advantage router™ 600 user manual
Contents
1. 78 X axis motor gears 79 X beleen a hii 86 A 86 Y axis motor gears 81 A iene 85 Y WAYS eege Aa 85 ll te gute geiergert 53 Cutting TOS iia ooo 51 D Daily Cleaning eee 77 Double Sided Tape 62 64 E Emergency Power Switch 14 Engraving Tools Cove Cutter 50 A ereaeiis 50 Equipment chip removal system 45 F Function Keys Sel ct norana 29 aa 23 A oad anand 23 A a ea 26 H Hard MetalS oooocincciiniconicncicnno 62 High Tack Tape 62 Home Position aseaeeeeeeeee 13 I Initializing Ka 12 Inspection daily 600 76 Installation Chip Removal System 45 Vacuum Ghroud 46 J Job Home Position 13 L Linear bearing seals 87 Linear bearings eee 84 Low tack tape c cere 63 M Main Power Switch 14 Material Selection 60 Menu Selection Absolute AV 31 Motor Delai 39 Return Home cooccccocccncccncnnnno 36 Set Job Home 32 Mist coolant fluid level eee 88 MOZO iaa data 88 N Non metals ccccoooccnccccocnnnn 63 D Pen Cartridge ceeee 58 Pen tools 50 Pressure Foot 71 R Replacement Dis 59 Restoring Dower eee 15 Routable Materials 60 Router 600 daily inspection 76 Router Control Station 16 front panel assas 17 Function Keys en 19 Power Up Tes2. 3 Turn OFF the router motor 50 ADVANTAGE Router Tool Selection PENS AND SCRIBE TOOLS The pen and scribe tools included in the tool kit look similar However the pen tool can be distinguished by making sure that it writes on paper When first learning to use the Router 600 be sure to learn as many system functions as possible with the pen tool Do not try to cut material with the router until you have mastered the basic system functions using the pen Lightly tighten the pen tool in the spindle ENGRAVING TOOLS A Cove Cutter and V Cutter are included in the tool kit Both engraving tools can be used to create specialized edge effects The Cove Cutter creates a rounded channel around the character Cove Cutter Channel System Preparation and Use 51 The V Cutter creates a pointed channel around the character The V Cutter creates a channel with a 90 degree angle Each side of the channel is 45 degrees V Cutter Channel Note Materials which have an uneven thickness may produce poor results when engraving CUTTING TOOLS The tool kit contains six spiral fluted solid carbide cutting tools Cutters used with the Router 600 must have a 499 500 249 250 or 124 125 inch shank for use with the 50 and 25 inch collets or the 125 inch collet adapter supplied in the tool kit All tool bits must have plunge capabilities Note Metric collets and tools are available from a Gerber distributor 52 ADV
3. slight beading of moisture on the workpiece Avoid an excessively dry mist Better cooling and mist placement are achieved when larger mist droplets are used Ideally the coolant should evaporate during cutting Adjust the drip rate and lubricant flow by turning the drip regulator on the top of the coolant reservoir To increase the drip rate turn the regulator counterclockwise To decrease the drip rate turn the regulator clockwise CLEANING AND MAINTENANCE The Router 600 is a sophisticated microprocessor based system yet it is relatively simple to operate and service A committed program of preventative maintenance can significantly reduce the likelihood of major problems Router maintenance is based on daily inspection of the equipment and daily and weekly cleaning procedures Daily and weekly inspections of the router are recommended to help establish a cleaning schedule appropriate to the environment Use the charts provided as inspection guidelines 76 ADVANTAGE Router Daily Inspection COMPONENT WHAT TO CHECK FOR Work table Chip buildup mist coolant buildup End housings Chips in and around the motor assem blies Belt wipers Chip buildup worn or missing bristles X and Y motors End housing pillow bearing seals X and Y ways X and Y belts Router motor carriage linear bearing seals Mist coolant nozzle Mist coolant tank Dirt buildup on gear teeth Debris and oil buildup Chip buildup Chip buildup
4. ADVANTAGE It is the absolute speed in inches per minute or millimeters per second at which the tool travels along the tool path To override this rate and reduce or increase the feed rate change the established Feed Rate by a percentage described below The feed rate will not exceed maximum velocity of the router Note The feed rate will not exceed the maximum velocity of the router However if the Feed Rate set in ART Path is less than the maximum you may increase it using the Feed Rate parameter A Feed Rate of 200 would double the Feed Rate set in ART Path To change feed rate 1 Press SELECT while in the STOP READY or STOP JOB mode Note The Feed Rate parameter is most frequently changed in the STOP JOB mode when the Feed Rate has been set too high or too low for the job in progress CAUTION The feed rate override is not cleared after the job completes and will be applied to the next job received 2 Press the right or left arrow key until Feed Rate appears in the message box 3 Press SELECT to obtain the Feed Rate percentage Feed Rate 1 100 4 Press the right or left arrow keys to move the cursor to the desired digit 5 Press the up or down arrow keys to increase or decrease the digit under the cursor Acceptable values are 1 to 1000 38 ADVANTAGE Router 6 Press SELECT to save the new value If the value is valid 1 1000 the system beeps twice and returns to the STOP READY or STOP JOB m
5. Absolute X Y display allows you to position the router tool with great precision and helps set the job home position Each coordinate is precise to three decimal places 000 000 in inches two decimal places 0000 00 in mm Note On systems that have not been upgraded to include limit switches the 0 0 position is the tool position when power is turned on To display the absolute X Y position 1 Press SELECT while in the STOP READY or STOP JOB mode 2 Press the right or left arrow key until Absolute X Y appears in the message box 3 Press SELECT to display the current position X 000 000 INCH Y 000 000 INCH 4 Press any arrow key to move the router carriage Release the arrow key to display the message box with the new coordinate position Press any key to exit 32 ADVANTAGE Router SET JOB HOME The job home position is the point that corresponds to the starting point of the job It is the point by which a job is positioned on the router table ART Path considers the current tool position to be job home The actual job starting position may be modified by a preposition either absolute or relative set in the ART Path Output dialog box The SET JOB HOME function allows the router operator to modify the home position after a job has been received at the ARC Box and the job header material and tool messages have been displayed The job home position of each job is stored when the job starts The RETURN HO
6. Hiei ees ede in oe 13 Power Guwitches a a a AE Ra AA reani 14 Main Power Switch 14 Emergency Power Gwitches AAA 14 Restoring EE 15 Router Motor Power Gwitch 15 ARC Box Router Control Gtaton E 16 OVO Wise ads eas did ER en 16 EA rates raed aes Sete e 17 Display Panel EE 17 PUIG een AA A 19 POW EE 19 Star Stop e PI E 20 Start Mode cc la 20 Start Ready EE 21 Slat JOD EE 21 Stop Ae 22 SHOP RT VE 22 Stop OD lla 23 Resume Processing ege eebe cher Ee ee SCENE 23 Change Tools teen 23 Repeat JOD ro 24 PROSC EREE AIEE Ee ee TE ane Od EE 25 In Menu Select Mode 25 In Other Modest rai n 25 ONIN tare cata ee eee ts cae tek etal tte hia Heth Ie Ta AS And a 26 Pero ML lion 26 Ein CT 28 Sel ele ble eee 29 USING Select aree iaten ranee AET TREA RR 29 Absolute AV 31 Le leie He ein 32 Job Home Position And Job Boundaries nonannnnnennnnaeannne 35 RRETUNAIAOMC gedeelt ebe 36 Feed Rate E 37 Motor Delay aca EE espe 39 Leet e A EE 40 Displa EE 41 Detalla a Ae Lr e De 43 EQUIPMENT INSTALLATION ocooocccccccnccccccnncccnononononononininono 45 Chip Removal SS Miceli dai 45 LIELER ee dee 45 Install The Vacuum Shroud cccoocccccccnccccccnnnccanc nana ca nano nncnn nana 46 Connect The Vacuum Tofhbebouter 47 SYSTEM PREPARATION AND USE occcccnnocccconicccccninoncnn 49 elei e In EE 50 Pens And Scribe Tools 50 Engraving EE 50 Cutting DK 51 Tool INFOFMATION oooonnccccncnccnccnnnannnnnananonano narco nor n conan
7. This function allows the user to set the language and units which display in the ARC Box message box and to turn Auto Scroll on or off When on Auto Scroll automatically scrolls messages that are too long to fit in the message box When Auto Scroll is off truncated messages are displayed Normally Auto Scroll should be left on To change the language 1 Press SELECT while in the STOP READY or STOP JOB mode 2 Press the right or left arrow key until Display appears 3 Press SELECT 4 Press the right or left arrow key until Language and the current language appear 5 Press the right or left arrow key to scroll through the language choices Language English 6 Press SELECT to save the selected choice 7 The system beeps twice and returns to the STOP READY or STOP JOB mode displayed in the entered language 42 ADVANTAGE Router To change units 1 Press SELECT while in the STOP READY or STOP JOB mode Press the right or left arrow key until Display appears Press SELECT Press the right or left arrow key until Units and the current units appear Press the right or left arrow key to scroll through the units choices inches or millimeters Units Inches Press SELECT to save the selected choice The system beeps twice and returns to the STOP READY or STOP JOB mode displayed To turn Auto Scroll on or off 1 Press SELECT while in the STOP READY or STOP JOB mode Press the right
8. get only the highest quality tool bits for use with the Router 600 60 ADVANTAGE Router Material Selection and Preparation The Router 600 can draw on any kind of material suitable for a ballpoint pen and cut virtually any routable material including those listed below ROUTABLE MATERIALS Plastics Woods Metals Acrylic Hard Aluminum Polycarbonate Soft Brass Phenolic Masonite Copper Styrene Plywood Bronze Foam Board Particle Board CAUTION Steel or stainless steel is not recommended for use with the Router 600 Because different routable materials have different densities varying cutting speeds are required A table of recommended cutting speeds for various materials is included at the back of this manual All metals require use of the Mist Coolant system System Preparation and Use 61 CHOOSING SACRIFICIAL MATERIAL Place a piece of sacrificial material under the paper or workpiece when cutting The best sacrificial materials are foam acrylic or pressed boards such as chip board and masonite Acrylic is recommended over pressed board because pressed board contains glue which is abrasive to cutters Abrasive materials can wear out the tips of cutters and degrade their plunge capabilities a When using acrylic as a sacrificial material remove the protective paper coating from the sacrificial acrylic surface Select sacrificial material of similar density to the material being cut No sacrificial materia
9. grounded outlet EMERGENCY POWER SWITCHES The emergency stop switches look like red mushrooms If an emergency occurs the operator can stop the router instantly by pressing the emergency stop switch The Router 600 table has two emergency power switches located on top of each beam end housing Operating Principles 15 Restoring Power The emergency power switches turn off all power to the router Restore power by turning on the main power switch specific to each router The router table emergency power switches on the Router 600 cannot be used to turn the router power on Router Motor Power Switch The router motor power switch turns the motor on and off The router motor has a thumb switch on the top labeled ON and OFF CAUTION The router motor switch should be off until the job is ready to begin DO NOT turn the router motor on when pen plotting or scribing The router motor must be OFF during vacuum shroud installation tool changing Z Axis initialization or when performing any other functions around the cutter When the job is ready to begin turn ON the router motor power switch Press the START key to start the job Note There is a delay before the tool begins cutting This delay gives the router motor time to come up to full speed before cutting begins and the operator time to stop the job if the router motor is not ON 16 ADVANTAGE Router ARC Box Router Control Station OVERVIEW The ARC Box is
10. nana n naaa nana 52 Gola ena en ad EE 53 Tool lnstallation EE 54 TOG ROMA a era 57 Tool Replacement a ini aba 58 Replacement Cutters AEN 59 Material Selection and Preparation oooonncccccnnnnccccccnoncncccncnnnncnnnnno 60 Routable Materials acorta 60 Choosing Sacrificial Mater 61 Attaching the Workpiece to Sacrificial Material 62 Hard Metals E 62 Thin d EE 63 Non Me etalS ai ege eege 63 E e WEE 64 Using Spray Adhesive ccccccecessseeeeeeeseeeeeeeeseeeeeeesseeaeees 65 Mounting the WOrkplOCe EE 66 SIR AMIS EE 66 BI le WEE 66 CU tas 66 Clamping the Material kA 67 Using the Chip Removal Gvstem 70 Pressure Foot And Pressure Foot Pad 71 Using the Mist Coolant System AEN 73 CLEANING AND MAINTENANCE AAA 75 Daly INSPECTION Get es coa s 76 Daly Oia ias is a A 77 A A heh aes 77 Cleaning the AR600 ungeet ege ege degen gege e ES SE 78 Work Table ti Sal eee deena eas 78 End HOUSIMOS EE 78 NA a daca tea Eege 79 Es ennet ane need eaea ra E OESR ESRA 81 GE 83 Replacing Belt Wipers wc conosca cio ci o 83 End Housing Linear Bearing Seals oococconnncccc nnncccccccnaccccccnnns 84 Y WAYS iS 85 K i 85 Po WAYS geegent 86 PoC EE 86 Router Motor Linear Bearing Seals c ccceeceeeeeeeeetneeeees 87 Mist Coolant Tank and Nozzle oocooooccccccoconcccnoncaccnnnananccnnnnnnancnnnnns 88 Check Mist Coolant ena annn a A i 88 Clean Mist Coolant Nozzle ooooooccconccconccconccconoc
11. or left arrow key until Auto Scroll appears Press SELECT Press the right or left arrow key to display On and Off Press SELECT to save the choice DEFAULT Operating Principles 43 This function allows the user to reset all value parameters back to the factory default settings To reset the defaults 1 Press SELECT while in the STOP READY mode 2 Press the right or left arrow key until Default appears 3 Press the SELECT key to reset all value parameters to the factory default settings The system beeps twice and returns to the STOP READY mode 44 ADVANTAGE Router EQUIPMENT INSTALLATION Chip Removal System OVERVIEW Because the router creates scrap chips while routing a shop vacuum is needed to remove the debris from the work area The shop vacuum is not supplied with the router system but all necessary extension hoses and fittings are provided A standard heavy duty wet dry shop vacuum such as the Sears Craftsman wet dry vacuum with a 2 5 inch 63 5 mm hose diameter is recommended WARNING Before installing the Chip Removal System turn OFF the router and unplug it from its electrical source Also unplug the router motor from the Z Axis housing The following steps outline the process for installing the Chip Removal System a Install the vacuum shroud Connect the shop vacuum to the vacuum block Before beginning installation be sure the collet retaining nut is installed on the router moto
12. pen scribe tool or cutting tool with a 2 diameter shank The other is a 25 inch collet intended for use with all 25 inch routing and engraving bits m A 25 inch bit must have a shank diameter of 249 250 and a 50 inch bit must have a shank diameter of 499 500 inches a If the routing bit has a 125 inch shank insert it into the 125 inch sleeve adapter provided and use the 25 inch collet The cleanliness of the collet and the spindle is essential Damaged surfaces will affect the holding ability of the collet Note Always make sure that the taper inside the spindle the taper outside the collet and the inside diameter of the collet are free of chips and debris The outside shank diameter of the cutting tool is an important factor in the collet s ability to hold tools tightly in place Use only cutting tools that are not more than 0 001 inch less than the nominal outside shank diameter Gerber authorized cutters comply with these tolerances 54 ADVANTAGE Router Tool Installation Solid carbide tools such as those included in the tool kit must be handled very carefully Do not strike the cutting edge with the collet or adapter during tool installation To install the tool 1 Turn OFF the router motor 2 Select the desired tool pen scribe engraver or cutter and the appropriate collet from the tool kit 3 Insert the tool into the collet Make sure the narrow end of the tapered collet points upward as s
13. the communication link between the GRAPHIX ADVANTAGE and the router system It can send and receive messages and commands to and from the GRAPHIX ADVANTAGE display messages to the operator control router motor movements change feed rates return the router carriage to the job home position set motor delay Operating Principles 17 FRONT PANEL The front panel of the ARC Box consists of a message display panel and nine function keys START STOP RESET Z INIT SELECT right left up and down arrow keys The ENTER key is not used DISPLAY PANEL The bottom right of the message display panel may contain four indicators for the operator W w Alternating uppercase and lowercase indicates that the router is waiting for a job a J j Alternating uppercase and lowercase indicates that there is a job ready for routing Pressing START will begin or continue processing the job i Alternating uppercase and lower case indicates the job is incomplete which occurs when a partial job is sent from ART Path Power interruption at the GRAPHIX ADVANTAGE or a pause status in the Plot Spooler application will cause partial transmission WARNING When the incomplete job indicator l i and START JOB are displayed the router may move without further warning The top right of the message display panel at times may contain an asterisk When a job is running and the operator presses the STOP key the asterisk appears t
14. 1 References in this manual to travel limits refer to the size of the table in the X and Y axes of movement unless otherwise specified 12 ADVANTAGE Router Z Axis The Z Axis of the router is the up and down movement of the tool The Z Axis represents the thickness of the material the cutting depth the engraving depth or when drawing the amount of downward pressure on the pen This axis of movement is controlled by the Z INIT function key aZ Axis adjustment knob located above the router motor the ART Path depth of cut Initializing the Z Axis is an essential procedure when using the ADVANTAGE Router 600 It establishes the location of the tool above the workpiece initially or at the start of a job Note The Z Axis must be initialized every time the tool or material is changed and whenever the operator prepares to cut draw or engrave Failure to initialize the Z Axis properly will cause the machine to cut at the wrong depth This may destroy the material and cause the tool to cut into the router table The workpiece and sacrificial material must be mounted on the router table when the Z Axis is initialized See the Z INIT portion in the ARC Box section in this manual for instructions on initializing the Z Axis Operating Principles 13 Job Home Position The job home position is the position on the router table that corresponds to the job 0 0 point or starting position of the job The job home position is st
15. ADVANTAGE ROUTER 600 USER MANUAL Gerber Scientific Products Error Switch argument not specified 151 Batson Drive Manchester Connecticut 06040 Document P54225A RevA COPYRIGHT NOTICE COPYRIGHT 1994 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 Advantage Router 600 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 2 This document or the contents herein under no circumstances shall be used in the manufacture or reproduction of the article shown and the delivery of this document shall not constitute any right or license to do so PRINTED IN U S A ADVANTAGE Router and ART Path are trademarks of Gerber Scientific Products Inc GRAPHIX ADVANTAGE is a registered trademark of Gerber Scientific Products Inc Sears Craftsman is a trademark of Sears Roebuck and Company 3 in 1 is a registered trademark of Boyle Midway Inc 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
16. ANTAGE Router Tool Information The tools supplied in the tool kit are basic tools for average cutting jobs As you gain more experience you may wish to purchase additional cutters The information below may be helpful in your use and selection of tools m The 25 inch cutter is the strongest cutter supplied and has a longer cutting edge length than the 125 inch cutter m The 25 inch cutter has a higher surface speed at the outside edge creating a higher chip removal rate and a smoother edge finish m The 25 inch cutter has a 0 75 cutting edge length Any material which is thicker than 0 75 requires a router bit with a longer cutting edge length m The 25 inch cutter creates a 125 inch radius on all inside corners a The 125 inch cutter creates a 0625 inch radius on all inside corners m A 25 inch bit may not fit through some openings If this occurs use the 125 inch cutter if possible a You may discover that characters can be cut smaller than the recommended limits If a 25 inch cutter is used double the size limit for the smallest characters in each style If larger bits are purchased scale the limitations proportionally for larger cutters Gerber sells a complete line of high quality cutting tools that provide optimum cutting performance Contact your Distributor for details Collets System Preparation and Use 53 The tool kit contains two collets One is a 50 inch collet intended for use with the
17. Debris and oil buildup Coolant buildup Coolant level Cleaning and Maintenance 77 Daily Cleaning SUPPLIES The daily cleaning procedures recommended are based on average use of the Router 600 Use the daily inspection to help establish a cleaning schedule that is appropriate for the router environment WARNING Before performing ANY cleaning procedure turn OFF the router and unplug it from its electrical source The following tools and supplies are recommended for the cleaning procedures Shop vacuum Lint free cloth Hand broom 1 25 mm nylon or natural bristle brush 2 5 mm and 4 mm hex wrenches Light machine oil 3 in 1 or equivalent CAUTION Do not use shop air to clean the Router 600 Shop air can drive chips into circuitry and cause damage 78 ADVANTAGE Router Cleaning the AR600 WORK TABLE Use a hand broom and lint free cloth to clean the router work table after each operation Use the hand broom to remove chips from around the router motor and the work table and the cloth to wipe the table clean END HOUSINGS The two end housings are located at either end of the router table beam Vacuum the chips from the end housings on a regular basis Complete the following steps to clean the end housings the steps are the same for both end housings Note Clean the X and Y belts before and after cleaning the end housings 1 Remove the end housing hood by lifting it up and off the housing 2 Wi
18. 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 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 1 Manual GontentS iii Chai Steinhart 2 CONVENTIONS cesta tds 2 ROUTER REQUIREMENTS eneren 3 System Specifications cid rindo 3 Serge EE 3 Compressed EE 3 Router Tables EE 3 Electrical Cabinet 5 cccc cece deeeceecnceecssvacesescetesssvesstacestasessvaccece 3 Router Package Contents AEN 4 TOOKIECON EE 5 SAFETY GUIDELINESGS 7 OPERATING DRINCIDLES cece cccccccceeeeeseeeeeeeseeeanaeeees 9 EEN 9 MN EE 10 EE 12 JOD Home Hosting ls
19. Lightly oil the X ways with light machine oil 3 in 1 or equivalent Complete these steps to clean the X belt 1 2 Locate the X belt between the two X ways Use a small brush to remove any chips or debris that might be clinging to the belt Move the carriage to the extreme right and clean Then move the carriage to the extreme left and clean This allows more area of the belt to be cleaned that cannot be reached inside the beam Note Clean the belts before and after cleaning the end housings Cleaning and Maintenance 87 ROUTER MOTOR LINEAR BEARING SEALS Locate the four linear bearings used by the router motor carriage to move along the X ways 1 Clean the linear bearings by wiping them with a lint free cloth to remove any debris 88 ADVANTAGE Router Mist Coolant Tank and Nozzle The mist coolant system requires two maintenance procedures Checking the mist coolant fluid level Cleaning the mist coolant nozzle CHECK MIST COOLANT Regularly check the mist coolant tank to ensure that it contains enough coolant to avoid running out during a job If the coolant level is low fill the tank to within 1 25 mm of the top of the level indicator Overfilling may result in leakage from the tank CLEAN MIST COOLANT NOZZLE The mist coolant nozzle which is blue is located on the router motor assembly Complete these steps to clean the mist coolant nozzle 1 Unscrew the white cap on the end of the nozzle 2 U
20. ME function returns the carriage to the stored job home position In the event of a power failure or other job interruption the operator can use the RETURN HOME function to return the router carriage easily to the stored home position To place multiple jobs in the same home position on the table the operator must use the Return Home parameter prior to sending the job from the GRAPHIX ADVANTAGE to move the motor carriage to the exact job home position Note If the motor carriage hits a clamp or fixture when moving position may be lost Turn power to the system off and on As instructed on the message display reestablish position by using the arrow keys to move the router carriage to the extreme front left point the point of orientation Operating Principles 33 To set job home The tool position when you press START STOP is the job home position unless a job preposition has been set in the Output dialog box in ART Path The preposition becomes the job home position You can set job home from the ARC Box using the following procedure 1 Slew the carriage to the desired job home position by pressing the arrow keys This position will be stored as job home when you press START STOP 2 Press SELECT while in the STOP JOB mode 3 Press the right or left arrow key until Set Job Home appears in the message box 4 Press SELECT The ARC Box will beep twice to indicate the position has been stored WARNING Do not use the Set Jo
21. There is more circuitry surrounding the Y axis motor than the X axis motor Use caution when cleaning the gear teeth 1 Unplug the router from its electrical source 2 Unplug the Y motor by removing the Y motor connector from its plug on the rear of the electrical cabinet The Y motor plug is clearly labeled and marked with a number on both the plug and the connector 3 Remove the end housing hood by lifting it up and off the housing 4 Locate the white gear on the torque tube 82 ADVANTAGE Router 5 Clean the gear teeth using a small dry brush Brush the debris out and away from the drive pulley 6 Reach in and around the gear box to locate the damper 7 Move the gear by turning the silver damper located on the end of the blue motor so the entire gear surface can be cleaned 8 When finished replace the end housing hood 9 Plug in the Y motor cable at the rear of the electrical cabinet CAUTION Be sure the X Y and Z motors are plugged in at the rear of the electrical cabinet before turning ON the router Cleaning and Maintenance 83 BELT WIPERS The belt wipers constantly sweep the Y belts keeping large chips from entering the end housing There is no need to remove the wipers to clean them Clean the wipers by using a shop vacuum to remove any chips Always inspect the belt wipers for worn or missing bristles Occasionally replacement is required REPLACING BELT WIPERS Follow the steps below to replace a be
22. als and thicknesses With experience noting the variations in workpiece size configuration rigidity of setup hardness of materials spindle speed in revolutions per minute and desired surface finish you may discover faster speeds are possible You may also decide to change the recommended Depth Per Pass amounts Pass Tool Depth Feed Plunge carbide per Pass Rate in min in min 1 4 acrylic 1 8 tool multipass 1 4 acrylic 1 4 tool single pass Basi 1 8 acrylic 1 8 tool single pass 1 2 PVC 1 4 tool multipass Finish 1 4 54 15 1 2 hardwood 1 4 O flute multipass Finish Is a eo 1 8 aluminum 1 8 tool single pass 1 4 aluminum 1 8 tool multipass Basic 1 4 aluminum 1 4 tool single pass 1 4 aluminum 1 4 tool multipass 5 Finish 15 1 8 brass 1 8 tool single pass 1 4 brass 1 4 tool multipass Finish INDEX A Absolute AV 31 ACTIVE pss ici 61 63 Axes of Movement 10 Dea E 10 C Changing Tools 23 Chip Removal System 45 70 chip shield oooomo 92 Clamping material 67 REI EEN 66 Cleaning belt WIpers een 83 lege 77 electrical cabinet air filters 93 end housing linear bearing SAS siehe ape 84 end housings 78 mist coolant tank and nozzle88 router motor chip shield 92 router motor linear bearing ld 87 Suppl Sicilia 77 SA 90 work table ooooommmooo
23. ark position within the job boundary Preposition set in ART Path is included in the job boundary If the Job Home position will cause the job being processed to exceed the table boundaries the ARC Box displays Job Will Exceed Table Boundary in the message box To clear the Boundary message 1 Press START STOP to display the correction necessary to permit the job to fit Press the arrow keys to move the carriage the distance in X and Y indicated in the message When the carriage is in an acceptable position the X and Y distances will be zero Press START STOP again If the job still exceeds boundaries the correction message is displayed again If the job fits Press START to SET HOME is displayed Press START STOP again to set the current position as Job Home and start the job 36 ADVANTAGE Router RETURN HOME The Return Home feature allows the operator to return the carriage to the last Job Home position The Job Home position is stored when a job is started or when the Set Home function is used To return home 1 To avoid hitting clamps or fixtures move the carriage near the home position using the arrow keys 2 Press SELECT while in the STOP READY or STOP JOB mode 3 Press the right or left arrow key until Return Home appears in the message box 4 Press SELECT to move the carriage to the precise Job Home position FEED RATE Operating Principles 37 The Feed Rate is set in ART Path at the GRAPHIX
24. b Home parameter to reset job home after cutting has begun The carriage will move unpredictably when the job is restarted To change job home Move the carriage to any position on the table and repeat the steps above The new position replaces the previously stored position in the ARC Box 34 ADVANTAGE Router To display current job home 1 To avoid hitting clamps slew the carriage near the home position using the arrow keys Press SELECT while in the STOP READY or STOP JOB mode Press the right or left arrow key until Return Home appears in the message box Press SELECT to move the carriage to the precise Job Home position Press the right or left arrow key until Absolute X Y appears in the message box Press SELECT to display the current position This is the current Job Home position Note Make note of this position If the carriage hits a clamp or fixture and router position is lost you can slew to this position or set an absolute preposition in ART Path and repeat the job Operating Principles 35 JOB HOME POSITION AND JOB BOUNDARIES Job boundaries cannot exceed the active cutting area of the router table The Advantage Router and ART Path interpret job boundaries for certain job types in these ways Output repeats includes all repeats within the job boundary Paneled jobs are treated as separate jobs The largest panel must fit on the table within job boundaries Inplace repeats includes the p
25. curs SET HOME is selected from the menu m the job completes m the operator presses RESET to abort the job and clear it from the ARC Box the ARC Box receives a terminate command from the GRAPHIX ADVANTAGE Plot Spooler STOP JOB Operating Principles 23 Pressing the START STOP key while in the START JOB mode enters PAUSE mode and results in the following the STOP JOB message appears no incoming data processes the job stops at the next logical break point the tool raises the router motor turns off an asterisk appears in the upper right corner of the message display When in PAUSE mode you can slew the router for tool changes or other tasks Press START STOP to return the router tool to the position in the job where the system was paused The job can be resumed without position or data loss RESUME PROCESSING 1 CHANGE TOOLS After pausing temporarily press the START key to resume processing without position or data loss If a tool change is required follow these steps 1 In STOP JOB mode slew the machine to a safe tool change position Note The machine remembers the tool position when a tool is changed during a job and returns from slew to the appropriate location Turn OFF the router motor and disconnect the power cable Change the tool See the sections on Tool Installation and Tool Replacement in this manual if necessary Initialize the Z Axis See the Z INIT function key explanation
26. e 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 ROUTER REQUIREMENTS System Specifications The purchase of a Router 600 includes complete unpacking installation and testing performed by Gerber Field Service when installed within the continental United States However the system does have specific work area power and compressed air requirements which must be supplied before Gerber Field Service can uncrate and install the system ELECTRICAL A 208 230 or 250 V single phase 20 Amp circuit 47 63 Hz ona dedicated line Gerber supplies a receptacle to be installed by a licensed electrician COMPRESSED AIR The mist coolant system requires 0 5 CFM at 40 to 90 psi which can be supplied by a 1 4 to 1 2 horsepower compressor ROUTER TABLE 100 2 500mm wide x 140 3 500mm long x 54 1 350mm high assembled ELECTRICAL CABINET 18 450mm wide x 33 825mm long x 32 800mm high 4 ADVANTAGE Router Router Package Contents The Router 600 is packed in four crates Check each part against the list and inspect all parts for any damage which may have occurred during shipping Crate 1 Packaged Beam Assembly 1 Beam assembly Crate 2 Packaged Large Componen
27. er DO NOT position the router motor over the table without any material underneath The tool might fall out when the retaining nut is loosened breaking or damaging the cutting edge To remove a tool 1 Use the slew keys to position the router motor near the front of the router table 2 Turn OFF the router motor 3 Loosen the retaining nut using one wrench while holding the router motor chuck firmly with the other wrench CAUTION Never strike the tool from the side to remove it Striking the tool will damage the spindle motor bearings 4 Remove the tool from the collet 58 ADVANTAGE Router Tool Replacement To replace a pen 1 2 3 4 5 Unscrew the top of the pen assembly Remove the spring Remove the pen Insert the replacement pen into the pen barrel Replace the spring and replace the cover on top of the barrel To replace a scribe tip 1 2 Unscrew the top of the scribe assembly Remove the spring Remove the scribe tip Insert the replacement scribe tip into the barrel and replace the spring Replace the cover on top of the barrel System Preparation and Use 59 Replacement Cutters Replacement cutters are available from Gerber Different cutters purchased from other dealers may or may not provide satisfactory results with the Router 600 Gerber is not responsible for results obtained with cutters not recommended in this manual or purchased from other dealers Be sure to
28. esive is especially suitable for securing plastic styrofoam wood or other non metallic materials Spray Adhesive is available at most industrial and office supply distributors The 3M Super 77 Spray Adhesive is recommended Low tack tape may also be appropriate for certain types of wood which tend to splinter when the tape is removed if the tape is the high tack type Note When using acrylic materials as workpieces do not remove the protective paper sheets which preserve the acrylic surface from scratches during cutting If the acrylic materials are supplied unmasked you may wish to apply the transfer tape before spraying on the adhesive 64 ADVANTAGE Router USING TAPE Follow these guidelines when using tape to attach the workpiece to the sacrificial material a Place the tape in closely spaced strips Do not overlap the strips Make sure the centers of letters like O B and P are held securely by the tape To use double sided tape Follow these steps when using double sided tape to secure the workpiece to the sacrificial material 1 Lay the tape across the underlying material 2 Place the workpiece on top of the tape 3 Press firmly to bond securely System Preparation and Use 65 USING SPRAY ADHESIVE Refer to the manufacturer s suggestion on the can Follow these steps when using spray adhesive to attach the workpiece to the sacrificial material WARNING Apply spray adhesive only in a well ventila
29. g Carefully secure the workpiece with clamps Use the proper tool for the material Do not use small tools with heavy material Make a test cut whenever possible to test the tool in the material Perform all periodic maintenance procedures on a regular basis OPERATING PRINCIPLES Overview The ADVANTAGE Router 600 consists of these major components the Router Table which includes the work table the beam and the router motor carriage the electrical cabinet m the Router Control Station also called the ARC Box which controls the start stop slew Z initialization and job home position functions Text and graphics are cut engraved scribed or drawn at the router table after being created and sent from the GRAPHIX ADVANTAGE system During router operation the cutting table and clamped workpiece remain stationary All operating motion is performed by the router motor beam and tool Note It is essential to read this section before trying to operate the ADVANTAGE Router This section introduces the operating principles of the router system 10 ADVANTAGE Router X Y Z Axes The ADVANTAGE Router 600 has three basic axes of movement The X horizontal axis is oriented from left to right The Y horizontal axis is oriented from front to back The Z vertical depth axis is oriented up and down When the router cuts a sign the tool moves in the X Y and Z axes of movement Operating Principles 1
30. hown below System Preparation and Use 55 When installing the pen or scribe tool the bottom of the collet should be positioned about half way up the barrel of the tool When installing an engraving bit position the bottom of the collet about halfway up the shank of the tool When installing a router bit position the bottom of the collet approximately even with the top of the flutes The collet should not cover any portion of the flutes and very little of the straight portion of the shank should be exposed below the collet Slew the router motor near the front edge of the router table Remove the retaining nut from the base of the router motor using the wrenches supplied in the tool kit 56 ADVANTAGE Router 6 Be sure that the collet and spindle are clean and undamaged 7 Insert both the tool and collet into the opening at the base of the router motor as shown below 8 Hold the collet to prevent the tool from falling out and hand tighten the retaining nut 9 Hold a wrench in one hand and place it on the flats of the router motor chuck 10 Hold the other wrench in the opposite hand and place it on the flats of the retaining nut 11 Tighten the retaining nut by pushing the wrenches with a firm even force 12 Turn ON the router motor System Preparation and Use 57 Tool Removal CAUTION When removing a tool do not attempt to gain leverage by jamming one wrench against the carriage while pushing on the oth
31. in this section of the manual if necessary 24 ADVANTAGE Router REPEAT JOB Change the Feed Rate parameter if necessary Turn ON the router motor To avoid hitting clamps manually slew close to where the job will resume Press the START STOP key to continue the job The router will return to the pause position then enter STOP JOB mode Press START STOP again to resume the job To repeat a job at the same position as the previous job before pressing START STOP 1 Press SELECT while in the STOP READY or STOP JOB mode to access the Menu Select mode Press the right or left arrow key until Return Home appears in the message box Press SELECT The motor carriage will move to the job home position Press START STOP to begin processing the job Operating Principles 25 Reset The RESET function key immediately halts the job that is d running Y IN START MODE If in START JOB mode and the operator presses the RESET key m the tool raises Xand Y travel stops current job data from the router and the GRAPHIX ADVANTAGE clears the STOP READY message displays Note The tool completes its drill cycle plunge and raise before stopping IN MENU SELECT MODE RESET exits the menu without saving changes IN OTHER MODES If in any other mode and the operator presses the RESET key the ABORT message appears To cancel the job press the RESET key again To continue the job without data los
32. l is required when engraving 62 ADVANTAGE Router Attaching the Workpiece to Sacrificial Material When not cutting to the mask attach the workpiece to the sacrificial material using one of the following methods Double Sided High Tack Tape Double Sided Tape m Spray Adhesive Follow the guidelines below when attaching the workpiece to the sacrificial material before mounting the workpiece on the table mats HARD METALS For brass other metals or hard wood Use Double Sided High Tack Tape Specially formulated Double Sided High Tack Tape is unaffected by mist coolant spray and is especially suitable for securing metals which produce high cutting forces High Tack Tape is available through Gerber or most industrial and office supply distributors Note Using both tape and spray adhesive is a good alternative on rough textured wood THIN METALS NON METALS System Preparation and Use 63 For thin aluminum or other thin metals Use less aggressive Double Sided Tape The 3M 410 Double Sided Tape is especially suitable for securing thin aluminum or other light materials to avoid bending the metal when lifting the material after cutting The 3M tape is available at most industrial and office supply distributors Note Do not use foam filled Double Sided mounting tape Spray adhesive works well on thin aluminum For plastic styrofoam thin wood or other non metallic materials Use Spray Adhesive Spray Adh
33. llowing precautions These guidelines are necessary for the safe and efficient operation of the ADVANTAGE Router WARNING Do not store wet aluminum chips in a closed container and do not use the vacuum hose to clean up wet aluminum Wet aluminum produces hydrogen gas This gas may reach explosive concentrations when wet aluminum chips are stored in a closed container 1 2 Only a trained operator should attempt to run the equipment Do not use the router in a damp or wet location Stand in front of the ARC box during system operation to provide easy access to the RESET key and the system power circuit breaker This also prevents any clothing from getting caught in the machine Keep the work area clear for easy access to the emergency stop switches These are located at each end of the router table beam Turn the router motor OFF or unplug the router when changing tools Wear protective eyewear such as goggles or safety glasses to cover the front and sides of the face Tie back or cover long hair Remove loose jewelry ties and loose clothing Wearing a long sleeved shop coat is strongly recommended 8 ADVANTAGE Router 9 10 11 12 13 14 15 Wear ear protection Do not operate the machine with the electrical cabinet doors open Doing so will expose high voltage circuitry to material chips and affect cooling airflow Keep all personnel at a safe distance from the machine when it is operatin
34. lt wiper 1 Using a 2 5 mm hex wrench remove the two screws that hold the belt wiper in place and remove the old belt wiper 2 Align the new belt wiper so that the bristles are touching the belt 3 Replace and fully tighten the two screws that hold the belt wiper in place 84 ADVANTAGE Router END HOUSING LINEAR BEARING SEALS 1 Locate the linear bearing seals beneath the two end housings one linear bearing seal on either side of the end housing 2 Clean the linear bearings by wiping them with a lint free cloth to remove any debris Y WAYS Y BELTS Cleaning and Maintenance 85 The Y ways are the rods on which the beam moves There is one Y way on each side of the work table running the length of the work table 1 Locate the Y ways 2 Clean the Y ways by wiping them with a lint free cloth 3 Lightly oil the Y ways with light machine oil 3 in 1 or equivalent Next to each of the Y ways is a belt that is used by the Y axis motor to move the router beam along the Y ways Although each belt is swept constantly by a belt wiper regular cleaning is still required 1 To clean the Y belts brush away chips and debris that may be clinging to the belts 86 ADVANTAGE Router X WAYS X BELT Complete these steps to clean the X ways 1 Locate the two X ways The X ways are the rods located on the beam on which the router motor carriage moves Clean the X ways by wiping them with a lint free cloth
35. n the tool so there is a 200 inch 5 mm overlap extending beyond both edges of the corner on the left front slat as shown in the diagram At the GRAPHIX ADVANTAGE select the output device GAGR3MILL 1 in the Router Select option in Art Path Open a file called AR600MIL RTP If cutlines appear select the output device again Note A plot file called AR600MIL RTP in Art Path is available if changes to the size of the table are necessary Double click on AR600MIL RTP The Current Engraving Info Dialog Box appears Set the Total Depth to the amount of surface to be removed depending on the roughness of the table surface Click on Generate Click on Output Click on Rout in the Job Output Dialog Box After the data is received at the console the system beeps Press START to run the job Cleaning and Maintenance 97 Maintain Overlap 14 Check every third slat to ensure that the tool remains lined up correctly 15 If the overlap is lost do the following Press STOP Reposition the tool m Press RESET 16 Return to ARGOOMIL RTP in Art Path and delete the completed slats ones which have been resurfaced 17 Resend the job from the GRAPHIX ADVANTAGE 18 At the STOP READY message press START to run the job 98 ADVANTAGE Router FEED AND DEPTH PER PASS VALUES This section lists the recommended Feed Rate in inches per minute and Depth Per Pass values used with a 1 4 and 1 8 cutter for various materi
36. o show that the machine has received the message and will stop at the next logical point 18 ADVANTAGE Router Power Up Tests When the power is turned ON the ARC Box performs diagnostic self tests and displays the operating set revision level If the Advantage router is equipped with the job home feature the ARC Box requests the operator to slew the motor carriage near the point of orientation which is the absolute 0 0 point To slew to the point of orientation use the arrow keys to move the motor carriage as far toward the front and to the left as possible When the carriage is at 0 0 the carriage will move away from the limit a preset distance in X and Y The ORIENTATION message will appear in the display panel followed by the STOP READY message If an error occurs The system emits a constant audible tone m Press the RESET key to clear the error and to rerun the failed test s Ifthe same error recurs or if RAM ERROR ROM ERROR or INTR_ERROR is displayed contact the Router Support Group at 800 336 1698 USA and Canada When testing successfully completes the STOP READY message displays Operating Principles 19 Function Keys The function keys located on the front panel of the ARC Box perform specific routines Each function key is discussed individually in the following pages ARROW KEYS The arrow keys are most frequently used to slew the router Lo i gt carriage into position Slewing refers to p
37. ode If the value is not valid the display remains until a valid value is entered or until RESET is pressed to exit the menu without changing the Feed Rate MOTOR DELAY Operating Principles 39 The Motor Delay parameter sets the time the tool will wait for the router to reach full speed before it descends to the material Valid values are 0 to 99 seconds To change motor delay 1 Press SELECT while in the STOP READY or STOP JOB mode Press the right or left arrow key until Motor Delay appears in the message box Press SELECT to obtain the Motor Delay time Motor Delay 01 Press the right or left arrow keys to move the cursor to the desired digit Press the up or down arrow keys to increase or decrease the digit under the cursor Acceptable values are 00 to 99 Press SELECT to save the new value or RESET to exit without saving the value 40 ADVANTAGE Router TEST This function allows testing the router and the ARC Box to ensure machine accuracy and integrity The ARC Box does not accept data from the GRAPHIX ADVANTAGE during testing A power on test restarts the system displays the revision level of the system and repeats orientation of the motor carriage at the lower left corner of the table The remaining tests are not used by the operator CAUTION The X and Y line test must be started only from the extreme lower left position orientation point on the table DISPLAY Operating Principles 41
38. ononccnnnccinnnnnnno 88 Weekly Inspection is 70 7EuEIRSEE EE EEN Eege EEN 89 Weekly Cleaning AAA 90 KENE 90 Router Motor Chip Shield kA 92 Electrical Cabinet Air Filters ANEN 93 E Elle iia ias 95 Feed And Depth Per Pass Values AA 99 INTRODUCTION The ADVANTAGE Router 600 can provide all the lettering and graphic design capabilities of the GRAPHIX ADVANTAGE Composer to dimensional signage The ART Path Software Option enables the GRAPHIX ADVANTAGE to fully control the router operation The user routs jobs directly from the GRAPHIX ADVANTAGE through the Router Control Station ARC Box communicator The ADVANTAGE Router can cut designs from a wide variety of materials as well as scribe engrave or draw all types of text or graphics This manual provides instructions in safety operation and maintenance for the ADVANTAGE Router 600 referred to as AR600 Your ADVANTAGE Router is a computer controlled machine tool and should be operated only by trained operators The safety guidelines in this manual must be followed at all times to avoid risk of injury 2 ADVANTAGE Router Manual Contents This manual covers the basic information needed for using the AR600 It is arranged as follows Requirements and package contents Safety guidelines Principles of operation Basic system preparation and use Cleaning and maintenance procedures Conventions The following conventions are used in this manual Note A not
39. ored in the ARC Box and is maintained even when power is interrupted The job home position start position is also controlled by ART Path ART Path considers the current tool position to be job home The actual job starting position may be modified by a preposition either absolute or relative set in the ART Path Output dialog box The SET JOB HOME ARC Box function allows the router operator to modify the home position after a job has been received at the ARC Box and the job header material and tool messages have been displayed The job home position of each job is stored when the job starts The RETURN HOME ARC Box function returns the carriage to the stored job home position In the event of a power failure or other job interruption the operator can use the RETURN HOME function to return the router carriage easily to the stored home position This also simplifies starting multiple jobs from the same position See the SET JOB HOME and RETURN HOME descriptions in the ARC Box section of this manual for more information Also see the ART Path User Manual for information on job positioning 14 ADVANTAGE Router Power Switches MAIN POWER SWITCH This power switch turns the router power on and off The Router 600 main power switch is located on the front panel of the electrical cabinet Before turning on the main power switch make sure that the control station power supply is connected to both the control station and the appropriate
40. ositioning the X ONES Me and Y axes where desired ge an The arrow keys are also used to scroll through available TL 4 choices after a selection has been made in the Menu Select we OH mode See the page in this section on Menu Select mode To slew the carriage To position the tool to the left or right over the router table surface press the left or right arrow keys until the desired placement is reached To position the tool forward or backward over the table surface press the up or down arrow keys until the desired placement is reached To slew diagonally press two keys at the same time left or right with up or down m You cannot slew past the table edges if the router is equipped with the limit switch feature 20 ADVANTAGE Router Start Stop e START MODE This key toggles between the START and STOP modes START mode as shown by a message in the display panel may be in one of two states START READY the system is ready to receive a job START JOB the system has received a job and is processing it The following keys are available in START mode RESET immediately aborts router movement and purges the job START STOP pauses processing the job Operating Principles 21 START READY START JOB 1 While in the STOP READY mode use the arrow keys to slew the carriage to the starting location of the job 2 Press the START STOP key to display the START READY message The AR600 is no
41. p of debris use a brush to clean the screen Cleaning and Maintenance 93 ELECTRICAL CABINET AIR FILTERS The air filters help prevent debris from entering the electrical cabinet and ensure clean air circulation which prevents the electrical cabinet from overheating There are two air filters located inside the electrical cabinet The Air Intake Filter is located on the front panel of the electrical cabinet The Air Exhaust Filter is located in the rear door of the electrical cabinet Both filters should be checked and cleaned weekly until a cleaning schedule appropriate for the environment can be established WARNING Before opening the electrical cabinet always turn it off and unplug it from its electrical source Complete the following steps to clean the electrical cabinet air filters 1 Use a 4 mm hex wrench to open the front door of the electrical cabinet 2 Make sure the circuit board lights are OFF If the circuit board lights are ON wait for them to fade out WARNING Electrical Shock Do not reach inside the electrical cabinet if the circuit board lights are ON 94 ADVANTAGE Router 3 Reach inside the electrical cabinet and release the Air Intake Filter from its bracket and carefully remove it Avoid touching any of the electrical cabinet circuitry with the filter as you remove it The Air Intake Filter is lined with black foam DO NOT remove the foam from the filter Use a shop vacuum to clean the filte
42. r Make sure the vacuum is pointed at the black foam so the particles that are lodged in the foam will be forced out Return the Air Intake Filter to its bracket with the foam side facing the door Close the cabinet door Use a 4 mm hex wrench to open the rear door of the electrical cabinet The Air Exhaust Filter is installed in the door itself There is no need to remove the Air Exhaust Filter 10 Use the shop vacuum to clean the filter 11 Close the cabinet door 12 Plug in the electrical cabinet and turn ON the power Cleaning and Maintenance 95 Table Surfacing The table of the Router 600 may need to be resurfaced periodically The frequency of resurfacing depends on how badly the surface is scratched or marred The resurfacing process takes about two hours total run time approximately ten minutes per slat Resurfacing Procedure 1 Change the tool to a 1 inch 25 mm end mill 2 Perform Z initialization Note It is recommended that Z initialization be performed on the extreme right slat so that if reinitialization is needed during the resurfacing process the surface will be at the original height rather than the modified height from the resurfacing D x RESURFACE START Z INIT 96 ADVANTAGE Router Establish Start Location 3 4 Set Up Job 5 10 11 12 13 Slew the machine all the way to the left front Positio
43. r a tool need not be installed 46 ADVANTAGE Router INSTALL THE VACUUM SHROUD 1 Using the Z Axis adjustment knob raise the router motor to its highest position 2 Rotate the locking key handles located on each side of the motor carriage until the handle points down 3 Slide the vacuum shroud onto the motor carriage using the locking handle studs and the pins in the rear to get the location correct 4 Rotate the locking key handles 90 to secure the vacuum shroud Equipment Installation 47 CONNECT THE VACUUM TO THE ROUTER 1 Connect the free end of the long vacuum extension hose into the open end of the vacuum tube Connect the shop vacuum to the vacuum tube Plug the shop vacuum power cord into the outlet marked VACUUM located on the rear panel of the electrical cabinet 48 ADVANTAGE Router SYSTEM PREPARATION AND USE This section discusses procedures to follow prior to and during the operation of the Router 600 Procedures covered are as follows Selecting installing removing and replacing tools Choosing sacrificial material Attaching the workpiece using tapes or spray adhesive Mounting the workpiece Using the Chip Removal System Using the Mist Coolant System Before preparing the Router 600 for operation complete the following steps 1 Turn OFF the electrical cabinet power switch 2 Move the router motor up by manually turning the Z Axis adjustment knob located on top of the Z Axis motor
44. s press START STOP 26 ADVANTAGE Router Z INIT D The Z INIT function key initializes the Z Axis tool height above the work surface The Z INIT key may be used only when the STOP JOB or STOP READY message displays You may use either the tool height gage or the step height gage for initialization Use of the step height gage is described in the Engraving section of this manual PERFORM Z INIT 1 2 Place the tool height gage on top of the material to be cut Slew the tool over the gage Press the Z INIT key The Z motor is now OFF to allow for manual adjustment The Z Unlocked message appears Turn the Z axis knob to lower the tool until it just touches the surface of the tool height gage Note Excessive pressure will cause tool damage Press Z INIT to raise the tool Note If RESET is pressed the Z motor locks and the Z INIT process is exited Remove the tool height gage Operating Principles 27 CAUTION Do not turn the Z Axis knob after the Z axis has been initialized The Z Axis must be initialized every time the tool or material is changed Failure to initialize the Z Axis properly will make the tool cut into the material at the wrong depth This may destroy the material and cause the tool to cut into the router table 28 ADVANTAGE Router Enter This function key is not used in this release Press SELECT to exit a selection and store values Press RESET to exit a selection without
45. se a lint free cloth to clean the tip of the nozzle 3 Replace the white cap Weekly Inspection COMPONENT Z Axis ways Router motor screen Electrical cabinet air filter Cleaning and Maintenance 89 WHAT TO CHECK FOR Debris buildup Chip and coolant buildup Dirt buildup on filter element 90 ADVANTAGE Router Weekly Cleaning The weekly cleaning procedures include the following the Z Axis ways the router motor chip shield the electrical cabinet air filters Z AXIS WAYS 1 Locate the Z Axis ways on either side of the router motor 2 The Z Axis ways may be protected by spring like metal covers 3 Lower the router motor to its lowest position by turning the Z Axis adjustment knob 4 Clean and oil the upper part of the Z Axis ways using a light oil such as 3 in 1 For each way first slide the metal cover upward and hold it in place Cleaning and Maintenance 91 5 Use a lint free cloth to clean the way 6 Lightly oil the axis way with light machine oil 8 in 1 or equivalent 7 Replace the cover 8 After cleaning the upper part of the Z ways raise the router motor to its highest position by turning the Z Axis adjustment knob 9 Use a lint free cloth to clean the way Lightly oil the way Replace cover 92 ADVANTAGE Router ROUTER MOTOR CHIP SHIELD The router motor chip shield is located above the tool assembly Clean the screen by wiping it with a damp cloth If there is a noticeable build u
46. storing values Operating Principles 29 Select i This function key allows access to the Menu Select mode a N to set system parameter values Itis available in STOP mode when the STOP READY or STOP JOB message is displayed V USING SELECT To access the Menu Select mode press SELECT while in the STOP READY or STOP JOB mode The choices available are as follows Absolute X Y Feed Rate Motor Delay Set Job Home Return Home Test Default Display A colon following a menu selection indicates additional choices are available when the item is selected Each menu selection is explained and contains directions on changing parameters To exit the Menu Select mode and return to STOP JOB mode without changing settings press RESET 30 ADVANTAGE Router To make a selection in Menu Select mode 1 Press the right arrow key to scroll forward right through the menu list or press the left arrow key to scroll backward left through the menu list 2 When the desired menu item appears press the SELECT key to display the choices available under the selected menu item if the item is followed by a colon or to execute the function 3 Use the arrow keys to display available choices Operating Principles 31 ABSOLUTE X Y The Absolute X Y function displays the exact position of the router tool relative to the absolute 0 0 position on the router table established during orientation when the router was turned on The
47. te the following steps 1 Press the slew key to move the router carriage to the back of the router table Place the workpiece in the center of the router table Locate the work clamps in the tool kit Each work clamp consists of a T nut a clamp and a knob and screw assembly Insert the knob and screw assembly through the center of the clamp 68 ADVANTAGE Router 5 Screw the T nut onto the bottom of the knob and screw assembly and then slide the work clamp into the router table slot System Preparation and Use 69 6 Position the work clamp next to the edge of the workpiece 7 Tighten the work clamp 8 Slew the router motor and tool over the workpiece CAUTION When moving the router motor with the slew keys or during router operation take care not to run the vacuum shroud into the work clamps 70 ADVANTAGE Router Using the Chip Removal System Use the Chip Removal System when cutting plastic Styrofoam and wood Disconnect the removal system when pen plotting scribing or cutting metals such as aluminum or brass The Chip Removal System cannot be used with the Mist Coolant System To use the chip removal system 1 Make sure that the Chip Removal System has been properly installed 2 Turn ON the vacuum at the start of the job 3 Press the START key on the ARC Box to start the job System Preparation and Use 71 PRESSURE FOOT AND PRESSURE FOOT PAD The Chip Removal System includes a pressure foot
48. ted area 1 Spray the adhesive in smooth even strokes across the back of the workpiece Coat the entire surface uniformly including edges and corners until tacky but not wet 2 Then press the workpiece firmly onto the sacrificial material CAUTION Spray adhesive is sticky Do not spray near the router table 66 ADVANTAGE Router Mounting the Workpiece USING CLAMPS DRAWING CUTTING After adhering the workpiece to the sacrificial material attach the entire workpiece to the router table with work clamps The more work clamps used the more securely the workpiece will be held in place The appropriate number of work clamps depends on several factors the size of the letters being cut the size of the workpiece the density of the workpiece material the selected cutting speed If the workpiece is thick use a clamp block of equal thickness under the free end of the work clamp to keep the clamp level and maximize its holding ability Make sure the work clamps are not in the tool path When drawing use two to four work clamps to hold the paper and sacrificial material securely in place If the workpiece is small two clamps located opposite each other should work well When cutting use four or more work clamps to hold the workpiece and sacrificial material securely in place System Preparation and Use 67 Clamping the Material After attaching the workpiece to the sacrificial material on the table mats comple
49. ten System Preparation and Use 73 Using the Mist Coolant System The Mist Coolant System has been designed to be used with Gerber Cool coolant Using other types of fluids may damage the system Note Gerber Cool should not be diluted prior to use CAUTION DO NOT use toxic or volatile liquids The adjustable drip rate allows for a wide range of mist wetness and cooling capability The evaporation of the mist provides the desired cooling effect and minimizes heat build up of the remaining lubricant as well 1 Turn on the compressor and set the air pressure at 20 40 psi as indicated on the mist coolant air pressure gage To increase air pressure turn the air pressure regulator clockwise To decrease air pressure turn the air pressure regulator counterclockwise 2 Remove the brass filler plug using a flat head screwdriver and fill the reservoir with Gerber Cool coolant The reservoir should remain full to assure proper lubrication Add coolant periodically to maintain the level 3 Adjust the coolant nozzle so that it is directed at the point of cutting CAUTION Keep the nozzle at a safe distance to avoid damaging it with the cutter 4 Open the shut off valve near the nozzle coupling mounting block When open the handle is aligned vertically with the coolant tubing 74 ADVANTAGE Router 5 Starting with a drip rate of six drops per minute adjust the drip rate and air pressure to provide a mist wet enough to create a
50. th a shop vacuum carefully remove any chips that may have entered the housing area 3 Before replacing the end housing hood determine if the motor gears need cleaning If not replace the hood by sliding it back into place Cleaning and Maintenance 79 X AXIS MOTOR GEARS The X axis motor is located inside the end housing to the left of the router motor Complete the steps below to clean the X axis motor gear teeth 1 Unplug the router from its electrical source 2 Unplug the X motor by removing the X motor connector from its plug on the rear of the electrical cabinet The X motor connector is clearly labeled and marked with a number on both the electrical cabinet and the connector 3 Remove the end housing hood by lifting it up and off the housing 4 Locate the two white gears in the X axis motor 80 ADVANTAGE Router 5 Use a small dry brush to clean the gear teeth Use the silver damper located on top of the blue motor to turn the gears so that the entire surface on both gears can be cleaned 6 When finished replace the end housing hood 7 Plug in the X motor cable at the rear of the electrical cabinet CAUTION Be sure the X Y and Z motors are plugged in at the rear of the electrical cabinet before turning ON the router Cleaning and Maintenance 81 Y AXIS MOTOR GEARS The Y axis motor is located to the right of the router motor Complete the steps below to clean the gear teeth in the Y axis motor Note
51. to hold material flat against the router table to prevent it from lifting while routing The pressure foot also makes the router safer by preventing chips and small pieces of material from being thrown out of the machine while routing Using the pressure foot saves time and money by reducing the need for bonding and sacrificial material The pressure foot has a removable pad that rests on the workpiece and slides smoothly over it during cutting operations The tool extends through an opening in the pressure foot pad Two pads are supplied one with a 1 5 38 mm diameter opening for normal use and one with a 0 4 10 mm diameter opening for cutting very small pieces without risk of pulling the piece off the table and into the vacuum To replace the pressure foot pad Use the following procedure to change the pressure foot pad HELPFUL HINT You may want to remove the router motor or vacuum shroud to make replacement easier 1 Remove the pressure foot window by removing two screws that secure it to the pressure foot 2 Remove four screws that secure the pressure foot pad to the pressure foot 3 Remove the cushion from the pad and place it on the replacement pad aligning the screw holes 4 Align the pad screw holes with the holes on the pressure foot 5 Replace the screws and tighten just enough to compress the cushion slightly 72 ADVANTAGE Router 6 Replace the pressure foot window 7 Replace the screws and tigh
52. ts 18 Router Maintenance 75 router motor chip shield 92 Router Motor Power Switch 15 Ki Sacrificial material 61 62 Scribe tip WE 58 Scribe tools sescscserpescdesteesencteans 50 Shop VACUUM eocccconnccccncnancncnnnn 45 LOW ica E ET 26 Spray adhesiVe 62 65 System Specifications 3 Tool EE 5 T ET 64 Thin metals e 63 TOO Mia 5 Tools A iertnstasa i 51 ONOTAVINO cocoa as 50 Ipform aen 52 installatiON 54 A EA 58 CN 57 replacement 58 59 Gel e E 58 Travel limits 11 W Weekly Cleaning 90 Work Clamps ccccccooocnonoccccncccnnnn 66 Workpiece attachment 62 MOUNTING EE 66 using double sided tape 64 using spray adhesive 65 El ee 64 X EE EE Ee 10 SE 86 PEW AWS ee 86 YAMS EEN Goen 10 Y Pells EE 85 K 85 Z Z AMIS n a 10 12 26 46 49 ROUSING EE 45 Initializing 12 15 24 26 95 Z AX S was 89 90 ZANT EE 12 24 26
53. ts 5 Cross member machining 8 Angle support machining 4 Leg assembly Crate 3 Packaged Frame and Table Top 1 Left side frame assembly 1 Right side frame assembly 1 Frame cable assembly 12 Router 600 table top assemblies 2 Table end machining 1 Cable support plate 1 Cable guide Crate 4 Packaged Small Components 1 Accessory kit 1 Electrical cabinet assembly 1 Hardware kit 1 1 gallon coolant tank 1 Router Control Station ARC Box 1 3 1 4 hp motor 1 Hose and cable guard box 1 GRAPHIX ADVANTAGE interface components 1 Vacuum shroud and pressure foot 1 Hose channel assembly Router Requirements 5 Tool Kit Contents Tool Kit contents are listed below and are identified in the photograph Metric sizes are shown in parenthesis 1 4 6 mm 2 spiral flute bit solid carbide endmill cutters 1 8 3 mm 2 spiral flute bit solid carbide endmill cutters 7 8 carbide V cutter 3 4 carbide ball cutter Scribe tool Pen tool Knob and screw assemblies T nuts Work clamps Tool height gage Step height gage 1 4 socket coupling hose 1 4 plug coupling hose 1 8 tool collet adapter 1 4 3 mm tool collet 1 2 6 mm tool collet Collet wrench set Spare fuses ba aS ck sch sch SS st OD OO A HSH HS D 6 ADVANTAGE Router SAFETY GUIDELINES WARNING The ADVANTAGE Router is a high speed cutting machine which throws out chips of metal wood or plastic Its use may be hazardous if you do not observe the fo
54. w in a ready state and the message remains until the data arrives from the GRAPHIX ADVANTAGE CAUTION In START READY mode the router carriage may move without further warning The current tool position becomes the start point for the job When the job data is received from the GRAPHIX ADVANTAGE the START JOB message appears indicating that the machine is ina run state The GRAPHIX ADVANTAGE sends a header or tool message the machine goes into STOP JOB mode and instructs the operator to load material Press START STOP again to display the tool assignment To begin the job press START STOP again CAUTION The router carriage may move without further warning 22 ADVANTAGE Router STOP MODE STOP mode as shown by a message in the display panel may be in one of two states STOP READY the router is in an idle state waiting to receive data STOP JOB the router is in a pause state during a job The following keys are available in STOP mode START STOP RESET Z INIT SELECT arrow keys STOP READY In STOP READY the GRAPHIX ADVANTAGE sends data to the ARC Box The system beeps when data is received and J j is displayed in the lower right corner of the message display panel Press the START STOP key to begin the job The carriage can be slewed to establish a start position for the next job The job start position can be changed in the STOP READY mode It can also be changed when one of the following oc
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