
50. the GS15 ii 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 GS15 PM 2 Remove the plotter power cord from the socket 3 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 54 GS15 Pus 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 Examine each fuse Remove any blown fuse Install a new fuse of the same type and rating in the same place Reinsert each carrier with the arrow pointing downward Be sure the carriers are inserted all the way Close the black plastic plate firmly Reinstall the power cord and the cable connector Turn the power on at the system and at the plotter 55 PLOTTER ADJUSTMENTS The 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 8
51. to accommodate small differences in the material width Securely close the front bail arm first and then the rear bail arm 18 GS15 Ps 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 roll 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
52. to off line status Clear Press the RESET key to stop the error signal after a power up or plotting failure See Error Conditions Section Access Hold the RESET key at power up to access additional diagnostics See Special Diagnostics Section GS15 P PLOTTER ERROR CODES DESCRIPTION OPERATOR RESPONSE CODE A TT TE E Zaslon Powerp again while holding down the RESET key Tr ani mor Tum off the system check connectors Note If the GS15 consistently fails the self check tests contact Gerber Field Service Department SUGGESTED GS15 TOOL FORCE SETTINGS Material Recommended Tangential GS Plotter Swivel Starting Tool Force Knife Blade Knife Controltac 180 Delux 210 Gold Silver Dusted Crystal 210 Florescent 210 Scotchcal 220 Translucent 230 Gerber Cal Gerber IP Plus GerberMask I amp II Heat Transfer Flock Hot Split Plastisol Metalized Polyester Screen Print Static Cling Sandblast 521 Sandblast 522 Service Department 800 828 5406 Fax 203 645 2448 International Customer Service 203 643 5716 INDEX Add Plotter vico 12 Adjustment drum end play sessen 73 theta axis tool rotation 61 X axis backlash 66 Y axis backlash 69 Z axis tool height 56 ATTOW KOYS cinereis ioneeniriatretrne tesan 35 Axis belt adjustment 66 Axis blacklash adjustment 69 Ball at MSnase nain 52 Bladesissa 27 30
53. wer 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 7 Click on Continue The screen will return to the GSP Setup Menu 8 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 GS15 ve plotter Add Plotters Multiple plotters can be added to your system They must be added one by one 1 Click on the plotter you wish to add from the plotters list box 2 Click on the port it will be connected to 3 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 GS 15 1 for the first plotter added GS 15 2 for the second Delete Plotters To remove plotters from the system 1 In the Ready for Plotting box click on the name of the plotter to be deleted 2 Click on Delete Setup 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 Highlight the name of the desired default plotter in the Plotters box 2 C
54. y to initialize the swivel knife so that the blade KNIFE faces 0 Press the INIT KNIFE key after loading the swivel knife and selecting swivel knife mode CAUTION Pressing INIT KNIFE when in swivel knife mode lowers the knife into the vinyl and cuts a 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 swivel knife before every job if you have changed material or after a new tool has been installed Operation 37 RUN SINGLE Plot Use RUN SINGLE to plot a single job This plot mode allows the RUN operator to reposition material between jobs and or to pen plot using SINGLE paper before cutting vinyl RUN SINGLE may be used with either swivel knife mode or tangential knife mode 1 Press SWIVEL KNIFE to select a knife mode For swivel knife mode the light over the SWIVEL KNIFE key is on For tangential knife mode the light is off 2 Press RUN SINGLE The light over the RUN SINGLE key comes on and the GS15 s 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 3 The GS15 returns to the off line status after the job plots It remains in the knife mode selected 4 The GS15 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
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